Download - BASF Martin Vallo Presentation
News Release
K 2013 Trade press conference
June 25 and 26 in Ludwigshafen, Germany
As stretchy as rubber but also light and springy
Infinergy: BASF develops the first expanded TPU
Presentation by
Martin Vallo
Sales Elastollan Footwear
BASF Polyurethanes GmbH
and
Gerd Manz
Senior Innovation Director Global Brands
adidas AG
June 25, 2013 P 301/13e Evelyn Naudorf Phone: +49 (0)621 60 42223 [email protected]
BASF SE D-67056 Ludwigshafen Phone: +49 621 60-0 http://www.basf.com/ Communications Performance Materials Phone: +49 621 60-22142 Fax: +49 621 60-49497 http://www.plasticsportal.net
Page 2 P 301/13e In plastics research, there are various ways of developing innovative
and potentially successful new materials. Additives help to give familiar
substances new properties, while mixing polymers can lead to some
interesting blends. Sometimes progress comes from using processing
techniques that were previously reserved for other materials: when it
came to the latest addition to the BASF foam plastics family, the
company's technological expertise in particle foams was combined with
its experience with thermoplastic polyurethanes.
The result is the world's first expanded thermoplastic polyurethane (E-
TPU), which BASF is now marketing under the name Infinergy™. The
first product making use of this entirely new, closed-cell particle foam
went on the market recently: the new "Energy Boost" running shoe from
adidas, which the sportswear manufacturer has developed in close
partnership with BASF. This means that BASF is now able to boast a
broad portfolio of particle foams, from rigid foam (EPS) to soft and
stretchy foam plastic (E-TPU).
Materials expertise + processing know-how = innovation
To produce Infinergy, the well-established BASF thermoplastic
polyurethane (Elastollan®) is expanded at the Ludwigshafen
headquarters, using an innovative procedure. In the process the
benefits of thermoplastic polyurethane (TPU) are retained, but to these
are added the typical properties of foams.
Being a particle foam, Infinergy has a low bulk weight, with a density of
about 110 kilograms per cubic meter, and, after processing on standard
molding machines, a molded part weight of between 200 and 320
kilogram per cubic meter. That puts the new foam somewhere between
expanded polystyrene (EPS) or polypropylene (EPP), which are
generally lighter, and the heavier elastomeric polyurethane foams.
Thanks to its closed-cell structure, Infinergy also absorbs little water,
Page 3 P 301/13e less than two percent by volume in 24 hours. Like the TPU on which it is
based, it is also characterized by very high breaking elongation
(between 100 and 150 percent depending on the density), tensile
strength (approx. 600 kilopascals) and abrasion resistance, combined
with good chemical resistance.
Good recovery behavior is retained - in heat and cold
One of the main features of Infinergy is its excellent recovery behavior
which is due partly to the closed-cell structure of the foam. This makes
it the most elastic particle foam currently available on the market. Tests
of the resilience elasticity under ISO 8307 (the ball rebound test) and
under DIN 53512 (using a pre-set pendulum hammer) show that the
rebound height for E-TPU can be as much as about 55 percent. This is
therefore significantly higher than other particle foams like EPS (less
than 20 percent) or EPP (30 percent).
Infinergy does not lose its excellent resilience even when under a
continuous load: during a high-frequency fatigue test using dynamic
loads at five cycles per second and a constant pressure of 250
kilopascals, the material performed about 75 percent better than EPE.
After 40,000 load cycles, the thickness of the test piece of E-TPU was
still 37 millimeters (starting figure: 40 millimeters), whereas the EPE
remained permanently compressed and the thickness of the test piece
was reduced to about nine millimeters. This means that Infinergy
returns almost all the energy that is applied to it.
Furthermore, Infinergy – unlike other foams – also remains highly
elastic and soft over a wide temperature range: dynamic mechanical
analysis has shown that, even in extremely low temperatures of minus
20 degrees Celsius, Infinergy is still very soft and stretchy and does not
go stiff.
Page 4 P 301/13e Many processing options - many possible areas of application
With the help of crack splitting and pressure filling, Infinergy can be
processed on the same molding machines as expanded polypropylene
(EPP). In a number of stages, the pre-foamed particles are pressed
together under hot steam and bonded together. In addition, because
polyurethane binders adhere so well to Infinergy, other processing
techniques are possible such as gluing and foam sealing of the
particles. This procedure enables large-scale processing.
