Artificial leather composition and upper for article of footwear comprising same

Abstract

The present application relates to an artificial leather composition and an upper for an article of footwear comprising the artificial leather composition. A variety of plates for footwear are provided, the plates comprising a polyolefin resin. Sole structures and articles of footwear formed therefrom are also provided. Methods of making the polyolefin resin compositions, panels, sole structures, and articles of footwear are also provided. In some aspects, a polyolefin resin composition includes an effective amount of a polymeric resin modifier. The effective amount may be an amount effective to allow the resin composition to pass a refractive test and particularly pass the refractive test without significant changes in wear loss. In some aspects, the resin composition also includes a clearing agent to improve the optical transparency of the sheet. In some aspects, the panel includes a textile disposed on one or both of a first side and a second side of the panel. The textile may provide improved bonding of the panel with other components such as a sole layer or upper.

Description

[0001] This application is a divisional application of an application with an application date of July 21, 2020, application number 202080067503.4, and invention name “Artificial leather composition and upper for footwear comprising the artificial leather composition”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of and priority to U.S. Provisional Application Serial No. 62 / 878,239, filed on July 24, 2019, titled “SYNTHETIC LEATHER HAVING POLYOLEFIN AND ARTICLES OF FOOTWEAR FORMED THEREFROM,” and U.S. Provisional Application Serial No. 62 / 939,809, filed on November 25, 2019, titled “SYNTHETIC LEATHER HAVING POLYOLEFIN AND ARTICLES OF FOOTWEAR FORMED THEREFROM,” and U.S. Provisional Application Serial No. 62 / 945,509, filed on December 9, 2019, titled “SYNTHETIC LEATHER HAVING POLYOLEFIN AND ARTICLES OF FOOTWEAR FORMED THEREFROM,” the disclosures of which are incorporated herein by reference in their respective entireties. Technical Field

[0004] The present disclosure generally relates to sole structures and plates comprising polyolefin resins and articles of footwear including the sole structures. background

[0006] The design and manufacture of footwear and athletic equipment involves a variety of factors, from aesthetics to comfort and feel, to performance and durability. While designs and fashions may change rapidly, the demand for enhanced performance in the footwear and athletic equipment market has not. In addition, the market has shifted to demand lower cost and recyclable materials that still meet the need for enhanced performance. To balance these demands, designers of footwear and athletic equipment use a variety of materials and designs for a variety of components. Summary of the invention

[0007] This application provides the following:

[0008] 1). A synthetic leather material, comprising:

[0009] a synthetic leather polymer coating attached to the synthetic leather textile layer;

[0010] wherein the synthetic leather polymer coating comprises a synthetic leather polymer coating composition;

[0011] wherein the synthetic leather textile layer comprises fibers or yarns comprising a fiber / yarn polymer composition; and

[0012] 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.

[0013] 2). The synthetic leather material according to 1), wherein the polyolefin resin composition comprises at least one polyolefin, wherein the at least one polyolefin comprises a polyolefin selected from polyethylene homopolymers, polyethylene copolymers, polypropylene homopolymers, polypropylene copolymers or combinations thereof.

[0014] 3). The synthetic leather material according to 1) or 2), wherein the polyolefin resin composition comprises the polypropylene copolymer.

[0015] 4). The synthetic leather material according to any one of 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 a polypropylene homopolymer, a polypropylene copolymer, or a combination of a polypropylene homopolymer and a polypropylene copolymer.

[0016] 5). The synthetic leather material according to any one of 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.

[0017] 6). The synthetic leather material according to any one of 2) to 5), wherein the polypropylene copolymer comprises a polypropylene / polyethylene copolymer.

[0018] 7). The synthetic leather material according to 6), wherein the polypropylene / polyethylene copolymer comprises about 1% to about 5% by weight of ethylene repeating units based on the total weight of the polypropylene / polyethylene copolymer.

[0019] 8). The synthetic leather material according to any one of 1) to 7), wherein the polyolefin resin composition further comprises a polymer resin modifier or a transparent agent or both.

[0020] 9). The synthetic leather material according to 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.

[0021] 10). The synthetic leather material according to 8) or 9), wherein the polyolefin resin composition comprises from about 0.1 weight percent to about 5 weight percent of the transparent agent based on the total weight of the polyolefin resin composition.

[0022] 11). An article of footwear, comprising:

[0023] 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 face the ground and the second side is defined by a first thermoplastic composition; and

[0024] an upper operably coupled to the second side of the sole component, the upper comprising a synthetic leather material, the 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 outwardly facing side of the upper;

[0025] wherein the synthetic leather coating composition or the synthetic leather textile composition or both comprise a polyolefin resin composition.

[0026] 12). The article of footwear according to 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.

[0027] 13). The footwear article according to 11) or 12), 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 textile layer, the second synthetic leather polymer coating is attached to the first synthetic leather polymer coating, and the second synthetic leather polymer coating contains the synthetic leather coating composition.

[0028] 14) The article of footwear according to any one of 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 braided textile.

[0029] 15). The article of footwear according to any one of 11) to 14), wherein the synthetic leather textile layer comprises a first fiber or a first yarn comprising the polyolefin resin composition.

[0030] 16). The footwear article according to 15), wherein the synthetic leather textile layer further comprises a second fiber or a second yarn comprising a second fiber / yarn thermoplastic composition, and the second fiber / yarn thermoplastic composition comprises a thermoplastic polymer selected from polyester, polyether, polyamide, polyurethane or any combination thereof.

[0031] 17). A method for manufacturing a synthetic leather material, the method comprising:

[0032] A synthetic leather polymer coating and a synthetic leather textile layer are attached 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.

[0033] 18). The method according to 17), wherein the attaching comprises laminating the synthetic textile layer to a film comprising the synthetic leather polymer coating.

[0034] 19). A method according to 17) or 18), wherein the attachment 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 into 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.

[0035] 20). The method according to any one of 17) to 19), wherein the side of the synthetic leather coating is defined by the synthetic leather polymer coating composition, and the synthetic leather polymer coating composition comprises the polyolefin resin composition. BRIEF DESCRIPTION OF THE DRAWINGS

[0037]

[0011] Further aspects of the present disclosure will be readily understood when the detailed description described below is read in conjunction with the accompanying drawings.

[0038] Figure 1A-1H An exemplary article of athletic footwear is depicted. Figure 1A is a lateral side perspective view of an example article of athletic footwear. Figure 1B is a lateral side elevation view of an exemplary article of athletic footwear.

[0039] Figure 1C is a medial side elevation view of an exemplary article of athletic footwear. Figure 1Dis a top view of an exemplary article of athletic footwear. Figure 1E is a front view of an exemplary article of athletic footwear. Figure 1F is a rear view of an exemplary article of athletic footwear. Figure 1G is an exploded perspective view of an exemplary article of athletic footwear. Figure 1H is a cross-sectional view along 1 - 1 of an exemplary article of athletic footwear.

[0040] Figure 2A-2C A second exemplary article of athletic footwear is depicted. Figure 2A is a lateral side elevation view of an exemplary article of athletic footwear. Figure 2B is an exploded perspective view of a second exemplary article of athletic footwear. Figure 2C is a cross-sectional view along 2 - 2 of a second exemplary article of athletic footwear.

[0041] Figure 3 Depicted is an exploded view of a third exemplary sole structure having a base layer and a rigid plate that provides rigidity without adding a lot of extra material and thus keeping weight low.

[0042] Figure 4A-4C A fourth exemplary article of athletic footwear is depicted. Figure 4A is a lateral side elevation view of an exemplary article of athletic footwear. Figure 4B is an exploded perspective view of a second exemplary article of athletic footwear. Figure 4C is a cross-sectional view along 4 - 4 of a second exemplary article of athletic footwear.

[0043] Figure 5A-Figure 5B A fifth exemplary article of athletic footwear is depicted. Figure 5A is a lateral side elevation view of a fifth exemplary article of athletic footwear. Figure 5B is an exploded perspective view of a fifth exemplary article of athletic footwear.

[0044] Figure 6A-6B A cross-sectional view of the disclosed synthetic leather material is shown. Fig. 6A is a cross-sectional view of a disclosed synthetic leather material 600 including a synthetic leather textile layer 610 to which a synthetic leather polymer coating 620 is attached. Figure 6B is a cross-sectional view of the disclosed synthetic leather material 600 including a synthetic leather textile layer 610 having a synthetic leather polymer coating 620 attached thereto, and further including a synthetic leather protective or decorative layer 630 attached to the synthetic leather polymer coating 620 .

[0045] Figure 7A-7B A cross-sectional view of the disclosed synthetic leather material is shown. Fig. 7A is a cross-sectional view of the disclosed synthetic leather material 700 including a synthetic leather textile layer 710 having a first synthetic leather polymer coating 720 attached thereto and a second synthetic leather polymer coating composition 730 attached to the first synthetic leather polymer coating 720 . Figure 7B is a cross-sectional view of the disclosed synthetic leather material 700, which includes 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 also includes a synthetic leather protective layer or decorative layer 740 attached to the second synthetic leather polymer coating 730. Detailed Description

[0047] State-of-the-art specialty polymers for footwear and athletic equipment include polymers such as polyurethane polymers and polyamide polymers, but there remains a need for lower cost alternatives to these performance polymers, particularly lower cost alternatives that are recyclable and easily processed. Alternatives such as polyolefins, while cost effective, traditionally have poor mechanical properties and poor surfaces and surface energies for bonding. New designs and materials are needed. In particular, there remains a need for improved polymer resins for making components for footwear and athletic equipment that resist stress whitening or cracking when flexed under cold conditions, are abrasion resistant, and are capable of adequate bonding for footwear and other athletic equipment applications.

[0048] In various aspects, the present disclosure provides a sole structure comprising a plate containing a polyolefin resin. In some aspects, the sole structure comprises a plate and a textile on one or more surfaces of the plate. The textile can improve the bonding of other components (e.g., an upper or bottom layer) to the plate. The textile can also be used for decorative purposes. Plates with polyolefin resin compositions can have improved mechanical properties, making them particularly suitable for parts of footwear and sports equipment. Specifically, these resin compositions are both able to resist stress whitening or cracking when flexed under cold conditions and are wear-resistant, reaching the levels required for footwear and sports equipment. The present disclosure provides a variety of plates for footwear articles, the plates comprising these polyolefin resin compositions.

[0049] 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 when the plate is a component of the article of footwear, the first side is configured to face the ground; and a textile, the textile being disposed on one or both of the first side and the second side. In some aspects, the sole structure also includes a bottom layer configured on the first side of the plate. When the sole structure is a component of the article of footwear, the bottom layer can wrap around the plate and be joined or attached to the upper, for example, the bottom layer can be attached to the upper at a bite line. In some aspects, the sole structure does not include the textile, for example, the sole structure can include the plate and bottom layer as described above and described in more detail below.

[0050]

[0011] In various aspects, the present disclosure also provides articles of footwear that include the sole structures described herein.

[0051] The present disclosure will be better understood after 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 present disclosure, and such combinations are intended to be part of this disclosure.

[0052] Aspect 1. A synthetic leather material 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 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.

[0053] Aspect 2. The synthetic leather material according to aspect 1, wherein the fiber / yarn polymer composition comprises or consists essentially of the polyolefin resin composition.

[0054] Aspect 3. The synthetic leather material according to aspect 2, wherein the synthetic leather polymer coating composition is substantially free of the polyolefin resin composition.

[0055] Aspect 4. The synthetic leather material according to aspect 3, wherein the synthetic leather polymer coating composition comprises one or more thermoplastic polymers selected from polyester, polyether, polyamide or polyurethane.

[0056] Aspect 5. A synthetic leather material according to Aspect 3 or Aspect 4, wherein the synthetic leather polymer coating composition has 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 fiber / yarn polymer composition; or wherein the synthetic leather polymer coating composition has 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 fiber / yarn polymer composition.

[0057] Aspect 6. A synthetic leather material according to Aspect 1, wherein the synthetic leather textile layer comprises: a first fiber or a first yarn comprising a first fiber / yarn polymer composition, the first fiber / yarn polymer composition comprising the polyolefin resin composition or essentially consisting of the polyolefin resin composition; and a second fiber or a second yarn comprising a second fiber / yarn polymer composition, the second fiber / yarn polymer composition comprising one or more thermoplastic polymers selected from polyester, polyether, polyamide or polyurethane.

[0058] Aspect 7. A synthetic leather material according to Aspect 6, wherein the second fiber / yarn polymer composition has 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 first fiber / yarn polymer composition; or wherein the first fiber / yarn polymer composition has 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 second fiber / yarn polymer composition.

[0059] Aspect 8. A synthetic leather material according to Aspect 6, wherein the one or more thermoplastic polymers of the second fiber or second yarn 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 fiber or first yarn; or wherein the one or more thermoplastic polymers of the second fiber or second yarn 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 fiber or first yarn.

[0060] Aspect 9. The synthetic leather material according to any one of aspects 6 to 8, wherein the synthetic leather polymer coating composition is substantially free of polyolefins.

[0061] Aspect 10. The synthetic leather material according to aspect 9, wherein the synthetic leather polymer coating composition comprises one or more thermoplastic polymers selected from polyesters, polyethers, polyamides or polyurethanes.

[0062] Aspect 11. A synthetic leather material according to Aspect 10, wherein the synthetic leather polymer coating composition has 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 first fiber / yarn polymer composition; or wherein the synthetic leather polymer coating composition has 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 first fiber / yarn polymer composition.

[0063] Aspect 12. A synthetic leather material according to Aspect 10, wherein the one or more thermoplastic polymers of the synthetic leather polymer coating 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 fiber or the first yarn; or wherein the one or more thermoplastic polymers of the synthetic leather polymer coating 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 fiber or the first yarn.

[0064] Aspect 13. The synthetic leather material of aspect 1, wherein the fiber / yarn polymer composition is substantially free of polyolefins; and wherein the fiber / yarn polymer composition comprises one or more thermoplastic polymers.

[0065] Aspect 14. A synthetic leather material according to Aspect 13, wherein the fiber / yarn polymer composition has 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 synthetic leather polymer coating composition; or wherein the fiber / yarn polymer composition has 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 synthetic leather polymer coating composition.

[0066] Aspect 15. The synthetic leather material according to aspect 13 or aspect 14, wherein the synthetic leather polymer coating composition comprises or consists essentially of the polyolefin resin composition.

[0067] Aspect 16. A synthetic leather material according to Aspect 15, wherein the one or more thermoplastic polymers of the fiber / yarn composition 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; or wherein the one or more thermoplastic polymers of the fiber / yarn composition 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.

[0068] Aspect 17. The synthetic leather material according to aspect 2, aspect 6 or aspect 13, wherein the synthetic leather polymer coating composition comprises the polyolefin resin composition.

[0069] Aspect 18. The synthetic leather material according to any one of aspects 1 to 17, wherein the one or more thermoplastic polymers are selected from polyesters, polyethers, polyamides or polyurethanes.

[0070] Aspect 19. The synthetic leather material according to aspect 18, wherein the one or more thermoplastic polymers comprise one or more polyesters.

[0071] Aspect 20. The synthetic leather material according to aspect 18 or aspect 19, wherein the polyester comprises polyethylene terephthalate (PET).

[0072] Aspect 21. The synthetic leather material according to aspect 18, wherein the one or more thermoplastic polymers comprise one or more polyamides.

[0073] Aspect 22. The synthetic leather material according to aspect 18 or aspect 21, wherein the polyamide comprises nylon 6,6, nylon 6, nylon 12, and combinations thereof.

[0074] Aspect 23. The synthetic leather material according to aspect 18, wherein the one or more thermoplastic polymers comprise one or more polyurethanes.

[0075] Aspect 24. The synthetic leather material according to any one of aspects 18 to 23, wherein the one or more thermoplastic polymers comprise one or more thermoplastic copolymers.

[0076] Aspect 25. The synthetic leather material according to 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.

[0077] Aspect 26. The synthetic leather material of aspect 24, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyester.

[0078] Aspect 27. The synthetic leather material according to aspect 24, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyether.

[0079] Aspect 28. The synthetic leather material of aspect 24, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyamide.

[0080] Aspect 29. The synthetic leather material of aspect 24, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyurethane.

[0081] Aspect 30. The synthetic leather material according to any one of aspects 18 to 29, wherein the one or more thermoplastic polymers comprise one or more thermoplastic polyether block amide (PEBA) copolymers.

[0082] Aspect 31. A synthetic leather material according to any one of Aspects 18 to 30, wherein the one or more thermoplastic polymers 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; or wherein the one or more thermoplastic polymers 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.

[0083] Aspect 32. A synthetic leather material according to any one of Aspects 18 to 30, wherein the fiber / yarn polymer composition comprising one or more thermoplastic polymers has 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 synthetic leather polymer coating composition; or the fiber / yarn polymer composition comprising one or more thermoplastic polymers has 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 synthetic leather polymer coating composition.

[0084] Aspect 33. A synthetic leather material according to any one of Aspects 18 to 30, wherein the fiber / yarn polymer composition comprising one or more thermoplastic polymers has 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 synthetic leather polymer coating composition comprising the polyolefin resin composition; or the fiber / yarn polymer composition comprising one or more thermoplastic polymers has 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 synthetic leather polymer coating composition comprising the polyolefin resin composition.

