Element prepared from a plurality of foam microspheres, method for producing an element from polyolefin foam microspheres, product using the foam microspheres

Description

1 / 41 ELEMENT PREPARED FROM A PLURALITY OF FOAM MICROSPHERES, METHOD FOR PRODUCING AN ELEMENT FROM POLYOLEFIN FOAM MICROSPHERES, PRODUCT AND USE OF FOAM MICROSPHERES, FIELD OF DISCLOSURE

[0001] This disclosure relates to polyolefin foam microspheres and a process for producing them. This disclosure also relates to an element prepared from the foam microspheres, a product comprising the element, and the use of the foam microspheres in sphere filling applications. BACKGROUND

[0002] Polyolefin products, for example, ENGAGE™ Polyolefin Elastomers (POE) and INFUSE™ Olefin Block Copolymers (OBC), find wide use in industry. For example, in the footwear industry, components such as midsoles are traditionally manufactured with cross-linked EVA / POE and EVA / OBC foams produced through chemical foaming. However, this process is very labor-intensive and therefore an alternative foam technology with an environmentally friendly and economical process is being sought.

[0003] Foam microsphere forming technology, a type of physical foaming, provides an option. The advantages of foam microspheres compared to chemical foam include: absence of unpleasant odor, less mold contamination, different visual and tactile perception, isotropic properties of parts. Most importantly, the foam microsphere forming process decouples the foaming process from the molding process.

[0004] Typically, there are two types of commercial use of foam microspheres in the footwear industry, represented by Adidas Boost (TPU) and Nike Joyride, respectively. The first involves microsphere production and steam molding, while the second involves microsphere production and filling separate microspheres into a cavity to form a Petition 870260055117, dated 08 / 06 / 2026, page 8 / 136 2 / 41 element (e.g., a midsole). To ensure good sintering during steam molding, the foam microspheres should not be cross-linked or may only be partially cross-linked with a relatively low level of gel content. For microsphere filling applications (not only in footwear but also in other applications such as saddles, pillows, and the like), cross-linked foam microspheres are permitted and therefore can have relatively good elasticity.

[0005] There is still a need for foam microspheres that have enhanced properties, such as elasticity. SUMMARY OF THE DISCLOSURE

[0006] In one aspect, the present disclosure provides a foam microsphere formed from a composition comprising one or more polyolefin interpolymers, wherein the foam microsphere has a gel content greater than or equal to 80%, and a tanδ at 1 rad / s less than or equal to 0.11.

[0007] In a second aspect, the present disclosure provides a method for producing polyolefin foam microspheres, comprising, (a) providing a composition comprising one or more polyolefin interpolymers; (b) pelletizing the composition to form pellets; (c) crosslink the pellets to a gel content greater than or equal to 80%; and (d) foam the crosslinked pellets into foam microspheres, wherein the foam microspheres have tanδ at 1 rad / s less than or equal to 0.11.

[0008] In another aspect, the present disclosure provides an element prepared from a plurality of foam microspheres, as described herein, comprising a cavity filled with the foam microspheres.

[0009] In another aspect, the present disclosure provides a product comprising the element, as described herein.

[0010] In another aspect, the present disclosure provides the use of Petition 870260055117, dated 08 / 06 / 2026, p. 9 / 136 3 / 41 foam microspheres, as described herein, in bead filling applications.

[0011] It should be understood that both the previous general description and the detailed description below are illustrative and explanatory only, and do not restrict the invention as claimed. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 is a graph showing Tanδ of various foam microspheres during frequency sweep.

[0013] Figure 2 is a scanning electron microscope (SEM) micrograph of the foam microspheres prepared in the Examples. DETAILED DESCRIPTION OF THE INVENTION

[0014] Unless otherwise defined, all technical and scientific terms used in this document have the same meaning commonly understood by a person of ordinary skill in the art to which the invention pertains. In addition, all publications, patent applications, patents and other references mentioned in this document are incorporated by reference.

[0015] The following detailed description refers to the accompanying drawings which show, by way of illustration, specific details and embodiments in which the invention can be practiced. Other embodiments may be used and modifications may be made without departing from the scope of the invention. The various embodiments are not necessarily mutually exclusive, since some embodiments may be combined with one or more other embodiments to form new embodiments.

[0016] In the context of various modalities, the articles a, an, and the, as used in relation to a feature or element, include a reference to one or more of the features or elements. All ranges include endpoints unless otherwise indicated.

[0017] As used herein, the terms comprising, including, having and their derivatives are not intended to exclude the presence of any additional component, step or procedure, whether or not it is included. Petition 870260055117, dated 08 / 06 / 2026, page 10 / 136 4 / 41 specifically disclosed. In order to avoid any doubt, all compositions claimed through the use of the term comprising may include any additional additive, adjuvant or compound, whether polymeric or otherwise, unless otherwise indicated. On the other hand, the term consisting essentially excludes from the scope of any subsequent recitation any other component, step or procedure, except those that are not essential for operability. The term consisting excludes any component, step or procedure not specifically outlined or mentioned.

[0018] As disclosed here, all percentages mentioned here are by weight and temperatures in °C, unless otherwise specified. A. Polyolefin foam microsphere

[0019] This disclosure provides a polyolefin interpolymer foam microsphere. The foam microsphere is formed from a composition comprising one or more polyolefin interpolymers.

[0020] In some embodiments, the foam microsphere may be formed from a composition comprising one or more polyolefin interpolymers and, optionally, one or more additives.

[0021] In some specific embodiments, the foam microsphere may be formed from a composition comprising one or more polyolefin interpolymers wherein not less than 70% by weight of one or more polyolefin interpolymers is grafted with silane.

[0022] In some specific embodiments, the foam microsphere may be formed from a composition comprising: (A) one or more polyolefin interpolymers, and (B) one or more optional additives, wherein not less than 70% by weight of one or more polyolefin interpolymers is grafted with silane. i. Polyolefin Interpolymer

[0023] The term polymer or olefin-based polymer, as used herein, refers to a polymer comprising, in polymerized form, 50% by weight or a major percentage by weight of a Petition 870260055117, dated 08 / 06 / 2026, page 11 / 136 5 / 41 olefin, such as ethylene or propylene (based on polymer weight), and optionally may comprise one or more comonomers.

[0024] The term ethylene-based polymer, as used in this document, refers to a polymer comprising, in polymerized form, 50% by weight or a major percentage by weight of ethylene monomer (based on the weight of the polymer), and may optionally comprise one or more comonomers.

[0025] The term polymer, as used in this document, refers to a polymeric compound prepared by polymerizing monomers, whether of the same type or of a different type. The generic term polymer therefore includes the term homopolymer (used to refer to polymers prepared from only one type of monomer, with the understanding that trace amounts of impurities may be incorporated within the polymeric structure) and the term interpolymer as defined hereinafter. Trace amounts of impurities, such as catalyst residues, may be incorporated into and / or within the polymer. Typically, a polymer is stabilized with very low amounts (amounts in ppm) of one or more stabilizers.

[0026] The term interpolymer, as used herein, refers to a polymer prepared by the polymerization of at least two different types of monomers. The term interpolymer therefore includes the term copolymer (used to refer to polymers prepared from two different types of monomers) and polymers prepared from more than two different types of monomers.

[0027] In some embodiments, the composition may comprise not less than 80% by weight, not less than 85% by weight, not less than 90% by weight, not less than 95% by weight, not less than 98% by weight, not less than 99% by weight or 100% by weight of the polyolefin interpolymer, based on the total weight of the composition, or based on the total weight of the foam microsphere. In some embodiments, the composition may contain from 80% by weight, or 85% by weight, or 90% by weight to 95% by weight, or 98% by weight, or 99% by weight, or 100% by weight of the interpolymer of Petition 870260055117, dated 08 / 06 / 2026, page 12 / 136 6 / 41 polyolefin, based on the total weight of the composition, or based on the total weight of the foam microsphere.

[0028] In one embodiment, the polyolefin interpolymer may have a melt index (MI) not exceeding 30 g / 10 min, not exceeding 20 g / 10 min, not exceeding 10 g / 10 min, or not exceeding 5 g / 10 min. In one embodiment, the polyolefin interpolymer may have an MI that is within the numerical range obtained by combining any two of the following endpoints: 0.1 g / 10 min, 0.5 g / 10 min, 0.8 g / 10 min, 1.0 g / 10 min, 1.5 g / 10 min, 2.0 g / 10 min, 5 g / 10 min, 10 g / 10 min, 20 g / 10 min, and 30 g / 10 min. In one embodiment, the polyolefin interpolymer may have an IF of 0.1 g / 10 min, or 0.5 g / 10 min, or 0.8 g / 10 min, to 1.0 g / 10 min, or 1.5 g / 10 min, or 2.0 g / 10 min, or 5 g / 10 min, or 10 g / 10 min, or 20 g / 10 min, or 30 g / 10 min. In another embodiment, the polyolefin interpolymer may have an IF of 0.1 g / 10 min to 30 g / 10 min, or 0.1 g / 10 min to 20 g / 10 min, or 0.1 g / 10 min to 5 g / 10 min, or 0.5 g / 10 min to 8 g / 10 min, or 1 g / 10 min to 5 g / 10 min.

