Non-crosslinked copolymer foam composition with polyamide blocks and polyether blocks

Abstract

The present invention relates to a non-crosslinked block copolymer foam composition, characterised in that it is in the form of a polymer matrix comprising closed cells containing gas, said matrix comprising: from 90 to 99.9% by weight of said block copolymer; and from 0.01 to 10% by weight of metal carbonate, for the total weight of the foam composition. The present invention also relates to a foamable composition and a method for manufacturing said foam, as well as the use of the foam in sports shoe soles, balloons or balls, gloves, personal protection equipment, rail soles, automobile parts, construction parts, electrical and electronic equipment parts, audio equipment, sound- and/or heat-proofing, and parts used to damp vibrations.

Claims

1. A non-crosslinked hard-soft block copolymer foam composition, wherein the composition is in the form of a polymer matrix containing closed cells containing gas, said matrix comprising: from 90 to 99.9% by weight of at least one block copolymer; and from 0.5 to 10% by weight of a metal carbonate dispersed in the matrix, for the total weight of the foam composition, wherein: the hard blocks in the copolymer have a number-average molecular mass of 200 to 2000 g/mol; the soft blocks in the copolymer have a number-average molecular mass of 800 to 2500 g/mol; and the weight ratio of the hard blocks to the soft blocks in the copolymer is from 0.1 to 2.

2. The foam composition according to claim 1, wherein said gas comprises at least one compound chosen among: CO.sub.2, H.sub.2O, N.sub.2 and mixtures thereof.

3. The foam composition according to claim 1, wherein said at least one block copolymer comprises at least one block chosen among: polyether blocks; polyester blocks; polyamide blocks; polyurethane blocks; and combinations thereof.

4. The foam composition according to claim 1, wherein said at least one copolymer comprises a copolymer with polyamide blocks and polyether blocks.

5. The foam composition according to claim 4, wherein the polyamide blocks in the copolymer are blocks comprising at least one of the following polyamide units: 11, 12, 6, 6.10, 6.12, 10.10, 10.12, and combinations thereof.

6. The foam composition according to claim 4, wherein the polyether blocks of the copolymer are blocks of polyethylene glycol or polytetramethylene glycol.

7. The foam composition according to claim 1, which also contains from 0.1 to 50% by weight of one or more additives chosen among ethylene vinyl acetate copolymers, ethylene-acrylate copolymers, and ethylene alkyl(meth)acrylate copolymers, and/or from 0.1 to 10% by weight of additives selected from nucleating agents.

8. An item consisting of the foam composition according to claim 1.

9. An item comprising at least one element consisting of the foam composition according to claim 1.

10. An item according to claim 8, chosen among a sports shoe sole, a balloon, a ball, gloves, personal protection equipment, a rail sole, an automobile part, a stroller part, a wheel, a handle, a seat component, a child car seat component, a construction part, an electrical or electronic equipment part, an audio equipment part, a part used in sound- and/or heat-proofing, a part designed to absorb shocks or damp vibrations, soft-ride wheels, and any item comprising a combination of these items.

11. The foam composition according to claim 1, wherein a foam formed from the foam composition is formed from an injection method, without any gas injection step, resulting in a flexible foam with a density of less than 600 kg/m.sup.3.

12. The foam composition according to claim 1, wherein the closed cells are uniform in size such that a difference between the inner diameters of the closed cells does not exceed 30%.

13. The foam composition according to claim 1, wherein a foam formed from the foam composition has a rebound resilience, in accordance with ISO standard 8307:2007, of more than 55%.

14. The foam composition according to claim 13, wherein the foam has a compression set, in accordance with ISO standard 7214:2012, of less than 10%.

Description

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(1) The invention is now described in greater detail and in a non-limiting manner in the description which follows.

(2) The invention uses a block copolymer.

