Thermoplastic Copolyester Elastomer Footwear Foam
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Solution Overview
Problem
Current materials for athletic footwear, such as thermosetting polymeric compositions, lack the ability to balance high energy return, low density, and recyclability, as they form irreversible chemical bonds during processing, limiting their reprocessing and sustainability.
Innovation Solution
The development of thermoplastic copolyester elastomer forms with a microcellular structure, composed of dihydroxy-terminated polydiol, diol, and aromatic dicarboxylic acid segments, which remain uncrosslinked and can be melted and reprocessed repeatedly, maintaining thermoplastic properties and offering improved energy return and split tear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermosetting polymeric compositions are used to form footwear components, then high energy return and cushioning performance are achieved, but the materials form irreversible chemical bonds during processing, limiting reprocessing and recyclability
Solution Approach 1:
The patent changes the chemical bonding parameters from irreversible crosslinks (thermosetting) to reversible physical bonds (thermoplastic), enabling the material to be melted and reprocessed multiple times while maintaining energy return properties through controlled crystallinity and phase structure
Solution Approach 2:
The patent uses copolyester elastomers with specific segment compositions (polydiol, diol, and aromatic dicarboxylic acid) to create a composite material that combines the energy return of thermosetting materials with the recyclability of thermoplastics, achieving both performance and sustainability
2Reliability
If thermosetting polymeric compositions are used, then cushioning and comfort are improved, but density cannot be reduced while maintaining performance
Solution Approach 1:
The patent incorporates a microcellular foam structure with closed cells into the copolyester elastomer matrix, creating a porous material that reduces density while maintaining cushioning performance through the compliant cellular structure that absorbs and dissipates impact forces
Solution Approach 2:
The patent creates a composite structure combining copolyester elastomer with specific segment ratios (including polydiol, diol, and aromatic dicarboxylic acid) with a microcellular foam matrix, achieving both low density and high cushioning performance through the synergistic effect of the material composition and cellular architecture
3Ease of manufacture
If conventional polymeric materials are used, then manufacturing processes are simple, but split tear resistance and durability are insufficient
Solution Approach 1:
The patent uses copolyester elastomers with specific segment compositions (polydiol, diol, and aromatic dicarboxylic acid) that provide inherent toughness and resistance to split tearing while maintaining thermoplastic processability, achieving both ease of manufacture and superior strength
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 thermoplastic copolyester elastomer forms provide a unique balance of high energy return, low density, and recyclability, enhancing the performance and sustainability of athletic footwear components while maintaining physical properties.
Implementation Method 1
which remain uncrosslinked and can be melted and reprocessed repeatedly, maintaining thermoplastic properties
Implementation Method 2
The thermoplastic copolyester elastomer forms provide a unique balance of high energy return, low density, and recyclability
Data Source
AI summary
A variety of forms and form components are provided, including form components for articles of footwear and athletic equipment. The articles include a composition having a form structure, wherein the composition includes a thermoplastic copolyester elastomer comprising: (a) a plurality of first segments, each first segment derived from a dihydroxy-terminated polydiol; (b) a plurality of second segments, each second segment derived from a diol; and (c) a plurality of third segments, each third segment derived from an aromatic dicarboxylic acid. Methods of making the compositions and forms are provided, as well as methods of making an article of footwear including at least one of the form components. In some aspects, the forms and form components can be made by extrusion or injection molding to form the polymeric composition, or extrusion or injection molding to form the polymeric composition followed by compression molding of the form.