CN114466604A - Artificial leather composition and upper for article of footwear comprising the same - Google Patents
Artificial leather composition and upper for article of footwear comprising the same Download PDFInfo
- Publication number
- CN114466604A CN114466604A CN202080067503.4A CN202080067503A CN114466604A CN 114466604 A CN114466604 A CN 114466604A CN 202080067503 A CN202080067503 A CN 202080067503A CN 114466604 A CN114466604 A CN 114466604A
- Authority
- CN
- China
- Prior art keywords
- synthetic leather
- polymer
- composition
- resin composition
- polyolefin resin
- Prior art date
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Images
Classifications
-
- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
- A43B23/02—Uppers; Boot legs
- A43B23/0205—Uppers; Boot legs characterised by the material
- A43B23/0215—Plastics or artificial leather
-
- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B13/00—Soles; Sole-and-heel integral units
- A43B13/02—Soles; Sole-and-heel integral units characterised by the material
-
- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B13/00—Soles; Sole-and-heel integral units
- A43B13/02—Soles; Sole-and-heel integral units characterised by the material
- A43B13/04—Plastics, rubber or vulcanised fibre
-
- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
- A43B23/02—Uppers; Boot legs
- A43B23/0205—Uppers; Boot legs characterised by the material
- A43B23/0235—Different layers of different material
-
- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
- A43B23/02—Uppers; Boot legs
- A43B23/0245—Uppers; Boot legs characterised by the constructive form
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
- Treatment And Processing Of Natural Fur Or Leather (AREA)
Abstract
Various panels for footwear are provided, the panels comprising a polyolefin resin. A sole structure and an article of footwear formed therefrom are also provided. Methods of making the polyolefin resin composition, plate, sole structure, and article of footwear are also provided. In some aspects, the polyolefin resin composition comprises an effective amount of a polymer resin modifier. The effective amount may be an amount effective to allow the resin composition to pass the flex test and particularly to pass the flex test without significant change in abrasion loss. In some aspects, the resin composition further comprises a transparency agent to improve the optical transparency of the sheet. In some aspects, the panel includes a textile disposed on one or both of the first side and the second side of the panel. The textile may provide improved bonding of the plate to other components, such as a base layer or an upper.
Description
Cross Reference to Related Applications
The present application claims the benefit and priority OF U.S. provisional application serial No. 62/878,239 with the title "SYNTHETIC LEATHER HAVING polymeric in AND ARTICLES OF powered FORMED thermally disposed rom" filed 24/7/2019 and U.S. provisional application serial No. 62/939,809 with the title "SYNTHETIC LEATHER HAVING polymeric in AND ARTICLES OF powered FORMED thermally disposed rom" filed 25/11/2019, and U.S. provisional application serial No. 62/945,509 with the title "SYNTHETIC LEATHER HAVING polymeric in AND ARTICLES OF powered FORMED thermally disposed ram" filed 9/12/2019, the disclosures OF which are incorporated herein by reference in their respective entireties.
Technical Field
The present disclosure relates generally to sole structures and plates comprising polyolefin resins and articles of footwear including the sole structures.
Background
The design and manufacture of footwear and athletic equipment involves a variety of factors ranging from aesthetic aspects, to comfort and feel, to performance and durability. While design and fashion may change rapidly, the footwear and athletic equipment market has not changed in demand for enhanced performance. Furthermore, the market has turned to a need for lower cost and recyclable materials that can still meet the need for enhanced performance. To balance these needs, designers of footwear and athletic equipment have adopted a variety of materials and designs for various components.
Brief Description of Drawings
Additional aspects of the disclosure will be readily appreciated when the detailed description set forth below is read in conjunction with the appended drawings.
1A-1H depict example articles of athletic footwear. FIG. 1A is a lateral side perspective view of an example article of athletic footwear. FIG. 1B is a lateral side elevational view of an exemplary article of athletic footwear. FIG. 1C is a medial side elevational view of the exemplary article of athletic footwear. FIG. 1D is a top view of an exemplary article of athletic footwear. FIG. 1E is a front view of an exemplary article of athletic footwear. FIG. 1F is a rear view of an exemplary article of athletic footwear. FIG. 1G is an exploded perspective view of an exemplary article of athletic footwear. FIG. 1H is a cross-sectional view along 1-1 of an exemplary article of athletic footwear.
Fig. 2A-2C depict a second example article of athletic footwear. Fig. 2A is a lateral side elevational view of an exemplary article of athletic footwear. Fig. 2B is an exploded perspective view of a second exemplary article of athletic footwear. FIG. 2C is a cross-sectional view along 2-2 of a second exemplary article of athletic footwear.
Figure 3 depicts an exploded view of a third example sole structure having a bottom layer and a rigid plate that provides rigidity without adding significant additional material and thus maintains low weight.
Fig. 4A-4C depict a fourth example article of athletic footwear. FIG. 4A is a lateral side elevational view of an exemplary article of athletic footwear. Fig. 4B is an exploded perspective view of a second exemplary article of athletic footwear. FIG. 4C is a cross-sectional view along 4-4 of a second exemplary article of athletic footwear.
Fig. 5A-5B depict a fifth exemplary article of athletic footwear. FIG. 5A is a lateral side elevational view of a fifth exemplary article of athletic footwear. FIG. 5B is an exploded perspective view of a fifth exemplary article of athletic footwear.
Fig. 6A-6B show cross-sectional views of the disclosed synthetic leather material. Fig. 6A is a cross-sectional view of the disclosed synthetic leather material 600, the synthetic leather material 600 including a synthetic leather textile layer 610 to which a synthetic leather polymer coating 620 is attached. Fig. 6B is a cross-sectional view of the disclosed synthetic leather material 600, the synthetic leather material 600 including a synthetic leather textile layer 610 to which a synthetic leather polymer coating 620 is attached, and further including a synthetic leather protective or decorative layer 630 attached to the synthetic leather polymer coating 620.
Fig. 7A-7B show cross-sectional views of the disclosed synthetic leather material. Fig. 7A is a cross-sectional view of the disclosed synthetic leather material 700, the synthetic leather material 700 including a synthetic leather textile layer 710 to which a first synthetic leather polymer coating 720 is attached and a second synthetic leather polymer coating composition 730 attached to the first synthetic leather polymer coating 720. Fig. 7B is a cross-sectional view of the disclosed synthetic leather material 700, the synthetic leather material 700 including a synthetic leather textile layer 710 to which a first synthetic leather polymer coating 720 is attached and a second synthetic leather polymer coating composition 730 attached to the first synthetic leather polymer coating 720, and further including a synthetic leather protective or decorative layer 740 attached to the second synthetic leather polymer coating 730.
Detailed Description
The latest levels of specialty polymers for footwear and athletic equipment include polymers such as polyurethane polymers and polyamide polymers, but there is still a need for lower cost alternatives to these performance polymers, particularly lower cost alternatives that are recyclable and easy to process. Alternatives such as polyolefins, while cost effective, have traditionally had poor mechanical properties as well as poor surface and surface energy for bonding. New designs and materials are needed. In particular, there remains a need for improved polymer resins for use in making parts of footwear and athletic equipment that resist stress whitening or cracking when flexed under cold conditions, are abrasion resistant, and can be adequately incorporated for footwear and other athletic equipment applications.
In various aspects, the present disclosure provides a sole structure including a plate including a polyolefin resin. In some aspects, a sole structure includes a plate and a textile on one or more surfaces of the plate. The textile may improve the bonding of other components (e.g., the upper or lower layer) to the panel. Textiles may also be used for decorative purposes. The panels having the polyolefin resin composition may have improved mechanical properties, making them particularly suitable for use in components of footwear and sports equipment. In particular, these resin compositions are both resistant to stress whitening or cracking when flexed under cold conditions and abrasion resistant to the levels required for use in footwear and athletic equipment. The present disclosure provides various panels for articles of footwear comprising these polyolefin resin compositions.
In some aspects, the present disclosure provides a sole structure for an article of footwear, the sole structure having: a plate comprising a polyolefin resin, the plate having a first side and a second side, wherein the first side is configured to be ground-facing when the plate is a component of an article of footwear; and a textile disposed on one or both of the first side and the second side. In some aspects, the sole structure further includes a bottom layer configured on the first side of the plate. When the sole structure is a component of an article of footwear, the bottom layer may wrap around the plate and engage or be attached to the upper, e.g., the bottom layer may be attached to the upper at a bite line. In some aspects, the sole structure does not include a textile, for example, the sole structure may include a plate and a bottom layer as described above and in more full detail below.
In various aspects, the present disclosure also provides an article of footwear including a sole structure described herein.
The present disclosure will be better understood upon reading the following numbered aspects, which should not be confused with the claims. In some cases, any of the following numbered aspects may be combined with aspects described elsewhere in the disclosure, and such combinations are intended to form part of the disclosure.
Aspect 3. the synthetic leather material of aspect 2, wherein the synthetic leather polymer coating composition is substantially free of the polyolefin resin composition.
Aspect 5 the synthetic leather material of aspect 3 or aspect 4, wherein the synthetic leather polymer coating composition has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the fiber/yarn polymer composition; or wherein the synthetic leather polymer coating composition has a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the fiber/yarn polymer composition.
Aspect 6 the synthetic leather material of aspect 1, wherein the synthetic leather textile layer comprises: a first fiber or first yarn comprising a first fiber/yarn polymer composition comprising or consisting essentially of the polyolefin resin composition; and a second fiber or second yarn comprising a second fiber/yarn polymer composition comprising one or more thermoplastic polymers selected from polyester, polyether, polyamide, or polyurethane.
The synthetic leather material of aspect 7. the synthetic leather material of aspect 6, wherein the second fiber/yarn polymer composition has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the first fiber/yarn polymer composition; or wherein the first fiber/yarn polymer composition has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the second fiber/yarn polymer composition.
The synthetic leather material of aspect 6, wherein the one or more thermoplastic polymers of the second fibers or second yarns have a melting temperature or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting temperature or softening temperature of the polyolefin resin composition of the first fibers or first yarns; or wherein the one or more thermoplastic polymers of the second fibers or second yarns have a melting temperature or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting temperature or softening temperature of the polyolefin resin composition of the first fibers or first yarns.
Aspect 9. the synthetic leather material of any of aspects 6 to 8, wherein the synthetic leather polymer coating composition is substantially free of polyolefins.
Aspect 10 the synthetic leather material of aspect 9, wherein the synthetic leather polymer coating composition comprises one or more thermoplastic polymers selected from polyesters, polyethers, polyamides, or polyurethanes.
The synthetic leather material of aspect 10, wherein the synthetic leather polymer coating composition has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the first fiber/yarn polymer composition; or wherein the synthetic leather polymer coating composition has a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher than the melting or softening temperature of the first fiber/yarn polymer composition.
The synthetic leather material of aspect 12, wherein the one or more thermoplastic polymers of the synthetic leather polymer coating have a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the polyolefin resin composition of the first fibers or first yarns; or wherein the one or more thermoplastic polymers of the synthetic leather polymer coating have a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the polyolefin resin composition of the first fibers or first yarns.
The synthetic leather material of aspect 1, wherein the fiber/yarn polymer composition is substantially free of polyolefin; and wherein the fiber/yarn polymer composition comprises one or more thermoplastic polymers.
Aspect 14 the synthetic leather material of aspect 13, wherein the fiber/yarn polymer composition has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the synthetic leather polymer coating composition; or wherein the fiber/yarn polymer composition has a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the synthetic leather polymer coating composition.
Aspect 15 the synthetic leather material of aspect 13 or aspect 14, wherein the synthetic leather polymer coating composition comprises or consists essentially of the polyolefin resin composition.
The synthetic leather material of aspect 16, wherein the one or more thermoplastic polymers of the fiber/yarn composition have a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the polyolefin resin composition; or wherein the one or more thermoplastic polymers of the fiber/yarn composition have a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the polyolefin resin composition.
Aspect 17 the synthetic leather material of aspect 2, aspect 6, or aspect 13, wherein the synthetic leather polymer coating composition comprises the polyolefin resin composition.
The synthetic leather material of any of aspects 1-17, wherein the one or more thermoplastic polymers are selected from polyesters, polyethers, polyamides, or polyurethanes.
The synthetic leather material of aspect 18, wherein the one or more thermoplastic polymers comprise one or more polyesters.
Aspect 20 the synthetic leather material of aspect 18 or aspect 19, wherein the polyester comprises polyethylene terephthalate (PET).
Aspect 21 the synthetic leather material of aspect 18, wherein the one or more thermoplastic polymers comprise one or more polyamides.
Aspect 22 the synthetic leather material of aspect 18 or aspect 21, wherein the polyamide comprises nylon 6, nylon 12, and combinations thereof.
Aspect 23 the synthetic leather material of aspect 18, wherein the one or more thermoplastic polymers comprise one or more polyurethanes.
The synthetic leather material according to any one of aspects 18-23, wherein the one or more thermoplastic polymers comprise one or more thermoplastic copolymers.
Aspect 25 the synthetic leather material of aspect 24, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolymer selected from the group consisting of: thermoplastic copolyesters, thermoplastic copolyethers, thermoplastic copolyamides, thermoplastic copolyurethanes, and combinations thereof.
Aspect 26 the synthetic leather material of aspect 24, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyester.
Aspect 27 the synthetic leather material of aspect 24, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyether.
Aspect 28. the synthetic leather material of aspect 24, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyamide.
Aspect 29 the synthetic leather material of aspect 24, wherein the one or more thermoplastic copolymers comprise a thermoplastic co-polyurethane.
Aspect 30 the synthetic leather material of any one of aspects 18 to 29, wherein the one or more thermoplastic polymers comprise one or more thermoplastic polyether block amide (PEBA) copolymers.
The synthetic leather material of any of aspects 18-30, wherein the one or more thermoplastic polymers have a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the polyolefin resin composition; or wherein the one or more thermoplastic polymers have a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the polyolefin resin composition.
The synthetic leather material according to any of aspects 18-30, wherein the fiber/yarn polymer composition comprising one or more thermoplastic polymers has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the synthetic leather polymer coating composition; or wherein the fiber/yarn polymer composition comprising one or more thermoplastic polymers has a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the synthetic leather polymer coating composition.
The synthetic leather material according to any of aspects 18-30, wherein the fiber/yarn polymer composition comprising one or more thermoplastic polymers has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the synthetic leather polymer coating composition comprising the polyolefin resin composition; or wherein the fiber/yarn polymer composition comprising one or more thermoplastic polymers has a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the synthetic leather polymer coating composition comprising the polyolefin resin composition.
Aspect 34 the synthetic leather material of any of aspects 18-30, wherein the second fiber/yarn polymer composition comprising one or more thermoplastic polymers has a melting or softening temperature at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the first fiber/yarn polymer composition; or wherein the second fiber/yarn polymer composition comprising one or more thermoplastic polymers has a melting or softening temperature at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the first fiber/yarn polymer composition.
The synthetic leather material of any of aspects 18-30, wherein the second fiber/yarn polymer composition comprising one or more thermoplastic polymers has a melting or softening temperature at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the first fiber/yarn polymer composition comprising the polyolefin resin composition; or wherein a second fiber/yarn polymer composition comprising one or more thermoplastic polymers has a melting or softening temperature at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than a first fiber/yarn polymer composition comprising the polyolefin resin composition.
The synthetic leather material of any of aspects 18-30, wherein the second fiber/yarn polymer composition comprising one or more thermoplastic polymers has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the synthetic leather polymer coating composition; or wherein the second fiber/yarn polymer composition comprising one or more thermoplastic polymers has a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the synthetic leather polymer coating composition.
The synthetic leather material of any of aspects 18-30, wherein the second fiber/yarn polymer composition comprising one or more thermoplastic polymers has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the synthetic leather polymer coating composition comprising the polyolefin resin composition; or wherein the second fiber/yarn polymer composition comprising one or more thermoplastic polymers has a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the synthetic leather polymer coating composition comprising the polyolefin resin composition.
The synthetic leather material of aspect 1, wherein the synthetic leather polymer coating comprises more than one synthetic leather polymer coating, optionally wherein at least one of the more than one synthetic leather polymer coating comprises the polyolefin resin composition.
The synthetic leather material of aspect 39, wherein the synthetic leather polymer coating comprises a first synthetic leather polymer coating and a second synthetic leather polymer coating, wherein the first synthetic leather polymer coating is attached to the synthetic leather textile layer and the second synthetic leather polymer coating is attached to the first synthetic leather polymer coating.
Aspect 40 the synthetic leather material of aspect 39, wherein the synthetic leather polymer coating composition of the first synthetic leather polymer coating is substantially free of a polyolefin and the synthetic leather polymer coating composition of the second synthetic leather polymer coating comprises the polyolefin resin composition.
The synthetic leather material of aspect 40, wherein the synthetic leather polymer coating composition of the first synthetic leather polymer coating comprises one or more polymers selected from polyesters, polyethers, polyamides, or polyurethanes, optionally wherein the one or more polymers comprise one or more thermoplastic polymers.
The synthetic leather material of aspect 40 or aspect 41, wherein the synthetic leather polymer coating composition of the first synthetic leather polymer coating has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the fiber/yarn polymer composition; or wherein the synthetic leather polymer coating composition of the first synthetic leather polymer coating has a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the fiber/yarn polymer composition.
The synthetic leather material of aspect 38-aspect 42, wherein the synthetic leather polymer coating composition of the second synthetic leather polymer coating has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the fiber/yarn polymer composition; or wherein the synthetic leather polymer coating composition of the second synthetic leather polymer coating has a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the fiber/yarn polymer composition.
Aspect 44. the synthetic leather material of aspect 38, wherein the first synthetic leather polymer coating composition comprises or consists essentially of the polyolefin resin composition, and the second synthetic leather polymer coating composition is substantially free of polyolefin.
Aspect 45 the synthetic leather material of aspect 44, wherein the second synthetic leather polymer coating composition comprises one or more thermoplastic polymers selected from polyesters, polyethers, polyamides, or polyurethanes.
