Crosslinked Polyolefin Foam Textile Laminates via Integrated Extrusion

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Solution Overview

Problem

The traditional method of laminating a polyolefin textile to a crosslinked polyolefin foam sheet requires a separate step after foaming, increasing manufacturing complexity and costs.

Innovation Solution

Integrate the laminating step into the extrusion process of the foam production, by extruding a foamable composition through a nip while simultaneously feeding a polyolefin textile, and then irradiating and foaming the laminate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If lamination is performed as a separate step after foam production, then the quality of laminate bonding is improved, but the manufacturing complexity and number of steps increase

Engineering Contradiction:

Improvelaminate bonding qualityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the lamination operation with the foam extrusion operation into a single integrated process. The textile is fed through the extrusion die along with the foamable composition, and both are bonded simultaneously during the extrusion and foaming process, eliminating the need for separate lamination equipment and steps while maintaining bonding quality through controlled melt adhesion.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The textile is positioned and fed through the extrusion die before the foaming occurs. This preliminary positioning ensures proper alignment and initial bonding of the textile to the foam substrate during the extrusion phase, allowing the subsequent foaming to proceed without requiring additional lamination steps.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If lamination is performed as a separate step after foam production, then the bonding quality is improved, but the production time and costs increase

Engineering Contradiction:

Improvebonding qualityVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

By merging the lamination and foam production operations into a single continuous process, the patent eliminates the time required for separate lamination steps, intermediate handling, and transfer between equipment. The textile and foam are bonded simultaneously during extrusion and foaming, reducing total production cycle time and increasing throughput.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated process maintains continuous operation from extrusion through foaming without interruption for separate lamination. The textile remains continuously fed through the extrusion die and remains bonded to the foam substrate throughout the foaming process, eliminating idle time and maintaining productive action throughout the entire manufacturing sequence.

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If traditional separate lamination equipment is used, then the lamination quality is improved, but the equipment investment and operational costs increase

Engineering Contradiction:

Improvelamination qualityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent utilizes the existing foam extrusion equipment to perform both extrusion and lamination functions. The extrusion die is configured to accept both the foamable composition and the textile, and the extrusion process itself provides the bonding mechanism, eliminating the need for separate lamination equipment and reducing capital investment and operational costs.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The foam extrusion equipment is designed to perform multiple functions: extruding the foamable composition, bonding the textile to the substrate, and initiating the foaming process. This multi-functional approach eliminates the need for dedicated lamination equipment while maintaining manufacturing capability through the integrated process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Reduces the number of manufacturing steps and costs by integrating the lamination process with foam production, resulting in a simplified and cost-effective method for producing laminates.

Implementation Method 1

extruding a foamable composition through a nip while simultaneously feeding a polyolefin textile into the nip to laminate the textile to the foamable composition

Methodology Applied

Scientific EffectHeat: Heating

Implementation Method 2

feeding the extruded foamable sheet and the textile through a plurality of rollers to bond the textile to a side of the extruded foamable sheet

Methodology Applied

Scientific EffectPressure: Pressurisation

Implementation Method 3

irradiating the laminate with ionizing radiation

Methodology Applied

Scientific EffectIonizing radiation: Radiation

Implementation Method 4

foaming the foamable sheet of the laminate

Methodology Applied

Scientific EffectFoaming: Foam

Data Source

PatentUS20250303667A1Methods of producing laminates of crosslinked polyolefin foam with polyolefin textiles

Publication Date: 2025.10.02 TORAY PLASTICS (AMERICA) INC

AI summary

Described herein are methods of preparing continuous polyolefin textiles laminated to a physically crosslinked, closed cell continuous foam sheet. The methods can include extruding a foamable sheet through a nip while simultaneously feeding a polyolefin textile into the nip to laminate the textile to the foamable sheet, irradiating the laminate, and foaming the laminate