[0085] Aspect 34. A synthetic leather material according to any one of Aspects 18 to 30, wherein the second fiber / yarn polymer composition comprising one or more thermoplastic polymers has a melting temperature or softening temperature that is at least 20 degrees Celsius lower, or at least 50 degrees Celsius lower, than the first fiber / yarn polymer composition; or the second fiber / yarn polymer composition comprising one or more thermoplastic polymers has a melting temperature or softening temperature that is at least 20 degrees Celsius higher, or at least 50 degrees Celsius higher, than the first fiber / yarn polymer composition.

[0086] Aspect 35. A synthetic leather material according to any one of Aspects 18 to 30, wherein the second fiber / yarn polymer composition comprising one or more thermoplastic polymers has a melting temperature or softening temperature that is 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 the second fiber / yarn polymer composition comprising one or more thermoplastic polymers has a melting temperature or softening temperature that is at least 20 degrees Celsius higher, or at least 50 degrees Celsius higher, than the first fiber / yarn polymer composition comprising the polyolefin resin composition.

[0087] Aspect 36. A synthetic leather material according to any one of Aspects 18 to 30, wherein the second fiber / yarn polymer composition comprising one or more thermoplastic polymers has 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 synthetic leather polymer coating composition; or the second fiber / yarn polymer composition comprising one or more thermoplastic polymers has 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 synthetic leather polymer coating composition.

[0088] Aspect 37. A synthetic leather material according to any one of Aspects 18 to 30, wherein the second fiber / yarn polymer composition comprising one or more thermoplastic polymers has 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 synthetic leather polymer coating composition comprising the polyolefin resin composition; or the second fiber / yarn polymer composition comprising one or more thermoplastic polymers has 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 synthetic leather polymer coating composition comprising the polyolefin resin composition.

[0089] Aspect 38. 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.

[0090] Aspect 39. A synthetic leather material according to Aspect 38, 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.

[0091] Aspect 40. The synthetic leather material according to Aspect 39, wherein the synthetic leather polymer coating composition of the first synthetic leather polymer coating is substantially free of polyolefins, and the synthetic leather polymer coating composition of the second synthetic leather polymer coating comprises the polyolefin resin composition.

[0092] Aspect 41. A synthetic leather material according to 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 include one or more thermoplastic polymers.

[0093] Aspect 42. A synthetic leather material according to Aspect 40 or Aspect 41, wherein the synthetic leather polymer coating composition of the first synthetic leather polymer coating has 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 fiber / yarn polymer composition; or wherein the synthetic leather polymer coating composition of the first synthetic leather polymer coating has 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 fiber / yarn polymer composition.

[0094] Aspect 43. A synthetic leather material according to Aspect 38 to Aspect 42, wherein the synthetic leather polymer coating composition of the second synthetic leather polymer coating has 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 fiber / yarn polymer composition; or wherein the synthetic leather polymer coating composition of the second synthetic leather polymer coating has 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 fiber / yarn polymer composition.

[0095] 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 essentially free of polyolefin.

[0096] Aspect 45. The synthetic leather material according to aspect 44, wherein the second synthetic leather polymer coating composition comprises one or more thermoplastic polymers selected from polyesters, polyethers, polyamides or polyurethanes.

[0097] Aspect 46. A synthetic leather material according to Aspect 44 or Aspect 45, wherein the first synthetic leather polymer coating composition has 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 fiber / yarn polymer composition; or wherein the first synthetic leather polymer coating composition has 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 fiber / yarn polymer composition.

[0098] Aspect 47. A synthetic leather material according to any one of Aspects 44 to 46, wherein the second synthetic leather polymer coating composition has 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 fiber / yarn polymer composition; or wherein the second synthetic leather polymer coating composition has 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 fiber / yarn polymer composition.

[0099] 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.

[0100] 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.

[0101] 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.

[0102] Aspect 51. The synthetic leather material according to any one of aspects 38 to 50, wherein the one or more thermoplastic polymers comprise one or more polyesters.

[0103] Aspect 52. The synthetic leather material according to aspect 51, wherein the polyester comprises polyethylene terephthalate (PET).

[0104] Aspect 53. The synthetic leather material according to any one of aspects 38 to 50, wherein the one or more thermoplastic polymers comprise one or more polyamides.

[0105] Aspect 54. The synthetic leather material according to aspect 53, wherein the polyamide comprises nylon 6,6, nylon 6, nylon 11, nylon 12, and combinations thereof.

[0106] Aspect 55. The synthetic leather material according to any one of aspects 38 to 50, wherein the one or more thermoplastic polymers comprise one or more polyurethanes.

[0107] Aspect 56. The synthetic leather material according to any one of aspects 38 to 50, wherein the one or more thermoplastic polymers comprise one or more thermoplastic copolymers.

[0108] Aspect 57. The synthetic leather material according to 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.

[0109] Aspect 58. The synthetic leather material of aspect 56, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyester.

[0110] Aspect 59. The synthetic leather material according to aspect 56, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyether.

[0111] Aspect 60. The synthetic leather material of aspect 56, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyamide.

[0112] Aspect 61. The synthetic leather material of aspect 56, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyurethane.

[0113] Aspect 62. The synthetic leather material according to any one of aspects 41 to 61, wherein the one or more thermoplastic polymers comprise one or more thermoplastic polyether block amide (PEBA) copolymers.

[0114] Aspect 63. A synthetic leather material according to any one of Aspects 38 to 62, wherein the fiber / yarn polymer composition has 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 synthetic leather polymer coating composition; or wherein the fiber / yarn polymer composition has 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 synthetic leather polymer coating composition.

[0115] Aspect 64. A synthetic leather material according to any one of Aspects 38 to 63, wherein the synthetic leather textile layer comprises: a first fiber or a first yarn comprising a first fiber / yarn polymer composition, wherein the first fiber / yarn polymer composition comprises the polyolefin resin composition; and a second fiber or a second yarn comprising a second fiber / yarn polymer composition, wherein the second fiber / yarn polymer composition comprises one or more thermoplastic polymers selected from the group consisting of polyesters, polyethers, polyamides and polyurethanes.

[0116] Aspect 65. A synthetic leather material according to Aspect 64, wherein the second fiber / yarn polymer composition has 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 first fiber / yarn polymer composition; or wherein the second fiber / yarn polymer composition has 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 first fiber / yarn polymer composition.

[0117] Aspect 66. A synthetic leather material according to Aspect 64, wherein the one or more thermoplastic polymers of the second fiber or second yarn 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 fiber or first yarn; or wherein the one or more thermoplastic polymers of the second fiber or second yarn 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 fiber or first yarn.

[0118] Aspect 67. The synthetic leather material according to any one of aspects 38 to 66, wherein each synthetic leather polymer coating comprises a film.

[0119] Aspect 68. The synthetic leather material according to any one of Aspects 1 to 66, wherein the synthetic leather textile layer is a knitted textile.

[0120] Aspect 69. The synthetic leather material according to aspect 68, wherein the knitted textile is a flat knitted textile, a circular knitted textile, or a weft knitted textile.

[0121] Aspect 70. The synthetic leather material according to any one of Aspects 1 to 66, wherein the synthetic leather textile layer is a crocheted textile.

[0122] Aspect 71. The synthetic leather material according to any one of Aspects 1 to 66, wherein the synthetic leather textile layer is a knitted textile.

[0123] Aspect 72. The synthetic leather material according to any one of Aspects 1 to 66, wherein the synthetic leather textile layer is a woven textile.

[0124] Aspect 73. The synthetic leather material according to any one of Aspects 1 to 66, wherein the synthetic leather textile layer is a non-woven textile.

[0125] Aspect 74. The synthetic leather material according to any one of Aspects 1 to 73, further comprising a protective layer or a decorative layer attached to the synthetic leather polymer coating.

[0126] Aspect 75. The synthetic leather material according to aspect 74, wherein the protective layer or decorative layer is substantially free of polyolefins.

[0127] Aspect 76. The synthetic leather material according to aspect 74, wherein the protective layer or decorative layer comprises a polyolefin resin composition.

[0128] Aspect 77. The synthetic leather material according to aspect 74, wherein the protective layer or decorative layer comprises one or more thermoplastic polymers.

[0129] Aspect 78. The synthetic leather material according to aspect 77, wherein the one or more thermoplastic polymers are selected from polyesters, polyethers, polyamides or polyurethanes.

[0130] Aspect 79. The synthetic leather material according to aspect 78, wherein the one or more thermoplastic polymers comprise one or more polyesters.

[0131] Aspect 80. The synthetic leather material according to aspect 78 or aspect 79, wherein the polyester comprises polyethylene terephthalate (PET).

[0132] Aspect 81. The synthetic leather material according to aspect 78, wherein the one or more thermoplastic polymers comprise one or more polyamides.

[0133] Aspect 82. The synthetic leather material according to aspect 78 or aspect 81, wherein the polyamide comprises nylon 6,6, nylon 6, nylon 12, and combinations thereof.

[0134] Aspect 83. The synthetic leather material according to aspect 77, wherein the one or more thermoplastic polymers comprise one or more polyurethanes.

[0135] Aspect 84. The synthetic leather material according to any one of aspects 77 to 83, wherein the one or more thermoplastic polymers comprise one or more thermoplastic copolymers.

[0136] Aspect 85. The synthetic leather material according to aspect 84, wherein the one or more thermoplastic copolymers include one or more thermoplastic copolymers selected from the group consisting of thermoplastic copolyesters, thermoplastic copolyethers, thermoplastic copolyamides, thermoplastic copolyurethanes, or combinations thereof.

[0137] Aspect 86. The synthetic leather material of aspect 84, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyester.

[0138] Aspect 87. The synthetic leather material according to aspect 84, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyether.

[0139] Aspect 88. The synthetic leather material according to aspect 84, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyamide.

[0140] Aspect 89. The synthetic leather material of aspect 84, wherein the one or more thermoplastic copolymers comprise a thermoplastic copolyurethane.

[0141] Aspect 90. The synthetic leather material according to any one of aspects 77 to 89, wherein the one or more thermoplastic polymers comprise one or more thermoplastic polyether block amide (PEBA) copolymers.

[0142] Aspect 91. A synthetic leather material according to any one of Aspects 77 to 90, wherein the one or more thermoplastic polymers 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; or wherein the one or more thermoplastic polymers 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.

[0143] Aspect 92. The synthetic leather material according to any one of aspects 1 to 145, wherein the polyolefin resin composition comprises a polyolefin homopolymer or a polyolefin copolymer or both a polyolefin homopolymer and a polyolefin copolymer.

[0144] Aspect 93. The synthetic leather material according to aspect 92, wherein the polyolefin composition comprises the polyolefin homopolymer.

[0145] Aspect 94. The synthetic leather material according to aspect 92, wherein the polyolefin composition comprises the polyolefin copolymer.

[0146] Aspect 95. The synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition comprises an effective amount of a polymer resin modifier.

[0147] Aspect 96. The synthetic leather material according to any one of Aspects 1 to 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 according to the Abrasion Loss Test using a pure material sampling procedure.

[0148] Aspect 97. The synthetic leather material of any one of Aspects 1 to 145, wherein the effective amount of the polymer resin modifier is an amount effective to allow the polyolefin resin composition to be flexed by a Cold Ross Flex Test using a substrate sampling procedure.

[0149] Aspect 98. A synthetic leather material according to any one of Aspects 1 to 145, wherein the effective amount of the polymer resin modifier is an amount that effectively allows the polyolefin resin composition to have no significant change in abrasion loss when measured according to the abrasion loss test using a substrate sampling procedure in accordance with the cold sole material flexure test, as compared to the abrasion loss of a second polyolefin resin composition that is identical to the polyolefin resin composition except that it lacks the polymer resin modifier, when measured according to the abrasion loss test using a neat material sampling procedure.

[0150] Aspect 99. The synthetic leather material according to any one of Aspects 1 to 145, wherein the abrasion loss of the polyolefin resin composition is from about 0.08 cubic centimeters to about 0.1 cubic centimeters.

[0151] Aspect 100. The synthetic leather material according to any one of aspects 1 to 145, wherein the polyolefin resin composition comprises a polyolefin copolymer, and the polyolefin copolymer is a random copolymer.

[0152] Aspect 101. A synthetic leather material according to any one of Aspects 1 to 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 an olefin monomer having from about 1 to about 6 carbon atoms.

[0153] Aspect 102. A synthetic leather material according to any one of Aspects 1 to 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.

[0154] Aspect 103. The synthetic leather material according to any one of aspects 1 to 145, wherein the polyolefin resin composition comprises a polyolefin copolymer, and the polyolefin copolymer comprises more than one repeating unit, each repeating unit being individually selected from Formula 1A to Formula 1D

[0155]

[0156] Aspect 104. The synthetic leather material according to any one of aspects 1 to 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

[0157]

[0158] Where R 1 is hydrogen or a substituted or unsubstituted straight or branched C1-C 12 Alkyl or heteroalkyl.

[0159] Aspect 105. The synthetic leather material according to any one of aspects 1 to 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.

[0160] Aspect 106. A synthetic leather material according to any aspect, wherein the polyolefin resin composition comprises a polyolefin copolymer, and the polyolefin copolymer is a random copolymer of a first more than one repeating unit and a second more than one repeating unit, and wherein each of the first more than one repeating unit is derived from ethylene, and each of the second more than one repeating unit is derived from a second olefin.

[0161] Aspect 107. The synthetic leather material according to aspect 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 about 3 to 12 carbon atoms.

[0162] Aspect 108. A synthetic leather material according to any one of Aspect 106 or Aspect 107, wherein each of the first more than one repeating units has a structure according to Formula 1A, and wherein each of the second more than one repeating units has a structure selected from Formula 1B-Formula 1D

[0163]

[0164] Aspect 109. A synthetic leather material according to any one of aspects 106 to 108, wherein each of the first more than one repeating units has a structure according to Formula 1A, and wherein each of the second more than one repeating units has a structure according to Formula 2

[0165]

[0166] Where R 1 is hydrogen or a substituted or unsubstituted straight or branched C2-C 12 Alkyl or heteroalkyl.

[0167] Aspect 110. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition comprises a polyolefin copolymer, and based on the total weight of the polyolefin copolymer, 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 repeating units.

[0168] Aspect 111. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition comprises a polyolefin copolymer, and based on the total weight of the polyolefin copolymer, 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.

[0169] Aspect 112. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition is substantially free of polyurethane; or the polyolefin resin composition comprises a polyolefin copolymer, and the polymer chain of the polyolefin copolymer is substantially free of urethane repeating units; or the polyolefin resin composition is substantially free of polymers having polymer chains containing urethane repeating units.

[0170] Aspect 113. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition is substantially free of polyamide; or the polyolefin resin composition comprises a polyolefin copolymer, and the polymer chain of the polyolefin copolymer is substantially free of amide repeating units; or wherein the polyolefin resin composition is substantially free of polymers having polymer chains comprising amide repeating units.

[0171] Aspect 114. The synthetic leather material according to any one of aspects 1 to 145, wherein the polyolefin resin composition comprises a polypropylene copolymer alone or in combination with an effective amount of a polymer resin modifier.

[0172] Aspect 115. The synthetic leather material according to any one of aspects 1 to 145, wherein the polyolefin resin composition has a wear loss of about 0.05 cubic centimeters (cm 3 ) to about 0.1 cubic centimeters (cm 3 ), about 0.07 cubic centimeters (cm 3 ) to about 0.1 cubic centimeters (cm 3 ), about 0.08 cubic centimeters (cm 3 ) to about 0.1 cubic centimeters (cm 3 ), or about 0.08 cubic centimeters (cm 3 ) to about 0.11 cubic centimeters (cm 3 ) wear loss.

[0173] Aspect 116. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition comprises an effective amount of a polymer resin modifier, the effective amount of the polymer resin modifier being an amount effective to allow the polyolefin resin composition to be tested for flexure according to the Cold Sole Material Flexure Test using a substrate sampling procedure.

[0174] Aspect 117. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polymer resin composition contains an effective amount of a polymer resin modifier, and the effective amount of the polymer resin modifier is such an amount: the amount effectively allows the polyolefin resin composition to pass a flexure test according to the Cold Sole Material Flexure Test using a substrate sampling procedure, and when measured according to the Abrasion Loss Test using a pure material sampling procedure, the abrasion loss is not significantly changed compared to the abrasion loss of a second polyolefin resin composition that is identical to the polyolefin resin composition except that it does not contain the polymer resin modifier.

[0175] Aspect 118. The synthetic leather material according to any one of aspects 1 to 145, wherein the polyolefin resin composition comprises a polypropylene copolymer, optionally wherein the polypropylene copolymer is a random copolymer.

[0176] Aspect 119. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition comprises a polypropylene copolymer, and based on the total weight of the polypropylene copolymer, the polypropylene 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 polypropylene repeating units.

[0177] Aspect 120. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition comprises a polypropylene copolymer, and based on the total weight of the polypropylene copolymer, 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.

[0178] Aspect 121. A synthetic leather material according to any one of Aspects 1 to 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 the first more than one repeating unit and about 80% to about 99% by weight of the 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

[0179]

[0180] Aspect 123. The synthetic leather material according to any one of aspects 1 to 145, wherein the polymer in the polyolefin resin composition consists essentially of a polymer comprising propylene repeating units.