(3) “Block copolymer”, according to the invention, means thermoplastic elastomer (TPE) polymers, which comprise, in alternation, blocks or segments referred to as “hard” or “rigid” (behaving more like thermoplastics) and blocks or segments referred to as “soft” or “flexible” (behaving more like elastomers). For example, polyamide blocks are known to be “hard” blocks at a melt temperature (TO or glass transition temperature (Tg), that is higher than the temperature at which the polymer is used, while polyether blocks are “soft” blocks if Tf or Tg is lower than the temperature at which said polymer is used

(4) More precisely, a block is referred to as “soft” if it has a low glass transition temperature (Tg). “Low glass transition temperature” means a glass transition temperature Tg below 15° C., preferably below 0° C., advantageously below −15° C. and yet more advantageously below −30° C., or even below −50° C.

(5) “Possible flexible or soft blocks in the copolymer according to the invention” means in particular those chosen from among the polyether blocks, polyester blocks, polysiloaxane blocks such as polydimethylsiloxane blocks i.e. PDMS, polyolefin blocks, polycarbonate blocks, and combinations thereof. The possible soft blocks are described, for example, in French patent application No.: 0950637, page 32, line 3, to page 38, line 23. As an example, the polyether blocks are chosen among poly(ethylene glycol) (PEG), poly(1,2-propylene glycol) (PPG), poly(1,3-propylene glycol) (PO3G), poly(tetramethylene glycol) (PTMG), and their copolymers or combinations.

(6) The hard blocks can be polyamide-based, polyurethane-based, polyester-based, or a combination of these polymers. These blocks are described in particular in French patent application No.: 0856752. Hard blocks are preferably polyamide-based. Polyamide (PA) blocks can comprise homopolyamides or copolyamides. The possible polyamide blocks in the composition of the invention are in particular those defined in application FR0950637, from page 27, line 18, to page 31, line 14.

(7) Advantageously, said at least one block copolymer comprises at least one block chosen among: the polyether blocks; the polyester blocks; the polyamide blocks; the polyurethane blocks; and combinations thereof. Examples of hard-soft block copolymers are, respectively, (a) copolymers with polyester blocks and polyether blocks (also known as COPEs or copolyesterethers), (b) copolymers with polyurethane and polyether blocks (also known as TPUs which is the abbreviation for thermoplastic polyurethanes) and (c) copolymers with polyamide and polyether blocks (also known as PEBAs according to the IUPAC, or as polyether-block-amides).

(8) Preferably, said at least one copolymer comprises a copolymer with polyamide blocks and polyether blocks (PEBA).

(9) PEBAs result from the polycondensation of polyamide blocks comprising reactive ends with polyether blocks comprising reactive ends, such as, among others, polycondensation:

(10) 1) of polyamide blocks comprising diamine chain ends with polyoxyalkylene blocks comprising dicarboxylic chain ends;

(11) 2) of polyamide blocks comprising dicarboxylic chain ends with polyoxyalkylene blocks comprising diamine chain ends, obtained for example by cyanoethylation and hydrogenation of polyoxyalkylène □,□-dihydroxylated aliphatic blocks referred to as polyetherdiols;

(12) 3) of polyamide blocks comprising dicarboxylic chain ends with polyether diols, the products obtained in this particular case being polyether ester amides.

(13) The polyamide blocks comprising dicarboxylic chain ends result, for example, from the condensation of polyamide precursors in the presence of a chain-limiting dicarboxylic acid. The polyamide blocks comprising diamine chain ends result, for example, from the condensation of polyamide precursors in the presence of a chain-limiting diamine.

(14) Three types of polyamide blocks can be advantageously used.

(15) According to a first type, the polyamide blocks result from the condensation of a dicarboxylic acid, in particular those having from 4 to 20 carbon atoms, preferably those having from 6 to 18 carbon atoms, and an aliphatic or aromatic diamine, in particular those having from 2 to 20 carbon atoms, preferably those having from 6 to 14 carbon atoms

(16) Examples of dicarbolixic acids include 1,4-cyclohexyldicarboxylic acid, the butanedioic, adipic, azelaic, suberic, sebacic, dodecane dicarboxylic, and octadecane dicarboxylic acids, and the terepthalic and isophthalic acids, but also the dimerised fatty acids.

