Published Technical Disclosure Archive

Advanced Composite Foam: Multi-Industry Thermal Solution

Publication ID: 24-11857024_0002_PTD
Published: October 27, 2025
Category:New Applications & Use Cases

Legal Citation

pr1or.art Inc., “Advanced Composite Foam: Multi-Industry Thermal Solution,” Published Technical Disclosure No. 24-11857024_0002_PTD, Published October 27, 2025, available at https://archive.pr1or.art/24-11857024_0002_PTD
This technical disclosure describes improvements that would be readily apparent to a Person Having Ordinary Skill In The Art (PHOSITA) when considered in combination with the foundational architecture disclosed in U.S. Patent No. 11,857,024.

Background and Problem Solved

The original patent disclosed a composite foam for midsoles in performance footwear, limited to the athletic footwear industry. However, the unique properties of this foam, such as its high performance, durability, and versatility, can be leveraged to address unmet needs in other industries. The new invention addresses the problem of limited thermal insulation, acoustic insulation, thermal energy storage, and refrigeration unit efficiency in these industries.

Novelty and Inventive Step

The new claims introduce novel applications and use cases for the composite foam, which were not contemplated in the original patent. The inventive step lies in recognizing the foam's potential beyond footwear and adapting it to address specific challenges in diverse industries.

Alternative Embodiments and Variations

Alternative embodiments may include varying the pelletized expanded thermoplastic elastomer's material composition, shape, and size to optimize performance in specific industries. Additional variations may involve combining the composite foam with other materials or incorporating it into existing systems to enhance its functionality.

Potential Commercial Applications and Market

The composite foam has significant commercial potential in industries such as construction, refrigeration, and energy storage. Its ability to provide efficient thermal insulation, acoustic insulation, and energy storage makes it an attractive solution for companies seeking to reduce energy consumption, improve efficiency, and minimize environmental impact.

CPC Classifications

SectionClassGroup
A A43 A43B13/026
A A43 A43B13/04
C C08 C08J9/0061
C C08 C08L75/04
C C08 C08J2367/02
C C08 C08J2375/04
C C08 C08J2377/00
C C08 C08J2467/02
C C08 C08J2475/04
C C08 C08J2477/00

Field of Art

Polymer composite materials and thermal insulation technologies, with expertise in thermoplastic elastomers, polyurethane matrix compositions, and material engineering across multiple industrial applications

Person of Ordinary Skill (PHOSITA) Profile

A materials engineer with advanced degree and 5-7 years experience in polymer science, capable of understanding material property transfer and cross-industry material adaptation strategies

Obviousness Rationale

A skilled practitioner would recognize the composite foam's fundamental thermal and structural properties are transferable across multiple technical domains. The polyurethane matrix and expanded thermoplastic elastomer combination provides inherent versatility for thermal management applications. The source patent's detailed material composition provides a clear technical foundation for exploring alternative industrial uses beyond footwear.

Obvious Combinations & Variations

Source Patent Element
Pelletized expanded thermoplastic elastomer mixed within polyurethane matrix
PTD Variation
Applying the composite foam as thermal insulation in buildings and refrigeration units
Obviousness Reasoning
Predictable extension of known thermal insulation properties, with material characteristics already optimized for consistent performance
Source Patent Element
Spheroid pellet configuration with 1-12mm dimensional range
PTD Variation
Adapting pellet geometry for acoustic dampening and thermal energy storage applications
Obviousness Reasoning
Pellet shape and size directly correlate with sound transmission and thermal transfer characteristics, representing a routine design optimization
Source Patent Element
Expanded thermoplastic polyester elastomer composition
PTD Variation
Utilizing composite foam in solar thermal energy capture and storage systems
Obviousness Reasoning
Material's inherent thermal stability and matrix composition make it naturally suitable for energy conversion and retention applications
Source Patent Element
Polyurethane matrix with embedded thermoplastic elastomer
PTD Variation
Creating multi-functional insulation systems for energy efficiency
Obviousness Reasoning
Composite material's inherent adaptability suggests predictable performance across thermal management contexts
Source Patent Element
Composite foam structural configuration
PTD Variation
Implementing foam in specialized thermal engineering contexts like solar stills
Obviousness Reasoning
Material's fundamental thermal properties translate directly to alternative technical domains through routine engineering adaptation
35 U.S.C. § 103 Summary: Based on US Patent 11857024's comprehensive disclosure of composite foam material composition, a person of ordinary skill would find the alternative industrial applications disclosed herein to represent obvious variations that do not rise to the level of non-obvious innovation, thereby establishing robust prior art against potential future patent claims in thermal management and material engineering domains.

Original Patent Information

Patent NumberUS 11,857,024
TitleComposite foam for midsole
Assignee(s)Columbia Sportswear North America, Inc.