[0181] Aspect 124. The synthetic leather material according to any one of aspects 1 to 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.

[0182] Aspect 125. The synthetic leather material according to any one of aspects 1 to 145, wherein the polyolefin resin composition comprises a polypropylene copolymer, and the polyolefin copolymer is a random copolymer of ethylene and propylene.

[0183] Aspect 126. A synthetic leather material according to any one of Aspects 1 to 145, wherein the abrasion loss of the polyolefin resin composition is within about 20% of the abrasion loss of an otherwise identical polyolefin resin composition except for the absence of the resin modifier when measured according to the Abrasion Loss Test using a neat material sampling procedure.

[0184] Aspect 127. The synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition has a crystallinity percentage of about 35%, about 30%, about 25% or less when measured according to the Crystallinity Test using a neat material sampling procedure.

[0185] Aspect 128. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition has a percent crystallinity that is at least 4 percentage points lower than the percent crystallinity of an otherwise identical polyolefin resin composition except for the absence of the polymer resin modifier when measured according to the Crystallinity Test using a neat material sampling procedure.

[0186] Aspect 129. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition contains an effective amount of the polymer resin modifier, and the effective amount of the polymer 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.

[0187] Aspect 130. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition contains an effective amount of the polymer resin modifier, and the effective amount of the polymer resin modifier is about 20%, about 15%, about 10%, about 5% or less by weight based on the total weight of the resin composition.

[0188] Aspect 131. The synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition comprises the polymer resin modifier, and the polymer resin modifier comprises about 10% to about 15% of ethylene repeating units based on the total weight of the polymer resin modifier.

[0189] Aspect 132. The synthetic leather material according to any one of Aspects 1 to 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.

[0190]

[0191] Aspect 133. The synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition has a total ethylene repeating unit content of about 3% to about 7% by weight based on the total weight of the resin composition.

[0192] Aspect 134. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition comprises a polymer resin modifier and the polymer resin modifier has an ethylene repeating unit content of about 10% to about 15% by weight based on the total weight of the polymer resin modifier.

[0193] Aspect 135. The synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition comprises a polymer resin modifier, and the polymer resin modifier is a copolymer comprising isotactic repeating units derived from an olefin.

[0194] Aspect 136. The synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition comprises a polymer resin modifier, and the polymer resin modifier is a copolymer comprising repeating units according to Formula 1B, and wherein the repeating units according to Formula 1B are arranged in an isotactic stereochemical configuration.

[0195]

[0196] Aspect 137. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition comprises the polymer resin modifier, and using the pure material sampling procedure, the polyolefin resin composition that is otherwise identical except for the absence of the polymer resin modifier does not pass the cold sole material flexure test.

[0197] Aspect 138. The synthetic leather material according to any one of aspects 1 to 145, wherein the polyolefin resin composition comprises a polymer resin modifier, and the polymer resin modifier is a copolymer comprising isotactic propylene repeating units and ethylene repeating units.

[0198] Aspect 139. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition comprises a polymer resin modifier, and the polymer resin modifier is a copolymer comprising a first one or more repeating units and a second one or more repeating units; wherein each of the first one or more repeating units has a structure according to Formula 1A, and each of the second one or more repeating units has a structure according to Formula 1B, and wherein the repeating units in the second one or more repeating units are arranged in an isotactic stereochemical configuration

[0199]

[0200] Aspect 140. The synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition comprises a polymer resin modifier, and the polymer resin modifier is a metallocene-catalyzed polymer, optionally a metallocene-catalyzed copolymer, optionally a metallocene-catalyzed propylene copolymer.

[0201] Aspect 140. The synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition further comprises a clarifying agent.

[0202] Aspect 141. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition contains a clarifier, and the clarifier 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.

[0203] Aspect 142. A synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition contains a transparent agent, and the transparent 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 its derivatives.

[0204] Aspect 143. The synthetic leather material according to any one of Aspects 1 to 145, wherein the polyolefin resin composition comprises a transparent agent, and the transparent agent comprises an acetal compound which is a condensation product of a polyol and an aromatic aldehyde.

[0205] Aspect 144. The synthetic leather material according to aspect 143, wherein the polyol is selected from: an acyclic polyol such as xylitol or sorbitol, or an acyclic deoxy polyol such as 1,2,3-trideoxynonenol or 1,2,3-trideoxynon-1-enol, or a combination of an acyclic polyol and an acyclic deoxy polyol.

[0206] Aspect 145. The synthetic leather material according to aspect 143, wherein the aromatic aldehyde is selected from the group consisting of benzaldehyde, substituted benzaldehydes, and mixtures of benzaldehyde and substituted benzaldehydes.

[0207] Aspect 146. A component comprising the synthetic leather material according to any one of aspects 1 to 145.

[0208] Aspect 147. The component according to Aspect 146, wherein the component is a component of an article of footwear, a component of an article of apparel, or a component of an article of sporting equipment.

[0209] Aspect 148. The component according to Aspect 147, wherein the component is a component of an article of footwear.

[0210] Aspect 149. The component according to Aspect 147, wherein the component is a component of an article of sporting equipment.

[0211] Aspect 150. The component according to aspect 149, wherein the component is a component of an article of sporting equipment, the component of the article of sporting equipment being selected from a component of a headgear, a component of a bag, a component of a ball, or a component of protective equipment.

[0212] Aspect 151. The component according to aspect 147, wherein the component is a component of an article of clothing.

[0213] Aspect 152. The component according to Aspect 147, wherein the component is a component of an article of footwear.

[0214] Aspect 153. The component according to Aspect 152, wherein the component is an upper for an article of footwear.

[0215] Aspect 154. A component according to Aspect 152, wherein the component is a component of an upper, and the upper is selected from the front opening area of ​​the shoe, the ankle collar area, the ground-facing area, the sole peripheral area, the heel area, the toe area, the tongue, the eye stay, the medial side, the lateral side or a combination thereof.

[0216] Aspect 155. A method for manufacturing a synthetic leather material, the method comprising: attaching a synthetic leather polymer coating and a 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 attachment comprises one or more steps selected from the following: laminating the textile onto the surface of the resin composition, laminating the resin composition onto the surface of the textile, welding the textile to the surface of the resin composition, welding the resin composition to the surface of the textile, bonding the textile to the surface of the resin composition using an adhesive, or bonding the resin composition to the surface of the textile using an adhesive.

[0217] Aspect 156. The process of aspect 155, further comprising attaching a protective layer or a decorative layer to the synthetic leather polymer coating.

[0218] Aspect 157. The process according to aspect 155 or aspect 156, wherein the synthetic leather material is a synthetic leather material according to any one of aspects 1 to 145.

[0219] Aspect 158. An article comprising: the synthetic leather material according to any one of aspects 1 to 145.

[0220] Aspect 159. The article according to Aspect 158, wherein the article is an article of footwear, an article of apparel, or an article of sporting equipment.

[0221] Aspect 160. The article according to Aspect 159, wherein the article is an article of clothing.

[0222] Aspect 161. The article according to Aspect 159, wherein the article is an article of sporting equipment.

[0223] Aspect 162. The article according to Aspect 161, wherein the article of sporting equipment is a hat, a bag, a ball, or protective equipment.

[0224] Aspect 163. The article according to Aspect 159, wherein the article is an article of footwear.

[0225] Aspect 164. A footwear article comprising: an upper and a sole structure; wherein the upper comprises the synthetic leather material according to any one of Aspects 1 to 145, the sole structure comprises the synthetic leather material according to any one of Aspects 1 to 145, or both the upper and the sole structure comprise the synthetic leather material according to any one of Aspects 1 to 145.

[0226] Aspect 165. The article according to aspect 164, wherein the upper comprises the synthetic leather material according to any one of aspects 1 to 145.

[0227] Aspect 166. The article of footwear according to any one of aspects 164 to 209, wherein the sole structure includes a sole component comprising a polyolefin resin.

[0228] Aspect 167. An article of footwear according to any one 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 the surface of the upper defined by the first polyolefin resin composition is bonded to the surface of the sole component defined by the second polyolefin resin composition.

[0229] Aspect 168. The article of footwear according to any one of Aspects 164 to 209, wherein the bond between the surface of the upper defined by the first polyolefin resin composition and the surface of the sole component defined by the second polyolefin resin composition is a thermal bond.

[0230] Aspect 169. The article of footwear according to any one 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 the polyolefin resin composition according to any one of Aspects 92 to 145.

[0231] Aspect 170. The article of footwear according to any one of Aspects 164 to 209, wherein the sole component includes a first side and a second side, wherein when the sole component is part of the article of footwear, the first side is configured to face the ground.

[0232] Aspect 171. The article of footwear according to any one of Aspects 164 to 209, wherein the sole structure further comprises a textile disposed on one or both of the first side and the second side of the sole component.

[0233] Aspect 172. The article of footwear according to any one of Aspects 164 to 209, wherein the bond between the upper and the sole component comprises a mechanical bond between the upper and the textile disposed on the sole component.

[0234] Aspect 173. The article of footwear according to any one of aspects 164 to 209, wherein the sole component is a plate.

[0235] Aspect 174. The article of footwear according to 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 according to any one of aspects 92 to 145.

[0236] Aspect 175. The article of footwear according to Aspect 174, wherein the textile of the sole structure further comprises a polymer coating composition attached to the textile; and wherein the polymer coating composition comprises the polyolefin resin composition according to any one of Aspects 92 to 145.

[0237] Aspect 176. The article of footwear according to Aspect 105, wherein the textile of the sole component further comprises a polymer coating composition attached to the textile; and wherein the polymer coating composition is substantially free of the polyolefin resin composition according to any one of Aspects 92 to 145.

[0238] Aspect 177. The article of footwear according to aspect 176, wherein the polymer coating composition comprises one or more thermoplastic polymers selected from polyesters, polyethers, polyamides, or polyurethanes.

[0239] Aspect 178. An article of footwear according to Aspect 177, wherein the polymer coating composition has 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 fiber / yarn polymer composition of the textile of the sole component; or wherein the polymer coating composition has 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 fiber / yarn polymer composition of the textile of the sole component.

[0240] Aspect 179. The article of footwear according to Aspect 173, wherein the textile of the sole component comprises: a first fiber or a first yarn comprising a first fiber / yarn polymer composition, wherein the first fiber / yarn polymer composition comprises a polyolefin resin composition according to any one of Aspects 92 to 145; and a second fiber or a second yarn comprising a second fiber / yarn polymer composition.

[0241] Aspect 180. The article of footwear according to aspect 179, wherein the second fiber / yarn polymer composition comprises one or more thermoplastic polymers selected from polyester, polyether, polyamide, or polyurethane.

[0242] Aspect 181. The article of footwear according to any one 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.

[0243] Aspect 182. An article of footwear according to any one of Aspects 171 to 209, wherein the textile is on a second side of the sole component, and wherein the bonding strength of the second side of the sole component to the upper is greater than the bonding strength of an otherwise identical sole component to an otherwise identical upper using an otherwise identical bonding procedure except that the textile is not disposed on the first side of the sole component.

[0244] Aspect 183. The article of footwear according to any one of Aspects 164 to 209, wherein the textile comprises a first textile on the first side of the sole component and a second textile on the second side of the sole component.

[0245] Aspect 184. The article of footwear according to any one 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.

[0246] Aspect 185. The article of footwear according to any one of Aspects 164 to 209, wherein the length of the sole component extends through a metatarsal region of the article of footwear to a midfoot region of the article of footwear.

[0247] Aspect 186. The article of footwear according to any one of Aspects 164 to 209, wherein the length of the sole component extends through a midfoot region of the article of footwear to a heel region of the article of footwear.

[0248] Aspect 187. The article of footwear according to any one of Aspects 164 to 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.

[0249] Aspect 188. The article of footwear according to any one of Aspects 164 to 209, wherein the first side of the sole component includes one or more traction elements.

[0250] Aspect 189. The article of footwear according to any one of Aspects 164 to 209, wherein the one or more traction elements are integrally formed in the sole component.

[0251] Aspect 190. The article of footwear according to any one of Aspects 164 to 209, wherein the traction elements comprise a polyolefin resin composition, optionally a polyolefin resin composition according to any one of Aspects 92 to 145.

[0252] Aspect 191. The article of footwear according to any one of Aspects 164 to 209, wherein the one or more traction elements comprise a second resin composition that is substantially free of polyolefins.

[0253] Aspect 192. The article of footwear according to any one of aspects 164 to 209, wherein the second resin comprises an elastomeric material, optionally an olefin elastomer.

[0254] Aspect 193. The article of footwear according to any one of Aspects 164 to 209, wherein the second resin comprises polystyrene, polyethylene, ethylene-α-olefin copolymers, ethylene-propylene rubber (EPDM), polybutylene, polyisobutylene, poly-4-methylpent-1-ene, polyisoprene, polybutadiene, ethylene-methacrylic acid copolymers, copolymers thereof, or blends or mixtures thereof.

[0255] Aspect 194. The article of footwear according to any one of Aspects 164 to 209, wherein the second resin composition comprises less than 10 weight percent or less than 5 weight percent of a polyolefin, optionally wherein the second resin composition comprises less than 10 weight percent or less than 5 weight percent of a polypropylene.

[0256] Aspect 195. The article of footwear according to any one of aspects 164 to 209, wherein the second resin composition comprises ethylene-propylene rubber (EPDM) dispersed in a polyolefin, optionally EPDM dispersed in polypropylene.

[0257] Aspect 196. The article of footwear according to any one of Aspects 164 to 209, wherein the second resin composition comprises a block copolymer comprising polystyrene blocks.

[0258] Aspect 197. The article of footwear according to any one of aspects 164 to 209, wherein the block copolymer comprises a copolymer of styrene with one or both of ethylene and butylene.

[0259] Aspect 198. An article of footwear according to any one of Aspects 171 to 209, wherein the textile is arranged on the sole component by: injection molding the sole component onto the textile, by laminating the textile to the sole component, by welding the textile to the sole component, and / or by bonding the textile to the sole component using an adhesive.

[0260] Aspect 199. The article of footwear according to any one of Aspects 171 to 209, wherein the textile is selected from the group consisting of a woven textile, a non-woven textile, a knitted textile, a knitted textile, and combinations thereof.

[0261] Aspect 200. The article of footwear according to any one of Aspects 171 to 209, wherein the textile comprises one or more fibers comprising a polymer selected from the group consisting of polyesters, polyamides, polyolefins, blends thereof, and combinations thereof.

[0262] Aspect 201. The article of footwear according to any one of aspects 164 to 171, wherein the textile comprises a yarn comprising fibers.

[0263] Aspect 202. The article of footwear according to any one of Aspects 164 to 209, wherein the surface roughness of a surface including the textile is greater than the surface roughness of an otherwise identical surface except for the absence of the textile.

[0264] Aspect 203. The article of footwear according to any one of Aspects 164 to 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 braided textile, or a combination thereof.

[0265] Aspect 204. The article of footwear according to any one of Aspects 164 to 209, wherein the sole structure further comprises an adhesive, primer or tie layer located between the ground-facing side and the elastomeric material.

[0266] Aspect 205. The article of footwear according to any one of Aspects 164 to 209, wherein one or more of the adhesive, the primer, and the connecting layer comprises a polymer having epoxy segments, urethane segments, acrylic segments, cyanoacrylate segments, silicone segments, or any combination thereof.

[0267] Aspect 206. The article of footwear according to any one of aspects 164 to 209, wherein one or more of the polyolefin resin of the plate, the adhesive, the primer, and the connecting layer comprises a polymer having maleic anhydride functional groups.

[0268] Aspect 207. The article of footwear according to any one of aspects 164 to 209, wherein one or more of the plate, the adhesive, the primer, and the connecting layer comprises maleic anhydride.

[0269] Aspect 208. The article of footwear according to any one of aspects 164 to 209, wherein the adhesive, the primer, or the connecting layer comprises thermoplastic polyurethane.

[0270] Aspect 209. The article of footwear according to any one of aspects 164 to 209, wherein the ground-facing side of the sole structure comprises texturing.

[0271] Aspect 210. A method for manufacturing an article of footwear, the method comprising: attaching an upper and a sole structure to each other, wherein the upper or the sole structure or both the upper and the sole structure comprise a synthetic leather material, and the synthetic leather material comprises 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 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, or the sole structure and the synthetic leather material.

[0272] Aspect 211. The method according to aspect 210, wherein the synthetic leather material is a synthetic leather material according to any one of aspects 1 to 145.

[0273] Aspect 212. The method of Aspect 210 or Aspect 211, wherein attaching the upper and the sole structure to each other comprises injection molding at least a portion of the sole structure onto at least a portion of the upper.

[0274] Aspect 213. The method of any one of Aspects 210 to 212, wherein the attaching comprises attaching a surface of the sole structure to a surface of the upper, wherein the surface of the sole structure is defined by a polyolefin resin composition.

[0275] Aspect 214. The method according to aspect 213, wherein the polyolefin resin composition defining the surface of the sole structure is a polyolefin resin composition according to any one of aspects 92 to 145.

[0276] Aspect 215. The method according to any one of Aspects 210 to 214, wherein the attaching comprises attaching a surface of the sole structure to a surface of the upper, wherein the surface of the upper is defined by a polyolefin resin composition.

