Supercritical-Foamed Damping Pad With Low Compression Set
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Solution Overview
Problem
Existing damping pads made from thermosetting materials like EVA and TPU suffer from high compression set, poor recyclability, and inadequate weather resistance, while thermoplastic elastomers like POE and OBC have insufficient compression set and adhesiveness, limiting their application and recyclability.
Innovation Solution
A damping pad with low compression set is developed using a thermoplastic ether ester elastomer, processed through injection molding with a supercritical fluid blend of nitrogen or carbon dioxide, creating a structure with a surface layer and a foam inner layer containing a high proportion of open pores, which achieves low compression set, high damping property, and high rebound resilience without the need for chemical foaming agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermosetting materials like EVA or TPU are used for damping pads, then shock-absorbing property and light-weight are improved, but compression set increases and recyclability deteriorates
Solution Approach 1:
The patent changes the material parameters by using thermoplastic polyolefin resin instead of traditional thermosetting materials, and controls the molecular weight distribution and composition ratio to achieve both low compression set and good shock-absorbing properties
Solution Approach 2:
The patent creates a composite structure by combining thermoplastic polyolefin resin with specific additives and using a multi-layer foam structure, achieving a balance between compression resistance and shock absorption
2Strength
If TPU is used for damping pads, then strength and toughness are improved, but compression set increases and weather resistance deteriorates
Solution Approach 1:
The patent changes the base material from TPU to thermoplastic polyolefin resin, and adjusts parameters such as molecular weight distribution and compositional ratios to achieve low compression set and improved weather resistance while maintaining strength
Solution Approach 2:
The patent uses readily available thermoplastic polyolefin resin that can be easily recycled, replacing TPU with a material that offers both environmental benefits and improved performance characteristics
3Shape
If chemical foaming agents are used in production, then foam structure is achieved, but toxic byproducts are generated and environmental harm increases
Solution Approach 1:
The patent uses physical blowing agents (carbon dioxide or nitrogen) as intermediaries to create the foam structure, replacing chemical foaming agents and avoiding toxic byproduct generation
Solution Approach 2:
The patent replaces the chemical reaction-based foaming mechanism with a physical gas dissolution and expansion mechanism, eliminating harmful chemical byproducts while achieving the desired foam structure
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 resulting damping pad exhibits a compression set of 40% or less, a deceleration g value of 20 or less, and rebound resilience of 50% or more, offering improved durability and recyclability while avoiding toxic byproducts and environmental concerns.
Implementation Method 1
processed through injection molding with a supercritical fluid blend of nitrogen or carbon dioxide
Data Source
AI summary
Provided is a damping pad with low compression set, which is prepared by a method comprising the following steps: (1) providing a polymer comprising a thermoplastic ether ester elastomer, in which the polymer material has specific melt flow index, Shore D hardness, tensile modulus, density, and elongation at break; (2) melting the polymer material to obtain a molten polymer material; (3) adding nitrogen gas or carbon dioxide into the molten polymer to obtain a mixture; (4) turning the mixture into a supercritical state and compounding the mixture, to obtain a supercritical fluid blend; and (5) injecting and molding the supercritical fluid blend to obtain the damping pad with low compression set which has compression set of 40% or less, deceleration value of 20 or less, and rebound resilience of 50% or more.