(17) Examples of diamines include tetramethylenediamine, hexamethylenediamine, 1,10-decamethylenediamine, dodecamethylenediamine, trimethylhexamethylenediamine, the isomers of bis(4-aminocyclohexyl)methane (BACM), bis(3-methyl-4-aminocyclohexyl)methane (BMACM), and 2-2-bis(3-methyl-4-aminocyclohexyl) propane (BMACP), para amino dicyclohexyl methane (PACM), isophorone diamine (IPDA), 2,6-bis(aminomethyl)norbornane (BAMN) and piperazine (Pip).

(18) Advantageously, polyamide blocks PA 4.12, PA 4.14, PA 4.18, PA 6.10, PA 6.12, PA 6.14, PA 6.18, PA 9.12, PA 10.10, PA 10.12, PA 10.14 and PA 10.18 are used. In the PAX.Y notation, X conventionally represents the number of carbon atoms from the diamine residues, and Y represents the number of carbon atoms from the diacid residues.

(19) According to a second type, the polyamide blocks result from the condensation of one or more α,Ω-aminocarboxylic acids and/or one or more lactams having from 6 to 12 carbon atoms in the presence of a dicarboxylic acid having from 4 to 12 carbon atoms or of a diamine. Examples of lactams include caprolactam, oenantholactam and lauryllactam. Examples of α,Ω-amino carboxylic acid, include the aminocaproic, 7-aminoheptanoic, 11-aminoundecanoic and 12-aminododecanoic acids.

(20) Advantageously, the polyamide blocks of the second type are blocks of PA 11 (polyundecanamide), PA 12 (polydodecanamide) or PA-6 (polycaprolactam). In the PA X notation, X represents the number of carbon atoms from the amino acid residues.

(21) According to a third type, the polyamide blocks result from the condensation of at least one α,Ω-aminocarboxylic acid (or a lactam), at least one diamine and at least one dicarboxylic acid.

(22) In this case, the polyamide (PA) blocks are prepared by polycondensation: of the linear or aromatic aliphatic diamine(s) having X carbon atoms; of the dicarboxylic acid(s) having Y carbon atoms; and of the comonomer(s) {Z}, chosen among the lactams and the α,Ω-aminocarboxylic acids having Z carbon atoms and equimolar mixtures of at least one diamine with X1 carbon atoms and at least one dicarboxylic acid having Y1 carbon atoms, (X1, Y1) being different from (X, Y), said comonomer(s) {Z} being introduced in a proportion by weight of up to 50%, preferably up to 20%, yet more preferably up to 10% in relation to the combined polyamide precursor monomers; in the presence of a chain limiter chosen among the dicarboxylic acids.

(23) Advantageously, said dicarboxylic acid having Y carbon atoms is used as chain limiter, which is introduced in excess relative to the stoichiometry of the diamine(s).

(24) According to a variant of this third type, the polyamide blocks result from the condensation of at least two α,Ω-aminocarboxylic acids or of at least two lactams having from 6 to 12 carbon atoms or of a lactam and of an aminocarboxylic acid not having the same number of carbon atoms in the possible presence of a chain limiter. Examples of α,Ω-aminocarboxylic aliphatic acid include the aminocaproic, 7-aminoheptanoic, 11-aminoundecanoic and 12-aminododecanoic acids. Examples of lactams include caprolactam, oenantholactam and lauryllactam. Examples of aliphatic diamines include hexamethylenediamine, dodecamethylenediamine and trimethylhexamethylenediamine. Examples of cycloaliphatic diacids include 1,4-cyclohexanedicarboxylic acid. Examples of aliphatic diacids include butanedioic, adipic, azelaic, suberic, sebacic, dodecanedicarboxylic acids and dimerised fatty acids. These dimerised fatty acids preferably have a dimer content of at least 98%; they are preferably hydrogenated. Examples of these acids are the products marketed under the brand name “PRIPOL” by CRODA, or under the brand name “EMPOL” by BASF, or under the brand name “RADICAID” by OLEON, and polyoxyalkylenes α,Ω-diacids Examples of aromatic diacids include terephthalic acid (T) and isophthalic acid (I). Examples of cycloaliphatic diamines include the isomers of bis(4-aminocyclohexyl)methane (BACM), bis(3-methyl-4-aminocyclohexyl)methane (BMACM) and 2-2-bis(3-methyl-4-aminocyclohexyl)propane (BMACP), and para amino dicyclohexyl methane (PACM). The other commonly-used diamines can be isophoronediamine (IPDA), 2,6-bis(aminomethyl)norbornane (BAMN) and piperazine.