[0277] Aspect 216. The method according to aspect 215, wherein the polyolefin resin composition defining the surface of the upper is a polyolefin resin composition according to any one of aspects 92 to 145.

[0278] Aspect 217. A method according to any one of Aspects 210 to 216, wherein the attachment comprises forming a thermal bond between a surface of the sole structure and a surface of the upper, wherein the thermal bond comprises a polyolefin resin composition, optionally a polyolefin resin composition according to any one of Aspects 92 to 145.

[0279] Aspect 218. The method according to aspect 217, wherein the polyolefin resin composition of the thermal bond comprises a polyolefin hot melt adhesive.

[0280] Aspect 219. A method according to any one of Aspects 210 to 218, wherein the attachment includes forming a thermal bond between a surface of the sole structure and a surface of the upper, wherein forming the thermal bond includes injecting the polyolefin resin composition onto the upper to form at least a portion of the sole structure including the surface of the sole structure, and bonding the surface of the sole structure to the upper.

[0281] Having now generally described aspects of the disclosure, further discussions of the aspects will be described in more detail.

[0282] Before describing the present disclosure in more detail, it should be understood that the present disclosure is not limited to the specific aspects described, and therefore can certainly vary. After consulting the following drawings and detailed description, it will be apparent or will become apparent to those skilled in the art that other systems, methods, features and advantages of resin compositions and articles and parts thereof. It is intended that all such other systems, methods, features and advantages are included in this description, are included within the scope of the present disclosure and are protected by the appended claims. It should also be understood that the terms used herein are only used to describe the purpose of specific aspects, and are not intended to be restrictive. The technician will recognize many variations and adjustments of the aspects described herein. These variations and adjustments are intended to be included in the teachings of the present disclosure, and are intended to be covered by the claims herein.

[0283] Footwear

[0284] In some aspects, the present disclosure relates to footwear articles comprising synthetic leather materials as described herein, wherein the upper of the footwear article or the sole structure of the footwear article or both comprise synthetic leather materials. The sole structure of the footwear article may include sole components, such as one or more plates. At least a portion of the surface of the upper attached to the sole structure may comprise synthetic leather materials as described herein, and optionally the surface of the upper attached thereto is defined by a polyolefin resin composition as described herein. In some aspects, the surface of the upper attached thereto and the surface of the sole structure attached thereto may both comprise polyolefin resin compositions. The bonding strength between the two surfaces both formed by the polyolefin composition is generally stronger than the bonding strength between the first surface formed by the polyolefin composition and the non-polyolefin polymer composition, because the surface energy of polyolefins is generally different from other types of polymer materials commonly used in footwear manufacturing. 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 a polyolefin resin composition, it is advantageous to attach the surfaces together using a thermal bond in which the polyolefin resin composition of the upper and / or the sole structure is softened or melted and then resolidified 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 polymers present in the polyolefin resin composition) 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 the two polyolefin resin compositions (i.e., the portion of the composition consisting of all polyolefins present in the polyolefin resin composition) 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.

[0285] In some aspects, the sole structure comprises a polyolefin resin composition, including a polyolefin resin composition as described herein. The sole structure and sole components comprising the polyolefin resin composition ideally show a high level of mechanical strength and also have flexural durability. However, the applicant has found that in some aspects, when the polyolefin resin composition is used to form the bonding surface of the sole structure or the sole component, it may be unsatisfactory to be bonded to the surface defined by the polyolefin resin composition (for example, the bonding between the plate and the upper), particularly when another surface to be attached to the bonding surface of the sole structure or the sole component (for example, the surface of the upper, such as the outward-facing surface of Strobel) is defined by a polymer composition with a surface energy significantly different from the polyolefin resin composition. For example, it may be difficult to bond polyurethane, polyamide or polyester agent to the polyolefin resin composition using only the adhesive system conventionally used in the footwear industry. One way to improve the bonding strength between the polyolefin resin composition and the polymer material relatively incompatible with polyolefin is to use a textile layer as the interface between the surface of the upper and the surface of the sole structure, and to bond one side of the textile to the surface of the upper, and to bond the opposite side of the textile to the surface of the sole structure. Therefore, in some aspects, the sole structure includes a sole component comprising a polyolefin resin composition and a textile arranged on one or more surfaces of the sole component. In an example, the use of a textile comprising a fiber or yarn formed by a polymer material having a different surface energy compared to the surface energy of the polyolefin resin composition of the sole component can contribute to the bonding between the uppers, the upper comprising a polymer material having such a surface energy, the surface energy being closer to the surface energy of the textile compared to the surface energy of the polyolefin resin composition of the sole component, thereby increasing the strength of the joint between the sole component and the upper compared to the sole component without textiles. Using textiles can provide a textured surface with a larger surface area, providing a greater chance of forming a mechanical joint between the upper and the sole component, thereby increasing the strength of the joint between the sole component and the upper compared to the sole component without textiles. As an additional benefit, textiles can in some aspects be used to provide a decorative or stylized surface.

[0286] Figure 1A is a lateral perspective view of an exemplary cleated athletic footwear article 110, such as a soccer boot / football boot. Figure 1A1, article of footwear 110 includes upper 112 and sole structure 113, sole structure 113 includes plate 116 and textile 114 disposed on upper side 152 of plate. Textile 114 is located between plate 116 and upper 112. Plate 116 includes a plurality of traction elements 118. When worn, traction elements 118 provide traction to the wearer to enhance stability. One or more of traction elements 118 may be integrally formed with the plate, such as Figure 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 traction element tip may be integrally formed with traction element 118. Optionally, the traction element tip may be formed of a different material than the rest of traction element 118 (e.g., a metal or a polymer material containing a different polymer). Figure 1B is a lateral side elevation view of article of footwear 110. When article of footwear 110 is worn, the lateral side of article 110 is generally oriented on the side facing away from the centerline of the wearer's body. Figure 1C is a medial side elevation view of article of footwear 110. When article of footwear 110 is worn, medial side generally faces the centerline of the wearer's body. Figure 1D 1 is a top view of an article of footwear 110 (without a sockliner in place) and without a last or other plate-like member 115, and also shows an upper 112. The upper 112 includes a padded collar 120. Alternatively or in addition, the upper can include an area (not shown) that is configured to extend upward to or cover the wearer's ankle. In at least one aspect, the upper 112 is tongueless, wherein the upper wraps from the medial side of the wearer's foot, over the top of the foot, and under the lateral side portion of the upper, as shown. Figure 1D Optionally, the article of footwear may include a tongue (not shown). Figure 1A-1G As shown in , the laces of the article of footwear 110 may optionally be located on the 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 laces. Figure 1E and Figure 1F 1 and 2 are front elevation views and rear elevation views, respectively, of article of footwear 110.

[0287] Figure 1G 1 is an exploded perspective view of article of footwear 110, showing upper 112, plate 116, and textile 114. Figure 1D As seen in FIG. 1 , the upper 112 includes a strobel 138. Figure 1DAs shown in , the strobel 138 is generally the shape of the wearer's foot and closes the bottom of the upper 112, and is sewn to other components along the perimeter of the strobel 138 with stitches 185 to form the upper 112. A lasting plate or other plate-like member 115 can be located above or below the strobel 138. In some aspects, the lasting plate or other plate-like member can replace the strobel. The lasting plate or other plate-like member 115 can extend substantially the entire length of the plate, or can be present in a portion of the length of the plate, such as, for example, in the toe area 130, or in the midsole area, or in the heel area. The upper 112 including the strobel 138 is bonded to the upper surface 140 ( Figure 1G-1H ). Lower surface 142 of textile 114 may be bonded or fused to 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 a polymer in textile 114 with a polymer resin of plate 116. Alternatively or in addition, upper 112 including strobel 138 may be mechanically bonded to upper surface 140 of textile 114 by fusing a polymer resin of upper 112 or strobel 138 with a polymer resin of plate 116. In some aspects, bonding may include both adhesive bonding and mechanical bonding.

[0288] In at least one aspect, plate 116 and textile 114 are first joined before upper 112 and / or strobel 138 are joined to textile 114. In some aspects, article of footwear 110 may include a removable sockliner (not shown). As is known in the art, a sockliner conforms to and lines the interior bottom surface of a shoe and is the component that is contacted by the sole of the wearer's foot (or the sole of the foot when wearing socks).

[0289] Figure 2A-2C A second exemplary article of athletic footwear is depicted. Figure 2A is a lateral side elevation view of an exemplary article of athletic footwear. Figure 2B is an exploded perspective view of a second exemplary article of athletic footwear. Figure 2C is a cross-sectional view along 2 - 2 of a second exemplary article of athletic footwear. Figure 2A 2 is a lateral side elevation view of an exemplary article of footwear 210 without a textile. Article of footwear 210 includes upper 212 and sole structure 213 having plate 216 and bottom layer 217. Bottom layer 217 includes a plurality of traction elements 218. Traction elements 218 may be formed entirely of bottom layer 217 material, or may be formed of a plurality of traction elements 218. Figure 2BAs illustrated in , traction elements 118 may have corresponding inner traction elements 219 formed in plate 216 and encased by bottom layer 217. Optionally, one or more of traction elements 218 may include a tip (not shown) configured to be a ground contacting traction element. Article of footwear 210 may include lasting member 215, which may extend substantially the entire length of plate 216.

[0290] In some aspects, the sole structure may include a plate to provide rigidity, strength, and / or support without substantially increasing weight. For example, some exemplary sole structure aspects may include a plate having certain features that provide resistance to vertical bending, lateral bending, and / or torsion. Figure 3 As depicted in , the plate 300 may include reinforcing ribs 310 along the longitudinal direction of the plate. The reinforcing ribs may include a hollow structure and, therefore, may provide rigidity without adding a large amount of additional material and, therefore, maintain a low weight. The plate 300 may be located within the bottom layer 330, such as within a recess 320 in the bottom layer 330.

[0291] In some aspects, when the sole structure includes a plate and a bottom layer configured to wrap around the plate and engage or be attached to the upper, when the sole structure is a component of an article of footwear, the sole structure also includes one or more textiles. 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 plate and the bottom layer. In aspects where the textile is between the plate and the bottom layer, the textile may provide improved adhesion between the plate and the bottom layer, and / or the textile may be a decorative textile or an ornamental textile. In some aspects, the sole structure may include a decorative textile on the outside of the bottom layer or on a ground-facing surface of the bottom layer. For example, as Figure 4A-4C , footwear 410 includes an upper 412 and a sole structure 413, the sole structure 413 having a plate 416 and a bottom layer 417. Bottom layer 417 includes a plurality of traction friction elements 418. Traction friction elements 418 may be formed entirely of bottom layer 417 material, as illustrated. Optionally, one or more of traction friction elements 418 may include a tip (i.e., end) (not shown) configured to be a traction friction element that contacts the ground. Textile 414 is positioned between plate 416 and bottom layer 417. Footwear 410 may include a lasting member 415, which may extend substantially the entire length of plate 416.

[0292] Figure 5A5 is a lateral side elevational view of an exemplary article of footwear 510 including separate heel plate 515, mid-shoe plate 516, and toe plate 517. Article of footwear 510 includes upper 512 and heel plate 515, mid-shoe plate 516, and toe plate 517. Each of heel plate 515, mid-shoe plate 516, and toe plate 517 includes a plurality of traction elements 518. When worn, traction elements 518 provide traction to the wearer to enhance stability. Figure 5A As illustrated in , 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. Figure 5B 5 is an exploded perspective view of article of footwear 510, which shows upper 512, heel plate 515, midfoot plate 516, and toe plate 517. In this aspect, upper surface 525 of heel plate 515 can include heel textile 535. Upper surface 527 of toe plate 517 can include toe textile 537. Likewise, upper surface 526 of midfoot plate 516 includes midfoot textile 536. The textile can provide an improved bond between upper 512, heel plate 515, midfoot plate 516, and toe plate 517.

[0293] The present disclosure provides a variety of sole structures, which include polyolefin plates, i.e., plates containing polyolefin resin compositions. The plates include polyolefin resin compositions, such as any polyolefin resin compositions described herein. The sole structure may also include an elastomeric material, which includes cured rubber. The cured rubber may form an outsole portion of the sole structure, or may form a tip of one or more traction friction elements.

[0294] The sole structure may include a textile on one or more surfaces of the plate. For example, when the plate has a first side and a second side, when the plate is a component of an article of footwear, the first side may be configured to face the ground and the second side may be configured to face upward. In some aspects, the textile is on one or both of the first side and the second side. The textile may provide an improved bond between the plate and other components of the sole structure, such as an improved bond between the plate and a bottom layer. When the sole structure is a component of an article of footwear, the textile may also provide an improved bond between the plate and the upper. In some aspects, the textile is a patterned textile or a decorative textile.

[0295] 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 the textiles. The bottom layer can be configured to be on a first side of the board or on a side of the board facing the ground. In some aspects, when the sole structure is a component of an article of footwear, the bottom layer is configured to wrap around the board and engage or be attached to the upper. The bottom layer can be attached to the upper at the bite line.

[0296] In some aspects, the traction friction element is made of a polyolefin resin composition that is the same or almost the same as the plate. In other aspects, the traction friction element is made of a second resin that is different from a 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-α-olefin copolymer, ethylene-propylene rubber (EPDM), polybutene, polyisobutylene, poly-4-methylpent-1-ene, polyisoprene, polybutadiene, ethylene-methacrylic acid copolymer, olefin elastomer, its copolymer or its blend or mixture. In some aspects, the second resin includes about 20%, about 10% or less polyolefin. The second resin may include about 20%, about 10% or less polypropylene. The second resin may include 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 one or both of ethylene and butene with styrene. Typically, the second resin may be any resin that is compatible with the polyolefin resin and has suitable durability and mechanical properties.

[0297] In particular, it has been found that a second resin (e.g., polystyrene, polyethylene, ethylene-α-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) combines well with the resin compositions of the present disclosure.

[0298] Additionally, second resins comprising ethylene-propylene rubber (EPDM) dispersed in polypropylene or comprising block copolymers having polystyrene blocks and wherein the block copolymers include copolymers of one or both of ethylene and butene with styrene have been found to be particularly useful in the ground contacting portions of traction friction elements because these compositions both bond well with the resin compositions of the present disclosure and can provide even higher levels of wear resistance than the resin compositions of the present disclosure, which may be desirable in the ground contacting portions of traction friction elements.

[0299] In some aspects, it may be beneficial to include a clarifying agent in the board (in the polyolefin resin) and / or in the bottom layer when there is a bottom layer. The clarifying agent may allow the textile to be clearly seen through the board. The clarifying agent may be present in any suitable amount to provide sufficient optical transparency of the final board or sole structure. In some aspects, the clarifying agent is present in an amount of 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 gross weight of the polyolefin resin. The clarifying agent may include those selected from the following group: 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 clarifying agent may include an acetal compound, which is a condensation product of a polyol and an aromatic aldehyde. The polyol 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-trideoxynonitol or 1,2,3-trideoxynon-1-enitol. The aromatic aldehyde may include those selected from the group consisting of benzaldehyde and substituted benzaldehyde.

[0300] Polyolefin resin composition

[0301] 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 and one or more additional ingredients selected from polymer resin modifiers, clarifiers, colorants, fillers, processing aids, non-polyolefin polymers, or any combination thereof.

[0302] Provided are a variety of polyolefin resin compositions having wear resistance and flex durability suitable for articles and components described above. In some aspects, provided are polyolefin resin compositions comprising a polyolefin copolymer and an effective amount of a polymer resin modifier. An effective amount of the resin modifier provides improved flex durability while maintaining suitable wear resistance. For example, in some aspects, the effective amount of the polymer resin modifier is an amount that effectively allows the resin composition to pass the flex test of the cold sole material flex test using a substrate sampling procedure. Meanwhile, when measured according to the abrasion loss test using a pure material sampling procedure, the resin composition can still have suitable abrasion loss. In some aspects, using the pure material sampling procedure, a resin composition that is otherwise identical except that there is no polymer resin modifier cannot pass the cold sole material flex test.

[0303] The polymer resin modifier can provide improved flexural strength, toughness, creep resistance or flexural durability without a significant loss in wear resistance. In some aspects, a resin composition comprising a polyolefin copolymer and an effective amount of a polymer resin modifier is provided, wherein the effective amount of the polymer resin modifier is such an amount that the amount effectively allows the resin composition to pass a flexure test according to a cold sole material flexure test using a substrate sampling procedure, and when measured according to an abrasion loss test using a pure material sampling procedure, the abrasion loss is not significantly changed compared to the abrasion loss of a second resin composition that is identical to the resin composition except that there is no polymer resin modifier. In other words, in some aspects, the effective amount of the polymer resin modifier is such an amount that the amount is sufficient to produce a resin composition that will not stress whiten or crack during 150,000 flexure cycles of the cold sole material flexure test, while the wear resistance of the resin composition is not significantly degraded, and therefore the wear resistance is not significantly different from that of a comparative resin composition that is otherwise identical to the resin composition except that there is no polymer resin modifier.

