FOAM COMPOSITIONS AND USES THEREOF

• US 20170267845A1
• Filed: 03/14/2017
• Published: 09/21/2017
• Est. Priority Date: 03/15/2016
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Baghdadi, Hossein A.
• Granted Patent: US 9,879,133 B2
• Time in Patent Office: Days
• CPC Class Codes: A43B 1/10 made of rubber
• CPC Class Codes: A43B 13/04 Plastics, rubber or vulcanised fibre
• CPC Class Codes: A43B 13/125 characterised by the midsole or middle layer
• CPC Class Codes: A43B 13/141 with a part of the sole being flexible, e.g. permitting articulation or torsion
• CPC Class Codes: A43B 13/16 Pieced soles with several layers of different material A43B13/12
• CPC Class Codes: A43B 13/186 Differential cushioning region, e.g. cushioning located under the ball of the foot resilient heel not included in the sole A43B21/26; resilient supports for the heel of the foot A43B21/32
• CPC Class Codes: A43B 13/188 Differential cushioning regions
• CPC Class Codes: A43B 13/223 Profiled soles
• CPC Class Codes: A43B 5/06 Running shoes; Track shoes
• CPC Class Codes: A43B 7/14 with foot-supporting parts
• CPC Class Codes: A43B 7/144 situated under the heel, i.e. the calcaneus bone
• CPC Class Codes: B29D 35/122 Soles
• CPC Class Codes: C08J 2201/026 Crosslinking before of after foaming
• CPC Class Codes: C08J 2207/00 Foams characterised by their intended use
• CPC Class Codes: C08J 2323/08 Copolymers of ethene C08J2323/16 takes precedence
• CPC Class Codes: C08J 2331/04 Homopolymers or copolymers of vinyl acetate
• CPC Class Codes: C08J 2353/00 Characterised by the use of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers
• CPC Class Codes: C08J 2353/02 of vinyl aromatic monomers and conjugated dienes
• CPC Class Codes: C08J 2423/02 not modified by chemical after treatment
• CPC Class Codes: C08J 2423/08 Copolymers of ethene C08J2423/16 takes precedence
• CPC Class Codes: C08J 2423/10 : Homopolymers or copolymers of propene
• CPC Class Codes: C08J 2453/00 : Characterised by the use of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Derivatives of such polymers
• CPC Class Codes: C08J 2453/02 : of vinyl aromatic monomers and conjugated dienes
• CPC Class Codes: C08J 9/0061 : characterized by the use of several polymeric components
• CPC Class Codes: C08J 9/06 : by a chemical blowing agent
• CPC Class Codes: C08L 2205/03 : containing three or more polymers in a blend
• CPC Class Codes: C08L 2205/035 : containing four or more polymers in a blend
• CPC Class Codes: C08L 23/0815 : Copolymers of ethene with aliphatic 1-olefins
• CPC Class Codes: C08L 23/0853 : Vinylacetate
• CPC Class Codes: C08L 23/14 : Copolymers of propene C08L23/16 takes precedence
• CPC Class Codes: C08L 53/00 : Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 53/025 : modified

Abstract

Components for articles of footwear and athletic equipment are provided including a foam. A variety of foams and foam components and compositions for forming the foams are provided. In some aspects, the foams and components including the foams can have exceptionally high energy return while also having improved durability and softness. In particular, midsoles including the foams are provided for use in an article of footwear. Methods of making the compositions and foams are provided, as well as methods of making an article of footwear including one of the foam components. In some aspects, the foams and foam components can be made by injection molding or injection molding followed by compression molding.

Claims

1. A component for an article of footwear, the component comprising the crosslinked reaction product of a first composition, wherein the first composition comprises

a block copolymer comprising

a first block and a third block, each independently comprising a linear or branched chain aliphatic polymer having a plurality of aromatic groups attached pendantly thereto,

a second block located between the first block and the third block and comprising an aliphatic polymer having a plurality of aliphatic side chains attached thereto, and

a plurality of first ethylenically unsaturated group present on one or more of the first block, second block, and third block;

wherein the block copolymer comprises about 60% to about 90% of the second blocks by weight based upon the weight of the block copolymer;

an olefinic copolymer comprising a plurality of first olefinic segments and a plurality of second olefinic segments having a different chemical structure from the first olefinic segments;

one or more linking polymers, each linking polymer comprising one or more third olefinic segments; and

an ethylene-vinyl acetate (EVA) copolymer.

wherein a sum of a ratio I, II, III, IV, and V is from about 1.00 to about 10.00;

wherein the ratio I is a ratio of a total parts by weight of the olefinic copolymers present in the composition to a total parts by weight of the block copolymer present in the composition;

wherein the ratio II is a ratio of a total parts by weight of the linking polymers present in the composition to a total parts by weight of the block copolymer present in the composition;

wherein the ratio III is ratio of a total parts by weight of the EVA copolymers present in the composition to a total parts by weight of the block copolymer present in the composition;

wherein the ratio IV is a ratio of the total parts by weight of the linking polymers present in the composition to a total parts by weight of the block copolymers present in the composition, and

wherein the ratio V is a ratio of the total parts by weight of the one or more EVA copolymers present in the composition to a total parts by weight of the one or more olefinic copolymers present in the composition.