[0029] In one embodiment, the polyolefin interpolymer may have a density of not less than 0.850 g / cm3, not less than 0.855 g / cm3, not less than 0.860 g / cm3, not less than 0.865 g / cm3, or not less than 0.870 g / cm3. In one embodiment, the polyolefin interpolymer may have a density that is within the numerical range obtained by combining any two of the following endpoints: 0.850 g / cm3, 0.855 g / cm3, 0.860 g / cm3, 0.865 g / cm3, 0.870 g / cm3, 0.875 g / cm3, 0.880 g / cm3, 0.885 g / cm3, 0.890 g / cm3, 0.895 g / cm3, 0.900 g / cm3, 0.905 g / cm3 and 0.910 g / cm3. In one embodiment, the polyolefin interpolymer may have a density of 0.850 g / cm3, or 0.855 g / cm3, or 0.860 g / cm3, or 0.865 g / cm3, or 0.870 g / cm3, or 0.875 g / cm3, to 0.880 g / cm3, or 0.885 g / cm3, or 0.890 g / cm3, or 0.895 g / cm3, or 0.900 g / cm3, or 0.905 g / cm3, or 0.910 g / cm3.In one embodiment, the polyolefin interpolymer may have a density of 0.850 g / cm3 to 0.910 g / cm3, of 0.855 g / cm3 to 0.910 g / cm3, of 0.860 g / cm3 to 0.910 g / cm3, of 0.865 g / cm3 to 0.905 g / cm3, or of 0.870 g / cm3a 0.905 g / cm3.

[0030] In one embodiment, the polyolefin interpolymer may have a Petition 870260055117, dated 08 / 06 / 2026, p. 13 / 136 7 / 41 Shore A hardness of not less than 30, not less than 35, not less than 40, not less than 45, or not less than 50. In one embodiment, the polyolefin interpolymer may have a Shore A hardness that is within the numerical range obtained by combining any two of the following endpoints: 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, and 90. In one embodiment, the polyolefin interpolymer may have a Shore A hardness of 30, or 35, or 40, or 45, or 50, or 55, or 60, or 65, or 70, or 75, to 80, or 85, or 90. In one embodiment, the polyolefin interpolymer may have a Shore A hardness of 30 to 90, from 35 to 90, from 40 to 90, from 45 to 90, from 50 to 90, or from 55 to 90.

[0031] In some embodiments, the polyolefin interpolymer may be a polyolefin elastomer (POE). In some embodiments, the polyolefin interpolymer may be selected from the group consisting of one or more ethylene / α-olefin multiblock interpolymers, one or more ethylene / α-olefin random copolymers, and any combination thereof. (1) Ethylene / α-olefin multiblock interpolymer

[0032] In some embodiments, the polyolefin interpolymer may comprise an ethylene / α-olefin multiblock interpolymer. In some embodiments, the polyolefin interpolymer may comprise an ethylene / α-olefin multiblock copolymer, for example, a C3-C20 ethylene / α-olefin multiblock copolymer consisting of ethylene and one or more copolymerizable C3-C20 α-olefin comonomers in polymerized form (and optional additives). Non-limiting examples of suitable α-olefins include 1-propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-undecene, 1-dodecene, 1-tridecylene and 1-tetradecene. In some exemplary embodiments, the polyolefin may be a C3-C10 α-olefin, for example, a C4-C8 α-olefin. In one exemplary embodiment, the polyolefin interpolymer may comprise an ethylene / octene multiblock copolymer.In one exemplary embodiment, the ethylene / octene multiblock copolymer is commercially available under the trade name. Petition 870260055117, dated 08 / 06 / 2026, p. 14 / 136 8 / 41 INFUSE™, near The Dow Chemical Company, Midland, Michigan, USA.

[0033] The term ethylene / α-olefin multiblock interpolymer or olefin block copolymer (OBC) as used herein, refers to an interpolymer comprising ethylene and one or more copolymerizable α-olefin comonomers in polymerized form, characterized by multiple blocks or segments of two or more (preferably three or more) polymerized monomer units, wherein the blocks or segments differ in chemical or physical properties. Specifically, this term refers to a polymer comprising two or more (preferably three or more) chemically distinct regions or segments (referred to as blocks) joined in a substantially linear manner, i.e., a polymer comprising chemically differentiated units that are joined (covalently bonded) end-to-end with respect to polymerized functionality, and not in a pendant or grafted manner.Block copolymers differ in the amount or type of comonomer incorporated within them, density, amount of crystallinity, type of crystallinity (e.g., polyethylene versus polypropylene), crystallite size attributable to a polymer of such composition, type or degree of tacticity (isotactic or syndiotactic), region regularity or region irregularity, amount of branching, including long-chain branching or hyper-branching, homogeneity, and / or any other chemical or physical property. Block copolymers are characterized by unique distributions of both polymer polydispersity (PDI or Mw / Mn) and block length distribution, for example, based on the effect of using a carrier agent (or carriers) in combination with catalytic systems.Non-limiting examples of the olefin block copolymers of the present disclosure, as well as processes for their preparation, are disclosed in U.S. Patents Nos. 7,858,706 B2, 8,198,374 B2, 8,318,864 B2, 8,609,779 B2, 8,710,143 B2, 8,785,551 B2, and 9,243,090 B2, which are all incorporated herein by reference in their entirety.

[0034] Illustratively, multiblock copolymers can be represented by the following formula: (AB)n, where n is at least 1, of Petition 870260055117, dated 08 / 06 / 2026, p. 15 / 136 9 / 41 Preferably, an integer greater than 1, such as 2, 3, 4, 5, 10, 15, 20, 30, 40, 50, 60, 70, 80, 90, 100 or greater. Here, A represents a rigid segment or block and B represents a soft segment or block. Preferably, segments A and segments B are linked in a substantially linear fashion, as opposed to a substantially branched or substantially star-shaped fashion. In other embodiments, segments A and segments B are randomly distributed along the polymer chain. In other words, for example, block copolymers generally do not have the following structure: AAA-AA-BBB-BB. Still in other embodiments, block copolymers generally do not have a third type of block or segment, comprising different comonomers. In still other embodiments, each of the A and B blocks has monomers or comonomers distributed in a substantially random manner within the block.In other words, neither block A nor block B comprises two or more subsegments (or sub-blocks) of distinct composition, such as a tip segment, which has a substantially different composition from the rest of the block.

[0035] Olefin block copolymers are generally produced by means of a chain transport process, such as that described in U.S. Patent 7,858,706, which is incorporated herein by reference. Some suitable chain transport agents and related information are mentioned in Column 16, line 39, to Column 19, line 44. Some catalysts are described in Column 19, line 45, to Column 46, line 19, and some cocatalysts in Column 46, line 20, to Column 51, line 28. Some process characteristics are described in Column 51, line 29, to Column 54, line 56. See also the following: U.S. Patent No. 7,608,668; U.S. Patent No. 7,893,166; and US Patent 7,947,793, as well as the publication of US Patent 2010 / 0197880. See also US Patent 9,243,173.

[0036] Preferably, ethylene comprises the major molar fraction of the entire ethylene / α-olefin multiblock copolymer, that is, ethylene comprises at least 50% by weight of the multiblock copolymer of Petition 870260055117, dated 08 / 06 / 2026, page 16 / 136 10 / 41 whole ethylene / α-olefin. More preferably, the ethylene comprises at least 60% by weight, at least 70% by weight, or at least 80% by weight, with the substantial remainder of the entire ethylene / α-olefin multiblock interpolymer comprising the C4-C8 α-olefin comonomer. Preferably, the C4-C8 α-olefin comonomer may be selected from 1-butene, 1-hexene, and 1-octene. In one embodiment, the ethylene / α-olefin multiblock interpolymer contains from 50% by weight, or 60% by weight, or 65% by weight to 80% by weight, or 85% by weight, or 90% by weight of ethylene. For many ethylene / octene multiblock interpolymers, the composition comprises an ethylene content greater than 80% by weight of the total ethylene / octene multiblock interpolymer and an octene content of 10% by weight to 15% by weight, or 15% by weight to 20% by weight of the total ethylene / octene multiblock interpolymer.

[0037] The ethylene / α-olefin multiblock copolymer includes varying amounts of rigid and soft segments. Rigid segments are blocks of polymerized units in which ethylene is present in an amount greater than 90% by weight or 95% by weight or greater than 95% by weight or greater than 98% by weight, based on the weight of the polymer, up to 100% by weight. In other words, the comonomer content (content of monomers other than ethylene) in the rigid segments is less than 10% by weight or 5% by weight or less than 5% by weight or less than 2% by weight, based on the weight of the polymer, and may be as low as zero. In some embodiments, the rigid segments include all or substantially all ethylene-derived units. Soft segments are blocks of polymerized units in which the comonomer content (content of monomers other than ethylene) is greater than 5% by weight, or greater than 8% by weight, greater than 10% by weight, or greater than 15% by weight, based on the weight of the polymer.In one embodiment, the comonomer content in the soft segments is greater than 20% by weight, or greater than 25% by weight, or greater than 30% by weight, or greater than 35% by weight, or greater than 40% by weight, or greater than 45% by weight, or greater than 50% by weight, or greater than 60% by weight, and may be up to 100%. Petition 870260055117, dated 08 / 06 / 2026, page 17 / 136 11 / 41 by weight.

[0038] Soft segments may be present in an ethylene / α-olefin multiblock interpolymer from 1% by weight, or 5% by weight, or 10% by weight, or 15% by weight, or 20% by weight, or 25% by weight, or 30% by weight, or 35% by weight, or 40% by weight, or 45% by weight to 55% by weight, or 60% by weight, or 65% by weight, or 70% by weight, or 75% by weight, or 80% by weight, or 85% by weight, or 90% by weight, or 95% by weight, or 99% by weight of the total weight of the ethylene / α-olefin multiblock interpolymer. Conversely, hard segments may be present in similar ranges. The soft segment weight percentage and the hard segment weight percentage can be calculated based on data obtained from DSC or NMR. Such methods and calculations are disclosed, for example, in USP document no. 7,608,668, the disclosure of which is incorporated herein by reference in its entirety.In particular, the weight percentages of the rigid and soft segments and the comonomer content can be determined as described in columns 57 to 63 of USP document 7,608,668.