(25) Examples of polyamide blocks of the third type include the following: PA 6.6/6, in which 6.6 denotes hexamethylenediamine units condensed with adipic acid and 6 denotes units resulting from the condensation of caprolactam; PA 6.6/6.10/11/12, in which 6.6 denotes hexamethylenediamine condensed with adipic acid, 6.10 denotes hexamethylenediamine condensed with sebacic acid, 11 denotes units resulting from the condensation of aminoundecanoic acid, and 12 denotes units resulting from the condensation of lauryllactam.

(26) The notations PA X/Y PA X/Y/Z, etc. relate to copolyamides in which X, Y, Z, etc. represent homopolyamide units as described above.

(27) Advantageously, the polyamide blocks in the copolymer used in the invention comprise polyamide blocks PA 6, PA 11, PA 12, PA 5.4, PA 5.9, PA 5.10, PA 5.12, PA 5.13, PA 5.14, PA 5.16, PA 5.18, PA 5.36, PA 6.4, PA 6.9, PA 6.10, PA 6.12, PA 6.13, PA 6.14, PA 6.16, PA 6.18, PA 6.36, PA 10.4, PA 10.9, PA 10.10, PA 10.12, PA 10.13, PA 10.14, PA 10.16, PA 10.18, PA 10.36, PA 10.T, PA 12.4, PA 12.9, PA 12.10, PA 12.12, PA 12.13, PA 12.14, PA 12.16, PA 12.18, PA 12.36, PA 12.T, or combinations or copolymers thereof; and preferably comprise polyamide blocks PA 6, PA 11, PA 12, PA 6.10, PA 10.10, PA 10.12, or combinations or copolymers thereof.

(28) The polyether blocks consist of alkylene oxide units. The polyether blocks can be in particular PEG (polyethylene glycol) blocks, i.e., consisting of ethylene oxide units, and/or PPG (propylene glycol) blocks, i.e. consisting of propylene oxide units and/or PO3G (polytrimethylene glycol) blocks, i.e. consisting of polytrimethylene ether glycol units and/or PTMG blocks, i.e. consisting of units of tetramethylene glycol also known as polytetrahydrofuran. The PEBA copolymers can include several types of polyethers in their chain; copolyethers can be block or random.

(29) Blocks obtained by bisphenol ethoxylation can also be used, such as bisphenol A, for example. These latter products are described in particular in EP 613919.

(30) The polyether blocks can also be comprised of ethoxylated primary amines. Examples of ethoxylated primary amines include the products of the formula:

(31) ##STR00001##

(32) wherein m and n are integers comprised between 1 and 20 and x an integer comprised between 8 and 18. These products are commercially available for example under the brand name NORAMOX® by CECA and under the brand name GENAMIN® by CLARIANT.

(33) The soft polyether blocks can include polyoxyalkylene blocks comprising NH2 chain ends; such blocks can be obtained by cyanoacetylation of □,□-dihydroxylated aliphatic polyoxyalkylene blocks known as polyether diols. More specifically, the commercial products Jeffamine or Elastamine can be used (for example Jeffamine® D400, D2000, ED 2003 XTJ 542, or commercial products from Huntsman, also described in JP 2004346274, JP 2004352794 and EP 1482011).