[0304] In some aspects, the polyolefin resin composition has a wear loss of about 0.05 cubic centimeters (cm 3 ) to about 0.1 cubic centimeter (cm) 3 ), about 0.07 cubic centimeters (cm 3 ) to about 0.1 cubic centimeters (cm) 3 ), about 0.08 cubic centimeters (cm 3 ) to about 0.1 cubic centimeters (cm) 3 ) or about 0.08 cubic centimeters (cm 3 ) to about 0.11 cubic centimeters (cm) 3 ). In some aspects, the resin composition does not have a significant change in abrasion loss when measured according to the Abrasion Loss Test using a neat material sampling procedure, compared to the abrasion loss of a second resin composition that is identical to the resin composition except for the absence of the polymeric resin modifier. A change in abrasion 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 Abrasion Loss Test using a neat material sampling procedure.

[0305] The polyolefin resin composition may include a variety 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 includes a plurality of repeating units, each of which is individually derived from an olefin monomer having about 1 to about 6 carbon atoms. In other aspects, the copolymer includes a plurality of repeating units, each of which is individually derived from a monomer selected from a group consisting of ethylene, propylene, 4-methyl-1-pentene, 1-butene, 1-octene, and a combination thereof. In some aspects, the polyolefin copolymer includes more than one repeating unit, each of which is individually selected from formula 1A-formula 1D. In some aspects, the polyolefin copolymer includes a first more than one repeating unit having a structure according to formula 1A, and a second more than one repeating unit having a structure selected from formula 1B-formula 1D.

[0306]

[0307] In some aspects, the polyolefin copolymer comprises a plurality of repeating units, each repeating unit individually having a structure according to Formula 2

[0308]

[0309] Where R 1 is hydrogen or a substituted or unsubstituted straight or branched C1-C 12 Alkyl, C1-C6 alkyl, C1-C3 alkyl, C1-C 12 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.

[0310] In some aspects, the polyolefin copolymer is a random copolymer of more than one repeating unit and more than one repeating unit, and each repeating unit in the first more than one repeating unit is derived from ethylene, and each repeating unit in the second more than one repeating unit is derived from a second olefin. In some aspects, the second olefin is an olefin monomer with about 1 to about 6 carbon atoms. In other aspects, the second olefin includes propylene, 4-methyl-1-pentene, 1-butene or other linear or branched terminal olefins with about 3 to 12 carbon atoms. In some aspects, the polyolefin copolymer comprises about 80% to about 99%, about 85% to about 99%, about 90% to about 99% or about 95% to about 99% of the polyolefin repeating units by weight based on the gross weight of the polyolefin copolymer. In some aspects, the polyolefin copolymer is substantially composed of polyolefin repeating units. In some aspects, the polymer in the resin composition is substantially composed of polyolefin copolymers.

[0311] The polyolefin copolymer may include ethylene, i.e., may include repeating 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 ethylene based on the total weight of the polyolefin copolymer.

[0312] 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 chain of the polyolefin copolymer is substantially free of carbamate repeating units. In some aspects, the resin composition is substantially free of polymer chains comprising carbamate repeating units. In some aspects, the polyolefin copolymer is substantially free of polyamide. In some aspects, the polymer chain of the polyolefin copolymer is substantially free of amide repeating units. In some aspects, the resin composition is substantially free of polymer chains comprising amide repeating units.

[0313] In some respects, the polyolefin copolymer comprises polypropylene or a polypropylene copolymer. In some respects, the polymer component of resin combination (i.e., the part of the resin combination formed by all polymers present in the composition) is substantially composed of a polypropylene copolymer. In some respects, a resin combination comprising a polypropylene copolymer and an effective amount of a polymer resin modifier is provided, wherein the resin combination has an abrasion loss as described above, and wherein the effective amount of the polymer resin modifier is the amount that effectively allows the resin combination to be tested by using a substrate sampling procedure according to the flexure test of a cold sole material flexure test. In some respects, the effective amount of the polymer resin modifier is such an amount: the amount effectively allows the resin combination to be tested by using a substrate sampling procedure according to the flexure test of a cold sole material flexure test, when using a pure material sampling procedure according to the abrasion loss test measurement, compared with the abrasion loss of the second resin combination identical with the resin combination except that there is no polymer resin modifier, the abrasion loss does not significantly change.

[0314] The polypropylene copolymer may include a random copolymer, such as a random copolymer of ethylene and propylene. The polypropylene copolymer may include about 80% to about 99%, about 85% to about 99%, about 90% to about 99%, or about 95% to about 99% propylene repeating units by weight based on the total weight of the polypropylene copolymer. In some aspects, the polypropylene copolymer includes about 1% to about 5%, about 1% to about 3%, about 2% to about 3%, or about 2% to about 5% ethylene by weight 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% of the first more than one repeating unit by weight based on the total weight of the polypropylene copolymer and about 80% to about 99% of the second more than one repeating unit by weight; 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.

[0315] The combination of wear resistance and flex durability can be related to the total crystallinity of the resin composition. In some aspects, when measured according to the crystallinity test using a pure material sampling procedure, the resin composition has a crystallinity percentage (crystallization %) of about 45%, about 40%, about 35%, about 30%, about 25% or less. It has been found that adding a certain amount of polymer resin modifier to the resin composition can produce a resin composition that can pass the cold sole material flexure test while maintaining a relatively low wear loss, and the amount of the polymer resin modifier only slightly reduces the crystallinity percentage of the resin composition compared to the resin composition that is otherwise identical except for the absence of the polymer resin modifier. In some aspects, the polymer resin modifier causes a reduction in the crystallinity percentage (crystallization %) of the resin composition. In some aspects, when measured according to the crystallinity test using a pure material sampling procedure, the resin composition has a crystallinity percentage (crystallization %) that is lower than at least 6, at least 5, at least 4, at least 3 or at least 2 percentage points than the crystallinity percentage (crystallization %) of the resin composition that is otherwise identical except for the absence of the polymer resin modifier.

[0316] In some aspects, the effective amount of the polymer 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, the effective amount of the polymer resin modifier is about 20%, about 15%, about 10%, about 5% or less by weight based on the total weight of the resin composition.

[0317] The polymer resin modifier may include a variety of exemplary resin modifiers described herein. In some aspects, the polymer resin modifier is a metallocene-catalyzed copolymer that mainly includes isotactic propylene repeating units and about 11% by weight-15% by weight of ethylene repeating units based on the total weight of the metallocene-catalyzed copolymer randomly distributed along the copolymer. In some aspects, the polymer resin modifier includes about 10% to about 15% by weight of ethylene repeating units based on the total weight of the polymer resin modifier. In some aspects, the polymer resin modifier includes about 10% to about 15% by weight of repeating units according to Formula 1A above based on the total weight of the polymer resin modifier. In some aspects, the polymer 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.

[0318] In some aspects, the polymer resin modifier is a copolymer comprising isotactic propylene repeating units and ethylene repeating units. In some aspects, 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 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 1B above, and wherein the repeating units in the second more than one repeating units are arranged in an isotactic stereochemical configuration.

[0319] The term "outward facing" as used in "outward facing layer" refers to the position where the element is expected to be when the element is present in the article during normal use. If the article is footwear, the element is positioned toward the ground during normal use by the wearer when in a standing position, and therefore when the footwear is used in a conventional manner, such as when standing, walking or running on an unpaved surface, the element can contact the ground including the unpaved surface. In other words, even if the element may not need to face the ground during multiple steps of manufacturing or transportation, if the element is expected to face the ground during normal use by the wearer, the element is understood to be facing outward or more specifically facing the ground for footwear articles. In some cases, due to the presence of elements such as traction friction elements, the surface facing outward (e.g., facing the ground) can be positioned toward the ground during regular use, but it is not necessary to contact the ground. For example, on a hard ground or paved surface, the end of the traction friction element on the outsole can directly contact the ground, while the part of the outsole positioned between the traction friction elements does not contact the ground. As described in this example, portions of the outsole positioned between traction elements are considered to be outwardly facing (eg, facing the ground), even though they may not directly contact the ground in all circumstances.

[0320] Synthetic leather material

[0321] 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 a 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 polymer coating.

[0322] It is believed that the disclosed synthetic leather material has several advantages, particularly for the advantages used in the manufacture of articles such as footwear articles or clothing articles. 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 polyolefin resin compositions in the disclosed synthetic leather materials can promote better combination between other parts or materials used in articles such as footwear articles or clothing articles or sports equipment articles. For example, in the aspect that the disclosed synthetic leather material comprising polyolefin resin compositions is used to manufacture uppers, such uppers can show enhanced combination with polyolefin parts such as sole structures. Therefore, using the same or similar polymer material for parts and synthetic leather materials increases the ability to recycle 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 leather provides a material with lower density compared to more traditional footwear materials such as TPU. Thus, using a high percentage of these polyolefins in an article of footwear can produce a lighter article of footwear than an article of footwear made using the same amount of a denser polymer such as TPU.

[0323] Fig. 6A is a cross-sectional view of the disclosed synthetic leather material 600, which includes a synthetic leather textile layer 610 having a synthetic leather polymer coating 620 attached thereto, wherein it should be 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. Figure 6B 6 is a cross-sectional view of the disclosed synthetic leather material 600, which includes a synthetic leather textile layer 610 to which a synthetic leather polymer coating 620 is attached, and further includes a synthetic leather protective layer or decorative layer 630 attached to the synthetic leather polymer coating 620. It should be understood that the synthetic leather textile layer can be any suitable textile, including but not limited to knitted textiles, woven textiles, non-woven textiles, crocheted textiles, and plaited textiles. Knitted textiles suitable for the disclosed synthetic leather material include but are not limited to flat knitted textiles, circular knitted textiles, or weft knitted textiles.

[0324] The disclosed synthetic leather material may include more than one synthetic leather polymer coating, wherein more than one as used herein is two or more coatings. Fig. 7Ais a cross-sectional view of a disclosed synthetic leather material 700 including a synthetic leather textile layer 710 having a first synthetic leather polymer coating 720 attached thereto, 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 comprises fibers or yarns comprising a synthetic leather fiber / yarn polymer composition. Fig. 7A As illustrated in , the synthetic leather textile layer 710 and the first synthetic leather polymer coating 720 can be different layers. Alternatively, the combination of the synthetic leather textile and the first synthetic leather polymer coating can form a single composite layer.

[0325] 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 by all 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 a polyolefin resin composition as described herein.

[0326] Optionally, 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 as described herein and comprises one or more polymers such as, for example, polyesters, polyethers, polyamides, and polyurethanes as provided herein.

[0327] 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 at different concentrations.

[0328] Figure 7B7 is a cross-sectional view of the disclosed synthetic leather material 700, which includes 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 also includes a synthetic leather protective layer or decorative layer 740 attached to the second synthetic leather polymer coating 730. It should be understood that the synthetic leather textile layer can be any suitable textile, including but not limited to a textile selected from a knitted textile, a woven textile, a non-woven textile, a crocheted textile, or a plaited textile. Knitted textiles suitable for the disclosed synthetic leather material include but are not limited to knitted textiles selected from a flat knitted textile, a circular knitted textile, or a weft knitted textile.

[0329] The thickness of the synthetic leather polymer coating can be modified as desired. In the case where two or more synthetic leather polymer coatings are used, the thickness of each layer can vary or can be modified. 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.

[0330] In one aspect, the synthetic leather polymer coating can be a film attached to a synthetic leather textile layer. For example, the polyolefin resin composition described herein can be extruded into a film, which is then attached to a synthetic leather textile layer. In other aspects, two or more different films can be extruded and attached sequentially to a synthetic leather textile layer. For example, in Fig. 7A and Figure 7B The first synthetic leather polymer coating composition and the second synthetic leather polymer coating composition depicted in can each be a film that has been attached to a synthetic leather textile layer.

[0331] The disclosed synthetic leather material may comprise the disclosed polyolefin resin composition in one or more of a synthetic leather textile layer, a synthetic leather polymer coating and / or a synthetic leather protective layer or decorative layer. As disclosed herein above, the disclosed polyolefin resin composition may comprise a polyolefin resin having a modified polymer resin (and optionally having a clarifier) ​​to form one or more layers of the synthetic leather material.

[0332] For example, the disclosed polyolefin resin composition can be used to form one or more films, which are combined with non-woven textiles to form the outer surface of synthetic leather materials. In other cases, the disclosed polyolefin resin can be used to form fibers or filaments, which can be used to form yarns, which can be used to form the non-woven textile portion of synthetic leather materials. In other cases, the disclosed polyolefin resin can be used to form an epidermis layer and a non-woven textile layer.

[0333] In some examples, the synthetic leather polymer coating can be porous (e.g., foamed). Alternatively, or in combination with the porous synthetic leather polymer coating, the porous polymer layer can be positioned between the synthetic leather polymer coating and the synthetic leather textile layer. Optionally, in various aspects, a transparent or colored protective coating or decorative coating can be applied to or attached to the outer surface of the polymer layer.

[0334] Although polyester (PET) yarns or fibers can be used to make synthetic leather textile layers, for example, can be used in the fibers or yarns used to make the textile layer, other types of synthetic fibers, natural fibers, or regenerated fibers can also be used. In addition, the synthetic leather textile layer can use one or more fibers or yarns comprising a thermoplastic polymer composition as disclosed herein. The use of microfibers in the synthetic leather textile layer can improve the feel (softness and flexibility) of the synthetic leather material.

[0335] 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 footwear articles, and polyvinyl chloride-based synthetic leather materials are typically used in sports equipment. In other cases, the synthetic leather polymer coating may include a synthetic leather polymer coating composition comprising the disclosed polyolefin resin composition.

[0336] As described above, synthetic leather material comprises the synthetic leather textile layer comprising textile (for example, first textile).Textile can be non-woven textile, knitted textile or woven textile." textile " can be defined as any material made of fiber, silk or yarn characterized by flexibility, fineness and high ratio of length to thickness.Textile usually falls into two categories.The first category comprises textile directly produced by the web (web) of silk or fiber by randomly interlocking, to construct non-woven fabric and felt.The second category comprises textile formed by the mechanical operation of yarn, thus produces woven fabric, knitted fabric, braided fabric, crocheted fabric and the like.

[0337] As used herein, the terms "filament", "fiber" or "fibers" refer to materials in the form of discrete elongated pieces that are significantly longer than they are wide. Fibers may include natural fibers, artificial fibers, or synthetic fibers. Fibers may be produced by conventional techniques such as extrusion, electrospinning, interfacial polymerization, drawing, and the like. Fibers may include carbon fibers, boron fibers, silicon carbide fibers, titanium dioxide fibers, aluminum oxide fibers, quartz fibers, glass fibers such as E, A, C, ECR, R, S, D, and NE glass and quartz or the like. The fibers may be fibers formed from synthetic polymers capable of forming fibers, such as poly(etherketones), polyimides, polybenzoxazoles, poly(phenylene sulfides), polyesters, polyolefins (e.g., polyethylene, polypropylene), aramids (e.g., aramid polymers such as para-aramid fibers and meta-aramid fibers), aramids, polybenzimidazoles, polyetherimides, polytetrafluoroethylene, acrylics, modacrylics, 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, vicuna, cotton, flax, hemp, jute, sisal). The fibers may be artificial fibers from regenerated natural polymers, such as rayon, lyocell, acetate, triacetate, rubber, and poly(lactic acid).

[0338] The fibers may have an indefinite length. For example, man-made fibers and synthetic fibers are typically extruded in a substantially continuous line. Alternatively, the fibers may be staple fibers, such as, for example, cotton fibers or extruded synthetic polymer fibers that may be cut to form staple fibers of relatively uniform length. The staple fibers may have a length of about 1 mm to 100 cm or more and any increments therein (e.g., 1 mm increments).

[0339] Fiber can have any one of multiple cross-sectional shapes. Natural fiber can have natural cross section, or can have modified cross-sectional shape (for example, by the process such as mercerization). Artificial fiber or synthetic fiber can be extruded to provide the line with predetermined cross-sectional shape. The cross-sectional shape of fiber can affect its property, such as its softness, gloss and wicking ability. Fiber can have circular cross section or substantially circular cross section. Alternatively, fiber can have non-circular cross section, such as flat, oval, octagonal, rectangular, wedge-shaped, triangle, dog bone, multi-lobed, multi-channel, hollow, core-shell or other shapes.

[0340] 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 (hardening) the fibers, and / or curling or texturing the fibers.

[0341] The fibers may be multicomponent fibers, such as fibers comprising two or more coextruded polymeric materials. The two or more coextruded polymeric materials may be extruded in a core-sheath configuration, islands-in-the-sea configuration, segmented-pie configuration, strip configuration, or side-by-side configuration. The multicomponent fibers may be processed so that more than one smaller fiber (e.g., microfibers) is formed from a single fiber, for example by removing a sacrificial material.

[0342] As used herein, the term "yarn" refers to an assembly of one or more fibers, wherein the thread has a considerable length and a relatively small cross-section and is suitable for use in the production of textiles by hand or by machine, including textiles produced using weaving, knitting, crocheting, plaiting, sewing, embroidery or rope-making techniques. Suture thread is a type of yarn commonly used for sewing.

[0343] Yarn can be made of fibers formed by natural materials, artificial materials and synthetic materials. Synthetic fibers are most commonly used for spinning made of staple fibers and silk yarn. Spinning is made by arranging and twisting staple fibers together to make a cohesive strand. The process of forming yarn by staple fibers generally includes combing and drawing fibers to form slivers, pulling out and twisting slivers to form rovings, and spinning rovings to form lines. Multiple lines can be twisted (twisted together) to make thicker yarns. The twisting direction of staple fibers and plies can affect the final properties of yarns. Silk yarn can be formed by a single long, substantially continuous silk (it is conventionally referred to as "monofilament yarn"), or by more than one separate silk grouped together. Silk yarn can also be formed by two or more long, substantially continuous silks, which are grouped together by twisting them or entangled them or twisted and entangled them. Like staple yarn, multiple lines can be plied together to form thicker yarns.