[0039] In one embodiment, the ethylene / α-olefin multiblock copolymer is produced in a continuous process and has a polydispersity index (Mw / Mn) of 1.7 to 3.5, or 1.8 to 3, or 1.8 to 2.5, or 1.8 to 2.2. When produced in a batch or semi-batch process, the ethylene / α-olefin multiblock copolymer has Mw / Mn of 1.0 to 3.5, or 1.3 to 3, or 1.4 to 2.5, or 1.4 to 2.

[0040] The suitable ethylene / α-olefin multiblock interpolymer can be either Dow's INFUSE™ or INFUSE™ D9130.05. (2) Ethylene / α-olefin random copolymer

[0041] In some embodiments, the polyolefin interpolymer may comprise a random ethylene / α-olefin interpolymer. A random ethylene / α-olefin copolymer may be a random ethylene / propylene copolymer or a random ethylene / α-olefin C4-C8 copolymer. In one embodiment, the ethylene / α-olefin copolymer may be a C4-C8 ethylene / α-olefin copolymer. The C4-C8 ethylene / α-olefin copolymer is composed of, or otherwise Petition 870260055117, dated 08 / 06 / 2026, page 18 / 136 12 / 41 consists of ethylene and a copolymerizable C4-C8 α-olefin comonomer in polymerized form. The C4-C8 α-olefin comonomer can be selected from 1-butene, 1-hexene, and 1-octene.

[0042] The suitable ethylene / α-olefin random copolymer can be either Dow's ENGAGE™, ENGAGE™ 8150, or ENGAGE™ 7467. ii Silane-grafted polyolefin interpolymer

[0043] At least a portion of the polyolefin interpolymer comprised in the composition to form the foam microsphere, as described, may be grafted with silane. In other words, the composition may comprise a silane-grafted polyolefin interpolymer, which is formed using the polyolefin interpolymer, as described, grafted with a silane monomer. In some exemplary embodiments, the silane-grafted polyolefin interpolymer may be a silane-grafted ethylene / α-olefin C3-C20 multiblock copolymer, for example, a silane-grafted ethylene / α-olefin C3-C10 multiblock copolymer. In another illustrative embodiment, the silane-grafted polyolefin interpolymer may be a silane-grafted ethylene / α-olefin random copolymer, for example, a silane-grafted C4-C8 ethylene / α-olefin random copolymer.

[0044] The silane monomer employed to functionalize the polyolefin interpolymer is a silane-containing monomer that can be grafted onto the polyolefin interpolymer to form a silane-functionalized polyolefin interpolymer, and is capable of crosslinking the polyolefin interpolymer. In some embodiments, the silane monomer may be a hydrolyzable silane monomer. Non-limiting examples of hydrolyzable silane monomers include vinyltrimethoxysilane (VTMS), vinyltriethoxysilane (VTES), vinyltriacetoxysilane, and gamma-(meth)acryloxypropyltrimethoxysilane. In an exemplary embodiment, the hydrolyzable silane monomer may be VTMS.

[0045] The silane-grafted polyolefin interpolymer can be formed by a process such as the Sioplas process, in which a monomer of Petition 870260055117, dated 08 / 06 / 2026, page 19 / 136 13 / 41 Hydrolyzable silane (such as a vinyl silane monomer) is grafted onto the main structure of the polyolefin interpolymer. The hydrolyzable silane monomer can be grafted onto the polyolefin interpolymer by using an appropriate amount of organic peroxide, such as 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane, to form a silane-grafted polyolefin interpolymer.

[0046] In some embodiments, the silane-grafted polyolefin interpolymer may comprise a silane graft ratio greater than 0.3% by weight, greater than 0.5% by weight, greater than 0.6% by weight, greater than 0.8% by weight, or greater than 1.0% by weight, based on the total weight of the silane-grafted polyolefin interpolymer. In some embodiments, the silane-grafted polyolefin interpolymer may comprise a silane graft ratio of 0.1% by weight, or 0.3% by weight, or 0.5% by weight, or 0.6% by weight, or 0.8% by weight, or 1.0% by weight, to 1.1% by weight, or 1.2% by weight, or 1.5% by weight, or 1.8% by weight, or 2.0% by weight, or 2.5% by weight, or 3.0% by weight, or 4.0% by weight, or 5.0% by weight, based on the total weight of the silane-grafted polyolefin interpolymer.In some embodiments, the silane-grafted polyolefin interpolymer may comprise a silane graft ratio of 0.1% by weight to 5.0% by weight, 0.3% by weight to 4.0% by weight, or 0.5% by weight to 3.0% by weight, based on the total weight of the silane-grafted polyolefin interpolymer. As used herein, the term silane graft ratio refers to the ratio of the weight of the silane grafted in the silane-grafted polyolefin interpolymer to the total weight of the silane-grafted polyolefin interpolymer.

[0047] In some embodiments, the foam microsphere may be formed from a composition comprising not less than 70% by weight, not less than 75% by weight, not less than 80% by weight, not less than 85% by weight, not less than 90% by weight, not less than 95% by weight, not less than 98% by weight, not less than 99% by weight or 100% by weight of silane-grafted polyolefin interpolymer, based on Petition 870260055117, dated 08 / 06 / 2026, page 20 / 136 14 / 41 total weight of the polyolefin interpolymer (or interpolymers) comprised in the composition. In some embodiments, the foam microsphere may be formed from a composition comprising from 70% by weight, or 75% by weight, or 80% by weight, or 85% by weight, to 90% by weight, or 95% by weight, or 98% by weight, or 99% by weight, or 100% by weight of the silane-grafted polyolefin interpolymer, based on the total weight of the polyolefin interpolymer (or interpolymers) comprised in the composition. In some embodiments, the foam microsphere may be formed from a composition comprising 100% by weight of the silane-grafted polyolefin interpolymer, based on the total weight of the polyolefin interpolymer (or interpolymers) comprised in the composition.

[0048] Silane-grafted polyolefin interpolymers are useful for silane chemistry crosslinking. It is understood that crosslinking can be carried out in other ways instead of silane chemistry, for example, electron beam irradiation, gamma irradiation or free radical chemistry-based crosslinking. iii. Non-grafted polyolefin interpolymer with silane

[0049] The composition for forming the foam microsphere comprising a silane-grafted polyolefin interpolymer, as described above, may comprise a non-silane-grafted polyolefin interpolymer. As used herein, a non-silane-grafted polyolefin interpolymer refers to one or more polyolefin interpolymers comprised in the composition for forming the foam microsphere in addition to the silane-grafted polyolefin interpolymer, as described above.

[0050] The non-silane-grafted polyolefin interpolymer may comprise any polyolefin interpolymer described herein that is not silane-grafted. The non-silane-grafted polyolefin interpolymer differs from the silane-grafted polyolefin interpolymer as described above, at least because the non-silane-grafted polyolefin interpolymer is not functionalized or silane-grafted. Petition 870260055117, dated 08 / 06 / 2026, page 21 / 136 15 / 41

[0051] In embodiments, the non-grafted silane polyolefin interpolymer and the polyolefin interpolymer that is used to form the silane-grafted polyolefin interpolymer may be physically, and / or compositionally and / or structurally identical or different.

[0052] In some embodiments, the foam microsphere may be formed from a composition comprising not more than 30% by weight, not more than 25% by weight, not more than 20% by weight, not more than 15% by weight, not more than 10% by weight, not more than 5% by weight, not more than 3% by weight, not more than 2% by weight, or not more than 1% by weight, or 0% by weight, of the silane-ungrafted polyolefin interpolymer, based on the total weight of the polyolefin interpolymer (or interpolymers) comprised in the composition. In some embodiments, the foam microsphere may be formed from a composition comprising from 0% by weight, or 1% by weight, or 2% by weight, or 3% by weight, or 5% by weight, to 10% by weight, or 15% by weight, or 20% by weight, or 25% by weight, or 30% by weight, of the silane-ungrafted polyolefin interpolymer, based on the total weight of the polyolefin interpolymer (or interpolymers) comprised in the composition.In some embodiments, the foam microsphere can be formed from a composition that is free of a silane-grafted polyolefin interpolymer.

[0053] In some embodiments, the non-grafted silane polyolefin interpolymer may be an unmodified polyolefin interpolymer. Examples of suitable unmodified polyolefin interpolymers include ethylene or propylene random / block copolymers, such as INFUSE™, ENGAGE™, VERSIFY™, etc.

[0054] In some embodiments, the composition for forming the foam microsphere may also comprise polyolefin derivatives, such as high-VA content ethylene-vinyl acetate (EVA) copolymer (for example, with a VA content greater than 18% by weight, based on the total weight of the EVA). Suitable examples of EVA copolymer include ELVAX®. Petition 870260055117, dated 08 / 06 / 2026, page 22 / 136 16 / 41 460, ELVAX® 360, ELVAX® 265, ELVAX® 260, ELVAX® 250, ELVAX® 40L03. iv. Additives

[0055] The composition may include one or more optional additives. Non-limiting examples of suitable additives include nucleating agents, cell size stabilizers, antioxidants, coloring agents, inorganic fillers, flow aids, viscosity control agents, and combinations thereof.

