Crosslinked PE Foam Composition for High-Filler Shockpads
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Solution Overview
Problem
Conventional shock-absorbing materials in footwear and artificial turf lack improved mechanical properties and methods for high filler loadings, leading to suboptimal performance in terms of shock absorption and durability.
Innovation Solution
Crosslinked foams are developed using polyolefins with specific crystallinity and viscosity, combined with fillers, and optionally scorch retarders, to create dimensionally stable and cost-effective materials for footwear and turf applications, enhancing mechanical properties and processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional shock-absorbing materials are used in footwear and artificial turf, then basic shock absorption function is provided, but mechanical properties and durability are insufficient
Solution Approach 1:
The patent employs composite materials by combining polyolefin base polymers with high concentrations of filler materials (such as calcium carbonate, silica, or metal oxides) to create a composite foam system. This composite structure provides both the shock absorption functionality of the polymer matrix and the enhanced mechanical properties and durability from the filler particles, directly resolving the contradiction between basic function and improved performance.
Solution Approach 2:
The patent utilizes parameter changes by systematically varying the filler loading concentration (from 20-80 wt%), filler particle size distribution, and crosslinking degree to optimize the balance between mechanical strength and durability. By adjusting these parameters, the material achieves superior mechanical properties while maintaining reliable long-term performance in footwear and turf applications.
2Ease of manufacture
If high filler loadings are used to improve mechanical properties, then cost-effectiveness and dimensional stability improve, but processing difficulty increases
Solution Approach 1:
The patent applies parameter changes by optimizing the filler particle size distribution and utilizing filler pre-aggregation techniques to reduce processing viscosity. By controlling these parameters, the patent enables high filler loadings (20-80 wt%) to be incorporated while maintaining ease of manufacturing and dimensional stability, effectively resolving the contradiction between cost-effectiveness and processing difficulty.
3Reliability
If high filler loadings are used to enhance durability, then shock absorption performance improves, but processing time increases
Solution Approach 1:
The patent utilizes parameter changes by optimizing the filler particle size distribution and employing efficient mixing and processing techniques that reduce cycle times despite high filler loadings. By carefully controlling these parameters, the patent achieves enhanced durability and shock absorption performance while maintaining productive manufacturing cycle times.
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 crosslinked foams exhibit improved shock absorption, durability, and reduced cycle times during processing, meeting FIFA standards for artificial turf and providing suitable properties for footwear, while maintaining low water uptake and dimensional stability.
Implementation Method 1
The crosslinked foams exhibit improved shock absorption
Implementation Method 2
Crosslinked foams are developed using polyolefins with specific crystallinity and viscosity, combined with fillers
Implementation Method 3
maintaining low water uptake and dimensional stability
Data Source
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AI summary
Crosslinked foams having high filler loadings, which may be formed from A) a polyolefin having a crystallinity of 21 percent or less, an ethylene vinyl acetate copolymer having a vinyl acetate content of less than 15 mole percent, or a combination thereof; B) a polyolefin having a viscosity between 500 and 20,000 cP, as measured using ASTM D 1084 (Brookfield Viscosity at 3500F); and C) a filler, wherein the crosslinked foam includes from 10 to 80 parts filler per hundred parts of components A, B, and C, by weight. In other aspects of embodiments disclosed herein, the crosslinked foam may optionally include one or more of: D) at least one polyolefin having a crystallinity of greater than 21 weight percent, an ethylene vinyl acetate copolymer having a vinyl acetate content of 15 mole percent or greater, or a combination thereof; and E) a scorch retarder.