Classifications

• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
  • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes
  • D06N3/142—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes mixture of polyurethanes with other resins in the same layer
  • D06N3/144—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes mixture of polyurethanes with other resins in the same layer with polyurethane and polymerisation products, e.g. acrylics, PVC
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
  • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
  • D04H1/68—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions the bonding agent being applied in the form of foam
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
  • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
  • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M15/263—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acids; Salts or esters thereof
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
  • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
  • D06M15/37—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M15/564—Polyureas, polyurethanes or other polymers having ureide or urethane links; Precondensation products forming them
  • D06M15/568—Reaction products of isocyanates with polyethers
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
  • D06M23/04—Processes in which the treating agent is applied in the form of a foam
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M23/00—Treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, characterised by the process
  • D06M23/08—Processes in which the treating agent is applied in powder or granular form
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
  • D06N3/14—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins with polyurethanes

Definitions

• This invention relates to a liquid locking, moldable, non-swelling, polyurethane foam impregnated into a non-woven fabric. More particularly, it relates to a durable, liquid absorbent, non-swelling, compression moldable composite material that locks in fluids when subjected to pressure.
• Foam footwear insoles are well-known in the art, typically being comprised of a laminate comprising a liner material as a top layer, a foam or other cushioning material, and a stiffener underneath the foam and liner layers.
• the foams are typically polyurethane or polyethylene foams.
• Current footwear insoles foams are resilient and provide a shock- components of the insoles of the prior art do not provide for wicking of moisture away from the foot and subsequent locking of the moisture in the insole.
• foams made from hydrophilic polymers as cushioning and absorptive insoles for footwear is one possible solution to the above problem.
• footwear insoles comprised of foams made from hydrophilic polymers have significant disadvantages. Swelling occurs upon liquid absorption in almost all polymeric foam compositions made from hydrophilic polymers. In these foams, i.e., those which use a hydrophilic polymer, absorption takes place in the polymer, which therefore swells. The swelling disfigures the thickness of the product, which is a problem in the limited volume of a shoe cavity. Further, changes in dimensions of the foam can cause stress on the junction of the foam with the other elements of the footwear material, increasing wear.
• the non-swelling absorbent capacity of the present invention is another su ⁇ rising and unexpected result of the novel composition of the present invention, providing results superior to the absorbent materials of the prior art.
• the novel composition of the polyurethane foam of the present invention is also su ⁇ rising and unexpected.
• Methylenediphenyl diisocyanate is a non-hydrophilic prepolymer which, when inco ⁇ orated into a foam, would be expected to block off access of moisture to any incorporated superabsoibent polymers, and would thus be expected to create a foam which would not have liquid-locking capabilities.
• An absorbent foam based on methylenediphenyl diisocyanate which incorporates superabsoibent polymers was not known in the art prior to the present invention, and thus its unique properties were also not appreciated by the art.
• Another object of the invention is to provide an absorbent, breathable cushioning footwear product which does not absorb moisture unless pressure is applied to the surface of the absorbent footwear product, and which continuously releases absorbed moisture by evaporation (i.e whether or not pressure is applied).
• the present invention is a durable, breathable, liquid absorbent, liquid locking, moldable composite material comprising a substrate and a polyurethane foam impregnated into or coated on the substrate, the polyurethane foam being made from a polyol, a non- hydrophilic prepolymer, a superabsorbent polymer and one or more surfactants.
• the composite material can further comprise an acrylic polymer to impart moldability and compressibility characteristics to the material.
• the composite material of this invention is comprised of an open cell, polyurethane foam impregnated into or coated onto a woven or non-woven substrate.
• the polyurethane foam is the reaction product of a methylenediphenyl diisocyanate prepolymer and a polyol, surfactants, and optionally an acrylic polymer.
• the acrylic polymer when added, is added in an amount sufficient to impart moldable characteristics to the foam.
• the composite material further comprises one or more superabsorbent polymers that have either been mechanically attached to the non-woven fabric or incorporated into the polyurethane foam. In a preferred embodiment, the superabsorbent polymer is incorporated into the polyurethane foam.
• the composite material can also optionally comprise a needlepunched fiber finish which serves to disperse liquid to the interior of the foam and to impart surface structure to the composite material.
• the superabsorbent polymer-containing polyurethane foam of the invention is prepared by mixing together one (1) part of a methylenediphenyl diisocyanate prepolymer and two (2) to six (6) parts of a polyol component.
• the polyol component contains a polyether polyol, surfactants, such as a propylene oxide/ethylene oxide block copolymer such as Pluronic L-62 (about 2-15% of polyol component by weight, preferably about 10% by weight), a 10% aqueous solution of a propylene oxide/ethylene oxide block copolymer such as Pluronic F-88 (about 0.25-3% of polyol component by weight, preferably about 2% by weight), one or more superabsorbent polymers (0.25-2% of polyol component by weight, preferably about 2% by weight) and, optionally, an acrylic polymer (.25-10% of polyol component by weight, preferably about 3% by weight).