The synthetic leather material of aspect 44 or aspect 45, wherein the first synthetic leather polymer coating composition has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the fiber/yarn polymer composition; or wherein the first synthetic leather polymer coating composition has a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the fiber/yarn polymer composition.
The synthetic leather material of any of aspects 44-46, wherein the second synthetic leather polymer coating composition has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the fiber/yarn polymer composition; or wherein the second synthetic leather polymer coating composition has a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the fiber/yarn polymer composition.
Aspect 48 the synthetic leather material of aspect 38, wherein the first synthetic leather polymer coating composition comprises a first polyolefin resin composition and the second synthetic leather polymer coating composition comprises a second polyolefin resin composition.
Aspect 49 the synthetic leather material of aspect 48, wherein the first synthetic leather polymer coating composition and the second synthetic leather polymer coating composition are substantially the same polyolefin resin composition.
Aspect 50 the synthetic leather material of aspect 48, wherein the first synthetic leather polymer coating composition and the second synthetic leather polymer coating composition comprise one or more different polyolefins, or comprise different concentrations of the same polyolefin.
Aspect 51 the synthetic leather material of any one of aspects 38 to 50, wherein the one or more thermoplastic polymers comprise one or more polyesters.
Aspect 52 the synthetic leather material of aspect 51, wherein the polyester comprises polyethylene terephthalate (PET).
The synthetic leather material of any of aspects 38-50, wherein the one or more thermoplastic polymers comprise one or more polyamides.
Aspect 54 the synthetic leather material of aspect 53, wherein the polyamide comprises nylon 6, nylon 11, nylon 12, and combinations thereof.
The synthetic leather material of any of aspects 38-50, wherein the one or more thermoplastic polymers comprise one or more polyurethanes.
The synthetic leather material of any of aspects 38-50, wherein the one or more thermoplastic polymers comprise one or more thermoplastic copolymers.
Aspect 57 the synthetic leather material of aspect 56, wherein the one or more thermoplastic copolymers include a thermoplastic copolymer selected from the group consisting of: thermoplastic copolyesters, thermoplastic copolyethers, thermoplastic copolyamides, thermoplastic copolyurethanes, or combinations thereof.
Aspect 58 the synthetic leather material of aspect 56, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyester.
Aspect 59. the synthetic leather material of aspect 56, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyether.
Aspect 60 the synthetic leather material of aspect 56, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyamide.
Aspect 61 the synthetic leather material of aspect 56, wherein the one or more thermoplastic copolymers comprise a thermoplastic co-polyurethane.
The synthetic leather material of any of aspects 41-61, wherein the one or more thermoplastic polymers comprise one or more thermoplastic polyether block amide (PEBA) copolymers.
The synthetic leather material of any of aspects 38-62, wherein the fiber/yarn polymer composition has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the synthetic leather polymer coating composition; or wherein the fiber/yarn polymer composition has a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the synthetic leather polymer coating composition.
The synthetic leather material of any of aspects 38 to 63, wherein the synthetic leather textile layer comprises: a first fiber or first yarn comprising a first fiber/yarn polymer composition comprising the polyolefin resin composition; and a second fiber or second yarn comprising a second fiber/yarn polymer composition comprising one or more thermoplastic polymers selected from the group consisting of polyesters, polyethers, polyamides, and polyurethanes.
The synthetic leather material of aspect 64, wherein the second fiber/yarn polymer composition has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the first fiber/yarn polymer composition; or wherein the second fiber/yarn polymer composition has a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the first fiber/yarn polymer composition.
The synthetic leather material of aspect 64, wherein the one or more thermoplastic polymers of the second fibers or second yarns have a melting temperature or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting temperature or softening temperature of the polyolefin resin composition of the first fibers or first yarns; or wherein the one or more thermoplastic polymers of the second fibers or second yarns have a melting temperature or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting temperature or softening temperature of the polyolefin resin composition of the first fibers or first yarns.
Aspect 67 the synthetic leather material of any one of aspects 38 to 66, wherein each synthetic leather polymer coating comprises a film.
Aspect 68 the synthetic leather material of any of aspects 1-66, wherein the synthetic leather textile layer is a knit textile.
Aspect 69 the synthetic leather material of aspect 68, wherein the knitted textile is a flat-bed knitted textile, a circular knitted textile, or a weft knitted textile.
Aspect 70 the synthetic leather material of any of aspects 1-66, wherein the synthetic leather textile layer is a crocheted textile.
Aspect 71 the synthetic leather material of any of aspects 1-66, wherein the synthetic leather textile layer is a knit textile.
Aspect 72 the synthetic leather material of any of aspects 1-66, wherein the synthetic leather textile layer is a woven textile.
Aspect 73 the synthetic leather material of any one of aspects 1 to 66, wherein the synthetic leather textile layer is a non-woven textile.
Aspect 74 the synthetic leather material of any of aspects 1-73, further comprising a protective or decorative layer attached to the synthetic leather polymer coating.
Aspect 75 the synthetic leather material of aspect 74, wherein the protective or decorative layer is substantially free of polyolefin.
Aspect 76 the synthetic leather material of aspect 74, wherein the protective or decorative layer comprises a polyolefin resin composition.
Aspect 77 the synthetic leather material of aspect 74, wherein the protective or decorative layer comprises one or more thermoplastic polymers.
The synthetic leather material of aspect 77, wherein the one or more thermoplastic polymers are selected from polyesters, polyethers, polyamides, or polyurethanes.
Aspect 79 the synthetic leather material of aspect 78, wherein the one or more thermoplastic polymers comprise one or more polyesters.
Aspect 80 the synthetic leather material of aspect 78 or aspect 79, wherein the polyester comprises polyethylene terephthalate (PET).
The synthetic leather material of aspect 81, wherein the one or more thermoplastic polymers comprise one or more polyamides.
Aspect 82 the synthetic leather material of aspect 78 or aspect 81, wherein the polyamide comprises nylon 6, nylon 12, and combinations thereof.
The synthetic leather material of aspect 83, wherein the one or more thermoplastic polymers comprise one or more polyurethanes.
The synthetic leather material of aspect 84, according to any one of aspects 77-83, wherein the one or more thermoplastic polymers comprise one or more thermoplastic copolymers.
The synthetic leather material of aspect 84, wherein the one or more thermoplastic copolymers comprise one or more thermoplastic copolymers selected from the group consisting of: thermoplastic copolyesters, thermoplastic copolyethers, thermoplastic copolyamides, thermoplastic copolyurethanes, or combinations thereof.
Aspect 86. the synthetic leather material of aspect 84, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyester.
The synthetic leather material of aspect 84, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyether.
The synthetic leather material of aspect 84, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyamide.
The synthetic leather material of aspect 84, wherein the one or more thermoplastic copolymers comprise a thermoplastic co-polyurethane.
The synthetic leather material of any of aspects 77-89, wherein the one or more thermoplastic polymers comprise one or more thermoplastic polyether block amide (PEBA) copolymers.
The synthetic leather material of any of aspects 77-90, wherein the one or more thermoplastic polymers have a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the polyolefin resin composition; or wherein the one or more thermoplastic polymers have a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the polyolefin resin composition.
The synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a polyolefin homopolymer or a polyolefin copolymer or both a polyolefin homopolymer and a polyolefin copolymer.
The synthetic leather material of aspect 92, wherein the polyolefin composition comprises the polyolefin homopolymer.
The synthetic leather material of aspect 92, wherein the polyolefin composition comprises the polyolefin copolymer.
Aspect 95 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises an effective amount of a polymeric resin modifier.
The synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition has an Abrasion Loss of about 0.05 cubic centimeters to about 0.1 cubic centimeters or about 0.08 cubic centimeters to about 0.1 cubic centimeters using the pure material sampling procedure according to the Abrasion Loss Test (Abrasion Loss Test).
Aspect 97 the synthetic leather material of any of aspects 1-145, wherein the effective amount of the polymer resin modifier is an amount effective to allow the polyolefin resin composition to pass a Flex Test according to the Cold sole Material Flex Test (Cold Ross Flex Test) using the substrate sampling procedure.
Aspect 98 the synthetic leather material of any of aspects 1-145, wherein the effective amount of the polymeric resin modifier is an amount of: the amount is effective to allow the polyolefin resin composition to pass a flex test according to the cold shoe sole material flex test using a substrate sampling procedure, when measured according to the abrasion loss test using a pure material sampling procedure, there is no significant change in abrasion loss as compared to the abrasion loss of a second polyolefin resin composition that is the same as the polyolefin resin composition except for the absence of the polymer resin modifier.
Aspect 99 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition has an abrasion loss of about 0.08 cubic centimeters to about 0.1 cubic centimeters.
Aspect 100 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a polyolefin copolymer, and the polyolefin copolymer is a random copolymer.
Aspect 101 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a polyolefin copolymer, and the polyolefin copolymer comprises more than one repeat unit, wherein each of the more than one repeat units is individually derived from an olefin monomer having from about 1 to about 6 carbon atoms.
Aspect 102 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a polyolefin copolymer, and the polyolefin copolymer comprises more than one repeating unit, wherein each of the more than one repeating units is individually derived from a monomer selected from the group consisting of ethylene, propylene, 4-methyl-1-pentene, 1-butene, and combinations thereof.
Aspect 103 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a polyolefin copolymer, and the polyolefin copolymer comprises more than one repeating unit, each repeating unit individually selected from formula 1A-formula 1D
Aspect 104 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a polyolefin copolymer, and the polyolefin copolymer comprises more than one repeating unit, each repeating unit individually having a structure according to formula 2
Wherein R is1Is hydrogen or substituted or unsubstituted, straight or branched C1-C12Alkyl or heteroalkyl.
Aspect 105 the synthetic leather material of any of aspects 1-145, wherein the polymer in the polyolefin resin composition consists essentially of a polyolefin copolymer, or consists essentially of a polyolefin copolymer and a polymer resin modifier.
The synthetic leather material of any of aspects 294-358, wherein the polyolefin resin composition comprises a polyolefin copolymer, and the polyolefin copolymer is a random copolymer of a first more than one repeat unit and a second more than one repeat unit, and wherein each repeat unit of the first more than one repeat unit is derived from ethylene, and each repeat unit of the second more than one repeat unit is derived from a second olefin.
Aspect 107. the synthetic leather material of any of aspects 106, wherein the second olefin is selected from the group consisting of: propylene, 4-methyl-1-pentene, 1-butene and other linear or branched terminal olefins having from about 3 to 12 carbon atoms.
The synthetic leather material of any of aspects 106 or 107, wherein each of the first more than one repeating unit has a structure according to formula 1A, and wherein each of the second more than one repeating unit has a structure selected from formula 1B-formula 1D
Aspect 109 the synthetic leather material of any one of aspects 106-108, wherein each of the first more than one repeating unit has a structure according to formula 1A, and wherein each of the second more than one repeating unit has a structure according to formula 2
Wherein R is1Is hydrogen or substituted or unsubstituted, straight or branched C2-C12Alkyl or heteroalkyl.
Aspect 111 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a polyolefin copolymer, and the polyolefin copolymer comprises about 1% to about 5%, about 1% to about 3%, about 2% to about 3%, or about 2% to about 5% by weight of ethylene, based on the total weight of the polyolefin copolymer.
Aspect 117 the synthetic leather material of any of aspects 1 to 145, wherein the polymer resin composition comprises an effective amount of a polymer resin modifier, and the effective amount of the polymer resin modifier is an amount of: the amount is effective to allow the polyolefin resin composition to pass a flex test according to the cold shoe sole material flex test using a substrate sampling procedure, when measured according to the abrasion loss test using a pure material sampling procedure, there is no significant change in abrasion loss as compared to the abrasion loss of a second polyolefin resin composition that is the same as the polyolefin resin composition except for the absence of the polymer resin modifier.
The synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a polypropylene copolymer, and the polypropylene copolymer comprises about 80% to about 99%, about 85% to about 99%, about 90% to about 99%, or about 95% to about 99% by weight of polypropylene repeat units, based on the total weight of the polypropylene copolymer.
Aspect 121. the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a polypropylene copolymer, and the polypropylene copolymer is a random copolymer comprising about 2% to about 3% by weight of a first more than one repeating unit and about 80% to about 99% by weight of a second more than one repeating unit, based on the total weight of the polypropylene copolymer; wherein each of the first more than one repeating unit has a structure according to formula 1A and each of the second more than one repeating unit has a structure according to formula 1B
Aspect 123 the synthetic leather material of any of aspects 1-145, wherein the polymer in the polyolefin resin composition consists essentially of a polymer comprising propylene repeating units.
Aspect 124. the synthetic leather material of any of aspects 1-145, wherein the polymer component of the polyolefin resin composition, consisting of all polymers present in the polyolefin resin composition, consists essentially of a polypropylene copolymer.
Aspect 125 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a polypropylene copolymer, and the propylene hydrocarbon copolymer is a random copolymer of ethylene and propylene.
Aspect 126 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition has an abrasion loss within about 20% of an abrasion loss of an otherwise identical polyolefin resin composition except for the absence of the resin modifier when measured according to an abrasion loss test using a pure material sampling procedure.
The synthetic leather material of aspect 127. any of aspects 1-145, wherein the polyolefin resin composition has a percent crystallinity of about 35%, about 30%, about 25%, or less, when measured according to the crystallinity test using the pure material sampling procedure.
Aspect 128 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition has a percent crystallinity that is at least 4 percentage points less than the percent crystallinity of an otherwise identical polyolefin resin composition except without the polymeric resin modifier when measured according to the crystallinity test using a pure material sampling procedure.
The synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises an effective amount of the polymeric resin modifier, and the effective amount of the polymeric resin modifier is about 5% to about 30%, about 5% to about 25%, about 5% to about 20%, about 5% to about 15%, about 5% to about 10%, about 10% to about 15%, about 10% to about 20%, about 10% to about 25%, or about 10% to about 30% by weight based on the total weight of the resin composition.
Aspect 130. the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises an effective amount of the polymeric resin modifier, and the effective amount of the polymeric resin modifier is about 20%, about 15%, about 10%, about 5%, or less by weight based on the total weight of the resin composition.
Aspect 131 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises the polymer resin modifier, and the polymer resin modifier comprises about 10% to about 15% ethylene repeat units based on the total weight of the polymer resin modifier.
Aspect 132 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises the polymer resin modifier, and the polymer resin modifier comprises about 10% to about 15% of the repeating unit according to formula 1A based on the total weight of the polymer resin modifier
Aspect 133 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition has a total ethylene repeat unit content of about 3% to about 7% by weight, based on the total weight of the resin composition.
The synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a polymer resin modifier, and the polymer resin modifier has an ethylene repeat unit content of about 10% to about 15% by weight, based on the total weight of the polymer resin modifier.
Aspect 135 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a polymer resin modifier, and the polymer resin modifier is a copolymer comprising isotactic repeat units derived from an olefin.
Aspect 136 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a polymer resin modifier, and the polymer resin modifier is a copolymer comprising a repeat unit according to formula 1B, and wherein the repeat unit according to formula 1B is arranged in an isotactic stereochemical configuration
Aspect 137. the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises the polymer resin modifier, and an otherwise identical polyolefin resin composition, except for the absence of the polymer resin modifier, fails a cold shoe sole material flex test using a pure material sampling procedure.
Aspect 139 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a polymer resin modifier, and the polymer resin modifier is a copolymer comprising a first more than one repeating unit and a second more than one repeating unit; wherein each of the first more than one repeating unit has a structure according to formula 1A and each of the second more than one repeating unit has a structure according to formula 1B, and wherein the repeating units of the second more than one repeating unit are arranged in an isotactic stereochemical configuration
The synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a transparentizing agent, and the transparentizing agent is present in an amount from about 0.5% by weight to about 5% by weight or about 1.5% by weight to about 2.5% by weight, based on the total weight of the polyolefin resin.
Aspect 142 the synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a transparentizing agent, and the transparentizing agent is selected from substituted or unsubstituted dibenzylidene sorbitol, 1,3-O-2, 4-bis (3, 4-dimethylbenzylidene) sorbitol, 1,2, 3-trideoxy-4, 6:5, 7-bis-O- [ (4-propylphenyl) methylene ], or a derivative thereof.
The synthetic leather material of any of aspects 1-145, wherein the polyolefin resin composition comprises a transparentizing agent, and the transparentizing agent comprises an acetal compound that is a condensation product of a polyol and an aromatic aldehyde.
Aspect 144 the synthetic leather material according to any one of aspects 143, wherein the polyol is selected from: acyclic polyols such as xylitol or sorbitol, or acyclic deoxy polyols such as 1,2, 3-trideoxynonene sugars or 1,2, 3-trideoxynon-1-enesugar alcohols, or combinations of acyclic polyols and acyclic deoxy polyols.
Aspect 145 the synthetic leather material of aspect 143, wherein the aromatic aldehyde is selected from the group consisting of benzaldehyde, substituted benzaldehydes, and mixtures of benzaldehyde and substituted benzaldehydes.
Aspect 146. a component comprising the synthetic leather material of any of aspects 1-145.
Aspect 147 the component of aspect 146, wherein the component is a component of an article of footwear, an article of apparel, or a component of an article of athletic equipment.
Aspect 148 the component of aspect 147, wherein the component is a component of an article of footwear.
Aspect 149. the component of aspect 147, wherein the component is a component of an article of athletic equipment.
Aspect 150. the component of aspect 149, wherein the component is a component of an article of athletic equipment selected from a component of a hat, a component of a bag, a component of a ball, or a component of protective equipment.
Aspect 151. the component of aspect 147, wherein the component is a component of an article of apparel.
Aspect 153 the component of aspect 152, wherein the component is an upper for an article of footwear.
Aspect 154 the component of aspect 152, wherein the component is a component of an upper selected from a forefoot opening area, an ankle collar area, a ground facing area, a sole perimeter area, a heel area, a toe area, a tongue, an eyelet (eye lay), a medial side, a lateral side, or a combination thereof.
