Foamed Thermoplastic Elastomer Articles via CO2 Phase Transition
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Solution Overview
Problem
Current methods for manufacturing foamed articles, particularly those using thermoplastic elastomeric materials, face challenges in achieving efficient and cost-effective production with extreme temperatures and pressures, limiting their scalability and adaptability to various geometries and materials.
Innovation Solution
A multi-step process involving the infusion of carbon dioxide into solid foamable materials, which undergo phase transition to expand without thermally softening, allowing for the production of foamed articles with a low-density, multi-cellular structure suitable for diverse applications, including athletic equipment and footwear, using simpler and less expensive equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extreme temperatures and pressures are used to manufacture foamed articles, then the foaming process can be achieved, but the equipment complexity and manufacturing cost increase
Solution Approach 1:
The patent changes the physical-chemical parameters of the foaming process by using liquid carbon dioxide infused at moderate conditions that undergo phase transition to gas at lower temperatures and pressures, replacing the need for extreme temperature and pressure conditions while achieving reliable foaming
Solution Approach 2:
The patent utilizes the phase transition of carbon dioxide from liquid to gas state to drive the foaming process. Liquid CO2 is infused into the thermoplastic elastomeric material at moderate conditions, then allowed to expand and phase transition, creating foam cells without requiring extreme manufacturing conditions
2Strength
If thermoplastic elastomeric materials are used for foaming, then the desired material properties are achieved, but the manufacturing cost increases
Solution Approach 1:
The patent changes the manufacturing parameters to use moderate temperatures and pressures with liquid CO2 infusion, replacing expensive extreme condition processes. This reduces manufacturing cost while maintaining the ability to process thermoplastic elastomeric materials and achieve desired material properties
Solution Approach 2:
The patent uses liquid carbon dioxide as a temporary foaming agent that is inexpensive compared to extreme temperature/pressure equipment requirements. The CO2 is infused, performs its foaming function through phase transition, and then dissipates, leaving the desired foam structure without requiring costly equipment
3Productivity
If traditional foaming methods are used, then production can be achieved, but the adaptability to various geometries and materials is limited
Solution Approach 1:
The patent creates a universal foaming process using liquid CO2 infusion that can be applied to various geometries and materials. The liquid CO2 can penetrate different material types and geometric configurations, making the process adaptable to diverse applications including athletic equipment and footwear components
Solution Approach 2:
The patent changes the foaming approach from extreme condition processing to moderate condition liquid CO2 infusion followed by phase transition. This parameter change enables the process to adapt to various materials and geometries that would be damaged or difficult to process under extreme temperatures and pressures
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 process reduces material costs, enhances sustainability by allowing the use of recycled materials, and achieves controlled volume expansion, resulting in lighter, more durable foamed articles with improved performance and adaptability.
Implementation Method 1
expanding the infused solid foamable material by expanding the infused carbon dioxide without thermally softening the solid foamable material, for example by phase transitioning the infused carbon dioxide into a gas
Implementation Method 2
infusing the solid foamable material with the carbon dioxide
Data Source
AI summary
Foamed articles including a foamed thermoplastic elastomeric material for articles of footwear. In one aspect, a method for making a foamed article comprises placing an article comprising a foamable material and carbon dioxide in a vessel, maintaining the vessel at a first pressure and first temperature at which the carbon dioxide is a liquid and carbon dioxide is soluble in the foamable material, optionally exposing the infused article to a second temperature and second pressure, and subjecting the article to a third pressure and third temperature at which the infused carbon dioxide phase transitions to a gas, thereby expanding the foamable material into a foamed material and forming the foamed article.