Graphene-Rubber Foam Sole Weight Reduction
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Solution Overview
Problem
Traditional rubber foamed soles are heavy and lack thermal contraction resistance and wear resistance, necessitating improvements in these properties.
Innovation Solution
An ultra-light graphene-rubber foam particle is developed using a specific composition and method involving natural rubber, modified graphene, inorganic nano-particles, and specific additives, ensuring uniform dispersion and improved mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional rubber foam is used for soles, then the sole is easy to manufacture, but the sole is heavy and has poor thermal contraction resistance and wear resistance
Solution Approach 1:
The patent uses composite materials by combining rubber base material with graphene particles and inorganic nano-particles to create a foam composition that achieves both lightweight properties and improved mechanical performance including thermal contraction resistance and wear resistance
Solution Approach 2:
The patent changes the physical and chemical parameters of the rubber foam by controlling the foaming process, particle size distribution, and cross-linking density to achieve optimal balance between weight reduction and mechanical property enhancement
2Reliability
If graphene is added to rubber to improve properties, then wear resistance and thermal stability are enhanced, but graphene agglomerates due to Van der Waals force and cannot disperse uniformly
Solution Approach 1:
The patent uses inorganic nano-particles as intermediary substances between graphene particles and the rubber matrix, preventing direct graphene-graphene contact and reducing Van der Waals attraction, thereby achieving uniform dispersion while maintaining enhanced wear resistance and thermal stability
Solution Approach 2:
The patent creates local quality differences by distributing different types of particles (graphene and inorganic nano-particles) in specific arrangements within the rubber matrix, optimizing both dispersion stability and mechanical property enhancement in different regions
3Stability of the object's composition
If chemical grafting is used to improve graphene dispersibility, then dispersity in high-molecular polymers is enhanced, but the crystal structure of graphene is destroyed and intrinsic properties are greatly affected
Solution Approach 1:
The patent extracts the problematic chemical grafting step and replaces it with physical mixing and surface modification approaches, thereby achieving good dispersibility without destroying the graphene crystal structure and preserving its intrinsic properties
Solution Approach 2:
The patent uses small amounts of inorganic nano-particles as disposable spacer elements that prevent graphene agglomeration during processing and can be sacrificed or transformed during vulcanization, achieving dispersibility without permanent chemical modification of graphene
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a lightweight foam particle with enhanced thermal stability, wear resistance, and tensile strength, reducing weight by over 50% and improving thermal contraction resistance and aging resistance.
Implementation Method 1
the laminated structure of the graphene can generate a large Van der Waals force
Implementation Method 2
the graphene can generate a large Van der Waals force or can easily interact with hydrogen bonds
Implementation Method 3
1.5-1.8 parts of foaming agents
Implementation Method 4
0.8-1.0 parts of cross-linking agents
Implementation Method 5
1.2-1.5 parts of activated zinc oxide, 0.8-1.0 parts of zinc stearate, 1.0-1.2 parts of stearic acid, 0.8-1.0 parts of cross-linking agents
Data Source
AI summary
An ultra-light graphene-rubber foam particle for soles is prepared from, by weight, 60-65 parts of natural rubber, 8-12 parts of isoprene rubber, 8-12 parts of butadiene rubber, 6-8 parts of styrene butadiene rubber, 0.8-1.0 parts of modified graphene, 0.08-0.12 parts of poly(N-vinylacetamide), 0.8-1.0 parts of silicone oil, 3.0-3.5 parts of inorganic nano-particles, 1.2-1.5 parts of activated zinc oxide, 0.8-1.0 parts of zinc stearate, 1.0-1.2 parts of stearic acid, 0.8-1.0 parts of cross-linking agents, 2.0-3.0 parts of flow promotors, and 1.5-1.8 parts of foaming agents. According to the invention, the modified graphene is uniformly dispersed into the rubber materials, so that the ultra-light graphene-rubber foam particle has good thermal stability, wear resistance and tensile strength, the permanent compressive-deformation performance and thermal contraction resistance are improved, and the weight is reduced by over 50%.