Integrated Polyurethane Article

Abstract

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

1 . An integrated article comprising (a) a flexible foam region; and (b) a non-foam region;
 wherein said flexible foam region and said non-foam region comprise a polyurethane composition wherein the foamed polyurethane composition of said flexible foam region has a weight average molecule weight of 120,000 to 500,000, and a polydispersity (Mw/Mn) of 1.85 to 2.51; and   wherein the non-foamed polyurethane composition of said non-foam region has a weight average molecule weight of 200,000 to 350,000, and a polydispersity (Mw/Mn) of 2.30 to 2.50.   
     
     
         2 . The integrated article of  claim 1  wherein the flexible foam region is an midsole, and wherein the non-foam region is an outsole. 
     
     
         3 . The integrated article of  claim 1  wherein said polyurethane composition comprises the reaction product of: (i) at least one polyol, (ii) at least one isocyanate, and (iii) at least one chain extender; and
 wherein said polyurethane composition is injection foam molded to form said flexible foam region, and wherein said polyurethane composition is injection molded to form said non-foam outsole. 
 
     
     
         4 . (canceled) 
     
     
         5 . The integrated article of  claim 1  wherein the foamed polyurethane composition of said flexible foam region has:
 (i) a vertical rebound, as measured by ASTM D2632, of at least 35%; 
 (ii) a compression set at room temperature, as measured by ASTM D395, of no more than 8%; 
 (iii) a compression set at 50° C., as measured by ASTM D395, of no more than 45%; and 
 (iv) an Asker C hardness, as measured by ASTM D2240, of 35 to 60. 
 
     
     
         6 . The integrated article of  claim 1  wherein the non-foamed polyurethane composition of said non-foam region has:
 (i) a volume loss at room temperature, as measured by the DIN abrasion test, of less than 100 mm 3 ; 
 (ii) a volume loss at 65° C., as measured by the DIN abreasion test, of less than 100 mm 3 ; 
 (iii) a dry coefficient of friction, as measured by the Plint COF test, of at least 0.5; and 
 (iv) a wet coefficient of friction, as measured by the Plint COF test, of at least 0.5. 
 
     
     
         7 . The integrated article of  claim 1  wherein the foamed polyurethane composition of said flexible foam region and the non-foamed polyurethane composition of said non-foam region both have:
 (i) a hard segment content of from 23.5 to 45.0 percent by weight, and the polyol component comprises a polyether polyol; 
 (ii) a hard segment content of from 24 to 30 percent by weight, and the polyol component comprises a polyester polyol; or 
 (iii) a hard segment content of greater than 30 percent by weight, and the polyol component comprises a polycaprolactone polyol. 
 
     
     
         8 . The integrated article of  claim 1  wherein the chain extender comprises benzene glycol, 1,4-butandiol, or a combination thereof; wherein the polyol comprises butanediol adipate polyester polyol, an ethylene glycol adipate polyester polyol, a mixed ethylene glycol butanediol adipate ester or a combination thereof; and wherein the isocyanate comprises 4,4′-methylene diphenyl diisocyanate. 
     
     
         9 . An article of footwear, comprising: a) the integrated outsole and midsole of  claim 2 , and b) a upper bonded to the integrated outsole and midsole. 
     
     
         10 . A process of making an integrated article comprising (a) a flexible foam region; and (b) a non-foam region, wherein said a flexible foam region and said non-foam region comprise a polyurethane composition, said process comprising the steps of:
 I. forming a non-foam part from said polyurethane composition;   II. forming a flexible foam part from said polyurethane composition directly on said non-foam part wherein the foamed polyurethane composition of said flexible foam region has a weight average molecular weight of 120,000 to 500,000, and a polydispersity (Mw/Mn) of 1.85 to 2.51; and   wherein the non-foamed polyurethane composition of said non-foam region has a weight average molecular weight of 200,000 to 350,000, and a polydispersity (Mw/Mn) of 2.30 to 2.50;   resulting in an integrated article.   
     
     
         11 . The process of  claim 10  wherein the flexible foam region is a midsole, and wherein the non-foam region is an outsole. 
     
     
         12 . The process of  claim 10  wherein said polyurethane composition comprises the reaction product of: (i) at least one polyol, (ii) at least one isocyanate, and (iii) at least one chain extender; and
 wherein said polyurethane composition is injection foam molded to form said flexible foam part, and wherein said polyurethane composition is injection molded to form said non-foam part. 
 
     
     
         13 . (canceled) 
     
     
         14 . The process of  claim 10  wherein the foamed polyurethane composition of said flexible foam region has:
 (i) a vertical rebound, as measured by ASTM D2632, of at least 35%; 
 (ii) a compression set at room temperature, as measured by ASTM D395, of no more than 8%; 
 (iii) a compression set at 50° C., as measured by ASTM D395, of no more than 45%; and 
 (iv) an Asker C hardness, as measured by ASTM D2240, of 35 to 60. 
 
     
     
         15 . The process of  claim 11  wherein the non-foamed polyurethane composition of said non-foam region has:
 (i) a volume loss at room temperature, as measured by the DIN abrasion test, of less than 100 mm 3 ; 
 (ii) a volume loss at 65° C., as measured by the DIN abrasion test, of less than 100 mm 3 ; 
 (iii) a dry coefficient of friction, as measured by the Plint COF test, of at least 0.5; and 
 (iv) a wet coefficient of friction, as measured by the Plint COF test, of at least 0.5.