[0056] In one embodiment, the foam microsphere is formed from a composition comprising from 0% by weight, or 0.01% by weight to 0.3% by weight, or 0.5% by weight, or 1% by weight, or 2% by weight, or 3% by weight, or 5% by weight of one or more optional additives, based on the total weight of the composition, or also based on the total weight of the foam microsphere. In another embodiment, the foam microsphere is formed from a composition containing from 0% by weight to 5% by weight, or from 0% by weight to 1% by weight, or from 0.01% by weight to 5% by weight of optional additive, based on the total weight of the composition, or additionally based on the total weight of the foam microsphere. v. Foam microspheres

[0057] The foam microsphere of the present application may be formed from a composition comprising one or more polyolefin interpolymers and, optionally, one or more additives. In some embodiments, the foam microsphere may be formed from a composition comprising 80% by weight, or 85% by weight, 90% by weight, to 95% by weight, or 98% by weight, or 99% by weight, or 100% by weight of the polyolefin interpolymer, as described herein, based on the total weight of the composition, or additionally based on the total weight of the foam microsphere, and from 0% by weight, or 0.01% by weight to 0.3% by weight, or 0.5% by weight, or 1% by weight, or 2% by weight, or 3% by weight, or 5% by weight of one or more optional additives, based on the total weight of the composition, or additionally based on the total weight of the foam microsphere. Petition 870260055117, dated 08 / 06 / 2026, page 23 / 136 17 / 41

[0058] In some specific embodiments, the foam microsphere of the present application may be formed from a composition comprising one or more polyolefin interpolymers wherein not less than 70% by weight of one or more polyolefin interpolymers is grafted with silane.

[0059] In some embodiments, the composition may optionally include one or more compatible additives.

[0060] In some embodiments, the foam microsphere may be formed from a composition comprising: (A) from 80% by weight, or 85% by weight, or 90% by weight, to 95% by weight, or 98% by weight, or 99% by weight, or 100% by weight, of one or more polyolefin interpolymers, based on the total weight of the composition, or the total weight of the foam microsphere; and, (B) optionally, from 0% by weight, or 0.01% by weight to 0.3% by weight, or 0.5% by weight, or 1% by weight, or 2% by weight, or 3% by weight, or 5% by weight, of one or more optional additives, based on the total weight of the composition, or the total weight of the foam microsphere; wherein one or more polyolefin interpolymers comprise from 70% by weight, or 75% by weight, or 80% by weight, or 85% by weight, to 90% by weight, or 95% by weight, or 98% by weight, or 99% by weight, or 100% by weight, of one or more silane-grafted polyolefin interpolymers, based on the total weight of the polyolefin interpolymer (or interpolymers) comprised in the composition; and from 0% by weight, or 1% by weight, or 2% by weight, or 3% by weight, or 5% by weight, to 10% by weight, or 15% by weight, or 20% by weight, or 25% by weight, or 30% by weight, of one or more non-silane polyolefin interpolymers, based on the total weight of the polyolefin interpolymer (or interpolymers) comprised in the composition.

[0061] In some embodiments, the foam microsphere may have a gel content greater than or equal to 80%, greater than or equal to 85%, or greater than or equal to 90%. In some embodiments, the foam microsphere may have a gel content of 80%, or 85% to 90%, or 95%, or 98%, or 99%, or 100%. Petition 870260055117, dated 08 / 06 / 2026, p. 24 / 136 18 / 41

[0062] In some embodiments, the foam microsphere can be formed from the pellets of the composition as described. In some embodiments, the foam microsphere can be formed from the cross-linked pellets of the composition as described. In some embodiments, the cross-linked pellets of the composition can have a gel content greater than or equal to 80%, greater than or equal to 85%, or greater than or equal to 90%. In some embodiments, the cross-linked pellets can have a gel content of 80%, or 85% to 90%, or 95%, or 98%, or 99%, or 100%. In some embodiments, the foam microsphere is formed from the composition as described above by cross-linking the pellets of the composition before foaming the pellets. In some embodiments, the foam microsphere is formed by foaming the cross-linked pellets of the composition as described above.

[0063] In some embodiments, the foam microsphere has a foam density of less than 0.20 g / cm3. In some embodiments, the foam microsphere has a foam density of 0.06 g / cm3, or 0.07 g / cm3, or 0.08 g / cm3, or 0.09 g / cm3, or 0.10 g / cm3, or 0.11 g / cm3, or 0.12 g / cm3, or 0.13 g / cm3, to 0.14 g / cm3, or 0.15 g / cm3, or 0.16 g / cm3, or 0.17 g / cm3, or 0.18 g / cm3, or 0.19 g / cm3, or 0.20 g / cm3. In some embodiments, the foam microsphere may have a density of 0.06 g / cm3 to 0.20 g / cm3, of 0.08 g / cm3 to 0.18 g / cm3, of 0.10 g / cm3 to 0.17 g / cm3, or of 0.12 g / cm3 to 0.16 g / cm3.

[0064] In some embodiments, the foam microsphere may have tanδ at 0.1 rad / s less than or equal to 0.16, less than or equal to 0.15, less than or equal to 0.14, less than or equal to 0.13, or less than or equal to 0.12. In some embodiments, the foam microsphere may have tanδ at 1 rad / s less than or equal to 0.15, less than or equal to 0.14, less than or equal to 0.13, less than or equal to 0.12, less than or equal to 0.11, or less than or equal to 0.10. In some embodiments, the foam microsphere may have tanδ at 10 rad / s less than or equal to 0.12, less than or equal to 0.11, less than or equal to 0.10, less than or equal to 0.09, or less than or equal to 0.08. Petition 870260055117, dated 08 / 06 / 2026, p. 25 / 136 19 / 41

[0065] In some embodiments, the foam microsphere may have an average cell size of less than about 100 μm. In some embodiments, the foam microsphere may have an average cell size of about 10 μm, about 15 μm, about 20 μm, to 80 μm or 85 μm or 90 μm or 95 μm or 100 μm.

[0066] In some embodiments, the foam microsphere can be prepared using the method for producing polyolefin foam microspheres, as described below. B. Method for producing polyolefin foam microspheres

[0067] This disclosure provides a method for producing polyolefin foam microspheres, comprising, (a) providing a composition comprising one or more polyolefin interpolymers; (b) pelletizing the composition to form pellets; (c) crosslink the pellets to a gel content greater than or equal to 80%; and (d) foam the crosslinked pellets into foam microspheres, wherein the foam microspheres have tanδ at 1 rad / s less than or equal to 0.11. I. Polyolefin composition

[0068] The method for producing polyolefin foam microspheres, as described in this document, comprises (a) providing a composition comprising one or more polyolefin interpolymers, wherein the composition may also be referred to in this document as the composition or polyolefin composition.

[0069] In some embodiments, the composition provided in this document may comprise one or more polyolefin interpolymers (for example, one or more of those described in the Polyolefin Foam Microsphere portion above) and, optionally, one or more additives.

[0070] In some forms, the composition may comprise not less than 80% by weight, not less than 85% by weight, not less than 90% by weight, not less than 95% by weight, not less than 98% by weight, Petition 870260055117, dated 08 / 06 / 2026, page 26 / 136 20 / 41 not less than 99% by weight or 100% by weight of the polyolefin interpolymer, based on the total weight of the composition. In some embodiments, the composition may comprise from 80% by weight, or 85% by weight, or 90% by weight, to 95% by weight, or 98% by weight, or 99% by weight, or 100% by weight of the polyolefin interpolymer, based on the total weight of the composition.

[0071] In one embodiment, the polyolefin interpolymer may have a melt index (MI) not exceeding 30 g / 10 min, not exceeding 20 g / 10 min, not exceeding 10 g / 10 min, or not exceeding 5 g / 10 min. In one embodiment, the polyolefin interpolymer may have an MI that is within the numerical range obtained by combining any two of the following endpoints: 0.1 g / 10 min, 0.5 g / 10 min, 0.8 g / 10 min, 1.0 g / 10 min, 1.5 g / 10 min, 2.0 g / 10 min, 5 g / 10 min, 10 g / 10 min, 20 g / 10 min, and 30 g / 10 min. In one embodiment, the polyolefin interpolymer may have an IF of 0.1 g / 10 min, or 0.5 g / 10 min, or 0.8 g / 10 min, to 1.0 g / 10 min, or 1.5 g / 10 min, or 2.0 g / 10 min, or 5 g / 10 min, or 10 g / 10 min, or 20 g / 10 min, or 30 g / 10 min. In another embodiment, the polyolefin interpolymer may have an IF of 0.1 g / 10 min to 30 g / 10 min, or 0.1 g / 10 min to 20 g / 10 min, or 0.1 g / 10 min to 10 g / 10 min, or 0.5 g / 10 min to 8 g / 10 min, or 1 g / 10 min to 5 g / 10 min.

[0072] In one embodiment, the polyolefin interpolymer may have a density of not less than 0.850 g / cm3, not less than 0.855 g / cm3, not less than 0.860 g / cm3, not less than 0.865 g / cm3, or not less than 0.870 g / cm3. In one embodiment, the polyolefin interpolymer may have a density that is within the numerical range obtained by combining any two of the following endpoints: 0.850 g / cm3, 0.855 g / cm3, 0.860 g / cm3, 0.865 g / cm3, 0.870 g / cm3, 0.875 g / cm3, 0.880 g / cm3, 0.885 g / cm3, 0.890 g / cm3, 0.895 g / cm3, 0.900 g / cm3, 0.905 g / cm3, and 0.910 g / cm3. In one embodiment, the polyolefin interpolymer may have a density of 0.850 g / cm3, or 0.855 g / cm3, or 0.860 g / cm3, or 0.865 g / cm3, or 0.870 g / cm3, or 0.875 g / cm3, to 0.880 g / cm3, or 0.885 g / cm3, or 0.890 g / cm3, or 0.895 g / cm3, or 0.900 g / cm3, or 0.905 g / cm3, or 0.910 g / cm3. In one embodiment, the Petition 870260055117, dated 08 / 06 / 2026, p. 27 / 136 21 / 41 polyolefin interpolymer may have a density of 0.850 g / cm3 to 0.910 g / cm3, of 0.855 g / cm3 to 0.910 g / cm3, of 0.860 g / cm3 to 0.910 g / cm3, of 0.865 g / cm3 to 0.905 g / cm3, or of 0.870 g / cm3 to 0.905 g / cm3.