[0344] Once formed, the yarn can be subjected to further processing, such as texturing, heat treatment or mechanical treatment, or coated with materials such as synthetic polymers. The fiber, yarn or textile used in the disclosed article or any combination thereof can be sized. The sizing fiber, yarn and / or textile are coated with a sizing composition on at least a portion of their surface, and the sizing composition is selected to change absorption characteristics or abrasion characteristics, or for compatibility with other materials. The sizing composition helps the coating or resin to be soaked and soaked on the surface, and helps to obtain desired physical properties in the final article. Exemplary sizing compositions can include, for example, epoxy polymers, carbamate-modified epoxy polymers, polyester polymers, phenol polymers, polyamide polymers, polyurethane polymers, polycarbonate polymers, polyetherimide polymers, polyamideimide polymers, polystyrene-based pyridine polymers, polyimide polymer bismaleimide polymers, polysulfone polymers, polyethersulfone polymers, epoxy-modified carbamate polymers, polyvinyl alcohol polymers, polyvinyl pyrrolidone polymers and mixtures thereof.

[0345] For example, two or more yarns can be combined to form a composite yarn, such as a single covered yarn or a double covered yarn and a core covered yarn. Thus, the yarn can have a variety of configurations that are generally consistent with the description provided herein.

[0346] The yarn may include at least one thermoplastic material (eg, one or more fibers may be made of a thermoplastic material). The yarn may be made of a thermoplastic material. The yarn may be coated with a layer of a material, such as a thermoplastic material.

[0347] The linear mass density or weight per unit length of a yarn can 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 a single filament of a fiber can also be expressed using denier per filament (DPF). Tex is the mass in grams of 1000 meters of yarn. Decitex is another measure of linear mass and is the mass in grams of 10,000 meters of yarn.

[0348] As used herein, tenacity is understood to refer to the amount of force (expressed in weight units, e.g., pounds, grams, centinewtons, or other units) required to break a yarn (i.e., the breaking force or breaking point of the yarn) divided by the linear mass density of the yarn, expressed, for example, in (unstrained) denier, decitex, or some other weight measure per unit length. The breaking force of a yarn is determined by subjecting a sample of the yarn to a known amount of force, e.g., using a strain gauge load cell, such as an INSTRON brand test system (Norwood, MA, USA). Yarn tenacity and yarn breaking force are distinct from the burst strength or bursting strength of a textile, which is a measure of how much pressure can be applied to a surface of a textile before the surface breaks.

[0349] Generally, in order to make the yarn withstand the force applied in the industrial knitting machine, the minimum toughness required is about 1.5 grams / denier.Most of the yarns formed by commodity polymer materials generally have a toughness in the range of about 1.5 grams / denier to about 4 grams / denier.For example, the polyester yarn commonly used for the knitting upper of footwear has a toughness in the range of about 2.5 grams / denier to about 4 grams / denier.The yarn formed by the commodity polymer material considered to have high toughness generally has a toughness in the range of about 5 grams / denier to about 10 grams / denier.For example, the commercially available package dyed polyethylene terephthalate yarn from National Spinning (Washington, NC, USA) has a toughness of about 6 grams / denier, and the commercially available solution dyed polyethylene terephthalate yarn from Far Eastern New Century (China, Taiwan, Taipei) has a toughness of about 7 grams / denier. Yarns formed from high performance polymer materials typically have a tenacity of about 11 g / denier or greater. For example, yarns formed from aramid fibers typically have a tenacity of about 20 g / denier, and yarns formed from ultra-high molecular weight polyethylene (UHMWPE) having a tenacity greater than 30 g / denier are available from Dyneema (Stanley, NC, USA) and Spectra (Honeywell-Spectra, Colonial Heights, VA, USA).

[0350] There are multiple technologies for mechanically operating yarn to form textiles. Such technologies include, for example, interweaving, entanglement and twisting, and interlocking. Interweaving is the crossing of two yarns, which cross and interweave each other at a vertical angle. The yarns used for interweaving are conventionally referred to as "warp" and "weft". Woven textiles include warp and weft. The warp extends in a first direction, and the weft (weft strand) extends in a second direction substantially perpendicular to the first direction. Entanglement and twisting cover a variety of procedures, such as plaiting and knotting, in which yarns are entangled with each other to form textiles. Interlocking relates to the formation of more than one row of intermeshing loops, wherein knitting is the most common method of interlocking. Textiles can be mainly formed by one or more yarns, which are mechanically operated, for example, by an interweaving process, an entanglement process and a twisting process and / or an interlocking process, as mentioned above.

[0351] Textiles can be non-woven textiles. Usually, non-woven textiles or fabrics are sheets or net structures made of fibers and / or yarns that are combined together. The bond can be a chemical bond and / or a mechanical bond, and can be formed using heat, solvents, adhesives or their combination. Exemplary non-woven fabrics are flat or tufted porous sheets directly made of separated fibers, molten plastics and / or plastic films. They are not made by weaving or knitting, and do not necessarily need to be converted into yarn by fibers, although yarn can be used as the source of fiber. Non-woven textiles are usually manufactured by: small fibers are put together in the form of sheets or nets (similar to paper on a paper machine), and then mechanically bonded (as in the case of felt, by utilizing serrated needles or barbed needles to interlock them, or by hydraulic entanglement (hydro-entanglement), so that friction between fibers produces a firmer fabric). Nonwoven textiles can be made from staple fibers (e.g., from wet-laid, air-laid, carded / crosslapped processes) or extruded fibers (e.g., from meltblown or spunbond processes or combinations thereof) or combinations thereof. The bonding of fibers in nonwoven textiles can be accomplished using thermal bonding (with or without calendering), hydroentanglement, ultrasonic bonding, needle punching (needling), chemical bonding (e.g., using adhesives such as latex emulsions or solution polymers or adhesive fibers or powders), meltblown bonding (e.g., fibers are bonded during simultaneous fiber formation and web formation with air attenuated fiber entanglement), spunbond, nonwoven, carded nonwoven, and meltblown nonwoven.

[0352] In some respects, the synthetic leather textile layer can include fibers or silk, and this fiber or silk include fiber / yarn polymer composition or basically consist of fiber / yarn polymer composition.Fiber / yarn polymer composition can be thermoplastic.Fiber / yarn polymer composition can include polyolefin, or polyamide, or polyurethane, or polyester, or polyether polymer, or any combination thereof.The polymer component of fiber / yarn polymer composition can basically consist of one or more polyesters.The polymer component of fiber / yarn polymer composition can basically consist of one or more polyolefins.One or more polyolefins can include one or more polypropylenes or basically consist of one or more polypropylenes.

[0353] The synthetic leather material can have a thickness of about 0.8 mm to about 2.5 mm, or about 0.9 mm to about 2.2 mm, or about 1 mm to about 2 mm, or about 1.2 mm to about 1.4 mm, or about 1.3 mm to about 1.5 mm, or about 1.4 mm to about 1.6 mm. The synthetic leather material can 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 can have a 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.

[0354] A variety of methods can be used to manufacture the disclosed synthetic leather material. Generally, these methods 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 can be applied to the synthetic leather textile layer as a liquid, followed by curing or drying. The specific method of providing a liquid polymer coating can be any suitable method for applying a liquid polymer composition to a textile layer, including but not limited to spreading to or spraying onto the textile layer. In some cases, depending on the properties and manufacturing process of the liquid, the liquid polymer coating can impregnate the textile layer. In another aspect, the polymer coating can first be formed into a film, and then 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, the film is attached to the textile layer. In some aspects, attaching the synthetic leather textile layer to the synthetic leather polymer coating includes 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 into a solid synthetic leather polymer coating composition when in contact with the synthetic leather textile layer, thereby forming a synthetic leather polymer coating, and mechanically bonding the synthetic leather polymer coating to the synthetic leather textile layer.

[0355] 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 can be applied to the synthetic leather textile in sequence. In some aspects, one or more layers of the polymer coating composition or layer can be applied to the synthetic leather textile layer in the form of a film, and the form of the film includes a monolayer film or a multilayer film. For example, the monolayer film can be an extruded film, or the multilayer film can be a coextruded multilayer film or a laminated multilayer film. In other aspects, one or more layers of the polymer coating can be applied to the synthetic leather textile layer in the form of a liquid. The specific method for providing a liquid polymer coating can be any suitable method for applying a liquid polymer composition to a substrate, including but not limited to spreading or spraying onto a polymer coating that has previously been applied to the textile layer.

[0356] It should be understood that the method of preparing the disclosed synthetic leather material may also 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 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.

[0357] In various aspects, the disclosed synthetic leather materials use a composition comprising the disclosed polyolefin resin, such as a polyolefin copolymer, and a polymer resin modifier as a coating for the synthetic leather material, or as a transparent or colored protective coating or decorative coating applied to the outer surface of a polymer layer, or both, wherein the polyolefin resin optionally has a transparent agent.

[0358] In various aspects, the disclosed synthetic leather materials use fibers comprising the disclosed polyolefin resins, such as polyolefin copolymers, and polymer resin modifiers in a textile layer, the polyolefin resins optionally having a clarifier, the synthetic leather materials optionally having a polyolefin-based coating or a protective coating / decorative coating or both.

[0359] The polyolefin-based coating or protective / decorative layer may be formed by extruding the disclosed polyolefin resin composition into one or more films, which may be attached to the textile layer.

[0360] In one aspect, a dispersion of the polyolefin resin composition, such as an aqueous dispersion, may be sprayed onto the textile layer, thereby impregnating the textile layer and forming the synthetic leather material.

[0361] 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 / decorative layer on the "top" or "front" side of the synthetic leather material) is that it provides an outer layer of the synthetic leather material that is more easily bonded to other polyolefin-based polymers. For example, the bonding score of a synthetic leather material having a polyolefin-based solid resin component (e.g., a polypropylene-based sheet) is improved compared to a PU-based synthetic leather material or a PVC-based synthetic leather material.

[0362] In various additional 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 a synthetic leather textile layer of a synthetic leather (the "bottom" or "back" side of the synthetic leather material) is that it produces an outer layer of a synthetic leather material that is more easily bonded to other polyolefin-based polymers. For example, the bond fraction with respect to a polyolefin-based solid resin component (e.g., a polypropylene-based sheet) is improved compared to a PU-based synthetic leather material or a PVC-based synthetic leather material.

[0363] Additionally or alternatively, when a synthetic leather material having a synthetic leather polymer coating and / or a synthetic leather protective layer / decorative layer comprises the disclosed polyolefin resin composition, the fibers 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 may be more easily bonded to other polyester or nylon-based materials.

[0364] In some aspects, the synthetic leather textile layer comprises lower melting point thermoplastic fibers or yarns (e.g., having a melting temperature or softening temperature of less than about 150 degrees Celsius, or having a melting temperature or softening temperature that is at least 20 degrees Celsius lower than the softening temperature of the polymer coating and, if present, the protective / decorative layer). In such cases, it is believed that an advantage of using lower melting point 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 heat bonded to another component without affecting the appearance of the "front" of the synthetic leather material.

[0365] It has been previously observed that for conventional materials containing polyolefin resins, the coloring of polyolefins can be more difficult than other polymers. For example, unlike many synthetic fibers, natural fibers, and regenerated fibers, package dyeing polyolefin fibers can be difficult. However, such problems can be avoided in the present disclosure by using package dyed fibers that are substantially free of polyolefins in combination with a clear or nearly clear polyolefin-based coating in the textile layer.

[0366] Polymer Materials

[0367] In many aspects, compositions and materials comprising one or more polymer materials such as thermoplastic polymer materials are disclosed herein, such as textiles, polymer coatings, and protective or decorative layers. The polymer used to prepare the disclosed compositions and materials may include polymers (e.g., homopolymers and copolymers, including terpolymers) having the same or different types of monomers. In some aspects, the polymer may include different monomers randomly distributed in the polymer (e.g., random copolymer). The term "polymer" refers to a molecule having one or more monomeric substances that may be the same or different. When the monomeric substances 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 substances, and includes terpolymers (i.e., copolymers having three monomeric substances). In aspects, "monomer" may include different functional groups or segments, but for simplicity, it is generally referred to as a monomer.

[0368] For example, a polymer can be a polymer that has relatively hard, repeating polymer units (hard segments) of the same chemical structure (segment) and relatively soft repeating polymer segments (soft segments). In many aspects, a polymer has repeated hard segments and soft segments. Physical crosslinking can be present in a segment or between segments or both in a segment and between segments. Specific examples of hard segments include isocyanate segments. Specific examples of soft segments include alkoxy groups, such as polyether segments and polyester segments. As used herein, polymer segments can be referred to as polymer segments of a specific type, such as, for example, isocyanate segments (e.g., diisocyanate segments), alkoxy polyamide segments (e.g., polyether segments, polyester segments) and similar segments. It should be understood that the chemical structure of the segments is derived from the described chemical structure. For example, an isocyanate segment is a unit of polymerization including an isocyanate functional group. When referring to polymer segments of a specific chemical structure, a polymer can include segments of other chemical structures up to 10 mole percent. For example, as used herein, a polyether segment is understood to include up to 10 mole percent of a non-polyether segment.

[0369] 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 may include an isocyanate segment (e.g., a diisocyanate segment) or be composed of an isocyanate segment (e.g., a diisocyanate segment). In the same or alternative aspects, the soft segment may include an alkoxy segment (e.g., a polyether segment, or a polyester segment or a combination of a polyether segment and a polyester segment) or be composed of an alkoxy segment. In specific aspects, the thermoplastic material may include or be substantially composed of an elastic thermoplastic polyurethane having a repeating hard segment and a repeating soft segment.

[0370] Polyamide

[0371] In many aspects, the polymer may include a polyamide, which includes a thermoplastic polyamide. The polyamide may be a polyamide homopolymer having a repeating polyamide segment of the same chemical structure. Alternatively, the polyamide may include a number of polyamide segments (e.g., polyamide 6 segments, polyamide 11 segments, polyamide 12 segments, polyamide 66 segments, etc.) having different polyamide chemical structures. The polyamide segments having different chemical structures may be randomly arranged, or may be arranged as repeating blocks.

[0372] The polyamide can be a copolyamide (i.e., a copolymer comprising a polyamide segment and a non-polyamide segment). The polyamide segment of the copolyamide can include or consist of the following: a polyamide 6 segment, a polyamide 11 segment, a polyamide 12 segment, a polyamide 66 segment, or any combination thereof. The polyamide segment of the copolyamide can be arranged randomly, or can be arranged as a repeating segment. In a specific example, the polyamide segment can include or consist of the following: a polyamide 6 segment, or a polyamide 12 segment, or both a polyamide 6 segment and a polyamide 12 segment. In an example in which the polyamide segment of the copolyamide includes a polyamide 6 segment and a polyamide 12 segment, the segment can be arranged randomly. The non-polyamide segment of the copolyamide can include or consist of the following: a polyether segment, a polyester segment, or both a polyether segment and a polyester segment. The copolyamide can be a copolyamide, or can be a random copolyamide. Thermoplastic copolyamides may be formed by polycondensation of a polyamide oligomer or prepolymer with a second oligomer prepolymer to form a copolyamide (ie, a copolymer comprising polyamide segments). Optionally, the second prepolymer may be a hydrophilic prepolymer.

[0373] In aspect, polyamide can be block copolyamide.For example, block copolyamide can have repeated hard segments and repeated soft segments.The hard segments can include polyamide segments, and the soft segments can include non-polyamide segments.Polymer can be elastomeric copolyamide, which includes or is composed of block copolyamide with repeated hard segments and repeated soft segments.In block copolymers including block copolymers with repeated hard segments and soft segments, physical crosslinking can be present in segments or between segments, or both in segments and between segments.In one aspect, polyamide can be poly (ether block amide) polymer.

[0374] Exemplary commercially available polyamide copolymers include, but are not limited to, copolymers available under the following trade names or other similar materials produced by various other suppliers: "VESTAMID" (Evonik Industries); "PLATAMID" (Arkema), for example, product code H2694; "PEBAX" (Arkema), for example, product codes "PEBAXMH1657" and "PEBAX MV1074"; "PEBAX RNEW" (Arkema); "GRILAMID" (EMS-Chemie AG).

[0375] Polyester

[0376] In aspect, polymer can include polyester, and this polyester includes thermoplastic polyester.Polyester can be formed by the reaction of one or more carboxylic acid or its ester-forming derivative with one or more divalent or polyvalent aliphatic alcohol, alicyclic alcohol, aromatic alcohol or aromatic aliphatic alcohol (araliphatic alcohol) or bisphenol.Polyester can be the polyester homopolymer of the repeating polyester segment with the same chemical structure.Selectively, polyester can include many polyester segments (such as polyglycolic acid segment, polylactic acid segment, polycaprolactone segment, polyhydroxyalkanoate segment (polyhydroxyalkanoate segment), polyhydroxybutyrate segment etc.) with different polyester chemical structures.Polyester segments with different chemical structures can be arranged randomly, or can be arranged as repeating blocks.

