Natural Fiber-Reinforced Foamed Rubber Composites: A Sustainable Approach to Achieving Lightweight and Structural Stability in Sole Materials

Lightweightness and durability are key consumer demands for footwear. To address the issues of deformation and poor durability in foamed sole materials, this study integrates natural fibers into the formulation of foamed rubber. The effects of natural fiber incorporation on density, mechanical properties, creep behavior, anti-slip performance, and aging resistance were comprehensively analyzed. Additionally, the study explored the mechanisms underlying the improved performance of the modified rubber materials. The results revealed that natural fiber integration significantly enhanced the structural stability, strength, and aging resistance of natural rubber (NR). Among the fibers compared, collagen fibers (CF) proved to be the most effective modifier for foamed NR. The density, tensile strength, tear strength, and coefficient of friction of CF-modified foamed NR (CF-NR) were found to be 0.72 g/cm³, 10.1 MPa, 48.0 N/mm, and 1.105, respectively, meeting the standard requirements for sole materials. Furthermore, CF-NR demonstrated a recoverable deformation of 4.58% and a negligible irreversible deformation of 0.10%, indicating a successful balance between comfort and durability. This performance enhancement can be attributed to the supportive role of CF in the pore structure, along with its inherent flexibility and recoverability. This work presents a novel approach for the development of high-quality, lightweight footwear in the sole material industry.