Designing Highly Entangled, Homogeneous, and Low-Defect Networks for High-Performance Rubbers

Rubbers are critical in a wide range of engineering applications; however, conventional processing methods often disrupt the entanglements and introduce defects that compromise their mechanical performance. In this study, we introduce a nondestructive, latex-based processing method for the fabrication of high-performance rubbers with highly entangled, homogeneous, and low-defect networks. As a proof of concept, natural rubber (NR) materials prepared using this novel approach retain their intrinsic entanglements while exhibiting a more homogeneous network structure with fewer defects. This optimized NR network enhances strain-induced crystallization (SIC), achieving a crystallinity of up to 38% and larger crystal sizes. These improvements lead to superior mechanical properties, including a tensile strength of 37.3 MPa, a toughness of 77.3 MJ/m³, a modulus of 2.37 MPa, and a fatigue threshold of 258 J/m², outperforming conventional NR materials. Furthermore, this method is versatile and can be applied to other rubbers, demonstrating its broad potential for producing high-performance rubber materials.