(34) The polyether diol blocks are either used in unmodified form and copolycondensed with polyamide blocks comprising carboxylic ends, or they are aminated to be converted into polyetherdiamines and condensed with polyamide blocks comprising carboxylic ends. The general method for preparation in two steps of the PEBA copolymers having ester bonds between the PA blocks and the PE blocks is known and is described, for example, in FR 2846332 The general method for preparation of the PEBA copolymers in the invention having amide bonds between the PA blocks and the PE blocks is known and is described, for example, in EP 1482011. The polyether blocks can also be combined with polyamide precursors and a diacid chain limiter to prepare the polymers comprising polyamide blocks and polyether blocks having randomly distributed units (one-step process).

(35) Of course, the PEBA designation in the present description of the invention also relates to the Pebax® marketed by Arkema, the Vestamid® marketed by Evonik®, the Grilamid® marketed by EMS, as well as to the PEBA-type Pelestat® marketed by Sanyo or to any other PEBA from other suppliers.

(36) While the block copolymers described above generally comprise at least one polyamide block and at least one polyether block, the present invention also covers all the alloys of copolymers comprising two, three, four (or more) different blocks chosen from those described in the present description, insofar as these blocks comprise at least one of the polyamide and polyether blocks.

(37) For example, the copolymer according to the invention can be a segmented block copolymer comprising three different blocks (or “triblock”), which results from the condensation of several of the blocks described above. Said triblock is preferably chosen from the copolyetheresteramides and the copolyetheramideurethanes.

(38) PEBA copolymers that are particularly preferred in the context of the invention are: PA12-PEG, PA6-PEG, PA6/12-PEG, PA11-PEG, PA12-PTMG, PA6-PTMG, PA6/12-PTMG, PA11-PTMG, PA12-PEG/PPG, PA6-PEG/PPG, PA6/12-PEG/PPG, PA11-PEG/PPG, PA11/PO3G, PA6.10/PO3G and/or PA10.10/PO3G.

(39) The foam of the invention comprises a block copolymer such as described above: preferably only one such copolymer is used. However, it is possible to use a mixture of two or more than two block copolymers, in particular several PEBAs, as described above.

(40) According to the invention, the number-average molecular mass of the hard blocks, e.g. polyamide, in the copolymer, e.g. PEBA, is comprised within the range from 200 to 2000 g/mol; the number-average molecular mass of the soft blocks, e.g. polyether, is comprised within the range from 800 to 2500 g/mol.

(41) The number-average molecular mass is set by the chain limiter content. It can be calculated according to the ratio:
Mn=(n.sub.monomern.sub.limiter)*M.sub.repeat unit+M.sub.limiter

(42) n.sub.monomer=number of moles of monomer

(43) n.sub.limiter=number of moles of excess diacid

(44) M.sub.repeat unit=Molecular mass of the repeat unit

(45) M.sub.limiter=Molecular mass of the excess diacid

(46) Moreover, according to the invention, the weight ratio of the hard blocks (e.g. polyamide in the case of PEBA) relative to the soft blocks (polyether in the case of PEBA) of the copolymer is from 0.1 to 2.

(47) This weight ratio can be calculated by dividing the number-average molecular mass of the hard blocks, in particular polyamides, by the number-average molecular mass of the soft blocks, in particular polyethers in the case of PEBA.

(48) According to particular embodiments, this ratio is from 0.1 to 0.2; or 0.2 to 0.3; or 0.3 to 0.4; or 0.4 to 0.5; or 0.5 to 0.6; or 0.6 to 0.7; or from 0.7 to 0.8; or 0.8 to 0.9; or 0.9 to 1; or 1 to 1.1; or 1.1 to 1.2; or 1.2 to 1.3; or 1.3 to 1.4; or 1.4 to 1.5; or 1.5 to 1.6; or 1.6 to 1.7; or 1.7 to 1.8; or from 1.8 to 1.9; or 1.9 to 2.

(49) Preferably, the copolymer used in the invention has an instantaneous hardness less than or equal to 40 Shore D, preferably less than or equal to 35 Shore D. Hardness measurements can be performed according to ISO 868: 2003.

