Pe-based crosslinked elastomeric foam with high filler loadings for making shockpads and articles used in footwear and flooring applications

{
  "publication_number": "US2009172970A1",
  "country": "US",
  "kind": "A1",
  "title": "Pe-based crosslinked elastomeric foam with high filler loadings for making shockpads and articles used in footwear and flooring applications",
  "abstract": "Crosslinked foams having high filler loadings, which may be formed from A) a polyolefin having a crystallinity of 21 percent or less, an ethylene vinyl acetate copolymer having a vinyl acetate content of less than 15 mole percent, or a combination thereof; B) a polyolefin having a viscosity between 500 and 20,000 cP, as measured using ASTM D1084 (Brookfield Viscosity at 350° F.); and C) a filler, wherein the crosslinked foam includes from 10 to 80 parts filler per hundred parts of components A, B, and C, by weight. In other aspects of embodiments disclosed herein, the crosslinked foam may optionally include one or more of: D) at least one polyolefin having a crystallinity of greater than 21 weight percent, an ethylene vinyl acetate copolymer having a vinyl acetate content of 15 mole percent or greater, or a combination thereof; and E) a scorch retarder.",
  "claims": [
    "1. A crosslinked foam for use in footwear or as a shockpad, the foam comprising the reaction product of: A. a polyolefin having a crystallinity of 21 percent or less, an ethylene vinyl acetate copolymer having a vinyl acetate content of less than 15 mole percent, or a combination thereof; B. a polyolefin having a viscosity between 500 and 20,000 cP, as measured using ASTM D1084; C. a filler, wherein the crosslinked foam comprises from 10 to 80 parts filler per hundred parts of components A, and B, by weight. 2. The crosslinked foam of claim 1, wherein the crosslinked foam comprises at least one of: D. a scorch retarder; and E. at least one polyolefin having a crystallinity of greater than 21 weight percent, an ethylene vinyl acetate copolymer having a vinyl acetate content of 15 mole percent or greater, or a combination thereof. 3. The crosslinked foam of claim 1, wherein the crosslinked foam comprises from 20 to 80 parts filler per hundred parts of components A, and B, by weight. 4. The crosslinked foam of claim 1, wherein components A and B were crosslinked using a peroxide curing agent. 5. The crosslinked foam of claim 1, wherein components A and B were crosslinked using a heat activated curing system or a radiation induced curing system. 6. The crosslinked foam of claim 5, wherein the heat activated curing system comprises at least one of sulfur and an epoxy. 7. The crosslinked foam of claim 5, wherein the radiation activated curing system comprises at least one of e-beaming and gamma radiation. 8. The crosslinked foam of claim 2, wherein components A and B were crosslinked using a silane derived compound. 9. The crosslinked foam of claim 1 wherein the foam comprises at least about 30 percent by weight gel content as measured using xylene extractables. 10. The crosslinked foam of claim 1, wherein the filler comprises at least one of regrind and calcium carbonate. 11. The crosslinked foam of claim 2, wherein, prior to crosslinking, comprises a thermoplastic composition, the thermoplastic composition comprising: i. 20 to 80 weight percent of component A; ii. 25 to 75 weight percent of component E; iii. greater than 0 to 6 weight percent of component B; iv. greater than 0 to 1 weight percent of component D; and v. 5 to 50 weight percent of component C; wherein the above weight percentages are based on the total weight of components A, B, C, D, and E. 12. The crosslinked foam of claim 1, wherein the crosslinked foam has a density within the range from about 50 to about 500 kg/m 3. 13. The crosslinked foam of claim 1, wherein the crosslinked foam has an open cell volume of less than 30 percent. 14. The crosslinked foam of claim 1, wherein the crosslinked foam has a thickness in the range from 1 to 80 nm. 15. A method for forming a crosslinked foam, the method comprising: combining the following ingredients to form an expandable composition: A. a polyolefin having a crystallinity of 21 percent or less, an ethylene vinyl acetate copolymer having a vinyl acetate content of less than 15 mole percent, or a combination thereof; B. a polyolefin having a viscosity between 500 and 20,000 cP, as measured using ASTM D1084; C. a filler, wherein the crosslinked foam comprises from 10 to 80 parts filler per hundred parts of components A, B, and C, by weight; and D. a blowing agent; crosslinking at least a portion of components A and B; and foaming the expandable composition. 