Method for Producing a Foam Component

Simple SummaryContent extracted from patent full text and abstract with AI.

This patent describes a method for manufacturing foam components from particulate material (such as polymer granules) within a mold, by softening the material (usually via heating) and inducing a pressure change (typically a reduction) to cause foaming—without the need for traditional chemical or physical blowing agents. The foamed structure is then solidified, resulting in lightweight and potentially multi-layered foam products. The process allows for precise control of foam characteristics (like cell size and density) and can be adapted for various polymer materials and mold shapes.

Use CasesContent extracted from patent full text and abstract with AI.

• Production of insulation materials for buildings or refrigeration appliances, leveraging controllable thermal properties without harmful blowing agents.
• Manufacturing of damping or cushioning elements for sports equipment (e.g., shoe soles, helmets, balls, protectors) with tailored shock-absorption and flexibility.
• Creation of lightweight structural components and hollow bodies, such as housings for devices, automotive parts, or containers.
• Fabrication of buoyant elements and flotation devices (boats, life vests, surfboards) due to the ability to control foam density and cell structure.
• Production of packaging materials requiring precise control over weight, impact-absorption, and environmental friendliness.
• Manufacturing multilayer or graded-foam components in a single process, reducing the need for adhesive bonding or multi-step assembly.

BenefitsContent extracted from patent full text and abstract with AI.

• Allows foam production without the use of chemical or physical blowing agents, reducing both environmental impact and health concerns associated with residual agents.
• Provides significant flexibility to adjust properties like density, cell size, and cell type (open, mixed, or closed) based on application needs by controlling process parameters such as temperature and pressure.
• Enables cost savings in both materials and equipment, as simpler and less robust (lower pressure) molds can be used and energy consumption is reduced.
• Supports production of foamed parts with integral solid (non-foamed) edge layers or multiple material regions, improving mechanical properties like strength and flexibility.
• Suitable for a wide variety of thermoplastic or thermosetting polymers, enhancing the scope of end-product designs.
• Potential for sustainable production and ease of recycling, as no hazardous additives are included and the process can accommodate recycled materials.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The present invention relates to a method for producing a foam component, comprising the steps of: (a.) Providing a particulate starting material (110, 111, 112) in a mold (230). (b.) Softening the starting material (110, 111, 112). (c.) Inducing a pressure change within the mold to cause foaming in at least a portion of the softened starting material (113) without the use of a blowing agent. (d.) Solidifying the foamed starting material (116).