(50) The block copolymer, in particular the copolymer with polyamide blocks and polyether blocks, is used to form a foam, without a crosslinking step. The foam according to the invention is formed by mixing the melted copolymer with a blowing or chemical foaming agent, and then performing a foaming step.

(51) According to one embodiment, the foam thus formed consists essentially, or consists, of the copolymer described above (or copolymers, if a mixture of copolymers is used) and the decomposition products of the blowing or chemical foaming agent, the latter being dispersed in the matrix rather than present in the foam cells.

(52) The block copolymer, in particular with polyamide blocks and polyether blocks, can be combined with various additives, e.g., ethylene vinyl acetate or EVA copolymers (such as those marketed under the brand name Evatane® by Arkema), or ethylene acrylate copolymers, or ethylene alkyl(meth)acrylate copolymers, such as those marketed under the brand name Lotryl® by Arkema. These additives can enable adjustment of the hardness, appearance and comfort of the foamed part. These additives can be added in a content of 0.1 to 50% by weight, preferably from 5 to 30% by weight, in relation to the total weight of the composition according to the invention.

(53) The composition according to the invention can also comprise additives, such as nucleating agents, in particular mineral fillers, such as talc. Preferably, their content is from 0.1 to 10% by weight, preferably from 0.1 to 3% by weight for the total weight of the composition according to the invention.

(54) The use in the composition according to the invention of a chemical foaming agent can be coupled to that of a physical blowing agent. Preferably, this is a physical agent such as e.g. dinitrogen or carbon dioxide, or a hydrocarbon, chloroflurocarbon, hydrochlorocarbon, hydrofluorocarbon, or hydrochlorofluorocarbon (saturated or unsaturated) For example, butane or pentane can be used. In this case, the physical blowing agent is preferably mixed in liquid or supercritical form with the foamable copolymer composition and converted into the gas phase during the foaming step.

(55) According to a preferred embodiment, the foamable copolymer composition according to the invention is injected into a mould and foaming the composition is performed either during its injection into the mould, or by opening the mould. These two techniques, alone or in combination, allow three-dimensional foamed objects with complex geometries to be produced.

(56) It is also a relatively simple technique to implement, in particular with respect to certain processes for melting foamed particles as described in the prior art: in fact, filling a mould with foamed polymer granules and then melting the particles to ensure the mechanical strength of the parts without destroying the foam structure, are complex operations.

(57) Other foaming techniques that can be used are, in particular, “batch” foaming and extrusion foaming.

(58) The foam produced according to the invention preferably has a density from 50 to 800 kg/m3, and in particular more preferably from 100 to 600 kg/m3. Density control can be achieved by adapting the settings to the manufacturing process. Advantageously, the foam according to the invention has a rebound resilience, in accordance with ISO standard 8307:2007, greater than or equal to 55%.

(59) Advantageously, the foam according to the invention has a compression set, in accordance with ISO standard 7214:2012, of less than or equal to 10%, and in particular more preferably less than or equal to 8%.

(60) Advantageously, this foam has excellent fatigue resistance and damping properties.

(61) The foam according to the invention can be used to manufacture sports equipment such as sports shoe soles, ski boot soles, midsoles, insoles, or functional components of soles, in the form of inserts in the various parts of the sole (heel or arch, for example), or components of shoe uppers in the form of reinforcements or inserts in the structure of the uppers, in the form of protective elements.

(62) It can also be used to manufacture balls, sports gloves (e.g. football gloves), components for golf balls and rackets, protective elements (jackets, linings for helmets and hulls, etc.).

(63) The foam according to the invention displays interesting shock-proofing, noise-proofing and damping properties, in combination with haptic properties adapted to capital goods. It can also be used to manufacture sports shoe soles (or cushioning pads), railway rails, or various parts for the automotive and transport industries, stroller parts such as wheels, handles, or seat components, components for child car seats, construction parts for electrical or electronic equipment and audio equipment, insulating equipment parts, in particular parts used in sound- and/or heat-proofing, in the manufacture of parts designed to absorb shocks or damp vibrations such as those generated by transport vehicles, parts for soft-ride wheels such as tyres but requiring no maintenance, construction parts or parts used in the manufacturing industry.