Aspect 155. a method of making a synthetic leather material, the method comprising: attaching the synthetic leather polymer coating and the synthetic leather textile layer to each other; wherein the synthetic leather polymer coating comprises a synthetic leather polymer coating composition; and wherein the synthetic leather textile layer comprises fibers or yarns comprising a fiber/yarn polymer composition, and wherein the synthetic leather polymer coating composition comprises a polyolefin resin composition, or the fiber/yarn polymer composition comprises the polyolefin resin composition, or both the synthetic leather polymer coating composition and the fiber/yarn polymer composition comprise the polyolefin resin composition; optionally, wherein the attaching comprises one or more steps selected from: laminating the textile to a surface of the resin composition, laminating the resin composition to a surface of the textile, welding the textile to a surface of the resin composition, welding the resin composition to a surface of the textile, bonding the textile to a surface of the resin composition using an adhesive, or bonding the resin composition to a surface of the textile using an adhesive.
Aspect 156 the process of aspect 155, further comprising attaching a protective or decorative layer to the synthetic leather polymer coating.
Aspect 157 the process of aspect 155 or aspect 156, wherein the synthetic leather material is the synthetic leather material of any one of aspects 1 to 145.
Aspect 158. an article, comprising: the synthetic leather material according to any one of aspects 1 to 145.
Aspect 159. the article of aspect 158, wherein the article is an article of footwear, an article of apparel, or an article of athletic equipment.
Aspect 160 the article of aspect 159, wherein the article is an article of apparel.
Aspect 161 the article of aspect 159, wherein the article is an article of athletic equipment.
Aspect 162 the article of aspect 161, wherein the article of athletic equipment is a hat, bag, ball, or protective gear.
Aspect 163 the article of aspect 159, wherein the article is an article of footwear.
Aspect 164. an article of footwear, comprising: an upper and a sole structure; wherein the upper comprises the synthetic leather material according to any one of aspects 1-145, the sole structure comprises the synthetic leather material according to any one of aspects 1-145, or both the upper and the sole structure comprise the synthetic leather material according to any one of aspects 1-145.
Aspect 165 the article of aspect 164, wherein the upper comprises the synthetic leather material of any one of aspects 1-145.
Aspect 166. the article of footwear of any of aspects 164 to 209, wherein the sole structure includes a sole component comprising a polyolefin resin.
Aspect 167 the article of footwear of any of aspects 164 to 209, wherein a surface of the synthetic leather material is defined by a first polyolefin resin composition, a surface of the sole component is defined by a second polyolefin resin composition, and a surface of the upper defined by the first polyolefin resin composition is bonded to a surface of the sole component defined by the second polyolefin resin composition.
Aspect 168. the article of footwear of any of aspects 164-209, wherein a bond between a surface of the upper defined by the first polyolefin resin composition and a surface of the sole component defined by the second polyolefin resin composition is a thermal bond.
The article of footwear of any of aspects 164 to 209, wherein the first polyolefin resin composition of the upper or the second polyolefin composition of the sole component, or both, comprises a polyolefin resin composition according to any of aspects 92 to 145.
Aspect 170 the article of footwear of any of aspects 164-209, wherein the sole component includes a first side and a second side, wherein the first side is configured to be ground-facing when the sole component is a component of an article of footwear.
The article of footwear of any of aspects 164-209, wherein the sole structure further includes a textile disposed on one or both of the first side and the second side of the sole component.
Aspect 172 the article of footwear of any of aspects 164 to 209, wherein the bond between the upper and the sole component includes a mechanical bond between the upper and the textile disposed on the sole component.
Aspect 173 the article of footwear of any of aspects 164 to 209, wherein the sole component is a plate.
Aspect 174. the article of footwear of aspect 173, wherein the textile of the sole component comprises a fiber/yarn polymer composition, and the fiber/yarn polymer composition comprises the polyolefin resin composition of any of aspects 92 to 145.
Aspect 175 the article of footwear of aspect 174, wherein the textile of the sole structure further comprises a polymer coating composition attached to the textile; and wherein the polymeric coating composition comprises the polyolefin resin composition of any of aspects 92-145.
The article of footwear of aspect 105, wherein the textile of the sole component further comprises a polymer coating composition attached to the textile; and wherein the polymeric coating composition is substantially free of the polyolefin resin composition of any of aspects 92-145.
Aspect 177. the article of footwear of aspect 176, wherein the polymeric coating composition comprises one or more thermoplastic polymers selected from polyesters, polyethers, polyamides, or polyurethanes.
The article of footwear of aspect 177, wherein the polymer coating composition has a melting or softening temperature that is at least 20 degrees celsius lower, or at least 50 degrees celsius lower, than the melting or softening temperature of the fiber/yarn polymer composition of the textile of the sole component; or wherein the polymer coating composition has a melting or softening temperature that is at least 20 degrees celsius higher, or at least 50 degrees celsius higher, than the melting or softening temperature of the fiber/yarn polymer composition of the textile of the sole component.
Aspect 179 the article of footwear of aspect 173, wherein the textile of the sole component includes: a first fiber or first yarn comprising a first fiber/yarn polymer composition comprising the polyolefin resin composition of any of aspects 92-145; and a second fiber or second yarn comprising a second fiber/yarn polymer composition.
Aspect 180 the article of footwear of aspect 179, wherein the second fiber/yarn polymer composition comprises one or more thermoplastic polymers selected from polyester, polyether, polyamide, or polyurethane.
Aspect 181 the article of footwear of any of aspects 171 to 209, wherein the textile is on the first side of the sole component, and wherein the textile comprises a patterned textile or a decorative textile.
Aspect 182 the article of footwear of any of aspects 171-209, wherein the textile is on a second side of the sole component, and wherein a bond strength of the second side of the sole component to the upper is greater than a bond strength of an otherwise identical sole component to an otherwise identical upper using an otherwise identical bonding procedure except for the textile that is not disposed on the first side of the sole component.
The article of footwear of any of aspects 164-209, wherein the textiles include a first textile on the first side of the sole component and a second textile on the second side of the sole component.
Aspect 184 the article of footwear of any of aspects 164 to 209, wherein the sole structure extends from a medial side of the article of footwear to a lateral side of the article of footwear.
The article of footwear of any of aspects 164-209, wherein a length of the sole component extends through a midfoot region of the article of footwear to a heel region of the article of footwear.
The article of footwear of any of aspects 164-209, wherein a length of the sole component extends from a toe region of the article of footwear to a heel region of the article of footwear.
Aspect 188 the article of footwear of any of aspects 164-209, wherein the first side of the sole component includes one or more traction elements.
The article of footwear of any of aspects 164-209, wherein the one or more traction elements are integrally formed in the sole component.
Aspect 190 the article of footwear of any of aspects 164 to 209, wherein the traction element comprises a polyolefin resin composition, optionally, the polyolefin resin composition of any of aspects 92 to 145.
The article of footwear of any of aspects 164-209, wherein the one or more traction elements comprise a second resin composition substantially free of polyolefin.
Aspect 192. the article of footwear of any of aspects 164 to 209, wherein the second resin includes an elastomeric material, optionally an olefinic elastomer.
Aspect 193 the article of footwear of any of aspects 164 to 209, wherein the second resin comprises polystyrene, polyethylene, ethylene-alpha-olefin copolymer, ethylene-propylene rubber (EPDM), polybutylene, polyisobutylene, poly-4-methylpent-1-ene, polyisoprene, polybutadiene, ethylene-methacrylic acid copolymer, copolymers thereof, or blends or mixtures thereof.
Aspect 194 the article of footwear of any of aspects 164 to 209, wherein the second resin composition comprises less than 10 weight percent or less than 5 weight percent of the polyolefin, optionally wherein the second resin composition comprises less than 10 weight percent or less than 5 weight percent of the polypropylene.
Aspect 195 the article of footwear of any of aspects 164 to 209, wherein the second resin composition comprises ethylene-propylene rubber (EPDM) dispersed in polyolefin, optionally EPDM dispersed in polypropylene.
Aspect 196 the article of footwear of any of aspects 164 to 209, wherein the second resin composition comprises a block copolymer comprising a polystyrene block.
Aspect 197 the article of footwear of any of aspects 164 to 209, wherein the block copolymer comprises a copolymer of styrene and one or both of ethylene and butene.
Aspect 198 the article of footwear of any of aspects 171-209, wherein the textile is disposed on the sole component by: the sole component may be attached to the sole component by injection molding the sole component onto the textile, by laminating the textile onto the sole component, by welding the textile to the sole component, and/or by bonding the textile to the sole component using an adhesive.
Aspect 199. the article of footwear of any of aspects 171 to 209, wherein the textile is selected from the group consisting of: woven textiles, non-woven textiles, knitted textiles, braided textiles, and combinations thereof.
Aspect 200 the article of footwear of any of aspects 171-209, wherein the textile includes one or more fibers comprising a polymer selected from the group consisting of: polyesters, polyamides, polyolefins, blends thereof, and combinations thereof.
Aspect 201 the article of footwear of any of aspects 164-171, wherein the textile includes a yarn including fibers.
Aspect 202 the article of footwear of any of aspects 164 to 209, wherein a surface comprising the textile has a surface roughness that is greater than a surface roughness of an otherwise identical surface except without the textile.
Aspect 203 the article of footwear of any of aspects 164-209, wherein the textile is on the ground-facing side of the sole structure, and wherein the textile is a knitted textile, a woven textile, a non-woven textile, a knitted textile, or a combination thereof.
Aspect 204 the article of footwear of any of aspects 164-209, wherein the sole structure further comprises an adhesive, primer, or tie layer (tie layer) between the ground-facing side and the elastomeric material.
Aspect 205 the article of footwear of any of aspects 164 to 209, wherein one or more of the adhesive, the primer, and the tie layer includes a polymer having an epoxy segment, a urethane segment, an acrylic segment, a cyanoacrylate segment, a silicone segment, or any combination thereof.
Aspect 206 the article of footwear of any of aspects 164 to 209, wherein one or more of the polyolefin resin of the plate, the adhesive, the primer, and the tie layer includes a polymer having maleic anhydride functional groups.
Aspect 207 the article of footwear of any of aspects 164 to 209, wherein one or more of the plate, the adhesive, the primer, and the tie layer comprises maleic anhydride.
Aspect 208 the article of footwear of any of aspects 164 to 209, wherein the adhesive, the primer, or the connecting layer comprises a thermoplastic polyurethane.
Aspect 209 the article of footwear of any of aspects 164-209, wherein a ground-facing side of the sole structure includes a texture.
Aspect 211. the method of aspect 210, wherein the synthetic leather material is the synthetic leather material of any of aspects 1-145.
Aspect 214. the method of aspect 213, wherein the polyolefin resin composition defining the surface of the sole structure is the polyolefin resin composition of any of aspects 92-145.
Having now generally described aspects of the present disclosure, additional discussion regarding the aspects will be described in more detail.
Before the present disclosure is described in greater detail, it is to be understood that this disclosure is not limited to particular aspects described, and as such may, of course, vary. Other systems, methods, features, and advantages of the resin compositions and articles and their components will be or become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. The skilled person will recognise many variations and adaptations of the aspects described herein. Such variations and modifications are intended to be included within the teachings of the present disclosure and are intended to be covered by the claims herein.
Article of footwear
In some aspects, the present disclosure relates to an article of footwear comprising a synthetic leather material as described herein, wherein an upper of the article of footwear or a sole structure of the article of footwear, or both, comprise the synthetic leather material. A sole structure of an article of footwear may include sole elements, such as one or more plates. At least a portion of a surface of the upper attached to the sole structure may comprise a synthetic leather material as described herein, optionally wherein the surface of the attached upper is defined by a polyolefin resin composition as described herein. In some aspects, both a surface of the attached upper and a surface of the attached sole structure may comprise the polyolefin resin composition. The bond strength between two surfaces, both formed from polyolefin compositions, is generally stronger than the bond strength between a first surface formed from a polyolefin composition and a non-polyolefin polymer composition, because the surface energy of polyolefins is generally different from other types of polymer materials commonly used in footwear manufacture. Since the bonding strength of the thermal bond formed between the two polyolefin resin compositions is generally greater than that of an adhesive bond (e.g., a bond formed using a hot melt adhesive or cement), when both the surface of the upper and the surface of the sole structure are defined by polyolefin resin compositions, it is advantageous to attach the surfaces together using a thermal bond in which the polyolefin resin compositions of the upper and/or of the sole structure are softened or melted and then re-cured into a bond. The polyolefin resin composition of the synthetic leather material may be the same as the polyolefin resin composition of the sole structure. The polymer components of the two polyolefin resin compositions (i.e., the portion of the composition consisting of all the polymers present in the polyolefin resin compositions) may include the same type of polymer at the same concentration, or may include the same type of polymer at different concentrations, or may include different types of polymers. The polyolefin components of both polyolefin resin compositions (i.e., the portion of the composition consisting of all of the polyolefins present in the polyolefin resin compositions) may include the same type of polyolefin at the same concentration, or may include the same type of polyolefin at different concentrations, or may include different types of polyolefins.
In some aspects, the sole structure comprises a polyolefin resin composition, including a polyolefin resin composition as described herein. Sole structures and sole components comprising polyolefin resin compositions desirably exhibit a high level of mechanical strength and also flex durability. However, applicants have found that, in some aspects, when the polyolefin resin composition is used to form a bonding surface of a sole structure or sole component, bonding to a surface defined by the polyolefin resin composition (e.g., a bond between a plate and an upper) may be unsatisfactory, particularly when another surface to be attached to a bonding surface of a sole structure or sole component (e.g., a surface of an upper, such as an outward-facing surface of a strobel) is defined by a polymer composition having a significantly different surface energy than the polyolefin resin composition. For example, it can be difficult to bond polyurethane, polyamide or polyester agents to polyolefin resin compositions using only adhesive systems that are conventionally used in the footwear industry. One way to improve the bond strength between the polyolefin resin composition and the polymer material that is relatively incompatible with the polyolefin is to use a textile layer as the interface between a surface of the upper and a surface of the sole structure, and bond one side of the textile to the surface of the upper and bond an opposite side of the textile to the surface of the sole structure. Accordingly, in some aspects, a sole structure includes a sole component comprising a polyolefin resin composition and a textile disposed on one or more surfaces of the sole component. In one example, the use of a textile comprising fibers or yarns formed from a polymer material having a different surface energy than the surface energy of the polyolefin resin composition of the sole component may facilitate bonding between uppers comprising a polymer material having a surface energy that is closer to the surface energy of the textile than the surface energy of the polyolefin resin composition of the sole component, thereby increasing the strength of the bond between the sole component and the upper as compared to using a plate without the textile. The use of a textile may provide a textured surface with a greater surface area, providing a greater opportunity to form a mechanical bond between the upper and the plate, thereby increasing the strength of the bond between the sole element and the upper as compared to using a sole element without a textile. As an additional benefit, textiles may be used in some aspects to provide decorative or stylized surfaces.
Fig. 1A is a lateral side perspective view of an exemplary cleated article of athletic footwear 110, such as a soccer boot. As seen in fig. 1A, article of footwear 110 includes an upper 112 and a sole structure 113, sole structure 113 including a plate 116 and a textile 114 disposed on an upper side 152 of the plate. Textile 114 is positioned between plate 116 and upper 112. Plate 116 includes a plurality of traction elements 118. Traction elements 118 provide traction for the wearer when worn, for enhanced stability. One or more of traction elements 118 may be integrally formed with the plate, as illustrated in fig. 1A, or may be removable. Optionally, one or more of traction elements 118 may include a traction element tip (not shown) configured to contact the ground. The tip of the traction element may be integrally formed with traction element 118. Optionally, the tip of the traction element may be formed of a different material (e.g., a metal or a polymer material containing a different polymer) than the remainder of traction element 118. Fig. 1B is a lateral side elevational view of article of footwear 110. The lateral side of article 110 is generally oriented on the side facing away from the centerline of the wearer's body when article 110 of footwear is worn. Fig. 1C is a medial side elevational view of article of footwear 110. The medial side generally faces a centerline of the wearer's body when the article of footwear 110 is worn. Fig. 1D is a top view of article of footwear 110 (without a footbed in place), and without a lasting board or other plate-like member 115, and also showing upper 112. Upper 112 includes a padded collar 120. Alternatively or additionally, the upper may include an area (not shown) configured to extend up to or cover the ankle of the wearer. In at least one aspect, upper 112 is tongue-less, wherein the upper wraps from a medial side of the wearer's foot, over a top of the foot, and under a lateral side portion of the upper, as illustrated in fig. 1D. Alternatively, the article of footwear may include a tongue (not shown). As illustrated in fig. 1A-1G, the lace of article of footwear 110 may optionally be located on a lateral side of the article. In other examples, the article of footwear may have a pull-on design or may include a closure system (not shown) other than a lace. Fig. 1E and 1F are front and rear elevation views, respectively, of article of footwear 110.
Fig. 1G is an exploded perspective view of article of footwear 110, showing upper 112, plate 116, and textile 114. As seen in fig. 1D, upper 112 includes strobel 138. As illustrated in fig. 1D, strobel 138 is generally in the shape of the wearer's foot and closes the bottom of upper 112 and is stitched to other components with stitching 185 along the perimeter of strobel 138 to form upper 112. A lasting board or other board like member 115 may be located above or below the strobel 138. In some aspects, a lasting board or other plate-like member may replace the strobel. Lasting board or other plate-like member 115 may extend substantially the entire length of the board, or may be present in a portion of the length of the board, such as, for example, in the toe region 130, or in the midfoot region, or in the heel region. Upper 112, which includes strobel 138, is bonded to upper surface 140 (fig. 1G-1H) of textile 114. The lower surface 142 of textile 114 may be bonded or fused to the upper surface 152 of plate 116. In some aspects, lower surface 142 of textile 114 may be mechanically bonded to upper surface 152 of plate 116 by fusing the polymer in textile 114 and the polymer resin of plate 116. Alternatively or additionally, upper 112 including strobel 138 is mechanically bonded to upper surface 140 of textile 114 by fusing the polymer resin of upper 112 or strobel 138 with the polymer resin of plate 116. In some aspects, bonding may include both adhesive bonding and mechanical bonding.
