Thermoplastic Copolyester Foams for Recyclable Footwear Outsoles
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Solution Overview
Problem
Conventional rubber materials used in footwear outsoles are difficult to recycle due to their thermoset nature and require manual, adhesive-based bonding processes, which are inefficient and labor-intensive.
Innovation Solution
Thermoplastic copolyester foams with multicellular structures, which can be recycled by melting and reforming, and can be directly molded onto other polymeric materials with a thermal bond, eliminating the need for adhesives and manual processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rubber materials are used in footwear outsoles, then good abrasion resistance and traction are achieved, but the materials are difficult to recycle due to their thermoset nature
Solution Approach 1:
The patent changes the fundamental chemical parameter of the material from thermoset to thermoplastic copolyester, enabling the material to be melted and reformed for recycling while maintaining the required mechanical properties for footwear outsoles
Solution Approach 2:
The patent uses copolyester composed of multiple polymer components (polyester backbone with elastomeric segments) to achieve both the durability needed for abrasion resistance and the thermoplastic properties needed for recyclability
2Reliability
If conventional rubber materials are used in footwear outsoles, then good traction is achieved, but manual adhesive-based bonding processes are required which are inefficient and labor-intensive
Solution Approach 1:
The patent combines the bonding function with the material itself through thermal bonding capability, eliminating the need for separate adhesive materials and manual bonding processes, thereby improving manufacturing efficiency while maintaining traction performance
Solution Approach 2:
The patent replaces manual adhesive-based bonding with automated thermal bonding processes, substituting mechanical labor with thermal energy application to achieve efficient bonding of footwear components
3Ease of manufacture
If thermoplastic copolyester foams are used, then recyclability and manufacturing efficiency are improved, but the material must provide sufficient abrasion resistance and traction
Solution Approach 1:
The patent employs copolyester composite structure combining rigid polyester segments for structural integrity and abrasion resistance with elastomeric segments for flexibility and traction, achieving both recyclability and required performance
Solution Approach 2:
The patent creates different regions within the foam material with varying properties - denser regions for structural support and abrasion resistance, and more open-cell regions for cushioning and flexibility, allowing the material to meet multiple performance requirements simultaneously
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 thermoplastic copolyester foams provide a recyclable, efficiently bondable material for footwear components, offering improved abrasion resistance, traction, and energy efficiency while simplifying the manufacturing process.
Implementation Method 1
thermoplastic copolyester foams with multicellular structures, which can be recycled by melting and reforming
Implementation Method 2
can be directly molded onto other polymeric materials with a thermal bond, eliminating the need for adhesives and manual processing steps
Data Source
AI summary
Components for articles of footwear and athletic equipment including a foam are provided. The foam portion of the components and articles include a composition which includes a thermoplastic copolyester, the composition having a foam structure. A polymer layer is provided on at least on surface of the foam portion. The polymer layer can control or reduce the water uptake of the foam portion. Methods of making the compositions, foams, and components 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.