Foamable Filament Composition with Controlled Activation Temperature
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Solution Overview
Problem
The production of foamable filaments faces challenges in achieving foaming without damaging incorporated materials, as high temperatures can cause stress or premature foaming, and existing methods struggle to control the type and density of foam structures, such as open or closed cell configurations, which affect cushioning and energy absorption properties.
Innovation Solution
A foamable filament composition comprising a single polymer or blend of polymers and a foaming agent with a controlled activation temperature, allowing for melt-processability below the foaming activation temperature, enabling the formation of filaments with tunable hardness and cell structure, either open or closed cell configurations, through careful selection of polymers like ethylene octene copolymers and thermoplastic polyurethanes, and the use of specific foaming agents and additives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high temperature is used for foaming, then foaming activation is achieved, but damage or stress occurs to incorporated materials
Solution Approach 1:
The patent changes the temperature parameter by using a foaming agent with a lower activation temperature that matches the melt processing temperature range. This allows foaming to occur at temperatures that do not damage incorporated materials, resolving the contradiction between achieving foaming activation and preventing material damage.
Solution Approach 2:
The foaming agent acts as an intermediary that enables foaming at lower temperatures. By selecting a foaming agent whose activation temperature corresponds to the melt processing temperature, the patent mediates between the need for foaming activation and the constraint of protecting incorporated materials from thermal damage.
2Temperature
If high extrusion temperature is used, then filament formation is achieved, but premature foaming occurs
Solution Approach 1:
The patent changes the temperature parameter relationship by ensuring the extrusion temperature is below the foaming activation temperature. This parameter configuration prevents premature foaming during extrusion while still allowing filament formation, and enables controlled foaming to occur after filament formation when the foamable filament is heated to activate the foaming agent.
3Strength
If foam density is increased for better cushioning, then energy absorption improves, but compressibility decreases
Solution Approach 1:
The patent changes the density parameter by producing foamed filaments with controlled, reduced density through the foaming process. This creates a cellular structure that maintains energy absorption capabilities while improving compressibility, as the lower density foam with controlled cell structure provides both cushioning and ease of compression.
4Temperature
If foaming activation temperature is lowered to protect materials, then material integrity is maintained, but filament formation becomes difficult
Solution Approach 1:
The patent changes the temperature parameter configuration by selecting a foaming agent whose activation temperature corresponds to the melt processing temperature range. This creates a coordinated temperature profile where filament formation and foaming activation occur at compatible temperatures, resolving the contradiction between protecting materials and enabling filament formation.
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
This approach allows for the production of filaments that can be processed at lower temperatures, avoiding premature foaming, and results in foamed structures with adjustable hardness and cell size, enhancing cushioning and energy absorption properties while maintaining material integrity.
Implementation Method 1
a foaming agent having an activation temperature from 90°C to 200°C
Implementation Method 2
The activation temperature of the foaming agent is from 90°C to 200°C
Implementation Method 3
The single polymer or blend of polymers is melt-processable at a temperature sufficiently below the activation temperature of the foaming agent
Data Source
Figure 1
AI summary
A foamable filament composition comprising a single polymer or blend of polymers and a foaming agent having an activation temperature, wherein the single polymer or blend of polymers has a sufficient molecular weight to allow for polymer chain entanglement, and wherein the single polymer or polymer blend is melt-processable at a temperature below the activation temperature of the foaming agent.