[0377] 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), liquid crystal polyester, or a blend or mixture of two or more of the foregoing.

[0378] The polyester may be a copolyester (i.e., a copolymer comprising a polyester segment and a non-polyester segment). The copolyester may be an aliphatic copolyester (i.e., a copolyester in which both the polyester segment and the non-polyester segment are aliphatic). Alternatively, the copolyester may comprise an aromatic segment. The polyester segments of the copolyester may include 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 randomly arranged or may be arranged as repeating blocks.

[0379] For example, the polyester can be a block copolyester having repeating blocks (hard segments) of polymer units of the same chemical structure (segments) that are relatively hard and repeating blocks (soft segments) of polymer segments that are relatively soft. In block copolyesters (including block copolyesters having repeating hard segments and soft segments), physical crosslinks can exist within a block or between blocks, or both within a block and between blocks. In one aspect, the material can include or consist essentially of an elastomeric thermoplastic copolyester having repeating block hard segments and repeating block soft segments.

[0380] The non-polyester segment of the copolyester may include or consist of the following: a polyether segment, a polyamide segment, or both a polyether segment and a polyamide segment. The copolyester may be a block copolyester, or may be a random copolyester. The thermoplastic copolyester may be formed by the 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 by the polycondensation of terephthalic acid or naphthalene dicarboxylic acid with ethylene glycol, 1,4-butanediol or 1,3-propylene glycol. Examples of copolyesters include polyethylene adipate, polybutylene succinate, poly(3-hydroxybutyrate-co-3-hydroxyvalerate), polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, and combinations thereof. In a specific example, the copolyamide may include or consist of polyethylene terephthalate.

[0381] 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 crystal 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 imide diacid / polybutylene terephthalate copolymer, or a blend or mixture of any of the foregoing copolymers.

[0382] Polyolefins

[0383] In some aspects, polymer can include polyolefin or be substantially composed of polyolefin, and the polyolefin includes thermoplastic polyolefin.Exemplary polyolefin includes but is not limited to polyethylene, polypropylene and thermoplastic olefin elastomer (for example, ethylene and the metallocene-catalyzed block copolymer of alpha-olefin with 4 to about 8 carbon atoms).In other aspects, polyolefin is to include following polymer: polyethylene, ethylene-alpha-olefin copolymer, ethylene-propylene rubber (EPDM), polybutene, polyisobutylene, poly-4-methylpent-1-ene, polyisoprene, polybutadiene, ethylene-methacrylic acid copolymer, and olefin elastomer, such as the dynamic cross-linked polymer (dynamically cross-linked polymer) obtained from polypropylene (PP) and ethylene-propylene rubber (EPDM), and aforesaid blend or mixture.Other exemplary polyolefin includes the polymer of cycloolefin such as cyclopentene or norbornene.

[0384] It should be understood that the polyethylene that may be optionally cross-linked includes 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 may also be a polyethylene copolymer derived from monomers of monoolefins and diolefins, which are copolymerized with vinyl, acrylic acid, methacrylic acid, ethyl acrylate, vinyl alcohol and / or vinyl acetate. The polyolefin copolymer comprising vinyl acetate derived units may be a high vinyl acetate content copolymer, such as a composition derived from vinyl acetate of greater than about 50 wt%.

[0385] In some aspects, polyolefin can be formed via free radical polymerization, cationic polymerization and / or anionic polymerization by methods well known to those skilled in the art (for example, using peroxide initiators, heat and / or light). In other aspects, disclosed thermoplastic polyolefin can be prepared by free radical polymerization under high pressure and at high temperature. Alternatively, polyolefin can be prepared by catalytic polymerization using a catalyst, and the catalyst generally comprises one or more metals from the metal of IVb family, Vb family, VIb family or VIII family. Catalyst generally has one or more than one ligand complexed with IVb family, Vb family, VIb family or VIII family metal, generally oxide, halide, alcoholate, ester, ether, amine, alkyl, alkenyl and / or aryl that can be coordinated to the para position or coordinated to the ortho position. In many aspects, metal complex can be in free form or fixed on substrate, generally fixed on activated magnesium chloride, titanium chloride (III), aluminum oxide or silicon oxide. It should be understood that metal catalyst can be soluble or insoluble in polymerization medium. The catalyst can be used alone for the polymerization, or an additional activator can be used, typically a metal alkyl of Group Ia, Group IIa and / or Group IIIa, a metal hydride, a metal alkyl halide, a metal alkyl oxide or a metal alkyloxane. The activator can conveniently be modified with additional ester groups, ether groups, amine groups or silyl ether groups.

[0386] Suitable polyolefins can be prepared by polymerization of monomers of monoolefins and diolefins 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-propylene, 3-methyl-1-pentene, 4-methyl-1-pentene, 5-methyl-1-hexene, and mixtures thereof.

[0387] Suitable ethylene-α-olefin copolymers may be obtained by copolymerization of ethylene with an α-olefin having a carbon number of 3 to 12 such as propylene, 1-butene, 1-hexene, 1-octene, 4-methyl-1-pentene or the like.

[0388] A suitable dynamically crosslinked polymer can be obtained by crosslinking a rubber component as a soft segment while physically dispersing a hard segment such as PP and a soft segment such as EPDM by using a kneading machine such as a Banbury mixer and a twin-screw extruder.

[0389] 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 can 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).

[0390] In some aspects, the polyolefin can be a copolymer of a suitable monoolefin monomer or a copolymer of 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 mixtures 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 mixtures thereof with carbon monoxide. or ethylene / acrylic acid copolymers, and their salts (ionomers), and terpolymers of ethylene with propylene and a diene such as hexadiene, dicyclopentadiene or ethylidene-norbornene; and mixtures of such copolymers with each other and with the polymers mentioned above under 1), 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 and mixtures thereof with other polymers, for example polyamides.

[0391] 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.

[0392] In some respects, polyolefin is polypropylene. As used herein, the term "polypropylene" is intended to encompass any polymer composition comprising propylene monomers, which are either alone or with other randomly selected and oriented polyolefins, dienes or other monomers (such as ethylene, butene and the like) or copolymers. Such terms also encompass any different configurations and arrangements of the component monomers (such as atactic, syndiotactic, isotactic, etc.). Therefore, the term as applied to fibers is intended to encompass actual long lines, bands, sutures and the like of drawn polymers. Polypropylene can have any standard melt flow (by testing); however, standard fiber-grade polypropylene resins have a melt flow index range between about 1 and 1000.

[0393] In some respects, polyolefin is polyethylene. As used herein, the term "polyethylene" is intended to encompass any polymer composition comprising ethylene monomers, which are either alone or with other randomly selected and oriented polyolefins, dienes or other monomers (such as, propylene, butene and the like) mixture or copolymer. Such terms also encompass any different configurations and arrangements (such as, atactic, syndiotactic, isotactic, etc.) of the constituent monomers. Therefore, the term as applied to fiber is intended to encompass actual long lines, bands, sutures and the like of drawn polymers. Polyethylene can have any standard melt flow (by testing); however, standard fiber-grade polyethylene resins have a melt flow index range between about 1 and 1000.

[0394] Method for preparing resin composition

[0395] In many aspects, the present disclosure describes a variety of polymer compositions, the polymer composition includes polyolefin resin composition, synthetic leather polymer coating composition and fiber / yarn polymer composition.Polymer composition can be prepared by dry blending or by melt blending of multiple components.The method of blended polymers can include film blending in a press, blending in a mixer (e.g., from Thermo Fisher Scientific, Waltham, MA with a commercially available mixer under the trade name "HAAKE"), solution blending, hot melt blending and extruder blending.In some aspects, polymer resin modifier and polyolefin copolymer are miscible, so that they can be easily mixed by the screw in the injection barrel during injection molding, such as without the need for a separate blending step.

[0396] The method can also include extruding a polymer composition to form an extruded polymer composition. The method for extruding a polymer composition can include manufacturing a long product (rod, sheet, tube, film, wire insulation coating) of a relatively constant cross section. The method for extruding a polymer composition can include conveying a softened polymer composition through a die with an opening. The polymer composition can be conveyed forward by a feed screw and forced through the die. The 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 coming out of the die can be cooled by the air blown in or cooled in a water bath to form an extruded polymer composition. Alternatively, the polymer composition coming out of the die can be granulated in the absence of almost cooling, as described below.

[0397] The method can also include injection molding polymer composition to form articles.Injection molding can include using a non-rotating cold plunger to force the polymer composition to pass through the heated cylinder, wherein the polymer composition is heated by the heat conducted to the polymer composition from the wall of the cylinder.Injection molding can include using a rotating screw arranged coaxially with the heated barrel, for conveying the polymer composition toward the first end of the screw and heating the polymer composition by conducting heat from the heated barrel to the polymer composition.Along with the polymer composition being conveyed toward the first end by the screw mechanism, the screw translates toward the second end, so as to produce a reservoir space (reservoir space) at the first end.When enough molten polymer compositions are collected in the reservoir space, the screw mechanism can be pushed to the first end, so that the polymer composition is injected into a selected mold.

[0398] Methods of making parts and articles

[0399] The present disclosure provides several methods for preparing the parts 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 include a textile or a multilayer film. For example, the second element may include an upper. The second element may include one or both of a polyolefin fiber and a polyolefin yarn. The second element may include an injection molded element. The method may also include injection molding a polymer composition as described herein, including a polyolefin resin composition, to form an injection molded second element. The present disclosure provides a method for manufacturing a part for an article of footwear, a garment, or sports equipment.

[0400] In some aspects, the polyolefin resin composition defines the side or outer layer of the second element, and the method includes attaching two sides or outer layers together, each side or outer layer is defined by the polyolefin resin composition. The second element may include yarn, textiles, films or some other elements. Attaching the component to the second element may include injecting a polymer composition such as a polyolefin resin composition directly onto the second element. 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 include a textile combined at the interface between the component and the second element. Attaching the component to the second element may include: (i) raising the temperature of the polymer composition to a first temperature higher than the melting temperature or softening temperature (e.g., Vicat softening temperature) of the polymer composition; (ii) when the polymer composition is at the first temperature, contacting the polymer composition with the second element; and (iii) keeping the polymer composition and the second element in contact with each other, while reducing the temperature of the polymer composition to a second temperature lower than the melting temperature or softening temperature of the polymer composition, forming a thermal bond between the polymer composition and the second element.

[0401] The second element may include a second polymer composition that is thermoplastic (e.g., a second thermoplastic composition), and attaching the component to the second element may include: (i) raising the temperature of the second thermoplastic composition to a first temperature that is higher than a melting temperature or a softening temperature of the second thermoplastic composition; (ii) contacting the polymer composition and the second element with each other when the second thermoplastic composition is at the first temperature; and (iii) maintaining the polymer composition and the second element in contact with each other while lowering the temperature of the second thermoplastic composition to a second temperature that is lower than a melting temperature or a softening temperature of the second thermoplastic composition, forming a thermal bond between the polymer composition and the second element.

[0402] The polymer composition may be a first thermoplastic composition, and the second component may include a second thermoplastic composition, and attaching the component to the second component may include: (i) raising the temperature of both the first thermoplastic composition and the second thermoplastic composition to a first temperature that is higher than both the melting temperature or softening temperature of the first thermoplastic composition and the melting temperature or softening temperature of the second thermoplastic composition, (ii) contacting the first thermoplastic composition and the second thermoplastic composition with each other when both the first thermoplastic composition and the second thermoplastic composition are at the first temperature, and (iii) maintaining the first thermoplastic composition and the second thermoplastic composition in contact with each other while lowering the temperature of both the first thermoplastic composition and the second thermoplastic composition to a second temperature that is lower than both the melting temperature or softening temperature of the first thermoplastic composition and the melting temperature or softening temperature of the second thermoplastic composition, forming a thermal bond between the first thermoplastic composition and the second thermoplastic composition, wherein polymer chains of the first thermoplastic composition and the second thermoplastic composition are intermixed with each other.

[0403] In some aspects, the article is an article of footwear and the method includes injection molding the plate directly onto an upper.

[0404] Cold sole material flexure test solution

[0405] The cold sole material flexure test is determined according to the following test method. The purpose of this test is to evaluate the crack resistance of the sample when it is repeatedly flexed to 60 degrees in a cold environment. The thermoformed substrate of the material used for the test is sized to fit inside the flexure test machine. Each material is tested as five independent samples. The flexure test machine is capable of flexing the sample to 60 degrees at a rate of 100 plus or minus 5 cycles per minute. The mandrel diameter of the machine is 10 mm. The machines suitable for this test are Emerson AR-6, Satra STM141F, Gotech GT-7006 and Shin II Scientific SI-LTCO (DaeSungScientific). According to the specific parameters of the flexure machine used, the sample is inserted into the machine. The machine is placed in a freezer set to -6 degrees Celsius for testing. Turn on the motor to start flexure, and count the flexure cycles until the sample cracks. The cracking of the sample means that the surface of the material is physically separated. Visible creases that do not actually penetrate the line of the surface are not cracks. The samples were measured to the point where they had cracked but not yet split in two.

[0406] Abrasion loss test protocol ASTM D 5963-97a

[0407] Abrasion loss was tested on cylindrical test pieces cut from sheets using an ASTM standard drill having a diameter of 16 mm plus or minus 0.2 mm and a minimum thickness of 6 mm. Abrasion loss was measured using Method B of ASTM D5963-97a on a Gotech GT-7012-D abrasion tester. The test was conducted at 22 degrees Celsius with a wear path of 40 meters. The No. 1 standard rubber used in the test had a mass of 1.336 grams per cubic centimeter (g / cm 3 ) density. The smaller the wear loss, the better the wear resistance.

[0408] Crystallinity Test Solution

[0409] In order to determine the percentage crystallinity of the homopolymer (such as polypropylene homopolymer polypropylene) of the copolymer and copolymer main component of the resin composition comprising copolymer or the copolymer in pure resin form, the sample is analyzed by differential scanning calorimetry (DSC) in a temperature range from -80 degrees Celsius to 250 degrees Celsius. A heating rate of 10 degrees Celsius per minute is used. The melting endotherm (melting endotherm) of each sample is measured during heating. General analysis software (TA Instruments, New Castle, DE, USA) is used to calculate the percentage crystallinity (crystallinity %) (for example, for 100% crystalline polypropylene material, 207 joules / gram) based on the melting endotherm of homopolymer. Specifically, the percentage crystallinity (crystallinity %) is calculated by dividing the melting endotherm measured for copolymer or for resin composition by 100% crystalline homopolymer melting endotherm.

[0410] Method for determining Vicat softening temperature test scheme

[0411] The Vicat softening temperature is determined according to the test method described in detail in the ASTM D1525-09 standard test method for Vicat softening temperature of plastics, preferably using load A and rate A. In short, the Vicat softening temperature is the temperature at which a flat-ended needle penetrates the sample to a depth of 1 mm 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 is penetrated to a depth of 1 mm by a flat-ended needle with a 1 square millimeter circular cross section or a square cross section. For the Vicat A test, a load of 10 Newtons (N) is used, while for the Vicat B test, the load is 50 Newtons. The test involves placing the test sample in a test apparatus so that the penetrated needle rests on its surface at least 1 mm from the edge. The load is applied to the sample as required by the Vicat A test or the Vicat B test. The sample is then lowered into an oil bath at 23 degrees Celsius. The bath is heated at a rate of 50 degrees Celsius or 120 degrees Celsius per hour until the needle penetrates 1 mm. The test specimen must be between 3 mm and 6.5 mm thick and at least 10 mm in width and length. No more than three layers may be stacked to achieve the minimum thickness.

[0412] Melting Temperature and Glass Transition Temperature Test Solution

[0413] According to ASTM D3418-97, a commercially available differential scanning calorimeter ("DSC") is used to measure the melting temperature and glass transition temperature. In short, 10-15 grams of sample are placed in an aluminum DSC pan, and then sealed with a tablet press lead. The DSC is configured to scan from -100 degrees Celsius to 225 degrees Celsius at a heating rate of 20 degrees Celsius / minute, keep 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 the scan is then analyzed using standard techniques to determine glass transition temperature and melting temperature.

[0414] Melt Flow Index Test Solution

[0415] Melt flow index is measured according to the test method of the procedure A described therein for the melt flow of thermoplastics by extrusion plastometer described in detail in ASTM D1238-13 standard test method. In short, melt flow index measures the rate at which thermoplastics are extruded through a hole at a specified temperature and load. In the test method, about 7 grams of material are loaded into the barrel of a melt flow device, which has been heated to a temperature specified for the material. The weight specified for the material is applied to the plunger, and the molten material is forced through the die. Timing extrudates are collected and weighed. The melt flow value is calculated in grams per 10 minutes. Alternatively, melt flow index can be measured using the melt mass flow rate (MFR) and melt volume flow rate (MVR) of international standard ISO1133 thermoplastics, using the procedure A described therein to determine at 190 degrees Celsius and a load of 2.16 kilograms.

[0416] Durometer Hardness Test Solution

[0417] The hardness of a material is determined using the Shore A scale according to the test method detailed in ASTM D-2240 Durometer Hardness.

[0418] Flexural modulus test solution

[0419] The flexural modulus (modulus of elasticity) of a material is determined according to the test method detailed in ASTM D 790. The modulus is calculated by taking the slope of stress (megapascals) versus strain on the steepest initial straight-line portion of the load-deflection curve.