In at least one aspect, plate 116 and textile 114 are first bonded before upper 112 and/or strobel 138 are bonded to textile 114. In some aspects, article of footwear 110 may include a removable insole (not shown). As is known in the art, an insole conforms to and lines the interior bottom surface of the shoe and is the component that is contacted by the sole of the wearer's foot (or the sole of the foot on which the sock is worn).
Fig. 2A-2C depict a second example article of athletic footwear. Fig. 2A is a lateral side elevational view of an exemplary article of athletic footwear. Fig. 2B is an exploded perspective view of a second exemplary article of athletic footwear. FIG. 2C is a cross-sectional view along 2-2 of a second exemplary article of athletic footwear. Fig. 2A is a lateral side elevational view of an exemplary article of footwear 210 without a textile. Article of footwear 210 includes an upper 212 and a sole structure 213, sole structure 213 having a plate 216 and a bottom layer 217. Bottom layer 217 includes a plurality of traction elements 218. Traction elements 218 may be formed entirely of the substrate 217 material, or as illustrated in fig. 2B, traction elements 118 may have corresponding internal traction elements 219 formed in plate 216 and wrapped by substrate 217. Optionally, one or more of traction elements 218 may include a tip (not shown) configured to be a ground-contacting traction element. The article of footwear 210 may include a lasting board member 215, and the lasting board member 215 may extend substantially the entire length of the board 216.
In some aspects, the sole structure may include a plate to provide rigidity, strength, and/or support without substantially increasing weight. For example, some example sole structure aspects may include a plate having certain features that provide resistance to vertical bending, lateral bending, and/or twisting. As depicted in fig. 3, the plate 300 may include strengthening ribs 310 along the longitudinal direction of the plate. The reinforcing ribs may comprise hollow structures and, therefore, may provide rigidity without adding a large amount of additional material and, thus, keep the weight low. The plate 300 may be located within the bottom layer 330, for example, within a recess 320 in the bottom layer 330.
In some aspects, when the sole structure includes a plate and a bottom layer configured to wrap around the plate and to be joined or attached to the upper, the sole structure also includes one or more textiles when the sole structure is a component of an article of footwear. For example, the textile may be between the plate and the upper, and may provide an improved bond between the plate and the upper. The textile may also be positioned between the board and the bottom layer. In aspects where the textile is between the board and the substrate, the textile may provide improved adhesion between the board and the substrate, and/or the textile may be a decorative textile (decorative textile) or an ornamental textile (aesthetic textile). In some aspects, the sole structure may include a decorative textile on an exterior of the bottom layer or a ground-facing surface of the bottom layer. For example, as depicted in fig. 4A-4C, article of footwear 410 includes an upper 412 and a sole structure 413, sole structure 413 having a plate 416 and a bottom layer 417. The bottom layer 417 includes a plurality of traction elements 418. Traction elements 418 may be formed entirely of the underlying layer 417 material, as illustrated. Optionally, one or more of traction elements 418 may include a tip (i.e., end) configured to be a ground-contacting traction element (not shown). Textile 414 is positioned between plate 416 and bottom layer 417. The article of footwear 410 may include a last plate member 415, and the last plate member 415 may extend substantially the entire length of the plate 416.
Fig. 5A is a lateral side elevational view of an exemplary article of footwear 510, the article of footwear 510 including separate heel plate 515, midfoot plate 516, and toe plate 517. Article of footwear 510 includes an upper 512 and a heel plate 515, a midfoot plate 516, and a toe plate 517. Each of heel plate 515, midfoot plate 516, and toe plate 517 includes a plurality of traction elements 518. Traction elements 518 provide traction for the wearer when worn, for enhanced stability. As illustrated in fig. 5A, one or more of traction elements 518 may be integrally formed with heel plate 515, midfoot plate 516, and/or toe plate 517, or may be removable. Fig. 5B is an exploded perspective view of article of footwear 510, showing upper 512, heel plate 515, midfoot plate 516, and toe plate 517. In this aspect, the upper surface 525 of the heel plate 515 may include a heel textile 535. The upper surface 527 of the toe plate 517 may include a toe textile 537. Likewise, the upper surface 526 of the midfoot plate 516 includes a midfoot textile 536. The textile may provide an improved bond between upper 512, heel plate 515, midfoot plate 516, and toe plate 517.
The present disclosure provides various sole structures that include a polyolefin plate, i.e., a plate that includes a polyolefin resin composition. The panel includes a polyolefin resin composition, such as any of the polyolefin resin compositions described herein. The sole structure may also include an elastomeric material that includes a cured rubber. The cured rubber may form an outsole portion of the sole structure or may form the tips of one or more traction elements.
The sole structure may include a textile on one or more surfaces of the plate. For example, when the board has a first side and a second side, the first side may be configured to be ground-facing and the second side may be configured to be upward-facing when the board is a component of an article of footwear. In some aspects, the textile is on one or both of the first side and the second side. The textile may provide improved bonding between the plate and other components of the sole structure, such as improved bonding between the plate and the bottom layer. When the sole structure is a component of an article of footwear, the textile may also provide improved bonding between the plate and the upper. In some aspects, the textile is a patterned textile or a decorative textile.
In some aspects, the sole structure includes a bottom layer. In some aspects, the bottom layer is combined with one or more textiles in the sole structure, while in some aspects, the sole structure includes the bottom layer and does not include textiles. The bottom layer may be configured on the first side of the board or on the ground-facing side of the board. In some aspects, when the sole structure is a component of an article of footwear, the bottom layer is configured to wrap around the plate and engage or be attached to the upper. The bottom layer may be attached to the upper at the bite line.
In some aspects, the traction elements are made from the same or nearly the same polyolefin resin composition as the plates. In other aspects, the traction elements are made of a second resin different from the polyolefin resin. In some aspects, the sole structure includes a bottom layer, and the bottom layer is made of a second resin. The second resin may include polystyrene, polyethylene, ethylene-alpha-olefin copolymers, ethylene-propylene rubber (EPDM), polybutylene, polyisobutylene, poly-4-methylpent-1-ene, polyisoprene, polybutadiene, ethylene-methacrylic acid copolymers, olefin elastomers, copolymers thereof, or blends or mixtures thereof. In some aspects, the second resin comprises about 20%, about 10%, or less polyolefin. The second resin may comprise about 20%, about 10%, or less polypropylene. The second resin may comprise ethylene-propylene rubber (EPDM) dispersed in polypropylene. The second resin may include a block copolymer including a polystyrene block. The block copolymer includes, for example, a copolymer of styrene and one or both of ethylene and butene. In general, the second resin may be any resin that is compatible with the polyolefin resin and has suitable durability and mechanical properties.
In particular, it has been found that the second resin (e.g., polystyrene, polyethylene, ethylene-alpha-olefin copolymer, ethylene-propylene rubber (EPDM), polybutylene, polyisobutylene, poly-4-methylpent-1-ene, polyisoprene, polybutadiene, ethylene-methacrylic acid copolymer, olefin elastomer, copolymers thereof, or blends or mixtures thereof) bonds well to the resin composition of the present disclosure.
Additionally, a second resin comprising an ethylene-propylene rubber (EPDM) dispersed in polypropylene or a block copolymer having polystyrene blocks, wherein the block copolymer comprises a copolymer of one or both of ethylene and butylene with styrene, has been found to be particularly useful in the ground-contacting portion of the traction element, as these compositions both bond well with the resin compositions of the present disclosure and can provide even higher levels of abrasion resistance than the resin compositions of the present disclosure, which can be desirable in the ground-contacting portion of the traction element.
In some aspects, it may be beneficial to include a clearing agent (clearing agent) in the board (in the polyolefin resin) and/or in the underlayer when present. The transparency may allow the textile to be clearly seen through the panel. The transparency agent can be present in any suitable amount to provide sufficient optical clarity of the final plate or sole structure. In some aspects, the clarifying agent is present in an amount from about 0.5% by weight to about 5% by weight or about 1.5% by weight to about 2.5% by weight, based on the total weight of the polyolefin resin. The clearing agent may comprise those selected from the group of: substituted or unsubstituted dibenzylidene sorbitol, 1,3-O-2, 4-bis (3, 4-dimethylbenzylidene) sorbitol, 1,2, 3-trideoxy-4, 6:5, 7-bis-O- [ (4-propylphenyl) methylene ] and derivatives thereof. The transparentizing agent can include an acetal compound that is a condensation product of a polyol and an aromatic aldehyde. The polyols may include those selected from the group consisting of: acyclic polyols such as xylitol and sorbitol, and acyclic deoxy polyols such as 1,2, 3-trideoxynonylene sugar (1,2, 3-trideoxyynonitol) or 1,2, 3-trideoxynon-1-enesugar alcohol (1,2, 3-trideoxyynon-1-enol). The aromatic aldehyde may include those selected from the group consisting of benzaldehyde and substituted benzaldehydes.
Polyolefin resin composition
As disclosed herein, the polyolefin resin composition is a mixture or blend of one or more polyolefins, optionally a mixture or blend of one or more polyolefins with one or more additional ingredients selected from a polymer resin modifier, a clarifying agent, a colorant, a filler, a processing aid, a non-polyolefin polymer, or any combination thereof.
Polyolefin resin compositions having abrasion resistance and flex durability suitable for use in the articles and components described above are provided. In some aspects, a polyolefin resin composition is provided that includes a polyolefin copolymer and an effective amount of a polymeric resin modifier. An effective amount of the resin modifier provides improved flex durability while maintaining suitable abrasion resistance. For example, in some aspects, an effective amount of a polymeric resin modifier is an amount effective to allow the resin composition to pass a flex test using a substrate sampling procedure according to the cold shoe sole material flex test. At the same time, the resin composition may still have suitable abrasion loss when measured according to the abrasion loss test using a pure material sampling procedure. In some aspects, using a pure material sampling procedure, a resin composition that is otherwise identical except for the absence of a polymeric resin modifier fails the cold sole material flex test.
The polymeric resin modifier may provide improved flexural strength, toughness, creep resistance, or flex durability without a significant loss in abrasion resistance. In some aspects, resin compositions are provided that include a polyolefin copolymer and an effective amount of a polymer resin modifier, wherein the effective amount of the polymer resin modifier is an amount of: the amount is effective to allow the resin composition to pass a flex test according to the cold shoe sole material flex test using a substrate sampling procedure, the wear loss being not significantly changed when measured according to the wear loss test using a pure material sampling procedure as compared to the wear loss of a second resin composition identical to the resin composition except for the absence of the polymeric resin modifier. In other words, in some aspects, an effective amount of the polymer resin modifier is an amount of: the amount is sufficient to produce a resin composition that does not stress whiten or crack during 150,000 flex cycles of a cold sole material flex test, while the abrasion resistance of the resin composition does not significantly degrade and therefore does not significantly differ from the abrasion resistance of a comparative resin composition that is otherwise identical to the resin composition except for the absence of the polymeric resin modifier.
In some aspects, the polyolefin resin composition has about 0.05 cubic centimeters (cm) according to the abrasion loss test using a pure material sampling procedure3) To about 0.1 cubic centimeter (cm)3) About 0.07 cubic centimeters (cm)3) To about 0.1 cubic centimeter (cm)3) About 0.08 cubic centimeters (cm)3) To about 0.1 cubic centimeter (cm)3) OrAbout 0.08 cubic centimeters (cm)3) To about 0.11 cubic centimeters (cm)3) The abrasion loss of (2). In some aspects, the resin composition does not have a significant change in abrasion loss when measured according to an abrasion loss test using a pure material sampling procedure as compared to the abrasion loss of a second resin composition that is the same as the resin composition except for the absence of the polymeric resin modifier. The change in wear loss as used herein is considered insignificant when the change is about 30%, about 25%, about 20%, about 15%, about 10% or less when measured according to the wear loss test using a pure material sampling procedure.
The polyolefin resin composition may include a plurality of polyolefin copolymers. The copolymer may be an alternating copolymer or a random copolymer or a block copolymer or a graft copolymer. In some aspects, the copolymer is a random copolymer. In some aspects, the copolymer comprises a plurality of repeat units, wherein each of the plurality of repeat units is individually derived from an olefin monomer having from about 1 to about 6 carbon atoms. In other aspects, the copolymer comprises a plurality of repeating units, wherein each of the plurality of repeating units is individually derived from a monomer selected from the group consisting of ethylene, propylene, 4-methyl-1-pentene, 1-butene, 1-octene, and combinations thereof. In some aspects, the polyolefin copolymer comprises more than one repeating unit, each of the more than one repeating units being individually selected from formula 1A-formula 1D. In some aspects, the polyolefin copolymer comprises a first more than one repeat unit having a structure according to formula 1A, and a second more than one repeat unit having a structure selected from formula 1B-formula 1D.
In some aspects, the polyolefin copolymer comprises a plurality of repeat units, each repeat unit individually having a structure according to formula 2
Wherein R is1Is hydrogen or substituted or unsubstituted, straight or branched C1-C12Alkyl radical, C1-C6Alkyl radical, C1-C3Alkyl radical, C1-C12Heteroalkyl group, C1-C6Heteroalkyl radicals or C1-C3A heteroalkyl group. In some aspects, each of the first more than one repeating units has a structure according to formula 1A above, and each of the second more than one repeating units has a structure according to formula 2 above.
In some aspects, the polyolefin copolymer is a random copolymer of a first more than one repeat unit and a second more than one repeat unit, and each repeat unit of the first more than one repeat unit is derived from ethylene and each repeat unit of the second more than one repeat unit is derived from a second olefin. In some aspects, the second olefin is an olefin monomer having from about 1 to about 6 carbon atoms. In other aspects, the second olefin comprises propylene, 4-methyl-1-pentene, 1-butene, or other linear or branched terminal olefins having from about 3 to 12 carbon atoms. In some aspects, the polyolefin copolymer comprises from about 80% to about 99%, from about 85% to about 99%, from about 90% to about 99%, or from about 95% to about 99% by weight of polyolefin repeat units based on the total weight of the polyolefin copolymer. In some aspects, the polyolefin copolymer consists essentially of polyolefin repeat units. In some aspects, the polymer in the resin composition consists essentially of the polyolefin copolymer.
The polyolefin copolymer may comprise ethylene, i.e. may comprise repeat units derived from ethylene, such as those in formula 1A. In some aspects, the polyolefin copolymer comprises about 1% to about 5%, about 1% to about 3%, about 2% to about 3%, or about 2% to about 5% by weight of ethylene based on the total weight of the polyolefin copolymer.
The polyolefin resin composition can be prepared without the need for polyurethane and/or without the need for polyamide. For example, in some aspects, the polyolefin copolymer is substantially free of polyurethane. In some aspects, the polymer chains of the polyolefin copolymer are substantially free of urethane repeating units. In some aspects, the resin composition is substantially free of polymer chains comprising urethane repeating units. In some aspects, the polyolefin copolymer is substantially free of polyamide. In some aspects, the polymer chains of the polyolefin copolymer are substantially free of amide repeat units. In some aspects, the resin composition is substantially free of polymer chains comprising amide repeat units.
In some aspects, the polyolefin copolymer comprises or is a polypropylene copolymer. In some aspects, the polymer component of the resin composition (i.e., the portion of the resin composition formed from all of the polymers present in the composition) consists essentially of the polypropylene copolymer. In some aspects, a resin composition is provided comprising a polypropylene copolymer and an effective amount of a polymeric resin modifier, wherein the resin composition has an abrasion loss as described above, and wherein the effective amount of the polymeric resin modifier is an amount effective to allow the resin composition to pass a flex test using a substrate sampling procedure according to a cold shoe sole material flex test. In some aspects, an effective amount of a polymer resin modifier is an amount of: the amount is effective to allow the resin composition to pass a flex test according to the cold shoe sole material flex test using a substrate sampling procedure, the wear loss being not significantly changed when measured according to the wear loss test using a pure material sampling procedure as compared to the wear loss of a second resin composition identical to the resin composition except for the absence of the polymeric resin modifier.
The polypropylene copolymer may comprise a random copolymer, for example a random copolymer of ethylene and propylene. The polypropylene copolymer may comprise about 80% to about 99%, about 85% to about 99%, about 90% to about 99%, or about 95% to about 99% by weight of propylene repeating units based on the total weight of the polypropylene copolymer. In some aspects, the polypropylene copolymer comprises about 1% to about 5%, about 1% to about 3%, about 2% to about 3%, or about 2% to about 5% by weight of ethylene based on the total weight of the polypropylene copolymer. In some aspects, the polypropylene copolymer is a random copolymer comprising about 2% to about 3% by weight of a first more than one repeating unit and about 80% to about 99% by weight of a second more than one repeating unit, based on the total weight of the polypropylene copolymer; wherein each of the first more than one repeating unit has a structure according to formula 1A above and each of the second more than one repeating unit has a structure according to formula 1B above.
The combination of abrasion resistance and flex durability can be related to the overall crystallinity of the resin composition. In some aspects, the resin composition has a percent crystallinity (percent crystallinity) of about 45%, about 40%, about 35%, about 30%, about 25%, or less when measured according to the crystallinity test using the pure material sampling procedure. It has been found that adding an amount of a polymeric resin modifier to a resin composition that only slightly reduces the percent crystallinity of the resin composition compared to an otherwise identical resin composition except that no polymeric resin modifier can result in a resin composition that is capable of passing the cold sole material flex test while maintaining relatively low wear loss. In some aspects, the polymeric resin modifier results in a reduction in the percent crystallinity (percent crystallinity) of the resin composition. In some aspects, the resin composition has a percent crystallinity (% crystallinity) that is at least 6, at least 5, at least 4, at least 3, or at least 2 percentage points lower than the percent crystallinity (% crystallinity) of an otherwise identical resin composition except for the absence of the polymeric resin modifier, when measured according to the crystallinity test using a pure material sampling procedure.
In some aspects, an effective amount of the polymeric resin modifier is about 5% to about 30%, about 5% to about 25%, about 5% to about 20%, about 5% to about 15%, about 5% to about 10%, about 10% to about 15%, about 10% to about 20%, about 10% to about 25%, or about 10% to about 30% by weight, based on the total weight of the resin composition. In some aspects, an effective amount of the polymeric resin modifier is about 20%, about 15%, about 10%, about 5%, or less by weight based on the total weight of the resin composition.