[0073] In one embodiment, the polyolefin interpolymer may have a Shore A hardness of not less than 30, not less than 35, not less than 40, not less than 45, or not less than 50. In one embodiment, the polyolefin interpolymer may have a Shore A hardness that is within the numerical range obtained by combining any two of the following endpoints: 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, and 90. In one embodiment, the polyolefin interpolymer may have a Shore A hardness of 30, or 35, or 40, or 45, or 50, or 55, or 60, or 65, or 70, or 75, to 80, or 85, or 90. In one embodiment, the polyolefin interpolymer may have a Shore A hardness of 30 to 90, 35 to 90, 40 to 90, 45 to 90, 50 to 90, or 55 to 90.

[0074] In some embodiments, the polyolefin interpolymer may be a polyolefin elastomer (POE). In some embodiments, the polyolefin interpolymer may be selected from the group consisting of ethylene / α-olefin multiblock interpolymer, ethylene / α-olefin random copolymer, and combinations thereof.

[0075] In some embodiments, the polyolefin interpolymer may comprise an ethylene / α-olefin multiblock interpolymer. In some embodiments, the polyolefin interpolymer may comprise an ethylene / α-olefin multiblock copolymer, for example, an ethylene / C3-C20 α-olefin multiblock copolymer, consisting of ethylene and one or more copolymerizable C3-C20 α-olefin comonomers in polymerized form (and optional additives). Non-limiting examples of suitable α-olefins include 1-propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-nonene, 1-decene, 1-undecene, 1-dodecene, 1-tridecylene and 1-tetradecene. In some exemplary embodiments, the α-olefin may be a C3-C10 α-olefin, for example, a C4-C8 α-olefin. In one exemplary embodiment, the polyolefin interpolymer may comprise a multi-block ethylene / octene copolymer. In another embodiment Petition 870260055117, dated 08 / 06 / 2026, page 28 / 136 22 / 41 For example, the ethylene / octene multiblock copolymer is commercially available under the trade name INFUSE™, from DOW.

[0076] The suitable ethylene / α-olefin multiblock interpolymer can be either Dow's INFUSE™ or INFUSE™ D9130.05.

[0077] In some embodiments, the polyolefin interpolymer may comprise a random ethylene / α-olefin interpolymer. A random ethylene / α-olefin copolymer may be a random ethylene / propylene copolymer or a random ethylene / α-olefin C4-C8 copolymer. In one embodiment, the ethylene / α-olefin copolymer may be an ethylene / α-olefin C4C8 copolymer. The ethylene / α-olefin C4-C8 copolymer is composed of, or otherwise consists of, ethylene and a copolymerizable C4-C8 α-olefin comonomer in polymerized form. The C4-C8 α-olefin comonomer may be selected from 1-butene, 1-hexene, and 1-octene.

[0078] The suitable ethylene / α-olefin random copolymer can be either Dow's ENGAGE™, ENGAGE™ 8150, or ENGAGE™ 7467.

[0079] In some embodiments, the composition given here may optionally include one or more additives. Non-limiting examples of suitable additives include nucleating agents, cell size stabilizers, antioxidants, coloring agents, inorganic fillers, flow aids, viscosity control agents, and combinations thereof.

[0080] In one embodiment, the composition may comprise from 0% by weight, or 0.01% to 0.3% by weight, or 0.5% by weight, or 1% by weight, or 2% by weight, or 3% by weight, or 5% by weight of one or more optional additives, based on the total weight of the composition. In another embodiment, the composition may comprise from 0% by weight to 5% by weight, or from 0% by weight to 1% by weight, or from 0.01% by weight to 5% by weight of additional additive, based on the total weight of the composition.

[0081] In some embodiments, the composition may comprise from 80% by weight, or 85% by weight, or 90% by weight, to 95% by weight, or 98% by weight, or 99% by weight or 100% by weight of the polyolefin interpolymer, as described herein, based on the total weight of the composition, and from 0% by weight, or Petition 870260055117, dated 08 / 06 / 2026, page 29 / 136 23 / 41 0.01% by weight to 0.3% by weight, or 0.5% by weight, or 1% by weight, or 2% by weight, or 3% by weight, or 5% by weight, of one or more optional additives, based on the total weight of the composition.

[0082] In some specific embodiments, the composition provided herein may comprise one or more polyolefin interpolymers wherein not less than 70% by weight of one or more polyolefin interpolymers is grafted with silane.

[0083] In some specific embodiments, the composition provided herein may optionally comprise one or more optional additives.

[0084] In some embodiments, the composition may comprise a silane-grafted polyolefin interpolymer. The silane-grafted polyolefin interpolymer may comprise any polyolefin interpolymer, as described herein, that is further functionalized or grafted with a silane monomer.

[0085] In some exemplary embodiments, the silane-grafted polyolefin interpolymer may be a C3-C20 ethylene / α-olefin multiblock copolymer grafted with silane monomer, for example, a C3-C20 ethylene / α-olefin multiblock copolymer grafted with silane, for example, a C3C10 ethylene / α-olefin multiblock copolymer grafted with silane. In another exemplary embodiment, the silane-grafted polyolefin interpolymer may be a random ethylene / α-olefin copolymer, as described, grafted with a silane monomer, that is, a random ethylene / α-olefin copolymer grafted with silane, for example, a random C4-C8 ethylene / α-olefin copolymer. In some embodiments, the silane monomer may be a hydrolyzable silane monomer.Non-limiting examples of hydrolyzable silane monomers include vinyltrimethoxysilane (VTMS), vinyltriethoxysilane (VTES), vinyltriacetoxysilane, and gamma-(meth)acryloxypropyltrimethoxysilane. In an exemplary embodiment, the hydrolyzable silane monomer may be VTMS.

[0086] The silane-grafted polyolefin interpolymer can be Petition 870260055117, dated 08 / 06 / 2026, page 30 / 136 24 / 41 formed by a process, such as the Sioplas process, in which a hydrolyzable silane monomer (such as a vinyl silane monomer) is grafted onto the main structure of the polyolefin interpolymer. The hydrolyzable silane monomer can be grafted onto the polyolefin interpolymer by using an appropriate amount of organic peroxide, such as 2,5-bis(tertbutylperoxy)-2,5-dimethylhexane, to form a silane-grafted polyolefin interpolymer.

[0087] In some embodiments, the silane-grafted polyolefin interpolymer may comprise a silane graft ratio greater than 0.3% by weight, greater than 0.5% by weight, greater than 0.6% by weight, greater than 0.8% by weight, or greater than 1.0% by weight, based on the total weight of the silane-grafted polyolefin interpolymer. In some embodiments, the silane-grafted polyolefin interpolymer may comprise a silane graft ratio of 0.1% by weight, or 0.3% by weight, or 0.5% by weight, or 0.6% by weight, or 0.8% by weight, or 1.0% by weight, to 1.1% by weight, or 1.2% by weight, or 1.5% by weight, or 1.8% by weight, or 2.0% by weight, or 2.5% by weight, or 3.0% by weight, or 4.0% by weight, or 5.0% by weight, based on the total weight of the silane-grafted polyolefin interpolymer.In some embodiments, the silane-grafted polyolefin interpolymer may comprise a silane graft ratio of 0.1% by weight to 5.0% by weight, 0.3% by weight to 4.0% by weight, or 0.5% by weight to 3.0% by weight, based on the total weight of the silane-grafted polyolefin interpolymer.

[0088] In one embodiment, the composition may comprise not less than 70% by weight, not less than 75% by weight, not less than 80% by weight, not less than 85% by weight, not less than 90% by weight, not less than 95% by weight, not less than 98% by weight, not less than 99% by weight, or 100% by weight of the silane-grafted polyolefin interpolymer, based on the total weight of the polyolefin interpolymer (or copolymers) comprised in the composition. In some embodiments, the composition may comprise from 70% by weight, or 75% by weight, or 80% by weight, or 85% by weight, to 90% by weight, or 95% by weight, or 98% by weight, or 99% by weight, or 100% by weight of Petition 870260055117, dated 08 / 06 / 2026, page 31 / 136 25 / 41 silane-grafted polyolefin interpolymer, based on the total weight of the polyolefin interpolymer (or interpolymers) comprised in the composition. In one embodiment, the composition may comprise 100% by weight of the silane-grafted polyolefin interpolymer, based on the total weight of the polyolefin interpolymer (or interpolymers) comprised in the composition.

[0089] In some embodiments, the composition may comprise a silane-ungrafted polyolefin interpolymer.

[0090] The non-silane-grafted polyolefin interpolymer may comprise any polyolefin interpolymer described herein that is not silane-grafted. The non-silane-grafted polyolefin interpolymer differs from the silane-grafted polyolefin interpolymer as described above, at least because the non-silane-grafted polyolefin interpolymer is not functionalized or silane-grafted.

[0091] In embodiments, the non-grafted silane polyolefin interpolymer and the polyolefin interpolymer that is used to form the silane-grafted polyolefin interpolymer may be physically, and / or compositionally and / or structurally identical or different.

[0092] In one embodiment, the composition may comprise not more than 30% by weight, not more than 25% by weight, not more than 20% by weight, not more than 15% by weight, not more than 10% by weight, not more than 5% by weight, not more than 3% by weight, not more than 2% by weight, or not more than 1% by weight, or 0% by weight, of the silane-ungrafted polyolefin interpolymer, based on the total weight of the polyolefin interpolymer (or interpolymers) comprised in the composition. In one embodiment, the composition may comprise a composition comprising from 0% by weight, or 1% by weight, or 2% by weight, or 3% by weight, or 5% by weight, to 10% by weight, or 15% by weight, or 20% by weight, or 25% by weight, or 30% by weight, of the silane-ungrafted polyolefin interpolymer, based on the total weight of the polyolefin interpolymer (or interpolymers) comprised in the composition. In another embodiment, the composition may be free of a polyolefin interpolymer. Petition 870260055117, dated 08 / 06 / 2026, page 32 / 136 26 / 41 not grafted with silane.