Infinergy can be used anywhere where customers require a
combination of low weight, excellent mechanical properties and good
durability across a wide temperature range - for example in the sports
sector or for technical applications in logistics. Possible uses include
floors for sports halls, bicycle inner tubes and upholstery. Infinergy
could also replace rubber as a cushioning element, anywhere where a
low-weight material is needed.
Boosting the energy and comfort of runners
When you talk to runners, they always express a need for "good
cushioning". In running shoes, this is the function of the midsole: in just
a few milliseconds, it absorbs the kinetic energy generated by the
runner as the foot lands - and returns some of it to the runner while the
foot is pressed down. High elasticity and deformability in the material
that is used will increase the efficiency with which this happens.
Previously, however, runners had to choose between wearing hard,
elastic competition shoes or very soft training shoes offering a lot of
cushioning. In less than three years, by working together, adidas and
BASF have succeeded in resolving this dilemma. In a close partnership,
the two companies developed the adidas BOOST™ technology – the
world's first application of the Infinergy material.
Page 5 P 301/13e The outstanding running characteristics of the new Energy Boost
running shoes are due mainly to the combination of softness and high
elasticity in the midsole. During the materials testing in the adidas
laboratory, the forces and deformation that occur during running were
simulated on test machines in order to calculate the wear and the
energy return. To guarantee maximum performance in all seasons and
all climate zones, the shoes were tested across a temperature range
from -20 to +40°C.
In tests in the biomechanics laboratory, the adidas product developers
tested the stability of the running shoes and the effect of the products
on the performance of athletes, using the VO2max test which measures
the maximal oxygen uptake by an athlete. The comfort, durability and
how they felt to wear were tested by working directly with runners at all
levels of ability. For example, among others, marathon world record-
holder Patrick Makau was involved in the development of the Boost
running shoes.
These tests showed the BOOST™ technology to be superior in many
ways when compared with the ethylene-vinyl acetate (EVA) cushioning
systems that are predominantly used in the industry. No other midsole
on the market generates more rebound (energy return). Compared with
EVA, BOOST™ shows three times better temperature resistance in its
deformation behavior – less hardening in the cold and less softening at
high temperatures. Its durability under cyclical dynamic loading is also
significantly better than with EVA cushioning systems.
However, what nearly all the runners who tested the Energy Boost
shoes highlighted above all was the very special feeling produced by
the shoe when they were running. Test runners at adidas found it to be
innovative and inspiring.
Page 6 P 301/13e Making the energy visible in the design
The huge importance of the new BOOST™ technology is underlined by
the striking design of this product range. A bright yellow line around the
white material highlights its characteristic cellular structure and makes
the energy and the potential of it clear to see. The sole is made up of a
total of about 2500 small beads and is really eye-catching.
In Germany there are around ten million runners who in 2011 spent
some 400 million euros on approximately six million pairs of running
shoes. With its Energy Boost, adidas was able to celebrate one of the
most successful market launches for a running shoe in the history of the
company. Since February, adidas has sold about a quarter of a million
pairs of the innovative shoes worldwide. The specialist press is full of
praise: for example, the shoe was voted "Best Debut" by the world's
leading running magazine, Runner’s World: "The Energy Boost is the
best the running shoe industry has to offer. It performed better than any
of the almost 800 other shoes we tested," wrote Runner’s World. Top
athlete Dennis Kimetto even set a new track record in the Tokyo
Marathon wearing Boost shoes.
www.infinergy.basf.com
Information on Infinergy: [email protected]
Press photo at:
www.basf.com/pressphoto-database under category “plastics”, search term “Infinergy”
or also at BASF’s plastics press archive: www.basf.de/plastics/pressreleases
About adidas
The adidas Group is one of the world's leading manufacturers of sports equipment,
with a wide range of products sold under brand names such as adidas, TaylorMade,
Rockport and Reebok. The adidas Group is based in Herzogenaurach (Germany); it
employs over 46,000 people and had a turnover of about 14.9 billion euros in 2012.