(64) An advantage of the foam objects according to the invention is that they can easily be recycled, for example by melting them in an extruder equipped with a degassing outlet (optionally after having cut them into pieces).

EXAMPLES

(65) The following examples illustrate the present invention without limiting the scope thereof. In the examples, unless otherwise stated, all percentages and portions are expressed in weight.

(66) The PEBA (Pebax® d′Arkema) copolymers used in the test compositions (examples and comparisons) have the following characteristics listed in the table below:

(67) TABLE-US-00001 PEBA No. A B Tf (° C.) 144 159 Tc (° C.) 61 126 Instantaneous 33 54 hardness (Shore D) Hardness at 15s 25 50 (Shore D) Type of PA PA 12 PA 12 blocks Type of PE PTMG PTMG blocks Weight ratio 0.4 2 PA blocks/PE blocks Mn PA blocks 850 2000 (g/mol) Mn PE blocks 2000 1000 (g/mol)

(68) Foaming chemical agents used in the test compositions: FCA1: a mixture based on citric acid and sodium hydrogen carbonate (NaHCO.sub.3) (product in the Hydrocerol® range by Clariant). FCA2: a mixture based on citric acid and sodium hydrogen carbonate (NaHCO.sub.3) and containing microspheres (product in the Hydrocerol® range by Clariant).

(69) Plate Extrusion and Density Tests in Accordance with ISO Standards 1183, Using the “Immersion” Measuring Method:

(70) TABLE-US-00002 Examples 1 2 Composition PEBA A + 2% FCA 2 PEBA B + 1% FCA1 Density 650 800 (kg/m3)

(71) Plates are extruded from 2 compositions according to the invention in Examples 1 and 2. It was found that these two compositions displayed a very high aptitude for conversion by extrusion. The foam plates obtained have a surface appearance that is uniform, smooth and seamless, with distinct edges, and a homogeneous distribution of the pores or cells within the foam matrix.

(72) It was found that this homogeneity, both in the distribution and the size of the cells in the foam according to the invention, is obtained: by a content of at least 1%, preferably at least 2%, by weight of metal carbonate-based foaming agent, used in the foamable composition according to the invention, and corresponding to a content in metal carbonate remaining in the matrix of the foam obtained of at least 0.1% by weight, preferably at least 0.5% by weight, for the total weight of the foam composition, measured by ATG according to ISO standard 11358: 2011.

(73) The parts obtained have a density of less than or equal to 800 kg/m3.

(74) Plate Injection and Density Tests in Accordance with ISO Standards 1183, Using the “Immersion” Measuring Method:

(75) TABLE-US-00003 % FCA Density (kg/m3) PEBA B FCA1 2% Ex3 510 3% Ex4 450 FCA2 2% Ex5 550 4% Ex6 430

(76) Use of a foamable composition according to the invention in examples 3 to 6, by a conventional injection method, makes it possible to obtain high-definition, flexible foam parts with a density of less than 600 kg/m3, and even less than 500 kg/m3, without any gas injection step.

(77) In the flexible foam pieces of the invention, the cells (foam pores) are uniform in size: the difference between the inner diameters of the pores (or closed cells) does not exceed 30%.

(78) The foam obtained in examples 1 to 6 according to the invention has a rebound resilience, in accordance with ISO standard 8307:2007, of more than 55%. Moreover, this foam has a compression set, in accordance with ISO standard 7214:2012, of less than 10%.

(79) The foam obtained according to the invention is characterised by its controlled and uniform structure and its mechanical properties, in particular fatigue resistance and damping, which are suitable for use in sports, personal protection equipment, sound- and/or heat-proofing, and the manufacture of parts designed to damp vibrations, in particular transport-related ones.