[0093] In some embodiments, the non-grafted silane polyolefin interpolymer may be an unmodified polyolefin interpolymer. Examples of suitable unmodified polyolefin interpolymers include ethylene or propylene random / block copolymers, such as INFUSE™, ENGAGE™, VERSIFY™, etc.

[0094] In some embodiments, the composition for forming the foam microsphere may also comprise polyolefin derivatives, such as high VA content ethylene-vinyl acetate (EVA) copolymers (e.g., with a VA content greater than 18% by weight, based on the total weight of the EVA). Suitable examples of EVA copolymer include ELVAX® 460, ELVAX® 360, ELVAX® 265, ELVAX® 260, ELVAX® 250, ELVAX® 40L03.

[0095] In some embodiments, the composition may comprise one or more optional additives. The one or more additives optionally included in the composition may be those described above.

[0096] In some modalities, the composition may include: (A) from 80% by weight, or 85% by weight, or 90% by weight, to 95% by weight, or 98% by weight, or 99% by weight, or 100% by weight, of one or more polyolefin interpolymers, based on the total weight of the composition, or the total weight of the foam microsphere; and, (B) optionally, from 0% by weight, or 0.01% by weight to 0.3% by weight, or 0.5% by weight, or 1% by weight, or 2% by weight, or 3% by weight, or 5% by weight, of one or more optional additives, based on the total weight of the composition, or the total weight of the foam microsphere; wherein one or more polyolefin interpolymers comprise from 70% by weight, or 75% by weight, or 80% by weight, or 85% by weight, to 90% by weight, or 95% by weight, or 98% by weight, or 99% by weight, or 100% by weight, of one or more silane-grafted polyolefin interpolymers, based on the total weight of the polyolefin interpolymer (or interpolymers) comprised in the composition; and from 0% by weight, or 1% by weight, or 2% by weight, or 3% by weight, or 5% by weight. Petition 870260055117, dated 08 / 06 / 2026, page 33 / 136 27 / 41 by weight, at 10% by weight, or 15% by weight, or 20% by weight, or 25% by weight, or 30% by weight, of one or more non-silane polyolefin interpolymers, based on the total weight of the polyolefin interpolymer (or interpolymers) comprised in the composition. ii. Pelletizing

[0097] The method for producing polyolefin foam microspheres as described herein comprises (b) pelletizing the composition to form pellets.

[0098] In some embodiments, the pellets (also referred to in this document as micropellets) may be substantially spherical. In some embodiments, the pellets may have a diameter of 1.8 mm, or 2.0 mm, or 2.3 mm to 3.0 mm, or 3.5 mm, or 3.8 mm. In one specific embodiment, the pellets may have a diameter of 2.3 mm to 3.0 mm.

[0099] In some embodiments, pelleting can be carried out using a pelletizer to produce pellets of the composition. In some embodiments, pelleting can be carried out by underwater pelleting. Generally, underwater pelleting can be carried out using an underwater pelletizer with a die plate, usually having a plurality of cavity systems with a plurality of holes. iii. Cross-linking

[0100] The method for producing polyolefin foam microspheres as described herein comprises (c) crosslinking of the pellets.

[0101] In the method of the present disclosure, the crosslinking step is carried out before the foaming step.

[0102] In some embodiments, the crosslinking is carried out to a gel content greater than or equal to about 80%, greater than or equal to about 85%, or greater than or equal to about 90%. In some embodiments, the crosslinking can be carried out to a gel content of about 80%, or about 85%, to about 90%, or about 95%, or about 98%, or about 99% or about 100%.

[0103] In some embodiments, crosslinking can be performed by methods using silane chemistry, electron beam irradiation, irradiation Petition 870260055117, dated 08 / 06 / 2026, p. 34 / 136 28 / 41 gamma or free radical chemistry-based crosslinking. In a specific embodiment, crosslinking can be performed using silane chemistry, i.e., silane crosslinking.

[0104] In some embodiments, a crosslinking agent may be used for crosslinking the pellets of the composition. The crosslinking agent is not particularly limited, provided that the crosslinking agent can crosslink the copolymer. The crosslinking agent used may be a known organic peroxide used for crosslinking a polyethylene-based resin. Examples include compounds of the Perumyl series, such as dicumyl peroxide and tert-butylcumyl peroxide; compounds of the Perbutyl series, such as 1,1-bis(tert-butylperoxy)-3,3,5-trimethylcyclohexane, 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane, and di-tert-butyl peroxide; compounds of the Perexyl series, such as tert-hexyl peroxybenzoate; and compounds of the Perocta series, such as 1,1,3,3-tetramethylbutylperoxy-2-ethylhexanoate. These compounds may be used alone or as a combination of two or more of them.In some illustrative embodiments, the lower limit of the amount of one or more crosslinking agents mixed in may be about 0.05 parts by weight, about 0.1 parts by weight, about 0.2 parts by weight, about 0.3 parts by weight, about 0.4 parts by weight, or about 0.5 parts by weight, per 100 parts by weight of the total polymer weight. The upper limit of the amount of one or more crosslinking agents mixed in may be about 5.0 parts by weight, about 4.5 parts by weight, about 4.0 parts by weight, about 3.5 parts by weight, about 3.0 parts by weight, or about 2.5 parts by weight per 100 parts by weight of the total polymer weight.

[0105] In some embodiments, crosslinking can be carried out at a temperature of about 20 °C, or about 40 °C, or about 60 °C, or about 80 °C, or about 100 °C, or about 120 °C, or about 150 °C, or about 180 °C, or about 200 °C, or about 220 °C.

[0106] In some modalities, crosslinking can be performed by irradiation at a dose of, for example, 30 KGy to 80 KGy, 40 KGy to 70 KGy, or 45 KGy to 60 KGy. Petition 870260055117, dated 08 / 06 / 2026, p. 35 / 136 29 / 41

[0107] In an illustrative embodiment where silane crosslinking is used, crosslinking can be carried out by soaking pellets of the composition comprising a silane-grafted polyolefin interpolymer with a catalyst (e.g., dibutyltin dilaurate) or its silane solution and exposing the pellets to air for moisture crosslinking of the silane portions.

[0108] In another illustrative embodiment in which silane crosslinking is used, crosslinking can be carried out by immersing pellets of the composition comprising a silane-grafted polyolefin interpolymer in hot water (e.g., at a temperature above 80 °C) for moisture crosslinking of the silane portions. iv. Foam formation

[0109] The method for producing polyolefin foam microspheres as described herein comprises (d) foaming the crosslinked pellets into foam microspheres.

[0110] In the method of the present disclosure, the foaming step is carried out after the crosslinking step.

[0111] In some forms, foam formation may be physical foam formation.

[0112] In some embodiments, an expanding agent may be used to foam the cross-linked pellets. The expanding agent used for foaming is not particularly limited, provided that the expanding agent can expand the cross-linked particles. Examples of blowing agents include inorganic physical blowing agents, such as air, nitrogen, carbon dioxide, argon, helium, oxygen, and neon, and organic physical blowing agents, such as aliphatic hydrocarbons, for example, propane, n-butane, isobutane, n-pentane, isopentane, and n-hexane; alicyclic hydrocarbons, for example, cyclohexane and cyclopentane; halogenated hydrocarbons, for example, chlorofluoromethane, trifluoromethane, 1,1-difluoroethane, 1,1,1,2-tetrafluoroethane, methyl chloride, ethyl chloride, and methylene chloride; and dialkyl ethers, for example, dimethyl ether, diethyl ether, and methyl ethyl ether. Among these, one Petition 870260055117, dated 08 / 06 / 2026, page 36 / 136 30 / 41 Inorganic physical blowing agents are preferred, as they do not deplete the ozone layer and are low cost; nitrogen, air, and carbon dioxide are more preferred, and carbon dioxide is particularly preferred. These blowing agents can be used alone or as a combination of two or more types. In some embodiments, the amount of blowing agent used can be determined by considering the apparent density of the target expanded microspheres, the type of multiblock copolymer, the type of blowing agent, and the like, and is generally from about 2 to about 20 parts by weight for an organic physical blowing agent and from about 0.5 to about 20 parts by weight for an inorganic physical blowing agent, per 100 parts by weight of the total polymer weight.

[0113] In some embodiments, foaming can be carried out at a temperature that is around the melting temperature of the polymer. In some embodiments, foaming can be carried out at a temperature of about 70 °C, or about 80 °C, or about 90 °C, or about 100 °C, or about 110 °C, or about 120 °C, or about 130 °C, or about 140 °C, or about 150 °C.

[0114] In some embodiments, foam formation can be carried out at a pressure of about 10 bar, or about 20 bar, or about 30 bar, or about 40 bar, or about 50 bar, or about 60 bar, to about 100 bar, or about 120 bar, or about 150 bar, or about 180 bar, or about 200 bar, or about 220 bar. In an illustrative embodiment, foam formation can be carried out at a pressure in the range of about 50 bar to about 200 bar.

[0115] In some embodiments, the foam microspheres can be conditioned (e.g., at room temperature) to allow gas exchange between the inside and outside of the microspheres.

[0116] In some embodiments, the foam microspheres may have an average cell size of less than about 100 µm. In some embodiments, the foam microspheres may have an average cell size of about 10 µm, about 15 µm, about 20 µm, to 80 µm or 85 µm or 90 µm or 95 µm. Petition 870260055117, dated 08 / 06 / 2026, p. 37 / 136 31 / 41 or 100 pm.