[0420] Modulus test solution (of substrate)

[0421] According to the test method described in detail in the ASTM D412-98 standard test method for vulcanized rubber, thermoplastic rubber and thermoplastic elastomer-tension, determine the (tensile) modulus for the thermoforming substrate of material, and have carried out the following modification.The sample size is ASTM D412-98 Die C, and the sample thickness used is 2.0 millimeters plus or minus 0.5 millimeter.The type of fixture used is the pneumatic fixture with metal serrated grip face (metal serrated grip face).The fixture distance used is 75 millimeters.The loading rate used is 500 millimeters per minute.Modulus (initial) is calculated by obtaining the slope of the stress in megapascals (MPa) relative to strain in the initial linear region.

[0422] Modulus test scheme (of yarn)

[0423] The modulus of the yarn was determined according to the test method described in detail in EN ISO 2062 (Textiles from packaging - Yarns) with the following modifications - single-end breaking force and elongation at break were determined using a constant rate of extension (CRE) tester. The sample length used was 600 mm. The equipment used was Instron and Gotech fixtures. The clamp distance used was 250 mm. The preload was set to 5 grams and the loading rate used was 250 mm per minute. The first meter of yarn was thrown away to avoid using damaged yarn. The modulus (initial) was calculated by taking the slope of the stress in megapascals (MPa) relative to the strain in the initial linear region.

[0424] Tenacity and Elongation Test Protocol

[0425] The tenacity and elongation of the yarn can be determined according to the test method detailed in EN ISO 2062, measuring the single-end breaking force and elongation at break using a constant rate of extension tester with the preload set to 5 grams.

[0426] Mullen Burst Test Protocol

[0427] The Mullen Burst of a web of material, such as a textile or synthetic leather material, can be determined according to the test method detailed in ASTM D3786, Standard Test Method for Bursting Strength of Textile Fabrics.

[0428] Sampling Procedure

[0429] Using the testing protocols described above, various properties of the materials disclosed herein, and parts and articles formed therefrom, can be characterized using samples prepared using the following sampling procedures:

[0430] Pure Material Sampling Procedure

[0431] The material sampling procedure can be used to obtain a pure sample of a polymer or polymer composition. The material is provided in a medium form such as flakes, particles, powders, pellets and the like. If the source of the polymer or polymer composition is not available in a pure form, the sample can be cut from a film or plate or other component containing the polymer composition to isolate a sample of the material.

[0432] Substrate Sampling Procedure

[0433] Prepare a sample of a polymer or polymer composition. Then a portion of the polymer or polymer composition is molded into a film or substrate, which is sized to fit inside the test device. For example, when using a sole material flexure tester, the film or substrate is sized to fit inside the sole material flexure 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 a size of about 15 centimeters (cm) × 2.5 centimeters (cm) and a thickness of about 1 millimeter (mm) to 4 millimeters (mm). The substrate sample is 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.

[0434] Parts Sampling Procedure

[0435] The program can be used to obtain a sample of a polymer or polymer composition from an article or a part of an article such as an article of footwear, an article of clothing or an article of sports equipment. Use a blade to cut a sample comprising a polymer or polymer composition (for example, at 25 degrees Celsius and 20 percent relative humidity) in a non-wet state from an article or a part. If a polymer or polymer composition is bonded to one or more other materials, the program can include separating other materials from a polymer or polymer composition to be tested. For example, in order to test a polymer or polymer composition on the bottom surface of a sole structure such as an outer sole, the top surface can be peeled, polished, scraped or otherwise cleaned to remove any adhesive, yarn, fiber, foam and the like attached to a polymer or polymer material to be tested. The sample obtained comprises a polymer or polymer composition, and can comprise any other material bonded to it.

[0436] definition

[0437] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the art to which the present disclosure belongs. It will also be understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning consistent with their meaning in the context of the specification and the relevant art, and should not be interpreted in an idealized or overly formal sense, unless explicitly defined herein.

[0438] All publications, patents and patent applications cited in this specification are cited to disclose and describe methods and / or materials related to the cited publications. All such publications, patents and patent applications are incorporated herein by reference, as if each individual publication or patent is specifically and individually indicated as being incorporated by reference. Such incorporation by reference is explicitly 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 regarded as such dictionary definitions, and should not be interpreted as defining any terms that appear in the attached claims.

[0439] Although any method and material similar or equivalent to the method and material described herein can also be used for the practice or test of the present disclosure, preferred methods and materials are now described. For the sake of brevity and / or clarity, functions or structures well known in the art may not be described in detail. Unless otherwise indicated, the various aspects of the present disclosure will adopt technologies such as nanotechnology, organic chemistry, material science and engineering in the technology of the art. Such technology is fully explained in the literature.

[0440] It should be noted that ratios, concentrations, amounts, and other numerical data may be expressed in range format herein. Where the stated range includes one or two of the extreme values, the range excluding any one or two of those included extreme values ​​is also included in the present disclosure, e.g., the phrase "x to y" includes a range from 'x' to 'y' and a range greater than 'x' and less than 'y'. The range may also be expressed as an upper limit, e.g., 'about x, y, z or less' and should be interpreted as including a specific range of 'about x', 'about y', and 'about z' and a range of 'less than x', 'less than y', and 'less than z'. Similarly, the phrase 'about x, y, z or greater' should be interpreted as including a specific range of 'about x', 'about y', and 'about z' and a range of 'greater than x', 'greater than y', and 'greater than z'. In addition, the phrase "about 'x' to 'y'", where 'x' and 'y' are numerical values, includes "about 'x' to about 'y'". It should be understood that such range format is used for convenience and brevity, and therefore, should be interpreted in a flexible manner to include not only the values ​​explicitly recited as the range extremes, but also all individual values ​​or sub-ranges encompassed within the range, as if each value and sub-range were explicitly recited. For illustration, a numerical range of "about 0.1% to 5%" should be interpreted as including not only the values ​​of about 0.1% to about 5% explicitly recited, but also 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.

[0441] The term "providing" as used herein and recited in the claims is not intended to require any specific delivery or receipt of the provided item. Rather, for the purpose of clarity and ease of reading, the term "providing" is used only to recite items that will be mentioned in subsequent elements of the claims.

[0442] Terms and phrases used herein in connection with sampling procedures and test protocols such as "pure material sampling procedure," "substrate sampling procedure," "cold sole material flexure test," "ASTM D 5963-97a," "crystallinity test," and the like refer to the corresponding sampling procedures and test methods described in the Property Analysis and Characterization Procedures section. These sampling procedures and test methods characterize the properties of the described materials, films, articles, parts, etc., and need not be performed as active steps in the claims.

[0443] As used herein, the term "about" may include traditional rounding according to significant figures of the 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.

[0444] As used herein, the articles "a" and "an" when applied to any feature in the aspects of the disclosure described in the specification and claims mean one or more. The use of "a" and "an" does not limit the meaning to a single feature unless such limitation is specifically stated. The article "the" preceding a singular or plural noun or noun phrase denotes one particular specific feature or more specific specific features and can have a singular or plural connotation depending on the context in which it is used.

[0445] A random copolymer of propylene and about 2.2% by weight (wt%) ethylene is commercially available from ExxonMobil Chemical Company, Houston, TX under the trade name "PP9054". It has an MFR of about 12 g / 10 min (ASTM-1238D, 2.16 kg, 230°C) and an MFR of 0.90 g / cm3 (g / cm 3 ) density.

[0446] PP9074 is a random copolymer of propylene and about 2.8 weight percent (wt%) ethylene and is commercially available from ExxonMobil Chemical Company, Houston, TX under the trade name "PP9074". It has an MFR of about 24 g / 10 min (ASTM-1238D, 2.16 kg, 230°C) and an OD of 0.90 g / cm3 (g / cm 3 ) density.

[0447] PP1024E4 is a propylene homopolymer commercially available from ExxonMobil Chemical Company, Houston, TX under the trade name "PP1024E4". It has an MFR of about 13 g / 10 min (ASTM-1238D, 2.16 kg, 230°C) and an MFR of 0.90 g / cm3 (g / cm 3 ) density.

[0448] "VISTAMAXX 6202" is a copolymer comprising primarily isotactic propylene repeating units with about 15 weight percent (wt%) ethylene repeating units randomly distributed along the copolymer. It is a metallocene-catalyzed copolymer available from ExxonMobil Chemical Company, Houston, TX, and has an MFR of about 20 g / 10 min (ASTM-1238D, 2.16 kg, 230°C), 0.862 g / cm3 (g / cm 3 ) and a durometer hardness (Shore A) of about 64.

[0449] Vistamaxx 3000 is a copolymer comprising primarily isotactic propylene repeating units with about 11 wt% ethylene repeating units randomly distributed along the copolymer. It is a metallocene-catalyzed copolymer available from ExxonMobil Chemical Company and has an MFR of about 8 g / 10 min (ASTM-1238D, 2.16 kg, 230° C.), 0.873 g / cm3 (g / cm 3 ) density and a durometer hardness (Shore D) of about 27.

[0450] "VISTAMAXX 6502" is a copolymer comprising primarily isotactic propylene repeating units with about 13% by weight of ethylene repeating units randomly distributed along the copolymer. It is a metallocene-catalyzed copolymer available from ExxonMobil Chemical Company and has an MFR of about 45 g / 10 min (ASTM-1238D, 2.16 kg, 230°C), 0.865 g / cm3 (g / cm 3 ) and a durometer hardness (Shore A) of about 71. Example

[0451] Having now described aspects of the present disclosure, in general, the following examples describe some other aspects of the present disclosure. Although aspects of the present disclosure are described in conjunction with the following examples and corresponding text and drawings, it is not intended that aspects of the present disclosure be limited to this description. On the contrary, it is intended to cover all alternatives, modifications, and equivalents included within the spirit and scope of the present disclosure.

[0452] Material

[0453] For the examples described below, the following base resins were used.

[0454] Table 1: Base resins

[0455]

[0456] The following polymer resin modifiers were used in the examples.

[0457] Table 2: Polymer resin modifiers

[0458]

[0459] Polyolefin resin composition

[0460] Polyolefin resin compositions comprising a polyolefin polymer (i.e., base resin) and varying amounts of polymer resin modifiers were prepared and tested to determine abrasion loss according to the Abrasion Loss Test and using the Pure Material Sampling Procedure; and to perform a flexure test according to the Cold Sole Material Flexure Test using the Base Plate Sampling Procedure. The results are presented in Table 3. The percent crystallinity (%) of the sample resin compositions was measured according to the Crystallinity Test using the Pure Material Sampling Procedure. The results are reported in Table 4.

[0461] Table 3: Summary of Density, DIN Abrasion Loss and Cold Sole Material Deflection of Resin Compositions with Different Amounts of Polymer Resin Modifiers

[0462]

[0463] *Undetermined

[0464] Table 4. Crystallinity percentage of representative resin compositions

[0465]

[0466] It should be emphasized that the above-described aspects of the present disclosure are merely possible examples of embodiments, and are merely set forth for the purpose of clearly understanding the principles of the present disclosure. Many variations and modifications may be made to the above-described aspects of the present disclosure without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included within the scope of the present disclosure in this article.

Claims

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 said synthetic leather textile layer comprises fibers or yarns, wherein said fibers or said yarns comprise a fiber / yarn polymer composition; and 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 according to claim 1 , wherein the polyolefin resin composition comprises at least one polyolefin, wherein the at least one polyolefin comprises a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer, a polypropylene copolymer, or a combination thereof. 3 . The synthetic leather material according to claim 2 , wherein the polyolefin resin composition comprises the polypropylene copolymer.

4. The synthetic leather material of claim 3, 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.

5. The synthetic leather material of claim 3, wherein the polypropylene copolymer comprises a polypropylene / polyethylene copolymer.

6. The synthetic leather material of claim 5, wherein the polypropylene copolymer comprises about 1% to about 5% by weight of ethylene repeating units based on the total weight of the polypropylene copolymer. 7 . The synthetic leather material according to claim 1 , wherein the polyolefin resin composition further comprises a polymer resin modifier or a transparent agent or both. 8 . The synthetic leather material according to claim 7 , 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. 9 . The synthetic leather material according to claim 7 , wherein the polyolefin resin composition comprises from about 0.1 weight percent to about 5 weight percent of the transparent agent based on the total weight of the polyolefin resin composition. 10 . The synthetic leather material according to claim 1 , wherein the polyolefin resin composition is a thermoplastic polyolefin resin composition.

11. The synthetic leather material according to claim 1, wherein the synthetic leather polymer coating composition comprises a synthetic leather coating thermoplastic polyolefin resin composition. 12 . The synthetic leather material according to claim 11 , wherein the synthetic leather coating thermoplastic polyolefin resin composition comprises at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer, a polypropylene copolymer, or a combination thereof. 13 . The synthetic leather material according to claim 12 , wherein the synthetic leather coating thermoplastic polyolefin resin composition comprises the polypropylene copolymer.

14. The synthetic leather material according to claim 11, wherein the synthetic leather coating thermoplastic polyolefin resin composition further comprises a polymer resin modifier or a transparent agent or both.

15. An upper for an article of footwear, the upper comprising the synthetic leather material of claim 1.

16. An article of footwear comprising: The shoe upper comprises: 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 said synthetic leather textile layer comprises fibers or yarns, wherein said fibers or said yarns comprise a fiber / yarn polymer composition; and wherein the synthetic leather polymer coating composition comprises a first polyolefin resin composition, or the fiber / yarn polymer composition comprises the first polyolefin resin composition, or both the synthetic leather polymer coating composition and the fiber / yarn polymer composition comprise the first polyolefin resin composition; and A sole structure, comprising: a sheet comprising a second polyolefin resin composition, a polymer resin modifier, and a clarifier; Wherein the upper is attached to the sole structure.

17. The article of footwear according to claim 16, wherein the first polyolefin resin composition comprises at least one polyolefin, wherein the at least one polyolefin comprises a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer, a polypropylene copolymer, or a combination thereof.

18. The article of footwear according to claim 17, wherein the first polyolefin resin composition comprises the polypropylene copolymer.

19. The article of footwear according to claim 18, wherein the polypropylene copolymer comprises from about 80% to about 99% by weight of polypropylene repeating units based on the total weight of the polypropylene copolymer.

20. The article of footwear according to claim 18, wherein the polypropylene copolymer comprises a polypropylene / polyethylene copolymer.

21. The article of footwear according to claim 20, wherein the polypropylene copolymer comprises from about 1% to about 5% by weight of ethylene repeating units based on the total weight of the polypropylene copolymer.

22. The article of footwear according to claim 16, wherein the first polyolefin resin composition is a thermoplastic polyolefin resin composition.

23. The article of footwear according to claim 16, wherein the synthetic leather polymer coating composition comprises a synthetic leather coating thermoplastic polyolefin resin composition.

24. The article of footwear according to claim 23, wherein the synthetic leather coating thermoplastic polyolefin resin composition comprises at least one of a polyethylene homopolymer, a polyethylene copolymer, a polypropylene homopolymer, a polypropylene copolymer, or a combination thereof.

25. The article of footwear according to claim 24, wherein the synthetic leather coating thermoplastic polyolefin resin composition comprises the polypropylene copolymer.

26. The article of footwear according to claim 16, wherein the second polyolefin resin composition comprises a polypropylene copolymer.

27. The article of footwear according to claim 16, wherein the second 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 second polyolefin resin composition.

28. The article of footwear according to claim 16, wherein the second polyolefin resin composition comprises from about 0.1 weight percent to about 5 weight percent of the clarifier based on the total weight of the second polyolefin resin composition.

29. The article of footwear according to claim 16, the sole structure further comprising a textile disposed on the first side of the plate.

30. 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.

31. The method of claim 30, wherein the attaching comprises laminating the synthetic leather textile layer to a film comprising the synthetic leather polymer coating.

32. A method according to claim 30, wherein the attachment includes 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 into 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 polymer coating to the synthetic leather textile layer.

33. The method of claim 30, wherein a side of the synthetic leather polymer coating is defined by the synthetic leather polymer coating composition, and the synthetic leather polymer coating composition comprises the polyolefin resin composition.

34. A polyolefin resin composition for preparing a synthetic leather material, the polyolefin resin composition comprising a polyolefin copolymer, the polyolefin copolymer being a random copolymer of a first more than one repeating unit and a second more than one repeating unit, wherein each of the first more than one repeating units is derived from ethylene, and each of the second more than one repeating units is derived from a second olefin, 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 about 3 to 12 carbon atoms, and wherein the polyolefin resin composition is substantially free of polyurethane; or the polyolefin resin composition comprises a polyolefin copolymer, and the polymer chain of the polyolefin copolymer is substantially free of urethane repeating units; or the polyolefin resin composition is substantially free of polymers having polymer chains containing urethane repeating units; and wherein the polyolefin resin composition further comprises an effective amount of a polymeric resin modifier, the effective amount of the polymeric resin modifier being an amount effective to allow the polyolefin resin composition to be tested by flexure testing according to the Cold Sole Material Flexure Test using a plaque sampling procedure, and wherein the abrasion loss of the polyolefin resin composition when measured according to the Abrasion Loss Test using a neat material sampling procedure is within about 20% of the abrasion loss of an otherwise identical polyolefin resin composition except for the absence of the resin modifier.

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