Soil-Modified Composite Elastomer via Silane Coupling
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Solution Overview
Problem
Current elastomer products, particularly rubber and thermoplastic elastomers, face limitations in thermal resistance, durability, and cost, with the vulcanization process generating toxic gases and relying heavily on chemical products, and existing methods do not effectively utilize inorganic materials beyond 60% content, especially for modifying normal soils like yellow, red, or black soils into composite elastomers.
Innovation Solution
A method for modifying normal soil by kinetic heating and surface modification using a surfactant mixture of silane coupling agents, polysiloxane, and emulsifiers to create a 'molecular bridge' with organic polymers, allowing the soil to form a stable composite elastomer with acrylic acid copolymer emulsions, reducing toxic gas emissions and organic solvent evaporation, and achieving high soil content (30-80%) in the final product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rubber vulcanization process is used to produce elastomer products, then mechanical strength and durability are improved, but toxic gases are generated during the process
Solution Approach 1:
The patent replaces the harmful vulcanization process with a water-based acrylic copolymer emulsion system that uses organic peroxide initiators. This converts the harmful chemical vulcanization (generating toxic gases) into a beneficial oxidation crosslinking process that produces water and oxygen as byproducts, eliminating toxic emissions while maintaining elastomer durability and mechanical strength.
Solution Approach 2:
The patent fundamentally changes the chemical parameters of the elastomer system by substituting sulfur-based vulcanization with organic peroxide-initiated polymerization. This parameter change transforms the crosslinking mechanism from sulfur bonding to peroxide-based radical polymerization, achieving similar mechanical properties without toxic gas generation.
2Ease of manufacture
If thermoplastic elastomers are used instead of rubber, then manufacturing cost is reduced and processing is simplified, but thermal resistance and durability are decreased
Solution Approach 1:
The patent creates a composite material system combining acrylic copolymer emulsion with organic peroxide crosslinking agents. This composite approach integrates the cost-effectiveness and ease of processing of thermoplastics with the thermal resistance and durability of vulcanized rubber, achieving a middle ground that combines advantages of both material types.
Solution Approach 2:
The patent utilizes phase transition during processing - the acrylic copolymer emulsion is processed in its liquid/emulsion state at lower temperatures (easy processing), then crosslinked in situ to form a solid elastomeric network with enhanced thermal resistance. This phase transition enables both easy manufacturing and high durability.
3Ease of manufacture
If inorganic fillers are added to reduce costs and improve physical properties, then manufacturing cost is reduced, but compatibility with organic compounds decreases without proper modification
Solution Approach 1:
The patent introduces silane coupling agents as intermediary substances that mediate between inorganic fillers and the organic acrylic copolymer matrix. The silane molecules have both inorganic-compatible groups (for bonding to filler surfaces) and organic-compatible groups (for integration with the polymer matrix), thereby improving compatibility and interfacial adhesion while maintaining cost benefits from filler usage.
4Ease of manufacture
If normal soils (yellow, red, black soils) are used as fillers, then cost is significantly reduced and eco-friendliness is improved, but compatibility with organic polymers and mechanical properties are insufficient without modification
Solution Approach 1:
The patent applies silane coupling agents to the surface of normal soils (yellow, red, or black soils) to create an intermediary layer that enhances compatibility with the organic acrylic copolymer matrix. This surface modification improves interfacial adhesion and stress transfer, thereby enhancing mechanical properties while maintaining the cost advantages of using locally available normal soils.
Solution Approach 2:
The patent modifies the surface chemical parameters of normal soils through silane treatment, transforming them from incompatible inorganic particles to compatible composite fillers. This parameter change in surface chemistry enables the soils to integrate effectively with the organic polymer matrix, improving mechanical strength, elasticity, and overall performance.
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 modified soil-based composite elastomer exhibits improved mechanical properties, stability, and eco-friendliness, meeting standards for elastomer sports flooring, wall bricks, and synthetic leather, with enhanced durability, thermal resistance, and reduced manufacturing costs, while being free from toxic emissions and solvent use.
Implementation Method 1
allowing the soil to form a stable composite elastomer with acrylic acid copolymer emulsions
Implementation Method 2
surface modification using a surfactant mixture of silane coupling agents, polysiloxane, and emulsifiers
Implementation Method 3
organic peroxide initiators, allowing the acrylic acid copolymer emulsion to be crosslinked
Implementation Method 4
allowing the acrylic acid copolymer emulsion to be crosslinked into an elastomer
Implementation Method 5
kinetic heating and surface modification using a surfactant mixture
Data Source
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AI summary
A method for modifying soil and a method for producing composite Elastomer of the soil are disclosed. The method for modifying soil includes drying, pulverizing, sieving, and purifying the soil to obtain soil powder, then dynamically heating the powder and adding surfactant, which includes coupling agent, polysiloxane having reactive functional, emulsifier of organosilicon and aliphatic amine, and water, and then drying the above obtained powder to obtain modified soil. The modified soil and acrylic acid copolymer emulsion are mixed with plasticizer, foaming agent, etc. to form a composite body which is used to produce elastomer floor board, elastomer wall brick, composite soil skin material, and so on. No emission of toxic gas and evaporation of organic solvent can be attained during production and use of the invention, and performance of the product is same as or has superiority over rubber in compression deformation rate, rebound elasticity and durability.