The polymeric resin modifier can include a variety of exemplary resin modifiers described herein. In some aspects, the polymer resin modifier is a metallocene catalyzed copolymer comprising predominantly isotactic propylene repeat units and from about 11% by weight to about 15% by weight ethylene repeat units based on the total weight of the metallocene catalyzed copolymer randomly distributed along the copolymer. In some aspects, the polymer resin modifier comprises about 10% to about 15% by weight of ethylene repeat units based on the total weight of the polymer resin modifier. In some aspects, the polymeric resin modifier comprises about 10% to about 15% by weight of recurring units according to formula 1A above, based on the total weight of the polymeric resin modifier. In some aspects, the polymeric resin modifier is a copolymer of repeating units according to formula 1B above, and the repeating units according to formula 1B are arranged in an isotactic stereochemical configuration.
In some aspects, the polymeric resin modifier is a copolymer comprising isotactic propylene repeat units and ethylene repeat units. In some aspects, the polymeric resin modifier is a copolymer comprising a first more than one repeat unit and a second more than one repeat unit; wherein each of the first more than one repeating unit has a structure according to formula 1A above and each of the second more than one repeating unit has a structure according to formula 1B above, and wherein the repeating units of the second more than one repeating unit are arranged in an isotactic stereochemical configuration.
The term "outwardly facing" as used in "outwardly facing layer" refers to the location where an element is intended to be when it is present in an article during normal use. If the article is footwear, the elements are positioned toward the ground during normal use by the wearer when in a standing position, and thus may contact the ground including an unpaved surface when the footwear is used in a conventional manner, such as standing, walking or running on an unpaved surface. In other words, even though an element may not necessarily face the ground during various steps of manufacture or transportation, the element is understood to be outwardly facing or, more particularly, ground-facing with respect to an article of footwear if the element is intended to face the ground during normal use by a wearer. In some cases, an outward-facing (e.g., ground-facing) surface may be positioned toward the ground during normal use, but may not necessarily contact the ground, due to the presence of elements such as traction elements. For example, on a hard ground or paved surface, the ends of the traction elements on the outsole may contact the ground directly, while the portions of the outsole positioned between the traction elements do not contact the ground. As described in this example, the portions of the outsole positioned between the traction elements are considered to be outward-facing (e.g., ground-facing), even though they may not directly contact the ground in all circumstances.
Synthetic leather material
In various aspects, disclosed herein are synthetic leather materials comprising a synthetic leather polymer coating attached to a synthetic leather textile layer; wherein the synthetic leather polymer coating comprises a synthetic leather polymer coating composition; and optionally wherein the synthetic leather textile layer comprises fibers or yarns comprising the synthetic leather fiber/yarn polymer composition. In some aspects, the disclosed synthetic leather materials may optionally further comprise a synthetic leather protective or decorative layer attached to the polymeric coating.
The disclosed synthetic leather material is believed to have several advantages, particularly for use in manufacturing articles such as articles of footwear or articles of apparel. In some aspects, the use of polyolefin resins makes it possible to manufacture synthetic leather materials that are less sensitive to stress whitening. Additionally or alternatively, it is believed that the use of the polyolefin resin composition in the disclosed synthetic leather material may facilitate better bonding between other components or materials used in articles such as articles of footwear or articles of apparel or articles of athletic equipment. For example, in aspects in which the disclosed synthetic leather materials comprising polyolefin resin compositions are used to manufacture uppers, such uppers may exhibit enhanced bonding with polyolefin components such as sole structures. Thus, the use of the same or similar polymer material for the parts and the synthetic leather material increases the ability to recycle the two parts in the same stream without having to separate them, which reduces waste. Additionally or alternatively, the use of polyolefin resin compositions in the disclosed synthetic leathers provides materials having lower densities than more traditional footwear materials such as TPU. Thus, using a high percentage of these polyolefins in an article of footwear may result in a lighter article of footwear compared to an article of footwear made using the same amount of a denser polymer such as TPU.
Fig. 6A is a cross-sectional view of the disclosed synthetic leather material 600, the synthetic leather material 600 including a synthetic leather textile layer 610 to which a synthetic leather polymer coating 620 is attached, wherein it is understood that the synthetic leather polymer coating comprises a synthetic leather polymer coating composition and the synthetic leather textile layer comprises fibers or yarns comprising a synthetic leather fiber/yarn polymer composition. Fig. 6B is a cross-sectional view of the disclosed synthetic leather material 600, the synthetic leather material 600 including a synthetic leather textile layer 610 to which a synthetic leather polymer coating 620 is attached, and further including a synthetic leather protective or decorative layer 630 attached to the synthetic leather polymer coating 620. It should be understood that the synthetic leather textile layer may be any suitable textile, including but not limited to knitted textiles, woven textiles, non-woven textiles, crocheted textiles, and knitted textiles. Knitted textiles suitable for use with the disclosed synthetic leather materials include, but are not limited to, flat-bed, circular, or weft knitted textiles.
The disclosed synthetic leather materials may include more than one synthetic leather polymer coating, where more than one as used herein is two or more coatings. Fig. 7A is a cross-sectional view of the disclosed synthetic leather material 700, the synthetic leather material 700 including a synthetic leather textile layer 710 to which a first synthetic leather polymer coating 720 is attached, and a second synthetic leather polymer coating 730 attached to the first synthetic leather polymer coating 720, wherein it is understood that each of the more than one synthetic leather polymer coatings comprises a synthetic leather polymer coating composition, and the synthetic leather textile layer includes fibers or yarns comprising a synthetic leather fiber/yarn polymer composition. As illustrated in fig. 7A, the synthetic leather textile layer 710 and the first synthetic leather polymer coating 720 may be different layers. Alternatively, the combination of the synthetic textile and the first synthetic leather polymer coating may form a single composite layer.
When more than one synthetic leather polymer coating is used, the polymer component of each polymer coating (i.e., the portion of the coating material formed from all of the polymers present in the material) may comprise the same or different types of polymers. Examples of different types of polymers include polyolefins, polyesters, polyethers, polyamides, polyurethanes, and polyacrylates. For example, referring to fig. 7A, the first synthetic leather polymer coating composition 720 is substantially free of the polyolefin resin composition described herein and comprises one or more thermoplastic polymers such as, for example, polyesters, polyethers, polyamides, and polyurethanes, and the second synthetic leather polymer coating composition 730 comprises the polyolefin resin composition as described herein.
Alternatively, the first synthetic leather polymer coating composition 720 comprises a polyolefin resin composition as described herein, and the second synthetic leather polymer coating composition 730 is substantially free of the polyolefin resin composition described herein and comprises one or more polymers such as, for example, polyesters, polyethers, polyamides, and polyurethanes as provided herein.
Alternatively, the first synthetic leather polymer coating composition 720 and the second synthetic leather polymer coating composition 730 are each a polyolefin resin composition as described herein, wherein the first synthetic leather polymer coating composition and the second synthetic leather polymer coating composition comprise the same or different polyolefin resin compositions. For example, when the first polymer coating composition and the second polymer coating composition comprise different polyolefin resin compositions, the polymer components of the different polyolefin resin compositions may comprise polyolefins having different chemical structures, or may comprise polyolefins having the same chemical structure but in different concentrations.
Fig. 7B is a cross-sectional view of the disclosed synthetic leather material 700, the synthetic leather material 700 including a synthetic leather textile layer 710 to which a first synthetic leather polymer coating 720 is attached and a second synthetic leather polymer coating 730 attached to the first synthetic leather polymer coating 720, and further including a synthetic leather protective or decorative layer 740 attached to the synthetic leather polymer coating 730. It is to be understood that the synthetic leather textile layer may be any suitable textile, including but not limited to textiles selected from knitted textiles, woven textiles, non-woven textiles, crocheted textiles, or knitted textiles. Knitted textiles suitable for use in the disclosed synthetic leather materials include, but are not limited to, knitted textiles selected from flat-bed knitted textiles, circular knitted textiles, or weft knitted textiles.
The thickness of the synthetic leather polymer coating may be modified as desired. In the case when two or more synthetic leather polymer coatings are used, the thickness of each layer may vary or may be modified. Referring to fig. 7A, in one aspect, the thickness of the first synthetic leather polymer coating composition 720 is less than the thickness of the second synthetic leather polymer coating composition 730, for example at least 5% less. In another aspect, the thickness of the first synthetic leather polymer coating composition 720 is greater than the thickness of the second synthetic leather polymer coating composition 730, for example at least 5% greater. In another aspect, the thickness of the first synthetic leather polymer coating composition 720 is equal to the thickness of the second synthetic leather polymer coating composition 730.
In one aspect, the synthetic leather polymer coating may be a film attached to a synthetic leather textile layer. For example, the polyolefin resin compositions described herein may be extruded into a film that is subsequently attached to a synthetic leather textile layer. In other aspects, two or more different films may be extruded and sequentially attached to the synthetic leather textile layer. For example, the first and second synthetic leather polymer coating compositions depicted in fig. 7A and 7B may each be a film that has been attached to a synthetic leather textile layer.
The disclosed synthetic leather materials may comprise the disclosed polyolefin resin compositions in one or more of a synthetic leather textile layer, a synthetic leather polymer coating layer, and/or a synthetic leather protective or decorative layer. As disclosed herein above, the disclosed polyolefin resin composition may comprise a polyolefin resin with a modified polymer resin and optionally with a transparency agent) to form one or more layers of synthetic leather material.
For example, the disclosed polyolefin resin composition may be used to form one or more films that are combined with a non-woven textile to form an outer skin layer of a synthetic leather material. In other instances, the disclosed polyolefin resins can be used to form fibers or filaments, which in turn can be used to form yarns, which can be used to form the non-woven textile portion of the synthetic leather material. In other instances, the disclosed polyolefin resins can be used to form skin layers and non-woven textile layers.
In some examples, the synthetic leather polymer coating may be porous (e.g., foamed). Alternatively, or in combination with the porous synthetic leather polymer coating, a porous polymer layer may be positioned between the synthetic leather coating and the synthetic leather textile layer. Optionally, in various aspects, a clear or colored protective or decorative coating may be applied to or attached to the outer surface of the polymeric layer.
Although Polyester (PET) yarns or fibers may be used in the manufacture of the synthetic leather textile layer, such as may be used in the fibers or yarns used in the manufacture of the textile layer, other types of synthetic, natural, or regenerated fibers may also be used. Further, the synthetic leather textile layer may use one or more fibers or yarns comprising the thermoplastic polymer composition as disclosed herein. The use of microfibers in the synthetic leather textile layer can improve the hand (softness and flexibility) of the synthetic leather material.
In some cases, the synthetic leather polymer coating may include a synthetic leather polymer coating composition comprising the disclosed thermoplastic polymer composition. For example, the synthetic leather polymer coating may include a synthetic leather polymer coating composition comprising polyurethane or polyvinyl chloride. It may be desirable to use polyurethane-based synthetic leather materials in articles of footwear, and polyvinyl chloride-based synthetic leather materials are commonly used in athletic equipment. In other instances, the synthetic leather polymer coating may include a synthetic leather polymer coating composition comprising the disclosed polyolefin resin composition.
As described above, the synthetic leather material includes a synthetic leather textile layer comprising a textile (e.g., a first textile). The textile may be a non-woven textile, a knitted textile or a woven textile. "textile" may be defined as any material made of fibers, filaments or yarns characterized by flexibility, fineness (fineness) and a high ratio of length to thickness. Textiles generally fall into two categories. The first category includes textiles produced directly from a web of filaments or fibers by randomly interlocking to construct non-woven fabrics and felts. The second category includes textiles formed by mechanical manipulation of yarns, thereby producing woven fabrics, knitted fabrics, crocheted fabrics, and the like.
The terms "filament", "fiber" or "fibers" as used herein refer to materials in the form of discrete elongated pieces that are significantly longer than their width. The fibers may include natural fibers, man-made fibers, or synthetic fibers. The fibers may be produced by conventional techniques such as extrusion, electrospinning, interfacial polymerization, drawing, and the like. The fibers may include carbon fibers, boron fibers, silicon carbide fibers, titanium dioxide fibers, alumina fibers, quartz fibers, glass fibers such as E, a, C, ECR, R, S, D, and NE glasses and quartz or the like. The fibers may be fibers formed from synthetic polymers capable of forming fibers such as poly (ether ketone), polyimide, polybenzoxazole, poly (phenylene sulfide), polyesters, polyolefins (e.g., polyethylene, polypropylene), aramids (e.g., aramid polymers such as para-aramid fibers and meta-aramid fibers), aromatic polyimides, polybenzimidazole, polyetherimides, polytetrafluoroethylene, acrylics, modacrylic, poly (vinyl alcohol), polyamides, polyurethanes, and copolymers such as polyether-polyurea copolymers, polyester-polyurethanes, polyether block amide copolymers, or the like. The fibers may be natural fibers (e.g., silk, wool, cashmere, camel's hair (vicuna), cotton, flax, hemp, jute, sisal). The fibers may be rayon from recycled natural polymers such as rayon, lyocell, acetate, triacetate, rubber, and poly (lactic acid).
The fibers may have an indefinite length. For example, rayon and synthetic fibers are typically extruded in substantially continuous strands. Alternatively, the fibers may be staple fibers, such as, for example, cotton fibers or extruded synthetic polymer fibers may be cut to form staple fibers of relatively uniform length. The staple fibers may have a length of about 1 millimeter to 100 centimeters or more and any increments therein (e.g., 1 millimeter increments).
The fibers may have any of a variety of cross-sectional shapes. The natural fibers may have a natural cross-section or may have a modified cross-sectional shape (e.g., by a process such as mercerization). Rayon or synthetic fibers may be extruded to provide a strand having a predetermined cross-sectional shape. The cross-sectional shape of the fiber can affect its properties, such as its softness, gloss, and wicking ability. The fibers may have a circular cross-section or a substantially circular cross-section. Alternatively, the fibers may have a non-circular cross-section, such as flat, oval, octagonal, rectangular, wedge, triangular, dog bone, multi-lobal, multi-channeled, hollow, core-shell, or other shapes.
The fibers may be processed. For example, the properties of the fibers may be at least partially affected by processes such as drawing (stretching) the fibers, annealing (stiffening) the fibers, and/or crimping or texturing the fibers.
The fibers may be multicomponent fibers, such as fibers comprising two or more co-extruded polymeric materials. The two or more co-extruded polymeric materials may be extruded in a core-sheath configuration, an island-in-the-sea configuration, a segmented-pie configuration, a strip-like configuration, or a side-by-side configuration. The multicomponent fibers can be processed to form more than one smaller fiber (e.g., microfiber) from a single fiber, such as by removing sacrificial material.
As used herein, the term "yarn" refers to an assembly formed from one or more fibers, wherein the thread has a substantial length and a relatively small cross-section, and is suitable for use in the production of textiles, either manually or by machine, including textiles manufactured using weaving, knitting, crocheting, braiding, sewing, embroidery, or cord making techniques. A stitch is a type of yarn commonly used in sewing.
The yarn may be made using fibers formed of natural materials, artificial materials, and synthetic materials. Synthetic fibers are most commonly made into spun yarns from staple fibers and filament yarns. Spun yarns are made by arranging and twisting short fibers together to make a bonded strand. Processes for forming yarns from staple fibers typically include carding and drawing the fibers to form a sliver, drawing and twisting the sliver to form a roving, and spinning the roving to form a yarn. Multiple wires may be twisted (twisted together) to produce a thicker yarn. The twist direction of the staple fibers and the plied yarns (plies) can affect the final properties of the yarn. The filament yarn may be formed from a single long, substantially continuous filament (which is conventionally referred to as a "monofilament yarn"), or from more than one individual filament grouped together. The yarn may also be formed from two or more long, substantially continuous filaments grouped together by twisting them or entangling them or twisting and entangling them to group the filaments together. As with the staple yarns, multiple yarns may be plied together to form a thicker yarn.
Once formed, the yarn may be subjected to further processing, such as texturing, heat treatment, or mechanical treatment, or coated with a material such as a synthetic polymer. The fibers, yarns, or textiles used in the disclosed articles, or any combination thereof, may be sized (sizing). The sized fibers, yarns and/or textiles are coated on at least a portion of their surface with a sizing composition (sizing composition) selected to modify the absorption or abrasion characteristics, or for compatibility with other materials. The sizing composition aids in the penetration and wet-through of the coating or resin on the surface and in achieving the desired physical properties in the final article. Exemplary sizing compositions can include, for example, epoxy polymers, urethane-modified epoxy polymers, polyester polymers, phenol polymers, polyamide polymers, polyurethane polymers, polycarbonate polymers, polyetherimide polymers, polyamideimide polymers, polystyrylpyridine polymers, polyimide polymers bismaleimide polymers, polysulfone polymers, polyethersulfone polymers, epoxy-modified urethane polymers, polyvinyl alcohol polymers, polyvinylpyrrolidone polymers, and mixtures thereof.
For example, two or more yarns may be combined to form a composite yarn, such as a single wrap yarn or a double wrap yarn, and a core spun yarn. Accordingly, the yarns may have a variety of configurations that generally conform to the description provided herein.
The yarn may comprise at least one thermoplastic material (e.g. one or more fibres may be made of a thermoplastic material). The yarns may be made of a thermoplastic material. The yarns may be covered with a layer of material, such as a thermoplastic material.
The linear mass density or weight per unit length of a yarn may be expressed using a variety of units including denier (D) and tex. Denier is the mass in grams of 9000 meters of yarn. The linear mass density of the filaments of a fiber can also be expressed using the Denier Per Filament (DPF). Tex is the mass in grams of a 1000 meter yarn. Dtex is another measure of linear quality and is the mass in grams of 10,000 meters of yarn.
