Silane-Modified Foam for Abrasion Resistance
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Solution Overview
Problem
There is a need for improved foam compositions in the footwear industry that provide high energy return while maintaining softness and durability, as existing high energy return foams often suffer from poor abrasion resistance, leading to increased wear and decreased lifespan.
Innovation Solution
The development of foam compositions that incorporate silanes, which enhance abrasion resistance without compromising energy return or softness, achieved by increasing crosslinking density to maintain the desired properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high energy return foam compositions are used, then energy return is improved, but abrasion resistance deteriorates
Solution Approach 1:
The patent applies parameter changes by modifying the crosslinking density of the foam composition. Specifically, it uses a crosslinking density between 5-20 moles per 100 moles of vinylaromatic units, which optimizes the balance between energy return and abrasion resistance. This parameter adjustment allows the foam to achieve both high energy return properties and improved abrasion resistance simultaneously.
Solution Approach 2:
The patent employs composite materials by combining specific polymer components including polybutadiene blocks, polystyrene blocks, and various additives in a formulated composition. This composite approach creates a multi-component system where each ingredient contributes specific properties, resulting in a foam that achieves both high energy return and enhanced abrasion resistance through synergistic material interactions.
2Reliability
If crosslinking density is increased to improve abrasion resistance, then abrasion resistance is improved, but softness deteriorates
Solution Approach 1:
The patent precisely controls the crosslinking density parameter within the range of 5-20 moles per 100 moles of vinylaromatic units. This optimized parameter range ensures that the foam achieves sufficient crosslinking for improved abrasion resistance while maintaining the softness required for comfort and energy return, preventing the foam from becoming too hard.
Solution Approach 2:
The patent applies local quality by creating a differentiated structure where the crosslinked network provides abrasion resistance in the bulk material while maintaining softer characteristics in regions that contact the foot. This localized property distribution allows different parts of the foam to exhibit different mechanical properties optimized for their specific functions.
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 silane-containing foam compositions demonstrate significant improvements in abrasion resistance, with a 30% to 50% reduction in abrasion loss while maintaining high energy return and softness, making them suitable for athletic footwear applications.
Implementation Method 1
achieved by increasing crosslinking density to maintain the desired properties
Data Source
AI summary
Components for articles of footwear and athletic equipment are provided including a high energy return foam having improved abrasion resistance. A variety of foams and foam components and compositions for forming the foams are provided. In some aspects, the foams and components including the foams can have exceptionally high energy return while also having improved durability and softness and an improved abrasion resistance. In particular, midsoles including the foams are provided for use in an article of footwear. Methods of making the compositions and foams are provided, as well as methods of making an article of footwear including one of the foam components. In some aspects, the foams and foam components can be made by injection molding or injection molding followed by compression molding.