Foamed Thermoplastic Elastomer via CO2 Phase Transition
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Solution Overview
Problem
Existing methods for producing foamed articles, such as athletic equipment and footwear, often require extreme temperatures and pressures, making them energy-intensive and costly. Additionally, these methods may not efficiently achieve a uniform multi-cellular foam structure.
Innovation Solution
A method involving the infusion of carbon dioxide into a solid foamable material, followed by phase transition of the carbon dioxide to gas without thermally softening the material, resulting in a physically foamed material with a uniform multi-cellular structure. This process can be conducted at relatively low temperatures and pressures, using simpler and less expensive equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extreme temperatures and pressures are used to produce foamed articles, then the foaming process can be achieved, but the energy consumption increases and production costs rise
Solution Approach 1:
The patent utilizes the phase transition of carbon dioxide from liquid to gas as a foaming agent. Liquid CO2 is infused into the thermoplastic elastomer material, and upon phase transition to gas, it creates uniform foam cells. This approach eliminates the need for extreme temperatures and pressures typically required in conventional foaming processes, thereby reducing energy consumption while achieving reliable foaming results.
2Reliability
If conventional foaming methods are used, then foaming can be achieved, but a uniform multi-cellular foam structure is not efficiently obtained
Solution Approach 1:
Carbon dioxide serves as an intermediary substance in this process. It is infused into the material in liquid form and then transitions to gas, acting as a mediator that creates uniform foam cells throughout the material. This intermediary approach ensures consistent nucleation and growth of foam cells, resulting in a uniform multi-cellular structure that conventional methods fail to achieve efficiently.
3Strength
If more material is used in foamed articles, then the structural integrity is maintained, but the density increases and sustainability decreases
Solution Approach 1:
The patent creates a composite structure by forming foam cells within the thermoplastic elastomer material. The foamed structure combines the polymer matrix with gas-filled cells, creating a lightweight composite that maintains structural integrity through the cellular architecture. This composite approach reduces material quantity while preserving strength, as the foam structure provides mechanical support with less material than solid counterparts.
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 method achieves a low-density, uniformly foamed material with beneficial properties suitable for mass-produced consumer products, such as athletic equipment and footwear. It reduces material costs and enhances sustainability by minimizing the amount of material needed while allowing for the use of recycled thermoplastic materials.
Implementation Method 1
producing a phase change that expands the infused carbon dioxide, thereby physically foaming the solid foamable material into a foamed material
Data Source
Figure 1A~1D
Figure 1E~1H
Figure 1I~1M
AI summary
Foamed articles (265; 319) including a foamed thermoplastic elastomeric material comprising one or more first thermoplastic polyurethane elastomeric homopolymers or copolymers, methods (300) of making the foamed articles (265; 319), and methods for manufacturing articles of footwear (100; 130; 160), apparel, and athletic equipment incorporating such foamed articles (265; 319) are provided. In one aspect, a method (300) for making a foamed article (265; 319) comprises placing (304) an article (214; 216; 218) comprising a foamable material (210; 502; 620a; 620b) and carbon dioxide (240; 246; 604; 614) in a vessel (234; 602), maintaining (305) the vessel (234; 602) at a first pressure and first temperature at which the carbon dioxide (240; 246; 604; 614) is a liquid and carbon dioxide (240; 246; 604; 614) is soluble in the foamable material (210; 502; 620a; 620b), optionally exposing (306) the infused article (255; 256) to a second temperature and second pressure, and subjecting (310) the article (255; 256) to a third pressure and third temperature at which the infused carbon dioxide (240; 246; 604; 614) phase transitions to a gas, thereby expanding the foamable material (210; 502; 620a; 620b) into a foamed material (506; 620c) and forming the foamed article (265; 319).