As used herein, tenacity is understood to refer to the amount of force (expressed in units of weight, e.g., pounds, grams, centenewtons, or other units) required to break a yarn (i.e., the force or point of break of the yarn) divided by the linear mass density of the yarn, e.g., expressed in (unstrained) denier, decitex, or some other measure of weight per unit length. The breaking force of a yarn is determined by subjecting a sample of the yarn to a known amount of force, for example, using a strain gauge load cell, such as the INSTRON brand test system (Norwood, MA, USA). Yarn tenacity and yarn breaking force are different from the burst strength (bursting strength) or bursting strength (bursting strength) of a textile, which is a measure of how much pressure can be applied to the surface of the textile before the surface ruptures.
Typically, in order for a yarn to withstand the forces exerted in an industrial knitting machine, the minimum tenacity required is about 1.5 grams per denier. Most yarns formed from commercial polymeric materials typically have a tenacity in the range of about 1.5 grams/denier to about 4 grams/denier. For example, polyester yarns typically used to manufacture knitted uppers for footwear have a tenacity in the range of about 2.5 grams/denier to about 4 grams/denier. Yarns formed from commercial polymeric materials that are believed to have high tenacity typically have a tenacity in the range of about 5 grams per denier to about 10 grams per denier. For example, commercially available packaged dyed polyethylene terephthalate yarn from the National Spinning mill (Washington, NC, USA) has a tenacity of about 6 grams per denier, and commercially available solution dyed polyethylene terephthalate yarn from Far Eastern New Century (china, taiwan, taipei) has a tenacity of about 7 grams per denier. Yarns formed from high performance polymeric materials typically have a tenacity of about 11 grams per denier or greater. For example, yarns formed from aramid fibers typically have a tenacity of about 20 grams per denier, and yarns formed from ultra-high molecular weight polyethylene (UHMWPE) having a tenacity greater than 30 grams per denier are available from Dyneema (Stanley, NC, USA) and Spectra (Honeywell-Spectra, colonal Heights, VA, USA).
There are a variety of techniques for mechanically manipulating yarns to form textiles. Such techniques include, for example, interweaving, intertwining and twisting, and interlocking. Interweaving is the crossing of two yarns that cross and interweave with each other at a perpendicular angle. The yarns used for interweaving are conventionally referred to as "warp" and "weft". The woven textile includes warp yarns and weft yarns. The warp yarns extend in a first direction and the weft yarns (weft strand) extend in a second direction substantially perpendicular to the first direction. Entanglement and twisting encompass a variety of procedures, such as knitting and knotting, in which yarns are entangled with one another to form a textile. Interlocking involves the formation of more than one column of intermeshed loops, with knitting being the most common method of interlocking. The textile may be formed primarily from one or more yarns that are mechanically manipulated, such as by an interweaving process, an entangling process and a twisting process and/or an interlocking process, as mentioned above.
The textile may be a non-woven textile. Generally, a non-woven textile or fabric is a sheet or web structure made of fibers and/or yarns that are bonded together. The bond may be a chemical bond and/or a mechanical bond, and may be formed using heat, a solvent, an adhesive, or a combination thereof. Exemplary nonwoven fabrics are flat or tufted porous sheets made directly from discrete fibers, molten plastic and/or plastic film. They are not made by weaving or knitting and do not necessarily require the fibers to be converted into yarns, although yarns may be used as a source of fibers. Non-woven textiles are typically manufactured by: the fibrils are brought together in the form of sheets or webs (similar to paper on a paper machine) and then they are mechanically bonded (as in the case of felts, by interlocking them with serrated or barbed needles, or by hydro-entanglement) with an adhesive or heat (by applying the adhesive (in the form of a powder, paste or polymer melt) and melting it onto the web by increasing the temperature) so that the inter-fiber friction produces a stronger fabric. The non-woven textile may be made from staple fibers (e.g., from a wet-laid, air-laid, carded/overlapped (crosslapped) process) or extruded fibers (e.g., from a melt-blown or spun-bonded process or a combination thereof) or a combination thereof. Bonding of the fibers in the nonwoven textile may be accomplished using thermal bonding (with or without calendering), hydroentanglement, ultrasonic bonding, needle punching (needle punching), chemical bonding (e.g., using a binder such as a latex emulsion or solution polymer or binder fiber or powder), melt blown bonding (e.g., bonding of fibers during simultaneous fiber formation and web formation with air attenuated fiber entanglement), spunbonding, nonwoven, carded nonwoven, and melt blown nonwoven.
In some aspects, the synthetic leather textile layer may comprise, consist essentially of, or consist of fibers or filaments comprising or consisting of a fiber/yarn polymer composition. The fiber/yarn polymer composition may be thermoplastic. The fiber/yarn polymer composition may comprise a polyolefin, or a polyamide, or a polyurethane, or a polyester, or a polyether polymer, or any combination thereof. The polymer component of the fiber/yarn polymer composition may consist essentially of one or more polyesters. The polymer component of the fiber/yarn polymer composition may consist essentially of one or more polyolefins. The one or more polyolefins may comprise or consist essentially of one or more polypropylenes.
The synthetic leather material may have a thickness of about 0.8 millimeters to about 2.5 millimeters, or about 0.9 millimeters to about 2.2 millimeters, or about 1 millimeter to about 2 millimeters, or about 1.2 millimeters to about 1.4 millimeters, or about 1.3 millimeters to about 1.5 millimeters, or about 1.4 millimeters to about 1.6 millimeters. The synthetic leather material may have a weight of about 400 grams per square meter to about 1,000 grams per square meter, or about 450 grams per square meter to about 900 grams per square meter, or about 500 grams per square meter to about 700 grams per square meter. The synthetic leather material may have a Mullen burst score (Mullen burst score) in the range of 15 to 25 or in the range of 10 to 22, as determined according to the Mullen burst test described herein.
The disclosed synthetic leather materials can be manufactured using a variety of methods. Typically, these processes have the step of bringing together a synthetic leather textile layer with a synthetic leather polymer coating and/or a synthetic leather polymer coating composition. In one aspect, the synthetic leather polymer coating may be applied as a liquid to the synthetic leather textile layer, followed by curing or drying. The particular method of providing the liquid polymer coating can be any suitable method for applying the liquid polymer composition to the textile layer, including but not limited to spreading or spraying onto the textile layer. In some cases, the liquid polymer coating may impregnate the textile layer, depending on the nature of the liquid and the manufacturing process. In another aspect, the polymeric coating may be first formed into a film and then the film is attached to the textile layer using a separate adhesive layer, or by applying a solvent and pressure to soften the film, or by applying heat and pressure to soften the film. In some aspects, attaching the synthetic leather textile layer to the synthetic leather polymer coating comprises applying a liquid synthetic leather polymer coating composition to the synthetic leather textile layer and allowing the liquid synthetic leather polymer coating composition to cure to a solid synthetic leather polymer coating composition when in contact with the synthetic leather textile layer, thereby forming the synthetic leather polymer coating, and mechanically bonding the synthetic leather coating to the synthetic leather textile layer.
In other aspects, when more than one synthetic leather polymer coating and/or synthetic leather polymer coating composition is applied to the synthetic leather textile layer, each polymer coating or composition may be applied to the synthetic leather textile in sequence. In some aspects, one or more layers of the polymeric coating composition or layer may be applied to the synthetic leather textile layer in the form of a film, including a monolayer film or a multilayer film. For example, the monolayer film may be an extruded film, or the multilayer film may be a coextruded multilayer film or a laminated multilayer film. In other aspects, one or more layers of the polymeric coating may be applied to the synthetic leather textile layer in liquid form. The particular method of providing the liquid polymer coating can be any suitable method for applying the liquid polymer composition to a substrate, including but not limited to spreading onto or spraying onto a polymer coating that has previously been applied onto a textile layer.
It should be understood that the method of making the disclosed synthetic leather material may further include the step of texturing the synthetic leather material. The texture may be applied during the formation of the coating, or during the adhesion of the coating and the textile layer to each other, or may be applied after the textile layer and the coating are attached to each other. The texture may be applied using a roller (e.g., a heated metal roller) or using a textured release paper.
In various aspects, the disclosed synthetic leather materials use a composition comprising the disclosed polyolefin resin, e.g., polyolefin copolymer, optionally with a transparency agent, and a polymer resin modifier, as a coating for the synthetic leather material, or as a clear or colored protective or decorative coating applied to the outer surface of the polymer layer, or both.
In various aspects, the disclosed synthetic leather materials use fibers comprising the disclosed polyolefin resins, such as polyolefin copolymers, optionally with a transparency agent, and polymer resin modifiers in the textile layer, optionally with a polyolefin-based coating or a protective/decorative coating or both.
The polyolefin-based coating or protective/decorative layer can be formed by extruding the disclosed polyolefin resin composition into one or more films that can be attached to the textile layer.
In one aspect, a dispersion, such as an aqueous dispersion, of the polyolefin resin composition can be sprayed onto the textile layer to impregnate the textile layer and form the synthetic leather material.
As stated above, it is believed that one advantage of using the disclosed polyolefin resin composition to form the outer surface of the disclosed synthetic leather material (i.e., the polymer coating or protective layer/decorative layer on the "top" or "front" side of the synthetic leather material) is that it provides an outer layer of synthetic leather material that is more easily bonded to other polyolefin-based polymers. For example, the bonding fraction of the synthetic leather material having a polyolefin-based solid resin component (e.g., a polypropylene-based sheet) is improved as compared to a PU-based synthetic leather material or a PVC-based synthetic leather material.
In various further aspects, it is believed that an advantage of using the disclosed polyolefin resin composition to form at least a portion of the fibers present in the synthetic leather textile layer of the synthetic leather (the "bottom" or "back" side of the synthetic leather material) is that it produces an outer layer of synthetic leather material that is more readily bonded to other polyolefin-based polymers. For example, the bonding fraction with respect to the polyolefin-based solid resin component (e.g., polypropylene-based sheet) is improved compared to the PU-based synthetic leather material or the PVC-based synthetic leather material.
Additionally or alternatively, when the synthetic leather material having a synthetic leather polymer coating and/or a synthetic leather protective/decorative layer comprises the disclosed polyolefin resin composition, the fibers that are present in the textile layer of the synthetic leather material (the "bottom" or "back" side of the synthetic leather material) may be formed from other polymers, such as TPU, polyester, or nylon, and may be substantially free of polyolefin-based fibers. In this case, the "front" of the synthetic leather material may be more easily bonded to other polyolefin-based polymers, while the "back" of the synthetic leather material is more easily bonded to other polyester or nylon-based materials.
In some aspects, the synthetic leather textile layer comprises lower melting thermoplastic fibers or yarns (e.g., having a melting or softening temperature less than about 150 degrees celsius, or having a melting or softening temperature at least 20 degrees celsius lower than the softening temperature of the polymeric coating and, if present, the protective/decorative layer). In such a case, it is believed that an advantage of using lower melting thermoplastic fibers or yarns in the synthetic leather textile layer is that it provides a synthetic leather material in which the "back" textile layer can be thermally bonded to another component without affecting the "front" appearance of the synthetic leather material.
It has been previously observed that with conventional materials comprising polyolefin resins, the coloration of polyolefins may be more difficult than with other polymers. For example, unlike many synthetic, natural, and regenerated fibers, packaging dyed polyolefin fibers can be difficult. However, such problems can be avoided in the present disclosure by using package dyed fibers substantially free of polyolefin in the textile layer in combination with a transparent or nearly transparent polyolefin-based coating.
Polymer material
In various aspects, disclosed herein are compositions and materials, such as textiles, polymeric coatings, and protective or decorative layers, comprising one or more polymeric materials, such as thermoplastic polymeric materials. The polymers used to prepare the disclosed compositions and materials can include polymers (e.g., homopolymers and copolymers, including terpolymers) having the same or different types of monomers. In certain aspects, the polymer can include different monomers randomly distributed in the polymer (e.g., a random copolymer). The term "polymer" refers to a polymerized molecule having one or more monomeric species that may be the same or different. When the monomer species are the same, the polymer may be referred to as a homopolymer, and when the monomers are different, the polymer may be referred to as a copolymer. The term "copolymer" is a polymer having two or more types of monomeric species, and includes terpolymers (i.e., copolymers having three monomeric species). In aspects, "monomers" may include different functional groups or segments, but for simplicity they are often referred to as monomers.
For example, the polymer may be a polymer that: the polymer has repeating polymer units (hard segments) that are relatively hard, of the same chemical structure (segments), and repeating polymer segments (soft segments) that are relatively soft. In various aspects, the polymer has repeating hard and soft segments. Physical crosslinks may be present within the segments or between the segments or both within and between the segments. Specific examples of the hard segment include isocyanate segments. Specific examples of the soft segment include alkoxy groups such as polyether segments and polyester segments. As used herein, a polymer segment may be referred to as a particular type of polymer segment, such as, for example, an isocyanate segment (e.g., a diisocyanate segment), an alkoxypolyamide segment (e.g., a polyether segment, a polyester segment), and the like. It is to be understood that the chemical structure of the segment is derived from the described chemical structure. For example, an isocyanate segment is a polymerized unit that includes an isocyanate functional group. When referring to polymer segments of a particular chemical structure, the polymer may contain up to 10 mole percent of segments of other chemical structures. For example, as used herein, a polyether segment should be understood to include up to 10 mole percent of non-polyether segments.
In certain aspects, the polymer may be a thermoplastic polyurethane (also referred to as "TPU"). The polyurethane polymer may include a hard segment and a soft segment. In aspects, the hard segment can include or consist of an isocyanate segment (e.g., a diisocyanate segment). In the same or alternative aspects, the soft segment can include or consist of an alkoxy segment (e.g., a polyether segment, or a polyester segment, or a combination of a polyether segment and a polyester segment). In particular aspects, the thermoplastic material may comprise or consist essentially of an elastomeric thermoplastic polyurethane having repeating hard segments and repeating soft segments.
Polyamide
In various aspects, the polymer can comprise a polyamide, including a thermoplastic polyamide. The polyamide may be a polyamide homopolymer having repeating polyamide segments of the same chemical structure. Alternatively, the polyamide may comprise a plurality of polyamide segments having different polyamide chemical structures (e.g., polyamide 6 segments, polyamide 11 segments, polyamide 12 segments, polyamide 66 segments, etc.). The polyamide segments having different chemical structures may be arranged randomly or may be arranged as repeating blocks.
The polyamide may be a copolyamide (i.e., a copolymer comprising polyamide segments and non-polyamide segments). The polyamide segments of the copolyamide may comprise or consist of: polyamide 6 segments, polyamide 11 segments, polyamide 12 segments, polyamide 66 segments, or any combination thereof. The polyamide segments of the copolyamide may be arranged randomly or may be arranged as repeating segments. In particular examples, the polyamide segments may include or consist of: polyamide 6 segments, or polyamide 12 segments, or both polyamide 6 segments and polyamide 12 segments. In examples where the polyamide segments of the copolyamide comprise polyamide 6 segments and polyamide 12 segments, the segments may be randomly arranged. The non-polyamide segments of the copolyamide may comprise or consist of: a polyether segment, a polyester segment, or both a polyether segment and a polyester segment. The copolyamide may be a copolyamide or may be a random copolyamide. The thermoplastic copolyamide may be formed by polycondensation of a polyamide oligomer or prepolymer with a second oligomer prepolymer to form a copolyamide (i.e., a copolymer comprising polyamide segments). Optionally, the second prepolymer may be a hydrophilic prepolymer.
In an aspect, the polyamide can be a block copolyamide. For example, the block copolyamide may have repeating hard segments and repeating soft segments. The hard segments may include polyamide segments and the soft segments may include non-polyamide segments. The polymer may be an elastomeric copolyamide comprising or consisting of a block copolyamide having repeating hard segments and repeating soft segments. In block copolymers comprising block copolymers having repeating hard and soft segments, physical crosslinks may be present within the segments or between the segments, or both within and between the segments. In one aspect, the polyamide can be a poly (ether block amide) polymer.
Exemplary commercially available polyamide copolymers include, but are not limited to, copolymers available under the following trade names or also other similar materials produced by a number of other suppliers: "VESTAMID" (Evonik Industries); "PLATAMID" (Arkema), e.g., product code H2694; "PEBAX" (Arkema), such as product codes "PEBAX MH 1657" and "PEBAX MV 1074"; "PEBAX RNEW" (Arkema); "GRILAMID" (EMS-Chemie AG).
Polyester
In aspects, the polymer can comprise a polyester, including a thermoplastic polyester. Polyesters may be formed by the reaction of one or more carboxylic acids or ester-forming derivatives thereof (ester-forming derivatives) with one or more divalent or polyvalent aliphatic, cycloaliphatic, aromatic or araliphatic alcohols or bisphenols. The polyester may be a polyester homopolymer having repeating polyester segments of the same chemical structure. Alternatively, the polyester may comprise a plurality of polyester segments having different polyester chemical structures (e.g., polyglycolic acid segments, polylactic acid segments, polycaprolactone segments, polyhydroxyalkanoate segments, polyhydroxybutyrate segments, etc.). The polyester segments having different chemical structures may be arranged randomly or may be arranged as repeating blocks.
In some aspects, the polyester is polybutylene terephthalate (PBT), polytrimethylene terephthalate, polyhexamethylene terephthalate, poly-1, 4-dimethylcyclohexane terephthalate, polyethylene terephthalate (PET), polyethylene isophthalate (PEI), Polyarylate (PAR), polybutylene naphthalate (PBN), a liquid crystalline polyester, or a blend or mixture of two or more of the foregoing.
The polyester may be a copolyester (i.e., a copolymer comprising polyester segments and non-polyester segments). The copolyester may be an aliphatic copolyester (i.e., a copolyester in which both the polyester segments and the non-polyester segments are aliphatic). Alternatively, the copolyester may comprise aromatic segments. The polyester segments of the copolyester may comprise or consist of: a polyglycolic acid segment, a polylactic acid segment, a polycaprolactone segment, a polyhydroxyalkanoate segment, a polyhydroxybutyrate segment, or any combination thereof. The polyester segments of the copolyester may be arranged randomly or may be arranged as repeating blocks.
For example, the polyester may be a block copolyester having repeating blocks of polymer units that are relatively hard, of the same chemical structure (segments) (hard segments) and repeating blocks of polymer segments that are relatively soft (soft segments). In block copolyesters (including block copolyesters having repeating hard and soft segments), physical crosslinking can occur in blocks or between blocks, or both in blocks and between blocks. In one aspect, the material may comprise or consist essentially of an elastomeric thermoplastic copolyester having hard segments of repeating blocks and soft segments of repeating blocks.
