Thermoplastic Elastomer Foam Density Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for improved methods of forming foams that can be customized for cushioning in footwear and protective wear, as existing methods do not adequately address the requirement for tailored density and stability.
Innovation Solution
A method involving thermoplastic elastomers infused with a supercritical fluid, followed by rapid depressurization and heating, which includes a nonpolar component such as fluoropolymers or perfluorinated reactants, to produce a lower density foam that can be molded into various shapes and forms, such as pellets, beads, or films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional blowing agents are used in thermoplastic elastomers, then foam formation is achieved, but the density and stability cannot be adequately customized for specific applications
Solution Approach 1:
The patent modifies the chemical composition parameters of the thermoplastic elastomer by incorporating nonpolar components (fluoropolymers, perfluorinated reactants, or saturated polyolefin polyol) to change the material's interaction with supercritical CO2, enabling customized foam density and stability for different applications
Solution Approach 2:
The invention creates a composite material system by combining thermoplastic elastomer with specific nonpolar components (fluoropolymers or perfluorinated reactants) to achieve enhanced compatibility with supercritical fluids, allowing tailored foam properties that meet specific application requirements
2Ease of manufacture
If polar thermoplastic elastomers are used with supercritical CO2, then foaming process is simplified, but compatibility and fluid absorption are insufficient
Solution Approach 1:
The patent changes the polarity parameter of the thermoplastic elastomer by incorporating nonpolar components, making the material more compatible with nonpolar supercritical CO2 and enhancing fluid absorption capacity while maintaining process simplicity
Solution Approach 2:
The invention creates a more homogeneous interaction between the elastomer matrix and supercritical CO2 by adding nonpolar components, improving overall compatibility and fluid distribution throughout the material
3Strength
If high density foam is produced, then structural integrity is maintained, but cushioning and protective properties are reduced
Solution Approach 1:
The patent applies local quality by creating a nonpolar component distribution within the elastomer matrix that enables localized foam cell formation with optimized density, providing both structural integrity and enhanced cushioning performance for specific application areas
Solution Approach 2:
The invention optimizes the density parameter of the foam by controlling the interaction between nonpolar components and supercritical CO2, enabling production of lower density foams that maintain sufficient structural integrity while providing superior cushioning and protective 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
This method allows for the production of foamed articles with customized density and stability, enabling enhanced cushioning and protective properties in applications like footwear and protective gear, while maintaining shape and stability.
Implementation Method 1
an article of a thermoplastic elastomer is infused with a supercritical fluid
Implementation Method 2
The article contains a nonpolar component... Including the nonpolar component allows the article to absorb more the supercritical fluid
Implementation Method 3
rapidly depressurized and heated... to heat and foam the article
Implementation Method 4
an article of a thermoplastic elastomer is infused with a supercritical fluid in a pressurized container, then rapidly depressurized
Implementation Method 5
heated either by immersion in a heated fluid that can rapidly heat the article
Implementation Method 6
heated either by immersion in a heated fluid that can rapidly heat the article or with infrared or microwave radiation
Implementation Method 7
heated either by immersion in a heated fluid that can rapidly heat the article or with infrared or microwave radiation
Data Source
AI summary
A foamed article is made by infusing the article of thermoplastic elastomer including a nonpolar component with a supercritical fluid, then removing the article from the supercritical fluid and either (i) immersing the article in a heated fluid or (ii) irradiating the article with infrared or microwave radiation.