Page 7 P 301/13e About BASF
BASF is the world’s leading chemical company: The Chemical Company. Its portfolio
ranges from chemicals, plastics, performance products and crop protection products
to oil and gas. We combine economic success with environmental protection and
social responsibility. Through science and innovation, we enable our customers in
nearly every industry to meet the current and future needs of society. Our products
and solutions contribute to conserving resources, ensuring nutrition and improving
quality of life. We have summed up this contribution in our corporate purpose: We
create chemistry for a sustainable future. BASF had sales of €72.1 billion in 2012 and
more than 110,000 employees as of the end of the year. BASF shares are traded on
the stock exchanges in Frankfurt (BAS), London (BFA) and Zurich (AN). Further
information on BASF is available on the Internet at www.basf.com.
Page 8 P 301/13e
Photo: BASF/adidas, 2013
BASF presents “Infinergy”, the world's first expanded thermoplastic polyurethane (E-
TPU). This closed-cell particle foam shows an excellent resilience and an especially high
durability over a wide temperature range. Other characteristics of the new foam are high
abrasion and chemical resistance plus high tear strength. This means that BASF is now
able to boast a broad portfolio of particle foams, from rigid foam (EPS) to soft and
stretchy foam plastic (E-TPU).
The first product making use of this innovative material is the new Energy Boost running
shoe from adidas, which the German sportswear manufacturer has developed in close
partnership with BASF. The midsole consisting of the new E-TPU with its combination of
softness and high elasticity is responsible for the outstanding running characteristics of
the Energy Boost running shoes. Their rebound is the highest of all available running
shoes and remains stable even at low temperatures of minus 20°C (68 °F).
InfinergyTM: BASF developsthe first expanded TPU As stretchy as rubber but also light and springy
Martin ValloElastollan FootwearBASF Polyurethanes GmbH
Gerd ManzSenior Innovation Director Global Brands adidas AG
0
Made easy:The first expanded TPU worldwide
Electron microscope E-TPU
Competence in materials
Elastollan® (TPU)
Processing know-how
Innovative expansion process
Innovation
InfinergyTM (E-TPU)
1
InfinergyTM combines properties of foams and TPU
Properties Origin
Low density Foams in general
Low water Closed-cell absorption structure
High breaking elonga- TPUtion, tensile strength and abrasion resistance
Good chemicalresistance
Elasticity over a widetemperature range
Excellent recovery Combinationbehavior under a TPU + Expansioncontinuous load
2
Good resilience due to closed-cell structure
3
Drop height: 50 cmBalll: Ø 16 mm / 16,3 g
Density:30 kg/m³ respectively 265 kg/m³ (E-TPU)
19
30
55
EPS EPP E-TPUInfinergy
Ball rebound test according to ISO 8307
Rebound height of E-TPU: about 55%
100 100
22
93
Elastic even under continuous load and over wide temperature range
High-frequency fatigue test
Dynamic loads of 250 kPaand 5 cycles / second
Thickness of the test piece after 40,000 cycles:EPE: 22% ( 9 mm)E-TPU: 93% (37 mm)
Dynamic mechanical analysis
Infinergy stays elastic up to -20°C
4
EPE E-TPU
Before test (40 mm = 100%)After test (40,000 Zyklen)
Density:30 kg/m³ (EPE), 265 kg/m³ (E-TPU)
Diverse applicationsin sports and leisure
Further applications: cushioning elements und upholstery
Processing:
On molding machines for expanded polyolefin
Gluing and foam sealing for large-scale processing
5
Sports and floors Inner tubes for bicycles Ship fenders
SLIDE: SOFT AND RESPONSIVE
COMBINED.
WE HAVE SOLVED IT. YEAH!
Adidas innovations
© adidas AG, FOR INTERNAL USE ONLY 2
3
ARE YOU READY FOR BOOST?
BOOST midsole
soft responsive
SLIDE: SOFT VERSUS RESPONSIVE
p. 6
p. 7
HIGHEST ENERGY RETURNIN THE RUNNING INDUSTRY
p. 8
HIGHEST ENERGY RETURNIN THE RUNNING INDUSTRY
p. 9
TEMPERATURE RESISTANCE LIKE
NEVER BEFORE
p. 10
FEELING IS BELIEVING.
TRY IT.
p. 12
Intuitive design
AND JUST LIKE THAT,
RUNNING WILL NEVER BE THE
SAME
p. 14View / Header and Footer 6/17/2013