Wide density range and flexible geometry design make bead foam parts capture a large share of the polymeric foams market. However, traditional steam-chest molding process used to prepare bead foams involves complex molding facilities and high energy consumption. Herein, a novel in-mold foaming and molding (IMFM) method using supercritical CO₂ as blowing agent was developed for the preparation of bead foam parts. TPU pellets were loaded in a special mold and TPU bead foam parts were fabricated in-mold after pressure quench. The molded parts with a density of 0.2 g/cm³ presented an elongation at break of 217 % and a ball rebound of 58 %. The energy loss coefficients of the bead foams remained lower than 12 % during the 100-time cyclic compression process. Restricted cell growth and simultaneous inter-bead welding in limited space were the key elements for this novel method. This method opens a new route to the production of bead foams with high performance in a convenient and efficient process.

宽密度范围和灵活的几何设计使珠状泡沫部件占据了聚合物泡沫市场的很大份额。然而，用于制备珠状泡沫的传统蒸汽箱成型工艺涉及复杂的成型设备和高能耗。_{在此，开发了一种使用超临界 CO 2}作为发泡剂的新型模内发泡成型 (IMFM) 方法，用于制备珠状泡沫部件。将 TPU 颗粒装入特殊模具中，并在压力淬火后在模具内制造 TPU 珠状泡沫部件。^{密度为0.2 g/cm 3}的成型件呈现出 217% 的断裂伸长率和 58% 的球回弹率。在 100 次循环压缩过程中，珠状泡沫的能量损失系数保持低于 12%。限制细胞生长和在有限空间内同时进行珠间焊接是这种新方法的关键要素。该方法为以便捷高效的工艺生产高性能珠粒泡沫开辟了一条新途径。