16. The method of claim 15, wherein the expandable composition further comprises: E. a scorch retarder; and F. at least one polyolefin having a crystallinity of greater than 21 weight percent, an ethylene vinyl acetate copolymer having a vinyl acetate content of 15 mole percent or greater, or a combination thereof; and the method comprising: crosslinking at least a portion of components A, B, and F 17. The method of claim 15, wherein the expandable composition comprises from 20 to 80 parts filler per hundred parts of components A and B, by weight. 18. The method of claim 15, wherein components A and B are crosslinked using a peroxide curing agent. 19. The method of claim 15, wherein components A and B are crosslinked using a heat activated curing system or a radiation induced curing system. 20. The method of claim 19, wherein the heat activated curing system comprises at least one of sulfur and an epoxy. 21. The method of claim 19, wherein the radiation activated curing system comprises at least one of e-beaming and gamma radiation. 22. The method of claim 15, wherein components A and B are crosslinked using a silane derived compound. 23. The method of claim 15, wherein the filler comprises at least one of regrind and calcium carbonate. 24. The method of claim 15, wherein the expandable composition comprises: i. 20 to 80 weight percent of component A; ii. 25 to 75 weight percent of component E; iii. greater than 0 to 6 weight percent of component B; iv. greater than 0 to 1 weight percent of component F; and v. 5 to 50 weight percent of component C; vi. 1 to 5 weight percent of component D; wherein the above weight percentages are based on the total weight of components A, B, C, D, E, and F. 25. The method of claim 24, wherein the expandable composition further comprises: G. 1 to 5 weight percent of a peroxide curing agent; wherein the weight percentages are based on the total weight of components A, B, C, D, E, F, and G. 26. The method of claim 16, wherein the combining comprises mixing components A, B, C, D, E, and F at a temperature sufficient to melt at least a portion of components A, B, and F. 27. The method of claim 16, wherein the combining comprises mixing the components in at least one of an extruder and a melt kneader. 28. The method of claim 27, further comprising: injecting the expandable composition into a hot mold; and maintaining the hot mold at a temperature and for a time sufficient for curing of the expandable composition and decomposition of the blowing agent; wherein the foaming the expandable composition comprises opening the mold. 29. An artificial turf, carpet, or flooring comprising a shock pad as defined in claim 1. 30. A shoe, boot, or footwear comprising a shock pad as defined in claim 1."
  ],
  "description_excerpt": "1. Field of the Disclosure\n\nEmbodiments disclosed herein relate generally to crosslinked foams suitable for use as a shock absorbing layer. In another aspect, embodiments disclosed herein relate to crosslinked foams useful in footwear, such as part of a shoe or boot, including soles, midsoles, or a complete shoes or boot. In another aspect, embodiments described herein relate to a synthetic turf and other flooring applications including a crosslinked foam shock absorbing layer, where the foam may include up to 50% of a filler.\n\n2. Background\n\nConventional articles of footwear include two primary elements, an upper and a sole structure. The upper provides a covering for the foot that securely receives and positions the foot with respect to the sole structure. In addition, the upper may have a configuration that protects the foot and provides ventilation, thereby cooling the foot and removing perspiration. The sole structure is secured to a lower surface of the upper and is generally positioned between the foot and the ground. In addition to attenuating ground reaction forces, the sole structure may provide traction and control potentially harmful foot motion, such as over-pronation. Accordingly, the upper and the sole structure operate cooperatively to provide a comfortable structure that is suited for a wide variety of ambulatory activities, such as walking and running. The general features and configuration of the upper and the sole structure are discussed in greater detail below.",
  "cpc": [
    "C08J 9/0014",
    "A43B 13/187",
    "C08J 2201/024",
    "C08J 2201/03",
    "C08J 2205/052",
    "C08J 2323/00",
    "C08J 2323/08",
    "C08J 2423/00",
    "C08J 9/0061",
    "C08J 9/0066",
    "C08L 2205/02",
    "C08L 23/02",
    "C08L 23/0853",
    "D06N 7/0086",
    "E01C 13/08"
  ],
  "ipc": [
    "A41G 1/00",
    "A43B 19/00",
    "B32B 27/32",
    "C08J 9/00",
    "A43B 13/18",
    "B32B 5/22",
    "C08L 23/08",
    "D06N 7/00"
  ],
  "assignees": [
    "Dow Global Technologies LLC"
  ],
  "inventors": [
    "Miguel A. Prieto",
    "Katja Oswald",
    "Enrique Torres",
    "Thomas T. Allgeuer"
  ],
  "filing_date": "2008-12-29",
  "publication_date": "2009-07-09",
  "priority_date": "2007-12-28",
  "application_number": "US-34505608-A",
  "family_id": "40521726",
  "cited_by_count": 35,
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}