Polyamide Pellets with Chain Extender for Molded Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing molded components from expanded polymer pellets lack efficiency in producing materials with optimal damping properties and low weight for broad applications, such as sports apparel and shoe soles, due to limitations in temperature stability and energy resilience.
Innovation Solution
A method involving the production of expanded polymer pellets by melting a polyamide, adding a blowing agent, expanding through a die, and pelletizing, followed by loading the pellets into a mold and connecting them with heat energy, where the expanded polymer material includes a chain extender to enhance amorphous content and interdiffusion across pellet boundaries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expanded polymer pellets are manufactured using conventional methods, then production is simpler, but temperature stability and energy resilience are insufficient
Solution Approach 1:
The patent changes the chemical composition parameters of the polymer material by incorporating polyetherblockamide segments with specific polyether content (1-90 wt%) and polyamide content (10-99 wt%). This parameter modification enables the material to achieve superior temperature stability and energy resilience while maintaining manufacturability through established extrusion and pelletization processes.
Solution Approach 2:
The patent creates a composite polymer structure by combining polyether blocks and polyamide blocks in specific ratios. This composite approach leverages the flexibility and low-temperature properties of polyether segments with the strength and thermal stability of polyamide segments, achieving enhanced reliability without significantly complicating the manufacturing process.
2Productivity
If expanded polymer pellets are manufactured using conventional methods, then production cost is lower, but damping properties and weight optimization are insufficient
Solution Approach 1:
The patent optimizes damping performance by adjusting the polyether block content to 1-90 wt% and polyamide block content to 10-99 wt%, creating a polymer composition that inherently provides superior damping properties. The specific parameter ranges enable energy absorption and resilience while maintaining a streamlined manufacturing process.
3Ease of operation
If the polyetherblockamide has high polyether content, then flexibility and low-temperature properties improve, but strength and structural stability decrease
Solution Approach 1:
The patent achieves the optimal balance between flexibility and strength by controlling the polyether block content within 1-90 wt% and polyamide block content within 10-99 wt%. This parameter optimization ensures that the polymer maintains adequate structural strength even at high polyether content, while still providing the desired flexibility and low-temperature performance.
Solution Approach 2:
The patent creates a block copolymer composite where polyether segments provide flexibility and low-temperature properties, while polyamide segments contribute structural strength and stability. This composite structure allows the material to simultaneously exhibit both flexibility and adequate strength, resolving the trade-off between these opposing properties.
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 produces molded components with improved temperature stability, energy resilience, and damping properties, suitable for a wide range of applications including sports apparel and shoe soles, offering enhanced performance and versatility.
Implementation Method 1
expanding the melt through at least one die for producing an expanded polymer
Implementation Method 2
melting a polymer comprising a polyamide
Implementation Method 3
connecting the pellets by providing heat energy
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention refers to a method for producing expanded polymer pellets, which comprises the following steps: melting a polymer comprising a polyamide; adding at least one blowing agent; expanding the melt through at least one die for producing an expanded polymer; and pelletizing the expanded polymer. The invention further concerns polymer pellets produced with the method as well as their use, e.g. for the production of cushioning elements for sports apparel, such as for producing soles or parts of soles of sports shoes. A further aspect of the invention concerns a method for the manufacture of molded components, comprising loading pellets of an expanded polymer material into a mold, and connecting the pellets by providing heat energy, wherein the expanded polymer material of the pellets or beads comprises a chain extender. The molded components may be used in broad ranges of application.