Thermoplastic Elastomer Foaming Material Recyclability
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Solution Overview
Problem
Traditional foaming materials, such as thermosetting rubbers, are environmentally hazardous, difficult to recycle, and not suitable for soft, low-specific-gravity applications due to poor compatibility and processing issues, limiting their use in flexible and mass-producible products.
Innovation Solution
A thermoplastic elastomer foaming material comprising a hydrogenated styrenic/conjugated diene series copolymer, polyolefinic material, and plasticizer, with optional additives, processed through specific mixing and foaming methods to achieve a soft and low-specific-gravity product suitable for mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional thermosetting rubbers (NR, SBR, CR) are used for foaming materials, then close-cell foam structure is achieved, but air pollution is produced during vulcanization and recycling is impossible
Solution Approach 1:
The patent changes the fundamental chemical parameter of the rubber material from thermosetting to thermoplastic elastomer. This parameter change eliminates the vulcanization process that produces SOx pollution, enabling environmentally friendly processing while maintaining foam structure formation capabilities
Solution Approach 2:
By switching to thermoplastic elastomers, the material becomes recyclable through melting and reprocessing. The patent enables recovery and reuse of the foam material without degradation, contrasting with the non-recyclable thermosetting rubbers
2Shape
If ethylene-propylene copolymer and ethylene-α-olefin copolymer are used for close-cell foaming, then foam structure is achieved, but the material is not soft and deforms easily under compression
Solution Approach 1:
The patent creates a composite material system combining polyolefin base resin with specific thermoplastic elastomers (SEBS, SEPS, TPEE). This composite approach leverages the foam-forming capability of polyolefin while the elastomer components provide softness and compression resistance, achieving both desired properties simultaneously
3Strength
If polyolefinic rubbers are added to improve softness and compression resistance, then material properties are improved, but compatibility between copolymers and rubbers is poor
Solution Approach 1:
The patent selects specific local compositions of thermoplastic elastomers with controlled styrene content (10-30%) and molecular weight (50,000-500,000). This local quality control ensures optimal compatibility with polyolefin while maintaining the required softness and mechanical properties
Solution Approach 2:
The patent optimizes the molecular weight parameter of the thermoplastic elastomer within a specific range (50,000-500,000). This parameter change improves compatibility and dispersion within the polyolefin matrix, preventing phase separation while maintaining material performance
4Ease of operation
If SEBS and plasticizer oil are added in low contents to improve flexibility, then processing is simplified, but hardness and specific gravity remain high
Solution Approach 1:
The patent significantly increases the plasticizer content parameter to 15-40 parts by weight per 100 parts of polyolefin, and optimizes SEBS content at 5-30 parts. This parameter change dramatically reduces hardness and specific gravity while maintaining processing feasibility through controlled composition ranges
Data Source
AI summary
A thermoplastic elastomer foaming material is provided. The thermoplastic elastomer foaming material includes a hydrogenated styrenic/conjugated diene copolymer in a range from 5 to 35 weight percent; at least one of an acetate copolymer and an acrylate copolymer in a range from 3 to 30 weight percent; an amorphous polyolefin in a range from 20 to 60 weight percent; and a plasticizer in a range from 10 to 40 weight percent.