The non-polyester segments of the copolyester may comprise or consist of: polyether segments, polyamide segments, or both polyether and polyamide segments. The copolyester may be a block copolyester, or may be a random copolyester. The thermoplastic copolyester may be formed by polycondensation of a polyester oligomer or prepolymer with a second oligomer prepolymer to form a block copolyester. Optionally, the second prepolymer may be a hydrophilic prepolymer. For example, the copolyester may be formed from the polycondensation of terephthalic acid or naphthalenedicarboxylic acid with ethylene glycol, 1, 4-butanediol or 1, 3-propanediol. Examples of copolyesters include polyethylene adipate, polybutylene succinate, poly (3-hydroxybutyrate-co-3-hydroxyvalerate), polyethylene terephthalate, polybutylene terephthalate, polypropylene terephthalate, polyethylene naphthalate, and combinations thereof. In a particular example, the copolyamide may comprise or consist of polyethylene terephthalate.
In some aspects, the polyester is a block copolymer comprising segments of one or more of the following: polybutylene terephthalate (PBT), polytrimethylene terephthalate, polyhexamethylene terephthalate, poly-1, 4-dimethylcyclohexane terephthalate, polyethylene terephthalate (PET), polyethylene isophthalate (PEI), Polyarylate (PAR), polybutylene naphthalate (PBN) and liquid crystalline polyesters. For example, a suitable thermoplastic polyester as a block copolymer may be a PET/PEI copolymer, a polybutylene terephthalate/tetraethylene glycol copolymer, a polyoxyalkylene diimide diacid/polybutylene terephthalate copolymer, or a blend or mixture of any of the foregoing copolymers.
Polyolefins
In some aspects, the polymer can comprise or consist essentially of a polyolefin, including a thermoplastic polyolefin. Exemplary polyolefins include, but are not limited to, polyethylene, polypropylene, and thermoplastic olefin elastomers (e.g., metallocene-catalyzed block copolymers of ethylene and an alpha-olefin having from 4 to about 8 carbon atoms). In a further aspect, the polyolefin is a polymer comprising: polyethylene, ethylene-alpha-olefin copolymers, ethylene-propylene rubber (EPDM), polybutylene, polyisobutylene, poly-4-methylpent-1-ene, polyisoprene, polybutadiene, ethylene-methacrylic acid copolymers, and olefin elastomers such as dynamically cross-linked polymers (dynamic cross-linked polymers) obtained from polypropylene (PP) and ethylene-propylene rubber (EPDM), as well as blends or mixtures of the foregoing. Additional exemplary polyolefins include polymers of cyclic olefins such as cyclopentene or norbornene.
It is to be understood that polyethylenes that may be optionally crosslinked include a variety of polyethylenes, including, but not limited to, Low Density Polyethylene (LDPE), Linear Low Density Polyethylene (LLDPE), (VLDPE), and (ULDPE), Medium Density Polyethylene (MDPE), High Density Polyethylene (HDPE), high density and high molecular weight polyethylene (HDPE-HMW), high density and ultra high molecular weight polyethylene (HDPE-UHMW), and blends or mixtures of any of the foregoing polyethylenes. The polyethylene can also be a polyethylene copolymer derived from monomers of mono-and di-olefins copolymerized with: vinyl, acrylic, methacrylic, ethyl acrylate, vinyl alcohol, and/or vinyl acetate. The polyolefin copolymer including vinyl acetate-derived units can be a high vinyl acetate content copolymer, such as greater than about 50 weight percent of a vinyl acetate-derived composition.
In some aspects, the polyolefin can be formed via free radical polymerization, cationic polymerization, and/or anionic polymerization by methods well known to those skilled in the art (e.g., using peroxide initiators, heat, and/or light). In further aspects, the disclosed thermoplastic polyolefins can be prepared by free radical polymerization at elevated pressures and at elevated temperatures. Alternatively, the polyolefin may be prepared by catalytic polymerization using a catalyst, which typically comprises one or more metals from the group IVb, Vb, VIb or VIII metals. The catalyst typically has one or more than one ligand, typically an oxide, halide, alcoholate, ester, ether, amine, alkyl, alkenyl, and/or aryl group that can be para-coordinated or ortho-coordinated, complexed with a group IVb, Vb, VIb, or VIII metal. In various aspects, the metal complex can be in free form or immobilized on a substrate, typically on activated magnesium chloride, titanium (III) chloride, alumina, or silicon oxide. It is understood that the metal catalyst may be soluble or insoluble in the polymerization medium. The catalyst may be used alone for polymerization, or an additional activator may be used, typically a group Ia, group IIa and/or group IIIa metal alkyl, metal hydride, metal alkyl halide, metal alkyl oxide or metal alkyl siloxane. The activators may be modified conveniently with further ester, ether, amine or silyl ether groups.
Suitable polyolefins may be prepared by polymerization of monomers of mono-and di-olefins as described herein. Exemplary monomers that can be used to prepare the disclosed thermoplastic polyolefins include, but are not limited to, ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 2-methyl-1-propene, 3-methyl-1-pentene, 4-methyl-1-pentene, 5-methyl-1-hexene, and mixtures thereof.
Suitable ethylene- α -olefin copolymers may be obtained by copolymerization of ethylene with α -olefins having a carbon number of 3 to 12 such as propylene, 1-butene, 1-hexene, 1-octene, 4-methyl-1-pentene, or the like.
Suitable dynamically crosslinked polymers can be obtained by crosslinking the rubber component as the soft segment while physically dispersing the hard segment such as PP and the soft segment such as EPDM using a kneading machine such as a Banbury mixer (Banbury mixer) and a twin-screw extruder.
In some aspects, the polyolefin can be a mixture of polyolefins, such as a mixture of two or more polyolefins disclosed above. For example, a suitable mixture of polyolefins may be a mixture of polypropylene and polyisobutylene, a mixture of polypropylene and polyethylene (e.g., PP/HDPE, PP/LDPE) or a mixture of different types of polyethylene (e.g., LDPE/HDPE).
In some aspects, the polyolefin can be a copolymer of a suitable monoolefin monomer or a suitable monoolefin monomer and a vinyl monomer. Exemplary polyolefin copolymers include, but are not limited to, ethylene/propylene copolymers, Linear Low Density Polyethylene (LLDPE), and blends thereof with Low Density Polyethylene (LDPE), propylene/but-1-ene copolymers, propylene/isobutylene copolymers, ethylene/but-1-ene copolymers, ethylene/hexene copolymers, ethylene/methylpentene copolymers, ethylene/heptene copolymers, ethylene/octene copolymers, propylene/butadiene copolymers, isobutylene/isoprene copolymers, ethylene/alkyl acrylate copolymers, ethylene/alkyl methacrylate copolymers, ethylene/vinyl acetate copolymers, and copolymers thereof with carbon monoxide or ethylene/acrylic acid copolymers, and salts thereof (ionomers), and terpolymers of ethylene with propylene and a diene such as hexadiene, dicyclopentadiene or ethylidene-norbornene; and mixtures of such copolymers with one another and with polymers mentioned in 1) above, for example polypropylene/ethylene-propylene copolymers, LDPE/ethylene-vinyl acetate copolymers (EVA), LDPE/ethylene-acrylic acid copolymers (EAA), LLDPE/EVA, LLDPE/EAA and alternating or random polyalkylene/carbon monoxide copolymers (alternating or random polyalkylene/carbon monooxide copolymers) and mixtures thereof with other polymers, for example polyamides.
In some aspects, the polyolefin can be a polypropylene homopolymer, a polypropylene copolymer, a polypropylene random copolymer, a polypropylene block copolymer, a polyethylene homopolymer, a polyethylene random copolymer, a polyethylene block copolymer, a Low Density Polyethylene (LDPE), a Linear Low Density Polyethylene (LLDPE), a medium density polyethylene, a High Density Polyethylene (HDPE), or a blend or mixture of one or more of the foregoing polymers.
In some aspects, the polyolefin is polypropylene. As used herein, the term "polypropylene" is intended to encompass any polymer composition comprising propylene monomers, either alone or in admixture or copolymer with other randomly selected and oriented polyolefins, dienes, or other monomers such as ethylene, butylene, and the like. Such terms also encompass any of the various configurations and arrangements of constituent monomers (such as atactic, syndiotactic, isotactic, etc.). Thus, the term as applied to fibers is intended to encompass actual long strands, ribbons, stitches, and the like of drawn polymer. The polypropylene may have any standard melt flow (passing the test); however, standard fiber grade polypropylene resins have a melt flow index range between about 1 and 1000.
In some aspects, the polyolefin is polyethylene. The term "polyethylene" as used herein is intended to encompass any polymer composition comprising ethylene monomers, either alone or in admixture or copolymers with other randomly selected and oriented polyolefins, dienes, or other monomers such as propylene, butylene, and the like. Such terms also encompass any of the various configurations and arrangements of constituent monomers (such as atactic, syndiotactic, isotactic, etc.). Thus, the term as applied to fibers is intended to encompass actual long strands, ribbons, stitches, and the like of drawn polymer. The polyethylene may have any standard melt flow (pass the test); however, standard fiber grade polyethylene resins have a melt flow index range between about 1 and 1000.
Method for preparing resin composition
In various aspects, the present disclosure describes polymer compositions including a polyolefin resin composition, a synthetic leather polymer coating composition, and a fiber/yarn polymer composition. The polymer composition may be prepared by dry blending or by melt blending the various ingredients. Methods of blending polymers may include film blending in a press, blending in a mixer (e.g., a mixer commercially available under the trade designation "HAAKE" from Thermo Fisher Scientific, Waltham, MA), solution blending, hot melt blending, and extruder blending. In some aspects, the polymer resin modifier and the polyolefin copolymer are miscible such that they can be easily mixed by a screw in a syringe during injection molding, e.g., without the need for a separate blending step.
The method can further include extruding the polymer composition to form an extruded polymer composition. The method of extruding the polymer composition may include producing a long product (rod, sheet, tube, film, wire insulation coating) of relatively constant cross-section. A method of extruding a polymer composition may include conveying a softened polymer composition through a die (die) having an opening. The polymer composition may be conveyed forward by a feed screw and forced through the die. A heating element placed above the barrel can soften and melt the polymer composition. The temperature of the polymer composition can be controlled by a thermocouple. The polymer composition exiting the die may be cooled by blown air or in a water bath to form an extruded polymer composition. Alternatively, the polymer composition exiting the die may be pelletized with little cooling, as described below.
The method can further include injection molding the polymer composition to form an article. Injection molding may include using a non-rotating cold plunger to force the polymer composition through a heated cylinder, wherein the polymer composition is heated by heat conducted from the wall of the cylinder to the polymer composition. Injection molding can include using a rotating screw disposed coaxially with a heated barrel for conveying the polymeric composition toward a first end of the screw and heating the polymeric composition by conducting heat from the heated barrel to the polymeric composition. As the polymer composition is conveyed by the screw mechanism toward the first end, the screw translates toward the second end so as to create a reservoir space (reservoir space) at the first end. When sufficient molten polymer composition is collected in the reservoir space, the screw mechanism may be urged toward the first end to inject the polymer composition into the selected mold.
Method of making parts and articles
The present disclosure provides several methods for making the components and articles described herein. The method includes attaching a synthetic leather material to a second element to form a part or article. The second element may comprise a textile or a multilayer film. For example, the second element may comprise an upper. The second element may include one or both of polyolefin fibers and polyolefin yarns. The second component may comprise an injection moulded component. The method can further include injection molding a polymer composition as described herein including the polyolefin resin composition to form an injection molded second component. The present disclosure provides methods for manufacturing a component for an article of footwear, apparel, or athletic equipment.
In some aspects, the polyolefin resin composition defines a side or outer layer of the second element, and the method includes attaching two sides or outer layers together, each side or outer layer defined by the polyolefin resin composition. The second element may comprise a yarn, a textile, a film or some other element. Attaching the part to the second component may include injecting a polymer composition, such as a polyolefin resin composition, directly onto the second component. Attaching the component to the second element may include forming a mechanical bond between the polymer composition and the second element. The mechanical bond may comprise a textile bonded at an interface between the component and the second element. Attaching the component to the second element may comprise: (i) increasing the temperature of the polymer composition to a first temperature above the melting temperature or softening temperature (e.g., Vicat softening temperature) of the polymer composition; (ii) contacting the polymer composition with a second member while the polymer composition is at a first temperature; and (iii) maintaining the polymer composition and the second member in contact with each other while reducing the temperature of the polymer composition to a second temperature below the melting temperature or softening temperature of the polymer composition, forming a thermal bond between the polymer composition and the second member.
The second element may comprise a second polymer composition (e.g., a second thermoplastic composition) that is thermoplastic, and attaching the component to the second element may comprise: (i) increasing the temperature of the second thermoplastic composition to a first temperature above the melting temperature or softening temperature of the second thermoplastic composition; (ii) contacting the polymer composition and the second member with each other while the second thermoplastic composition is at the first temperature; and (iii) maintaining the polymer composition and the second member in contact with each other while reducing the temperature of the second thermoplastic composition to a second temperature that is below the melting temperature or softening temperature of the second thermoplastic composition, forming a thermal bond between the polymer composition and the second member.
The polymer composition may be a first thermoplastic composition and the second element may comprise a second thermoplastic composition, and attaching the part to the second element may comprise: (i) increasing the temperature of both the first and second thermoplastic compositions to a first temperature that is greater than both the melting or softening temperature of the first thermoplastic composition and the melting or softening temperature of the second thermoplastic composition, (ii) contacting the first and second thermoplastic compositions with each other while both the first and second thermoplastic compositions are at the first temperature, and (iii) maintaining the first and second thermoplastic compositions in contact with each other while reducing the temperature of both the first and second thermoplastic compositions to a second temperature that is less than both the melting or softening temperature of the first and second thermoplastic compositions, forming a thermal bond between the first and second thermoplastic compositions, wherein the polymer chains of the first thermoplastic composition and the second thermoplastic composition are intermixed with each other.
In some aspects, the article is an article of footwear and the method includes injection molding the plate directly onto the upper. Procedure for Property analysis and characterization
Cold sole material bending test scheme
The cold sole material deflection test was determined according to the following test method. The purpose of this test was to evaluate the crack resistance of the samples when repeatedly flexed to 60 degrees in a cold environment. The thermoformed substrate of material for testing was sized to fit inside the refraction tester. Each material was tested as five independent samples. The refractometer was able to refract the sample to 60 degrees at a rate of 100 plus or minus 5 cycles per minute. The diameter of the mandrel of the machine was 10 mm. Suitable machines for this test are Emerson AR-6, Satra STM141F, Gotech GT-7006 and Shin II Scientific SI-LTCO (DaeSung Scientific). The samples were inserted into the machine according to the specific parameters of the bending machine used. The machine was placed in a freezer set at-6 degrees celsius for testing. The motor was turned on to begin the flexion and the flexion cycles were counted until the sample cracked. Cracking of the sample means that the surfaces of the material are physically separated. The visible crease, which in fact has no line penetrating the surface, is not a crack. The sample was measured to the extent that it had cracked but had not been bisected.
Abrasion loss test protocol ASTM D5963-97 a
The abrasion loss was tested on cylindrical test pieces cut from sheet material using an ASTM standard drill with a diameter of 16 mm plus or minus 0.2 mm and a minimum thickness of 6 mm. Abrasion loss was measured on a Gotech GT-7012-D abrasion tester using method B of ASTM D5963-97 a. The test was conducted at 22 degrees celsius with a wear path of 40 meters. Standard rubber No. 1 used in the test had a weight per cubic centimeter (g/cm) of 1.336 grams3) The density of (c). The smaller the wear loss, the better the wear resistance.
Crystallinity test protocol
To determine the percent crystallinity of the resin composition comprising the copolymer or the copolymer in pure resin form and the homopolymer of the major component of the copolymer (e.g., polypropylene homopolymer polypropylene), samples were analyzed by Differential Scanning Calorimetry (DSC) over a temperature range from-80 degrees celsius to 250 degrees celsius. A heating rate of 10 degrees celsius per minute was used. The melting endotherm (melting endotherm) of each sample was measured during heating. General analysis software (TA Instruments, New Castle, DE, USA) was used to calculate the percent crystallinity (% crystallinity) based on the melt endotherm of the homopolymer (e.g., 207 joules/gram for 100% crystalline polypropylene material). Specifically, the percent crystallinity (% crystallinity) is calculated by dividing the heat absorption from the melt measured for the copolymer or for the resin composition by the heat absorption from the melt for the 100% crystalline homopolymer.
Method for determining Vicat softening temperature test scheme
Vicat softening temperature according to ASTM T at Vicat softening temperature for plasticsmD1525-09, preferably using load a and rate a. Briefly, the vicat softening temperature is the temperature at which a flat-ended needle (flat-ended needle) penetrates a sample to a depth of 1mm under a specific load. The temperature reflects the softening point expected when the material is used in high temperature applications. It is considered to be the temperature at which the sample passes with 1 square millimeter2A flat-headed needle of circular cross-section or square cross-section was penetrated to a depth of 1 mm. For the Vicat A test, a load of 10 newtons (N) is used, whereas for the Vicat B test, the load is 50 newtons. The test involves placing the test specimen in the test apparatus such that the penetrating needle rests on its surface at least 1mm from the edge. A load is applied to the sample as required by either the vicat a test or the vicat B test. The sample was then lowered into an oil bath at 23 degrees celsius. The bath was warmed at 50 degrees celsius or 120 degrees celsius per hour until the needle penetrated 1 millimeter. The test specimen must be between 3mm and 6.5mm thick and at least 10mm in width and length. No more than three layers may be stacked to achieve a minimum thickness.