• the acrylic polymer when added, provides moldability to the finished product
• a preferred method of mixing utilizes a foam machine of the type well-known in the art, with a mixing head rotating at between 2500 and 4000 ipm.
• the mixture is discharged into a substrate, preferably a carded, airlaid non-woven material, which has been positioned on top of a flat release material, such as silicone coated release paper (e.g. 92# Stay Flat L-3 Liner, Technicote/Siltech, Inc., Miamisburg, OH).
• the foam is sandwiched on top by another piece of the release material.
• the non-woven substrate can be a material such as 2.5 ounce/square foot Better Blend (Carlee Corporation, Rockleigh, NJ).
• the papers carrying the substrate travel horizontally at a speed determined to be sufficient to deposit an amount of the isocyanate/polyol mixture which will yield a product of the desired thickness.
• the polymer is allowed to react with the polyol, yielding carbon dioxide and a polyurethane, causing a foam impregnated non-woven to form.
• the evolving gas is trapped in the reacting mixture and form the cells of the foam.
• the cells enlarge and the reactant mass expands proportionately, causing the foam to rise.
• the limiting reactant isocyanate functional prepolymer
• gas generation halts, typically in 4 to 6 minutes.
• the top and bottom release papers are continuously removed, exposing the composite material.
• the composite material is then moved into a forced air convection oven maintained at 220°F to 275 °F in order to finish cure the material.
• the product is typically, but not limited to, from one-eighth inch to one- half inch in thickness.
• the material can be die cut to the desired shape and molded. The resulting material typically is capable of absorbing from about five to about twenty times its weight in water.
• a preferred isocyanate prepolymer is Flexible Products isocyanate FP 100-A polyurethane prepolymer derived from methylenediphenyl diisocyanate.
• a preferred polyol for use in the polyol component is FP 100-B.
• FP 365-6 Fluorescence-based F-88
• Pluronic L-62 and Pluronic F-88 BASF Co ⁇ ., Charlotte, NC.
• a preferred acrylic polymer for use in the invention is Rhoplex TR407 emulsion (Rohm & Haas Co, Philadelphia, PA).
• Preferred superabsorbent polymers are characterized by being able to absorb from about 1000 to about 5000 percent by weight of aqueous solutions and to hold such fluid under pressures of up to about 80 psi without dewatering.
• Such superabsorbent polymers include crosslinked polyacrylate polymer, starch grafted polyacrylate polymer, crosslinked potassium polyacrylate/polyacrylamide, sodium salt of crosslinked polyacrylic acid polyalcohol graft copolymer, partial sodium salt of crosslinked polyacrylic acid, crosslinked polyvinyl py ⁇ olidone, crosslinked sulfonated polystyrene, crosslinked polysulfoethyl(meth)acrylate, crosslinked poly(2-ethylhexylacrylate), and crosslinked hydrolyzed polyacrylonitrile.
• a preferred superabsorbent polymer for use in the material of the invention is AP80HS superabsorbent polymer (Stockhausen, Inc., Greensboro, NC).
• the polymer is generally attached to the non-woven using a pressure-sensitive cement or contact adhesive.
• the adhesive may be water born, solvent born, or hot melt.
• the amount of adhesive applied will be dependent on the amount of superabsorbent polymer which is to be attached, and can be readily ascertained by those of ordinary skill in the art.
• a non-limiting example of such an adhesive is Super 77 spray adhesive (3M Corporation, St. Paul, MN).
• the foam to be used in this embodiment does not contain superabsorbent polymers. This foam is prepared by the same method as the foam containing superabsorbent polymers, except that water is substituted for the superabsorbent polymer in the polyol component.
• the composite materials of this invention can be further modified utilizing a needlepunching process that embeds and punctures fibers of a finish material into the foam material.
• This needlepunching process can enhance the performance characteristics of the product and provide the product with a finished surface, which can be beneficial for aesthetic as well as functional reasons.
• a fiber finish material can aid in passing fluids to be absorbed into the underlying foam matrix.
• the fibers of the finish can be either hydrophilic or hydrophobic, and serve to guide or draw fluids into the foam matrix leaving a soft, dry surface.
• Nonlimiting examples of fibers which can be used in this finish of the present invention are acrylic, polypropylene, or polyester fibers, or a blend of these.
• a polyurethane foam was prepared by mixing together one (1) part of an isocyanate FP 100-A prepolymer and four (4) parts of a polyol component.
• the polyol component comprised polyol FP 100-B, Pluronic L-62 (10% by weight), a 10% aqueous solution of Pluronic F-88 (2% by weight), Rhoplex TR 407 (3% by weight) and superabsorbent polymer AP80HS (2% by weight).
• the two components were brought together in a mixing head at about 4000 tpm.
• the mixture was allowed to discharge into a carded, airlaid non-woven on top of a silicone coated release paper and sandwiched on top by another silicone coated release paper.
• the papers traveled horizontally at 4 feet per minute, yielding a thickness of one-quarter inch in the product.
• the polymer reacted with the polyol causing a foam impregnated non- woven to form.
• the top and bottom release papers were continuously removed from the top surface, exposing the material.
• the product was then carried by a moving belt into a forced air convection oven maintained at 220°F for the purpose of finish curing.
• the resulting material was an open cell foam, impregnated non-woven, white in color, one-quarter inch thick, that was wettable when pressure was applied to the surface in contact with moisture.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Dispersion Chemistry (AREA)
• General Chemical & Material Sciences (AREA)
• Mechanical Engineering (AREA)
• Laminated Bodies (AREA)
• Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
• Polyurethanes Or Polyureas (AREA)

Priority Applications (3)

Applications Claiming Priority (2)

Publications (1)

Family

ID=21790326

Family Applications (1)

Country Status (5)

Cited By (3)

Citations (1)

• 1997
  • 1997-05-30 AU AU32343/97A patent/AU3234397A/en not_active Abandoned
  • 1997-05-30 CA CA 2257170 patent/CA2257170A1/en not_active Abandoned
  • 1997-05-30 JP JP09543093A patent/JP2000511952A/ja active Pending
  • 1997-05-30 WO PCT/US1997/010216 patent/WO1997045206A1/en not_active Application Discontinuation
  • 1997-05-30 EP EP97928026A patent/EP0902730A1/en not_active Withdrawn

Patent Citations (1)

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