[0117] It has been unexpectedly discovered that crosslinking before foam formation results in improved elasticity. When crosslinking is conducted before the formation of foam microspheres (i.e., micropellet crosslinking before foam formation, pre-XL), the energy loss (characterized by tanδ in dynamic-mechanical analysis (DMA)) of the resulting foam microspheres can be significantly reduced compared to the post-crosslinking approach (i.e., crosslinking of the foam microspheres, post-XL). In other words, pre-XL can be a factor that is able to significantly improve elasticity. This is especially true when such pre-XL microsphere foams have a gel content > 80%, especially > 90%. Such highly crosslinked and highly elastic foam microspheres may find promising potential use in microsphere filling applications. C. Elements and products filled with foam microspheres

[0118] This disclosure also provides an element prepared from foam microspheres, as described herein.

[0119] In some embodiments, the element may be a foam microsphere-filled element. In some embodiments, the element may comprise a cavity filled with the foam microspheres, as described. In some embodiments, the element may be prepared from the foam microspheres, as described, by applying microsphere filling. In some embodiments, the element may be prepared by (i) filling the foam microspheres, as described, into a cavity through a cavity sphere filling port and (ii) closing the cavity, for example, closing all cavity openings, including the cavity sphere filling port. In some embodiments, the cavity may be a mold cavity. In some embodiments, the cavity may be of a predetermined shape.In some forms, the cavity can be made of inorganic and / or organic materials, including fabrics, polymers, leather, rubber, fibers, and the like. Petition 870260055117, dated 08 / 06 / 2026, page 38 / 136 32 / 41

[0120] This disclosure also provides a product comprising the element as described above. In some embodiments, the product may comprise a foam microsphere filler element as a single piece. Examples of the product may include, but are not limited to, products for use in automotive parts, footwear components (such as midsoles), molded products (such as toys or other household items), building materials, etc.

[0121] This disclosure further provides for the use of foam microspheres as described herein in sphere filling applications. Examples

[0122] Some embodiments of the invention will now be described in the following Examples, wherein all parts and percentages are by weight, unless otherwise specified. Raw materials

[0123] INFUSE™ D9130.05: olefin block copolymer (ethylene / octene multiblock copolymer), density 0.886 g / cm3 (ASTM D792), MI 1.5 g / 10 min (ASTM D1238, at 190 °C / 2.16 kg), Shore A = 80 (ASTM D2240).

[0124] Luperox 101 Peroxide: 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane available near Arkema.

[0125] XIAMETER OFS-6300: Vinyltrimethoxysilane (VTMS), available from Dow Corning.

[0126] DBTDL: dibutyltin dilaurate, catalyst for moisture curing of silane from Sinopharm Chemical Reagent Co., Ltd.

[0127] n-octyl triethoxysilane: solvent DBTDL, available from Sinopharm Chemical Reagent Co., Ltd. Sample preparation Preparation of Silane-g-OBC pellets

[0128] The silane-grafted INFUSE™ D9130.05 was prepared on a Coperion ZSK-40 twin-screw extruder with a 40 mm diameter, 48 L / D, and 12 drums. The line was equipped with a 135 kW motor and had Petition 870260055117, dated 08 / 06 / 2026, page 39 / 136 33 / 41 maximum speed of 1,200 revolutions per minute (RPM). INFUSE™ D9130.05 was fed into the twin-screw extruder by loss-weight feeder. To prevent polymer oxidation, nitrogen was fed into the second drum during the compounding process to sweep oxygen from the system. Melt discharge temperatures were measured using a handheld thermocouple placed directly in the melt stream (barrel set temperatures, from hopper to die, were 23 / 60 / 60 / 60 / 190 / 230 / 230 / 230 / 230 / 190 / 190 / 180 °C). A mixture of silane (XIAMETER OFS-6300) and peroxide (LUPEROX 101) was formed and injected via the liquid pump into the extruder at Drum 6.

[0129] In order to minimize the concentration of volatile components and residual silane in the infusion, a vacuum system was used to remove residual volatile components from the melt in drum 11 in the process. A vacuum of 0.065 to 0.070 MPa was used.

[0130] An underwater pelletizer with a 16-hole die was used to produce composite pellets. Twelve of the 16 holes were plugged to suppress the formation of pellet currents during pelletizing. A 6-blade pelletizing unit was used.

[0131] The obtained OBC had varying levels of silane grafting (0.36% to 2.93% by weight), based on the total weight of the silane-grafted ethylene / octene multiblock copolymer, as measured using Fourier transform infrared spectroscopy (FTIR) according to Chuanmei Jiao et al., Silane Grafting and Crosslinking of Ethylene-Octene Copolymer, 41 European Polymer J. 1204 (2005), the entire contents of which are incorporated herein by reference. Table 1 lists the information on the silane-grafted resins. Table 1. INFUSE™ D9130.05 pellets grafted with silane to prepare various foam microspheres. Resin pellets grafted with silane Silane loading (%) Silane grafting rate (%) For examples Petition 870260055117, dated 08 / 06 / 2026, page 40 / 136 34 / 41 No. 1 0 0 CE1 No. 2 0.75 0.36 CE2 No. 3 1.0 0.68 CE3 No. 4 1.0 0.56 CE4, CE5, CE6 No. 5 1.5 1.08 CE7, CE8, IE9, IE10 No. 6 2 1.53 CE11, CE12 No. 7 4.0 2.93 CE13 CE: Comparative example; IE: Inventive example Crosslinking of silane-g-OBC pellets and foam microspheres

[0132] Pre-crosslinking of OBC micropellets grafted with silane was performed in two ways: (1) Soaking the pellets with DBTDL catalyst solution in n-Octyltriethoxysilane solvent (DBTDL / n-Octyltriethoxysilane = 3 / 10) at room temperature. 0.65% by weight of this catalyst solution (based on the weight of the pellets) was placed in a sealable fluoroplastic bottle, followed by the addition of the heavy grafted OBC micropellets. To ensure homogeneous distribution and complete soaking of the additives in the pellets, the bottle was first stirred for 1 min and then placed on a roller (Model No. 88881004, Thermo Scientific) for further homogenization. After soaking, the soaked pellets were exposed to air for moisture crosslinking for 7 days to ensure complete crosslinking of the silane portions. (2) Soaking the silane-grafted OBC micropellets in water at 85 °C for several days for moisture crosslinking. The gel content was controlled by controlling the soaking time. The soaking crosslinking was stopped after reaching a desired gel content.

[0133] Post-XL foam microspheres were carried out in the manner (1). Preparation of foam microspheres by batch foaming in an autoclave

[0134] The micropellets were fed into an autoclave equipped with a heating unit and a gas injection valve. The autoclave is heated to the melting temperature of the polymer. At the same time, Petition 870260055117, dated 08 / 06 / 2026, page 41 / 136 35 / 41 The blowing agent (high-pressure CO2 in this case) is injected into the autoclave for saturation (0.5 ~ 2 hours). The autoclave pressure will vary depending on the type of polymer. A typical range is 50 to 200 bar. After the polymer is saturated with CO2 gas, rapid depressurization occurs and the foam microspheres are prepared. The prepared foam microspheres are conditioned at room temperature for several days to allow gas exchange between the inside and outside of the microspheres. Performance measurement (1) Gel content

[0135] The gel content is obtained as follows. A specimen of pellets or microspheres was placed in a 120 mesh metal mesh bag and boiled in 600 ml of xylene for 5 hours. The total weight of pellets or microspheres in 600 ml of xylene was approximately 2 g. After boiling for 5 hours, the mesh bags were removed and dried in a vacuum oven at 120 °C for 2 hours and then weighed. The result is recorded as a percentage (%), based on the total weight of the material. The gel percentage typically increases with increasing crosslinking levels. (2) Foam Density

[0136] The density of the foam microspheres was measured using the water displacement method according to ASTM D792. The result was recorded in grams (g) per cubic centimeter (g / cm3). (3) DMA test for characterization of energy loss Instrument: - RSA-G2, TA Instruments - Geometry: compression fitting, 15 mm disc Method: Frequency sweep Frequency: 0.1~100 rad / s Temperature: 25 °C Effort: 10%

[0137] Three specimens for each example of foam microsphere were Petition 870260055117, dated 08 / 06 / 2026, page 42 / 136 36 / 41 tested and an average value at each frequency was used. Results and discussion (1) Foamability properties and microspheres

[0138] The foam microsphere samples were prepared from INFUSE™ D9130.05 micropellets grafted with silane at various silane graft levels, as shown in Table 2. Crosslinking (XL) was performed before (pre) and after (post) foaming. Pre means that the silane-grafted pellets were XL-foamed by catalyst soaking and cured at RT (or immersion in hot water for curing), and then the XL pellets were foamed into microspheres. Post means that the silane-grafted pellets were first foamed into microspheres, and then the resulting microspheres were soaked with catalyst and cured at room temperature.