2. The component according to claim 1, wherein the sum of ratio I, II, III, IV, and V is from about 3.50 to about 5.00.

3. The component according to claim 1, wherein the component is a midsole.

4. The component according to claim 3, wherein the midsole has an energy return of about 60% to about 85%.

5. The component according to claim 1, wherein the first composition comprises a first alpha-olefin linking polymer and a second alpha-olefin linking polymer,

wherein the first alpha-olefin linking polymer and the second alpha-olefin linking polymer are copolymers of ethylene and 1-butene, each having a different ratio of ethylene to 1-butene monomer content in the copolymer.

6. The component according to claim 1, wherein one or both of the first block and the third block consist essentially of polystyrene.

7. The component according to claim 1, wherein the olefinic copolymer is a copolymer of ethylene and the second alpha-olefin.

8. The component according to claim 7, wherein the second alpha-olefin has 6 to 12 carbon atoms.

9. The component according to claim 1, wherein the ethylene-vinyl acetate copolymer having a vinyl acetate content of about 10% to about 45% by weight based upon the weight of the ethylene-vinyl acetate copolymer.

10. The component according to claim 1, wherein the crosslinked reaction product has a crosslink density of about 50% to 99%.

11. An article of footwear comprising a component, wherein the component is made by a process comprising crosslinking and foaming a first composition, wherein the first composition comprises:

a partially hydrogenated thermoplastic elastomeric block copolymer, the partially hydrogenated thermoplastic elastomeric block copolymer comprising;

one or more A blocks comprising aromatic repeat units,

one or more B blocks comprising aliphatic repeat units, and

one or more first ethylenically unsaturated groups present on one or both of the aromatic repeat units and the aliphatic repeat units;

an olefinic block copolymer, wherein the olefinic block copolymer is a copolymer of a first alpha-olefin and a second alpha-olefin different from the first alpha-olefin, and wherein the olefinic block copolymer comprising one or more second ethylenically unsaturated groups;

an alpha-olefin linking polymer, wherein the alpha-olefin linking polymer comprises one or more aliphatic sidechains; and

an ethylene-vinyl acetate copolymer;

wherein a sum of a ratio I, II, III, IV, and V is from about 1.00 to about 10.00;

wherein the ratio I is a ratio of a total parts by weight of the olefinic copolymers present in the composition to a total parts by weight of the partially hydrogenated thermoplastic elastomeric block copolymer present in the composition;

wherein the ratio II is a ratio of a total parts by weight of the alpha-olefin linking polymers present in the composition to a total parts by weight of the partially hydrogenated thermoplastic elastomeric block copolymer present in the composition;

wherein the ratio III is ratio of a total parts by weight of the ethylene-vinyl acetate copolymers present in the composition to a total parts by weight of the partially hydrogenated thermoplastic elastomeric block copolymer present in the composition;

wherein the ratio IV is a ratio of the total parts by weight of the alpha-olefin linking polymers present in the composition to a total parts by weight of the partially hydrogenated thermoplastic elastomeric block copolymer present in the composition, and

wherein the ratio V is a ratio of the total parts by weight of the one or more ethylene-vinyl acetate copolymers present in the composition to a total parts by weight of the one or more olefinic copolymers present in the composition.

12. The article of footwear according to claim 11, wherein the sum of ratio I, II, III, IV, and V is from about 3.50 to about 5.00.

13. The article of footwear according to claim 11, wherein the component is a midsole.

14. The article of footwear according to claim 11, wherein the first composition comprises about 5 parts by weight to about 20 parts by weight of the partially hydrogenated thermoplastic elastomeric block copolymer based upon an entire weight of the first composition.

15. The article of footwear according to claim 11, wherein the first composition comprises about 5 parts by weight to about 20 parts by weight of the olefinic block copolymer by weight based upon an entire weight of the first composition.

16. The article of footwear according to claim 11, wherein the first composition comprises about 15 parts by weight to about 35 parts by weight of the alpha-olefin linking polymer based upon an entire weight of the first composition.

17. The article of footwear according to claim 11, wherein the first composition further comprises one or both of a free-radical initiator and a chemical blowing agent.

18. The article of footwear according to claim 17, wherein the first composition comprises the free-radical initiator, and

wherein the free-radical initiator is selected from the group consisting of dicumyl peroxide;

n-butyl-4,4-di(t-butylperoxy) valerate;

1,1-di(t-butylperoxy)3,3,5-trimethylcyclohexane;

2,5-dimethyl-2,5-di(t-butylperoxy) hexane;

di-t-butyl peroxide;

di-t-amyl peroxide;

t-butyl peroxide;

t-butyl cumyl peroxide;

2,5-dimethyl-2,5-di(tbutylperoxy)hexyne-3;

di(2-t-butyl-peroxyisopropyl)benzene;

dilauroyl peroxide;

dibenzoyl peroxide;

t-butyl hydroperoxide; and

a combination thereof.

19. The article of footwear according to claim 17, wherein the first composition comprises a chemical blowing agent, and

wherein the chemical blowing agent is selected from the group consisting of a carbonate, bicarbonate, carboxylic acid, azo compound, isocyanate, persulfate, peroxide, and a combination thereof.

20. The article of footwear according to claim 11, wherein the component has an energy return of about 60% to about 85%.