Composite structures including a bonding layer and methods of making the composite structure

Patent metadata

Field	Value
Publication number	US-11523653-B2
Application number	US-201916689336-A
Country	US
Kind code	B2
Filing date	Nov 20, 2019
Priority date	Feb 21, 2019
Publication date	Dec 13, 2022
Grant date	Dec 13, 2022

Abstract

Aspects of the present disclosure provide for composite structures including a bonding layer that adheres a substrate (e.g., including a polymeric composition such as rubber) to a material (e.g., including a polymer such as polyurethane). The adhesion of the substrate to the material through the bonding layer can include chemical bonds such as, but not limited to, siloxane linkages, silanol linkages, silyl linkages, or any combination thereof in the bonding layer.

First claim

What is claimed:

1. A method of making an article of footwear, the method comprising:
forming a bonding layer that comprises a plurality of silicates on a polymeric composition defining a surface of a component of footwear;
contacting the bonding layer with a material comprising a plurality of polyurethane (PU) polymer chains; and
forming chemical bonds between a portion of the plurality of silicates of the bonding layer and a first portion of the plurality of PU polymer chains of the material, thereby bonding the component of footwear to the material.

2. The method of claim 1 , wherein the forming the bonding layer comprises treating the surface of the component of footwear using a process chosen from flame silanization, deposition of silicates, or both, thereby forming the plurality of silicates on the surface of the component of footwear.

3. The method of claim 1 , wherein the forming chemical bonds includes forming siloxane linkages, silanol linkages, silyl linkages, or any combination thereof.

4. The method of claim 3 , wherein the forming chemical bonds includes forming urethane-siloxane linkages, urethane-silanol linkages, urethane-silyl linkages, or any combination thereof.

5. The method of claim 1 , wherein, during the contacting, the material is a liquid resin or a foam.

6. The method of claim 1 , wherein the polymeric composition of the component of footwear comprises a plurality of polymer chains chosen from cured rubber polymer chains, polyether block amide polymer chains, ethylene vinyl acetate polymer chains, or any combination thereof.

7. The method of claim 6 , wherein the polymeric composition of the component of footwear comprises the plurality of polyether block amide polymer chains.

8. The method of claim 6 , wherein the polymeric composition of the component of footwear comprises the plurality of ethylene vinyl acetate polymer chains.

9. The method of claim 6 , wherein the component of footwear comprises the plurality of cured rubber polymer chains.

10. The method of claim 9 , wherein the plurality of cured rubber polymer chains comprise a plurality of cured rubber chains individually having a maleic anhydride moiety grafted to the rubber chain.

11. The method of claim 1 , wherein the step of forming the bonding layer further comprises forming a bonding layer that comprises a plurality of free radical moieties on the polymeric composition defining the surface of the component of footwear; and the step of forming the chemical bonds further comprises forming chemical bonds between a portion of the plurality of free radical moieties of the bonding layer and a second portion of the plurality of PU polymer chains of the material.

12. The method of claim 11 , wherein the forming the bonding layer comprises treating the surface of the component of footwear using a process chosen from hydrocarbon flame processing, plasma processing, corona processing, or any combination thereof, thereby forming the plurality of free radical moieties on the surface of the component of footwear.

13. The method of claim 11 , wherein forming the chemical bonds includes forming chemical bonds between a portion of the plurality of free radical moieties of the bonding layer and a second portion of urethane moieties of the plurality of PU polymer chains of the material.

Assignees

• Nike Inc

Inventors

• Archer Paul
• Bee Jennifer
• Darland Jeffrey E

Classifications

• B32B2310/0445

  using gas or flames (B32B2310/0427 takes precedence) · CPC title

• B32B7/12

  using interposed adhesives or interposed materials with bonding properties · CPC title

• B32B25/08

  of synthetic resin · CPC title

• A43B13/04

  Plastics, rubber or vulcanised fibre · CPC title

• B32B37/15

  with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state · CPC title