Multi-layered TPE Foam Adhesion via Direct Foaming
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Solution Overview
Problem
Current methods for manufacturing multi-layered thermoplastic elastomer (TPE) foams are complex and require adhesives or intermediate layers to achieve satisfactory adhesion, limiting their practical application.
Innovation Solution
A process involving a TPE raw material composition with specific components, including a matrix, cross-linking agent, and blowing agent, is used to form a continuous sheet, which is then cut and stacked before direct foaming, eliminating the need for adhesives or intermediate layers, and allowing for uniform properties and multi-layered structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional processes are used to manufacture multi-layered TPE foam, then adhesion between layers can be achieved by using adhesive and/or intermediate fabric cloth layer, but the process becomes complicated and requires additional materials
Solution Approach 1:
The patent removes the adhesive layer and intermediate fabric cloth layer from the multi-layered TPE foam structure, achieving adhesion between layers directly through the TPE material itself without requiring additional bonding materials or complex thermocompression steps
Solution Approach 2:
The patent combines the adhesion function and the structural TPE material into a single integrated system, where the TPE material itself provides both structural support and inter-layer bonding, eliminating the need for separate adhesive layers and intermediate fabrics
2Reliability
If adhesive layer or intermediate fabric cloth layer is used to achieve multi-layered structure, then adhesion can be improved, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The patent extracts and eliminates the adhesive layer and intermediate fabric cloth layer from the manufacturing process, allowing direct formation of multi-layered TPE foam structures through a simplified one-step extrusion process that reduces manufacturing time
Solution Approach 2:
The patent incorporates adhesion-promoting components directly into the TPE material composition during the extrusion process, enabling layers to bond directly as they are formed without requiring subsequent adhesive application or thermocompression steps
3Reliability
If conventional multi-layered TPE foam is manufactured with adhesive and intermediate layers, then adhesion is achieved, but the product has more harmful factors and reduced environmental friendliness
Solution Approach 1:
The patent removes adhesive layers and intermediate fabric cloth layers from the multi-layered TPE foam structure, eliminating the harmful factors associated with these additional materials and improving the overall environmental friendliness of the product
Solution Approach 2:
The patent uses homogeneous TPE material for all layers, ensuring consistent material composition and properties throughout the multi-layered structure without introducing heterogeneous adhesive or fabric components that would compromise environmental friendliness
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 enables the production of multi-layered TPE foams with enhanced mechanical properties such as high peeling strength, density, tensile strength, and elongation rate, suitable for commercial applications, without the complexity of thermocompression steps.
Implementation Method 1
a cross-linking agent... heating the same by a kneader until the mixture melts and is uniformly mixed
Implementation Method 2
a blowing agent... directly foaming the multi-layered raw material sheet stack obtained in c) and cooling the same to obtain a multi-layered TPE foam
Implementation Method 3
heating the same by a kneader until the mixture melts and is uniformly mixed
Implementation Method 4
heating the same by a kneader until the mixture melts
Implementation Method 5
directly foaming the multi-layered raw material sheet stack obtained in c) and cooling the same to obtain a multi-layered TPE foam
Data Source
AI summary
The present invention is related to a multi-layered thermoplastic elastomer (TPE) foam. Due to a specific formulation of the multi-layered TPE foam, adjacent layers of said TPE foam can be perfectly adhered to each other without adhesive or thermocompression after foaming. The present invention is also related to a specific process for forming a multi-layered foam.