Integrated polyurethane article

Patent metadata

Field	Value
Publication number	US-10973281-B2
Application number	US-201916673094-A
Country	US
Kind code	B2
Filing date	Nov 4, 2019
Priority date	Jun 24, 2014
Publication date	Apr 13, 2021
Grant date	Apr 13, 2021

Abstract

This technology relates to an integrated article that includes (a) a flexible foam region and (b) a non-foam region. The flexible foam region and the non-foam region are each made of a polyurethane composition. In some embodiments, the flexible foam region is a midsole, and wherein the non-foam region is an outsole. The flexible foam region is made from a flexible polyurethane injection molded foam. The non-foam region is made from a non-foamed polyurethane, which may be extruded or thermoformed. The invention relates to this integrated article, as well as the methods of making and using the same.

First claim

What is claimed is:

1. An article of footwear comprising:
an integrated outsole and midsole, and an upper bonded to the integrated outsole and midsole;
wherein said midsole comprises a flexible foamed polyurethane composition, wherein the foamed polyurethane composition of said flexible foam region has a weight average molecular weight of 120,000 to 500,000, and a polydispersity (Mw/Mn) of 1.85 to 2.51;
wherein said outsole comprises a non-foamed polyurethane composition, wherein the non-foamed polyurethane composition has a weight average molecular weight of 200,000 to 350,000, and a polydispersity (Mw/Mn) of 2.30 to 2.50;
wherein said foamed polyurethane composition and said non-foamed polyurethane composition comprise the reaction product of: (i) at least one polyol, (ii) at least one isocyanate, and (iii) at least one chain extender, wherein the combined isocyanate and chain extender make up a hard segment of the polyurethane compositions;
wherein said foamed polyurethane composition is injection foam molded to form said midsole, and wherein said non-foamed polyurethane composition is injection molded to form said outsole; and
wherein the chain extender comprises benzene glycol, 1,4-butandiol, or a combination thereof; wherein the polyol comprises a polyester polyol, a polyether polyol, a polycaprolactone polyol, or a combination thereof; and wherein the isocyanate comprises 4,4′-methylene diphenyl diisocyanate, m-xylene diisocyanate, phenylene-1,4-diisocyanate, naphthalene-1,5-diisocyanate, toluene diisocyanate, isophorone diisocyanate, 1,4-cyclohexyl diisocyanate, decane-1,10-diisocyanate, lysine diisocyanate, 1,4-butane diisocyanate, isophorone diisocyanate, 3,3′-dimethyl-4,4′-biphenylene diisocyanate, 1,5-naphthalene diisocyanate, dicyclohexylmethane-4,4′-diisocyanate or combinations thereof.

2. The article of footwear of claim 1 wherein the foamed polyurethane composition has:
(i) a vertical rebound, as measured by ASTM D2632, of at least 35%;
(ii) a compression set at room temperature, as measured by ASTM D395, of no more than 8%;
(iii) a compression set at 50° C., as measured by ASTM D395, of no more than 45%; and
(iv) an Asker C hardness, as measured by ASTM D2240, of 35 to 60.

3. The article of footwear of claim 1 wherein the non-foamed polyurethane composition has:
(i) a volume loss at room temperature, as measured by the DIN abrasion test, of less than 100 mm 3 ;
(ii) a volume loss at 65° C., as measured by the DIN abrasion test, of less than 100 mm 3 ;
(iii) a dry coefficient of friction, as measured by the Plint COF test, of at least 0.5; and
(iv) a wet coefficient of friction, as measured by the Plint COF test, of at least 0.5.

4. The article of footwear of claim 1 , wherein the polyol comprises butanediol adipate polyester polyol, an ethylene glycol adipate polyester polyol, a mixed ethylene glycol butanediol adipate ester or a combination thereof.

5. The article of footwear of claim 1 , wherein the foamed polyurethane composition has a hard segment content of from 23.5 to 45.0 percent by weight, and the polyol component comprises a polyether polyol.

6. The article of footwear of claim 1 , wherein the foamed polyurethane composition has a hard segment content of from 24 to 30 percent by weight, and the polyol component comprises a polyester polyol.

7. The article of footwear of claim 1 , wherein the foamed polyurethane composition has a hard segment content of greater than 30 percent by weight, and the polyol component comprises a polycaprolactone polyol.

8. The article of footwear of claim 1 , wherein the non-foamed polyurethane composition has a hard segment content of from 23.5 to 45.0 percent by weight, and the polyol component comprises a polyether polyol.

9. The article of footwear of claim 1 , wherein the non-foamed polyurethane composition has a hard segment content of from 24 to 30 percent by weight, and the polyol component comprises a polyester polyol.

10. The article of footwear of claim 1 , wherein the non-foamed polyurethane composition has a hard segment content of greater than 30 percent by weight, and the polyol component comprises a polycaprolactone polyol.

Assignees

• Lubrizol Advanced Mat Inc

Inventors

• Vontorcik Jr Joseph J
• Plessers An
• Kim Kenneth H
• Farkas Julius
• Jung Ungyeong

Classifications

• C08G2410/00

  Soles · CPC title

• A43B13/141

  with a part of the sole being flexible, e.g. permitting articulation or torsion · CPC title

• C08G2110/0008

  flexible · CPC title

• C08L75/04 Primary

  Polyurethanes · CPC title

• C08G18/76

  aromatic · CPC title