[0139] Table 2 provides the foaming temperature as well as the density and gel content of the final foam microspheres. The foaming temperature is related to the polymer Tm, molecular weight, and XL degree (i.e., gel content). If the temperature is too low, the polymer viscosity will be too high, and therefore the expansion rate will be very low or even no expansion. If the temperature is too high, the pellets (non-XL or with low gel content) may adhere to each other due to the melting of the polymer's crystalline phase and therefore do not form free-flowing microspheres. But for sufficiently XL pellets (i.e., with relatively high gel content), a relatively high foaming temperature will be necessary to overcome the high melt resistance induced by XL and obtain a high expansion ratio.As can be seen in Table 2, to obtain similar microsphere density, a relatively higher foaming temperature was required for pre-XL pellets compared to non-XL pellets (shown in Table 4). The higher the gel content obtained by the pellets, the higher the foaming temperature required. This can be explained by the higher viscosity / melt resistance caused by pre-XL. For the pellet of... Petition 870260055117, dated 08 / 06 / 2026, page 43 / 136 37 / 41 Untouched INFUSE™ D9130.05 (CE1), it was found that it was difficult to achieve a microsphere density below 0.17 g / cm3. In this sense, the silane graft (reduced MI due to certain chain couplings) and pre-XL improved the foaming capacity of the pellets. Table 2. Summary of foaming temperature and basic information on foamed microspheres. Examples of foam microspheres Silane graft rate (%) Crosslinking XL Temp. Foam formation (°C) Microsphere density (g / cm3) Gel content (%) Tanδ 0.1 rad / s 1 rad / s 10 rad / s CE1 0 No 100 0.175 0 0.191 0.168 0.133 CE2 0.36 Pre 102 0.130 9.1 0.177 0.155 0.119 CE3 0.68 Pre* 104 0.130 44.5 0.151 0.144 0.110 CE4 0.56 Pre 108 0.075 69.6 0.154 0.138 0.103 CE5 0.56 Pre 108 0.110 69.6 0.150 0.138 0.105 CE6 0.56 Pre 108 0.135 69.6 0.154 0.142 0.109 CE7 1.08 No 99 0.140 1.4 0.154 0.146 0.118 CE8 1.08 Post 99 0.130 100 0.125 0.122 0.099 IE9 1.08 Pre 117 0.130 95.5 0.109 0.096 0.072 IE10 1.08 Pre 117 0.155 95.5 0.111 0.098 0.073 CE11 1.53 Post 100 0.157 100 0.127 0.127 0.104 CE12 1.53 Post 100 0.172 100 0.130 0.130 0.108 CE13 2.93 Post 101 0.184 100 0.109 0.115 0.095 *XL by immersing pellets in water at 85 °C

[0140] All other XLs were conducted by imbibition catalyst in foam pellets or microspheres at room temperature.

[0141] The DMA test was used to characterize tanδ (i.e., energy loss) of foam microspheres during compression. Lower tanδ means less energy loss and better elasticity. Good elasticity and low energy loss are very important in microsphere filling applications.

[0142] As shown in Table 3, the same silane-grafted pellets (graft ratio of 1.08%) were produced in different foamed microspheres: CE7, non-XL, gel content of 1.4%; CE8, post-XL, gel content of 100%; IE9, pre-XL, gel content of 95.5%. These examples had very similar foam density. Their tanδ results of Petition 870260055117, dated 08 / 06 / 2026, page 44 / 136 38 / 41 DMA at typical frequencies: 0.1, 1.0, and 10 rad / s are given in Table 3. The tanδ curves during the frequency sweep (0.1 to 10 rad / s) are plotted in Figure 1, where more tanδ values ​​are available for further comparison.

[0143] Clearly, the XL microspheres (pre or post) had lower tanδ than the non-XL ones (CE7 and CE1), which formed in a common sense that XL is able to reduce energy loss for a POE foam. However, what was surprising was that the pre-XL microsphere (IE9) had significantly lower tanδ than the post-XL one (CE8) (although the postXL has an even higher gel content). IE10 used the same pellet grafted with 1.08% silane and produced a foamed microsphere with relatively high density. Still, the tanδ was significantly lower than the post-XL CE8. These results demonstrated that the pre-XL approach could significantly increase the elasticity of foam microspheres versus the post-XL approach.

[0144] In CE11 and CE13, micropellets grafted with much higher silane content were foamed into microspheres and then post-XL. The resulting gel content was also 100%, but the crosslinking density should definitely be higher than CE8 and IE9 as the DBTDL catalyst could catalyze XL of almost all the silane in a sufficient period of time. It is well known that higher crosslinking density usually leads to better elasticity. However, IE9 and IE10 still had a lower tanδ than CE11 and CE13, which further demonstrated the effectiveness of elasticity improvement by pre-XL (versus post-XL). The foam densities of some examples were not very close. It should be noted that the foamed density in the study range had a smaller effect on tanδ, as discussed below. Table 3. Effect of pre-XL and post-XL on the Tanδ of the foam microsphere. Examples Silane graft rate (%) As XL Gel content (%) Microsphere density (g / cm3) Tanδ a 0.1 rad / s 1 rad / s 10 rad / s CE1 0 No 0 0.175 0.191 0.168 0.133 CE7 1.08 No 1.4 0.140 0.154 0.146 0.118 Petition 870260055117, dated 08 / 06 / 2026, p. 45 / 136 39 / 41 CE8 1.08 Post 100 0.130 0.125 0.122 0.099 IE9 1.08 Pre 95.5 0.130 0.109 0.096 0.072 IE10 1.08 Pre 95.5 0.155 0.111 0.098 0.073 CE11 1.53 Post 100 0.157 0.127 0.127 0.104 CE13 2.93 Post 100 0.184 0.109 0.115 0.095

[0145] Although pre-XL led to an effective reduction in tanδ, the examples in Table 4 still indicated that a relatively high gel content was necessary. Generally, tanδ decreases with increasing gel content. However, the change was not linear. As seen from CE2, CE3, and CE6, no significant decrease in tanδ was observed with a significant increase in gel content. However, for IE9 with the highest gel content (95.5%), a much lower tanδ was achieved. Therefore, it is believed that a sufficiently high gel content is critically important to result in a very low tanδ, i.e., good elasticity. Petition 870260055117, dated 08 / 06 / 2026, p. 46 / 136 40 / 41 Table 4. Effect of gel content level on Tanδ of pre-XL foam microspheres. Examples As 0.130 0.151 0.144 0.110 CE6 Pre 69.6 0.135 0.154 0.142 0.109 IE9 Pre 95.5 0.130 0.109 0.096 0.072

[0146] In some examples above, the tanδ comparison was made between foam microspheres of different densities. It is important to understand whether the microsphere density itself is a significant factor influencing tanδ and decoupling it from other factors (pre-XL versus post-XL, gel content). In Table 5, three sets of examples were studied, where the silane graft ratio, such as XL and gel content, were the same for the examples in each set. No significant tanδ differences were found for the examples in each set, indicating that the microsphere density in the range (~0.07 to 0.17 g / cm3) was not a major factor affecting tanδ. Table 5. Effect of foam microsphere density on Tanδ Examples Silane grafting rate (%) As 0.150 0.138 0.105 CE6 0.56 Pre 69.6 0.135 0.154 0.142 0.109 IE9 1.08 Pre 95.5 0.130 0.109 0.096 0.072 IE10 1.08 Pre 95.5 0.155 0.111 0.098 0.073 CE11 1.53 Post 100 0.157 0.127 0.127 0.104 CE12 1.53 Post 100 0.172 0.130 0.130 0.108 (2) Morphology of foam microspheres

[0147] Figure 2 shows the cellular morphology of the foam microspheres. Petition 870260055117, dated 08 / 06 / 2026, page 47 / 136 41 / 41 The cell size of these samples was comparable. All foams had a uniform cell size smaller than 100 microns.

[0148] In summary, highly crosslinked polyolefin interpolymer microsphere (OBC) foams have much better elasticity than non-XL foams. Pre-XL can help make foam microspheres with significantly enhanced elasticity compared to those made using the post-XL approach. The preferred gel content is > 80%, more preferably > 90%. These highly crosslinked foam microspheres are promising for microsphere filling applications. Petition 870260055117, dated 08 / 06 / 2026, page 48 / 136

Claims

1 / 2 CLAIMS 1. An element prepared from a plurality of foam microspheres, characterized in that it comprises a cavity filled with foam microspheres, wherein the foam microspheres are formed from a composition comprising one or more polyolefin interpolymers, wherein the foam microsphere has a gel content greater than or equal to 80%, and a tanδ at 1 rad / s less than or equal to 0.11; wherein not more than 70% by weight of one or more polyolefin interpolymers is grafted with silane;wherein the silane-grafted polyolefin interpolymer has a silane graft ratio greater than 0.3% by weight, based on the total weight of the silane-grafted polyolefin interpolymer, wherein the foam microsphere is formed from the composition by crosslinking the pellets of the composition before the foaming of the pellets, and wherein the gel content is recorded as a percentage (%) based on the total weight of the material and tanδ is measured by dynamic-mechanical analysis (DMA).

2. An element according to claim 1, characterized in that one or more polyolefin interpolymers comprise a polyolefin elastomer.

3. Method for producing an element from polyolefin foam microspheres, characterized in that it comprises: (a) providing a composition comprising one or more polyolefin interpolymers; (b) pelletizing the composition to form pellets; (c) crosslinking the pellets to a gel content greater than or equal to 80%; and (d) foaming the crosslinked pellets into foam microspheres, (e) filling the foam microspheres within a cavity via a cavity microsphere filling gate, and (f) closing the cavity, Petition 870260055117, dated 08 / 06 / 2026, page 49 / 136 2 / 2 wherein the foam microspheres have a tanδ at 1 rad / s less than or equal to 0.11; wherein no more than 70% by weight of one or more polyolefin interpolymers is grafted with silane, and wherein the silane-grafted polyolefin interpolymer has a silane graft ratio greater than 0.3% by weight, based on the total weight of the silane-grafted polyolefin interpolymer.

4. A method according to claim 3, characterized in that one or more polyolefin interpolymers comprise a polyolefin elastomer.

5. Method according to claim 3, characterized in that one or more polyolefin interpolymers are selected from the group consisting of one or more ethylene / α-olefin multiblock interpolymers, one or more ethylene / α-olefin random copolymers and any combination thereof.

6. Method according to claim 3, characterized in that one or more polyolefin interpolymers have a melt index (MI) of 0.1 g / 10 min to 30 g / 10 min.

7. Product, characterized by comprising the element as defined in claim 1.

8. Use of foam microspheres, as defined in claim 1, characterized by being for microsphere filling applications. Petition 870260055117, dated 08 / 06 / 2026, page 50 / 136

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