Melting temperature and glass transition temperature test protocol
The melting temperature and glass transition temperature were determined according to ASTM D3418-97 using a commercially available differential scanning calorimeter ("DSC"). Briefly, 10-15 grams of the sample was placed in an aluminum DSC pan and then lead was sealed with a tablet press. The DSC was configured to scan from-100 degrees celsius to 225 degrees celsius at a heating rate of 20 degrees celsius/minute, hold at 225 degrees celsius for 2 minutes, and then cool to 25 degrees celsius at a rate of-10 degrees celsius/minute. The DSC curve generated by this scan was then analyzed using standard techniques to determine the glass transition temperature and the melting temperature.
Melt flow index test protocol
Melt flow index is determined according to the test method detailed in ASTM D1238-13 for melt flow of thermoplastics by an extrusion plastometer using procedure a described therein. Briefly, melt flow index measures the rate at which a thermoplastic is extruded through an orifice at a specified temperature and load. In the test method, about 7 grams of material was loaded into a barrel of a melt flow apparatus, which barrel had been heated to a temperature specified for the material. A prescribed weight for the material is applied to the plunger and molten material is forced through the die. The timed extrudates were collected and weighed. Melt flow values are calculated in grams per 10 minutes. Alternatively, the melt flow index can be determined using the melt Mass Flow Rate (MFR) and melt volume flow rate (MVR) of the international standard ISO1133 thermoplastic, using procedure a described therein at 190 degrees celsius and a load of 2.16 kilograms.
Hardness tester hardness test scheme
The hardness of the material is determined using the shore a scale according to the test method detailed in ASTM D-2240 durometer hardness.
Flexural modulus test protocol
The flexural modulus (elastic modulus) of the material was determined according to the test method detailed in ASTM D790. The modulus is calculated by taking the slope of stress (megapascals) versus strain at the steepest initial linear portion of the load-deflection curve.
Modulus test protocol (of substrates)
The (tensile) modulus of the thermoformed substrate for the material was determined according to the test method described in detail in ASTM D412-98 standard test methods for vulcanized rubber, thermoplastic rubber and thermoplastic elastomer-tensile, with the following modifications. The sample size was ASTM D412-98 Die C, and the sample thickness used was 2.0 millimeters plus or minus 0.5 millimeters. The type of gripper used is a pneumatic gripper with a metal serrated gripper face. The distance of the clamps used was 75 mm. The loading rate used was 500 millimeters per minute. The modulus (initial) is calculated by taking the slope of stress versus strain in megapascals (MPa) in the initial linear region.
Modulus test protocol (of yarn)
The modulus of the yarn was determined according to the test method described in detail in EN ISO 2062 (textile from packaging — yarn) using a constant elongation rate (CRE) tester to determine the single end force at break and the elongation at break, with the following modifications. The sample length used was 600 mm. The equipment used was an Instron and Gotech fixture. The distance of the clamps used was 250 mm. The preload was set to 5 grams and the loading rate used was 250 millimeters per minute. The first meter of yarn is thrown away to avoid using damaged yarn. The modulus (initial) is calculated by taking the slope of stress versus strain in megapascals (MPa) in the initial linear region.
Tenacity and elongation test protocol
The tenacity and elongation of the yarn can be determined according to the test method described in detail in EN ISO 2062, measuring single end break force and elongation at break using a constant elongation tester with a preload set at 5 grams.
Mullen burst test protocol
Mullen breakage of a web of material such as Textile or synthetic leather material can be determined according to ASTM D3786, a Test Method detailed in the Standard Test Method for Bursting Strength of Textile Fabrics (Standard Test Method for Bursting Strength of Textile Fabrics).
Sampling procedure
Using the test protocols described above, various properties of the materials disclosed herein, as well as components and articles formed therefrom, can be characterized using samples prepared with the following sampling procedure:
pure material sampling procedure
The material sampling procedure can be used to obtain pure samples of the polymer or polymer composition. The material is provided in a media form such as flakes, granules, powders, pellets, and the like. If the polymer or source of the polymer composition is not available in pure form, a sample may be cut from a film or sheet or other part comprising the polymer composition, thereby isolating a sample of the material.
Substrate sampling procedure
Samples of the polymer or polymer composition were prepared. A portion of the polymer or polymer composition is then molded into a film or substrate that is sized to fit inside the test device. For example, when using the sole material deflection tester, the film or substrate is sized to fit inside the sole material deflection tester used by thermoforming the polymer or polymer composition in a mold, or extruding the polymer or polymer composition into a film and cutting the film to size, the substrate having dimensions of about 15 centimeters (cm) by 2.5 centimeters (cm) and a thickness of about 1 millimeter (mm) to 4 millimeters (mm). Substrate samples were prepared by: mixing the components of the polymer or polymer composition together, melting the components, pouring or injecting the molten polymer or polymer composition into a mold cavity, cooling the molten polymer or composition to solidify it in the mold cavity to form a substrate, and then removing the solid substrate from the mold cavity.
Part sampling procedure
The program may be used to obtain samples of a polymer or polymer composition from an article or part of an article, such as an article of footwear, an article of apparel, or an article of athletic equipment. A blade is used to cut a sample comprising a polymer or polymer composition in a non-wet state (e.g., at 25 degrees celsius and 20 percent relative humidity) from an article or part. If the polymer or polymer composition is bound to one or more additional materials, the procedure can include separating the additional materials from the polymer or polymer composition to be tested. For example, to test a polymer or polymer composition on a bottom surface of a sole structure, such as an outsole, the top surface may be peeled, polished, scratched, or otherwise cleaned to remove any adhesive, yarn, fiber, foam, and the like attached to the polymer or polymer material to be tested. The resulting sample comprises a polymer or polymer composition and may comprise any additional material bound thereto.
Definition of
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
All publications, patents, and patent applications cited in this specification are cited to disclose and describe the methods and/or materials in connection with which the publications are cited. All such publications, patents and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent was specifically and individually indicated to be incorporated by reference. Such incorporation by reference is expressly limited to the methods and/or materials described in the cited publications, patents, and patent applications and does not extend to any dictionary definitions from the cited publications, patents, and patent applications. Any dictionary definitions in the cited publications, patents and patent applications that have not been explicitly repeated in this specification should not be construed as such dictionary definitions, and should not be construed as defining any terms appearing in the appended claims.
Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present disclosure, the preferred methods and materials are now described. For the sake of brevity and/or clarity, functions or configurations well known in the art may not be described in detail. Unless otherwise indicated, aspects of the present disclosure will employ nanotechnology, organic chemistry, material science, and engineering, among others, within the skill of the art. Such techniques are explained fully in the literature.
It should be noted that ratios, concentrations, amounts, and other numerical data may be expressed herein in a range format. Where the stated range includes one or both of the extremes, ranges excluding either or both of those included extremes are also encompassed within the disclosure, e.g., the phrase "x to y" includes ranges from 'x' to 'y' as well as ranges greater than 'x' and less than 'y'. Ranges can also be expressed as upper limits, e.g., 'about x, y, z, or less' and should be interpreted to include specific ranges of 'about x', 'about y', and 'about z' as well as ranges of 'less than x', 'less than y', and 'less than z'. Likewise, the phrase 'about x, y, z or greater' should be construed to include specific ranges of 'about x', 'about y' and 'about z' as well as ranges of 'greater than x', 'greater than y' and 'greater than z'. Further, the phrase "about 'x' to 'y'", where 'x' and 'y' are numerical values, includes "about 'x' to about 'y'". It is to be understood that such a range format is used for convenience and brevity, and thus, should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For purposes of this specification, a numerical range of "about 0.1% to 5%" should be interpreted to include not only the explicitly recited values of about 0.1% to about 5%, but also include individual values (e.g., 1%, 2%, 3%, and 4%) and sub-ranges (e.g., 0.5%, 1.1%, 2.4%, 3.2%, and 4.4%) within the indicated range.
The term "providing," as used herein and as recited in the claims, is not intended to require any particular delivery or receipt of the provided items. Rather, for the purposes of clarity and readability, the term "provided" is used merely to recite an item that will be referred to in the elements that follow the claim.
The terms and phrases used herein in reference to sampling procedures and testing protocols such as "pure material sampling procedure", "substrate sampling procedure", "cold sole material flex test", "ASTM D5963-97 a", "crystallinity test", and the like refer to the corresponding sampling procedures and testing methods described in the property analysis and characterization procedure section. These sampling procedures and testing methods characterize the properties of the recited materials, films, articles, components, etc., and need not be performed as an effective step in the claims.
The term "about" as used herein can include conventional rounding according to the significant digits of a numerical value. In some aspects, the term "about" is used herein to mean a deviation of 10%, 5%, 2.5%, 1%, 0.5%, 0.1%, 0.01%, or less from the specified value.
The articles "a" and "an" as used herein mean one or more when applied to any feature in aspects of the present disclosure described in the specification and claims. The use of "a" and "an" does not limit the meaning to a single feature unless such a limit is specifically stated. The article "the" preceding singular or plural nouns or noun phrases denotes a particular specified feature or particular specified features and may have a singular or plural connotation depending upon the context in which it is used.
Random copolymers of propylene with about 2.2% by weight (wt%) ethylene are commercially available from ExxonMobil Chemical Company, Houston, TX under the trade name "PP 9054". It has an MFR (ASTM-1238D, 2.16 kg, 230 ℃) of about 12 g/10 min and 0.90 g/cc (g/cm)3) The density of (c).
PP9074 is a random copolymer of propylene with about 2.8 weight-to-weight (wt%) ethylene and is commercially available from ExxonMobil Chemical Company, Houston, TX under the trade name "PP 9074". It has an MFR (ASTM-1238D, 2.16 kg, 230 ℃) of about 24 g/10 min and 0.90 g/cc (g/cm)3) The density of (c).
PP1024E4 is a propylene homopolymer commercially available from ExxonMobil Chemical Company, Houston, TX under the trade designation "PP 1024E 4". It has an MFR (ASTM-1238D, 2.16 kg, 230 ℃) of about 13 g/10 min and 0.90 g/cc (g/cm)3) The density of (c).
"VISTAMAXX 6202" is a copolymer comprising predominantly isotactic propylene repeat units, with about 15% by weight (wt%) ethylene repeat units randomly distributed along the copolymer. It is available from ExxonMobil Chemical Company, Houston, TXAnd has an MFR (ASTM-1238D, 2.16 kg, 230 ℃) of about 20 g/10 min, 0.862 g/cubic centimeter (g/cm)3) And a durometer hardness (shore a) of about 64.
Vistamaxx 3000 is a copolymer comprising predominantly isotactic propylene repeat units with about 11% by weight (wt%) of the ethylene repeat units randomly distributed along the copolymer. It is a metallocene catalyzed copolymer available from ExxonMobil Chemical Company and has an MFR (ASTM-1238D, 2.16 kg, 230 ℃) of about 8 g/10 min, 0.873 g/cc (g/cm)3) And a durometer hardness (shore D) of about 27.
"VISTAMAXX 6502" is a copolymer comprising predominantly isotactic propylene repeat units, with about 13% by weight of ethylene repeat units randomly distributed along the copolymer. It is a metallocene catalyzed copolymer available from ExxonMobil Chemical Company and has an MFR (ASTM-1238D, 2.16 kg, 230 ℃) of about 45 g/10 min, 0.865 g/cc (g/cm)3) And a durometer hardness (shore a) of about 71.
Examples
Having now described aspects of the present disclosure, the following examples, in general, describe some additional aspects of the present disclosure. While aspects of the disclosure are described in connection with the following embodiments and the corresponding text and drawings, there is no intent to limit aspects of the disclosure to this description. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the disclosure.
Material
For the examples described below, the following base resins were used.
Table 1: base resin
The following polymeric resin modifiers were used in the examples.
Table 2: polymer resin modifier
Polyolefin resin composition
Polyolefin resin compositions comprising a polyolefin polymer (i.e., a base resin) and varying amounts of a polymeric resin modifier were prepared and tested to determine abrasion loss according to the abrasion loss test and using a pure material sampling procedure; and performing a bending test according to the cold sole material bending test by using a substrate sampling program. The results are presented in table 3. The percent crystallinity (%) of the sample resin composition was measured according to the crystallinity test using the pure material sampling procedure. The results are reported in table 4.
Table 3: summary of Density, DIN abrasion and Cold sole Material inflections of resin compositions with varying amounts of Polymer resin modifier
Uncertainty of
TABLE 4 crystallization percentages of representative resin compositions
It should be emphasized that the above-described aspects of the present disclosure are merely possible examples of implementations, and are merely set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described aspects of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure.
Claims (20)
1. A synthetic leather material comprising:
a synthetic leather polymer coating attached to the synthetic leather textile layer;
wherein the synthetic leather polymer coating comprises a synthetic leather polymer coating composition;
wherein the synthetic leather textile layer comprises fibers or yarns comprising a fiber/yarn polymer composition; and is
Wherein the synthetic leather polymer coating composition comprises a polyolefin resin composition, or the fiber/yarn polymer composition comprises the polyolefin resin composition, or both the synthetic leather polymer coating composition and the fiber/yarn polymer composition comprise the polyolefin resin composition.
2. The synthetic leather material of claim 1, wherein the polyolefin resin composition comprises at least one polyolefin, wherein the at least one polyolefin comprises a polyolefin selected from a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer, a polypropylene copolymer, or a combination thereof.
3. The synthetic leather material according to claim 1 or 2, wherein the polyolefin resin composition comprises the polypropylene copolymer.
4. The synthetic leather material according to any one of claims 1 to 3, wherein the polyolefin component in the polyolefin resin composition consisting of all polyolefin polymers present in the polyolefin resin composition consists essentially of polypropylene homopolymer, polypropylene copolymer or a combination of both polypropylene homopolymer and polypropylene copolymer.
5. The synthetic leather material according to any one of claims 2 to 4, wherein the polypropylene copolymer comprises about 80% to about 99% by weight of polypropylene repeating units based on the total weight of the polypropylene copolymer.
6. The synthetic leather material according to any one of claims 2 to 5, wherein the polypropylene copolymer comprises a polypropylene/polyethylene copolymer.
7. The synthetic leather material of claim 6, wherein the polypropylene/polyethylene copolymer comprises about 1% to about 5% by weight ethylene repeat units based on the total weight of the polypropylene/polyethylene copolymer.
8. The synthetic leather material according to any one of claims 1 to 7, wherein the polyolefin resin composition further comprises a polymer resin modifier or a transparency agent or both.
9. The synthetic leather material of claim 8, wherein the polyolefin resin composition comprises from about 1 weight percent to about 30 weight percent of the polymer resin modifier based on the total weight of the polyolefin resin composition.
10. The synthetic leather material according to claim 8 or 9, wherein the polyolefin resin composition comprises from about 0.1 weight percent to about 5 weight percent of the transparentizing agent based on the total weight of the polyolefin resin composition.
11. An article of footwear comprising:
a sole structure comprising a sole component having a first side and a second side, wherein when the component is a component of an article of footwear, the first side is configured to be ground-facing and the second side is defined by a first thermoplastic composition; and
an upper operatively coupled with the second side of the sole component, the upper comprising a synthetic leather material comprising a synthetic leather polymer coating attached to a synthetic leather textile layer, the synthetic leather coating comprising a synthetic leather coating composition, the synthetic leather textile layer comprising a synthetic leather textile composition, and the synthetic leather coating composition or the synthetic leather textile composition defining an outward-facing side of the upper;
wherein the synthetic leather coating composition or the synthetic leather textile composition or both comprise a polyolefin resin composition.
12. The article of footwear of claim 11, wherein the second side of the sole component is at least partially thermally bonded to the upper through the polyolefin resin composition of the synthetic leather coating composition or the synthetic leather textile composition.
13. The article of footwear of claim 11 or claim 12, wherein the synthetic leather polymer coating includes a first synthetic leather polymer coating and a second synthetic leather polymer coating, wherein the first synthetic leather polymer coating is attached to the textile layer, the second synthetic leather polymer coating is attached to the first synthetic leather polymer coating, and the second synthetic leather polymer coating comprises the synthetic leather coating composition.
14. The article of footwear of any of claims 11 to 13, wherein the synthetic leather textile layer comprises a knitted textile, a woven textile, a non-woven textile, a crocheted textile, or a knitted textile.
15. The article of footwear of any of claims 11 to 14, wherein the synthetic leather textile layer includes first fibers or first yarns comprising the polyolefin resin composition.
16. The article of footwear of claim 15, wherein the synthetic leather textile layer further comprises a second fiber or second yarn comprising a second fiber/yarn thermoplastic composition, and the second fiber/yarn thermoplastic composition comprises a thermoplastic polymer selected from a polyester, a polyether, a polyamide, a polyurethane, or any combination thereof.
17. A method of manufacturing a synthetic leather material, the method comprising:
attaching the synthetic leather polymer coating and the synthetic leather textile layer to each other; wherein the synthetic leather polymer coating comprises a synthetic leather polymer coating composition; and wherein the synthetic leather textile layer comprises fibers or yarns comprising a fiber/yarn polymer composition, and wherein the synthetic leather polymer coating composition comprises a polyolefin resin composition, or the fiber/yarn polymer composition comprises the polyolefin resin composition, or both the synthetic leather polymer coating composition and the fiber/yarn polymer composition comprise the polyolefin resin composition.
18. The method of claim 17, wherein the attaching comprises laminating the synthetic textile layer to a film comprising the synthetic leather polymer coating.
19. The method of claim 17 or 18, wherein the attaching comprises applying a liquid synthetic leather polymer coating composition to the synthetic leather textile layer and allowing the liquid synthetic leather polymer coating composition to cure to a solid synthetic leather polymer coating composition when in contact with the synthetic leather textile layer, thereby forming the synthetic leather polymer coating, and mechanically bonding the synthetic leather coating to the synthetic leather textile layer.
20. The method of any one of claims 17 to 19, wherein the synthetic leather coating is bounded on its sides by the synthetic leather polymer coating composition and the synthetic leather polymer coating composition comprises the polyolefin resin composition.
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| US201962878239P | 2019-07-24 | 2019-07-24 | |
| US62/878,239 | 2019-07-24 | ||
| PCT/US2020/042862 WO2021016231A1 (en) | 2019-07-24 | 2020-07-21 | Artificial leather composition and upper for article of footwear comprising said artificial leather composition |
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