Polyolefin-based synthetic leather and articles formed therefrom
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for lower-cost, recyclable polymer alternatives for footwear and sporting equipment that offer improved mechanical properties, resistance to stress whitening and cracking under cold conditions, and adequate bonding, as existing polymers like polyurethane and polyamide are costly and have poor surface properties for bonding.
Innovation Solution
The use of polyolefin resin compositions in sole structures and synthetic leather materials, which include a polyolefin resin composition affixed to a textile layer, providing improved mechanical properties and bonding capabilities while being resistant to stress whitening and abrasion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polyurethane and polyamide polymers are used in footwear components, then mechanical properties and durability are improved, but cost increases and bonding performance deteriorates due to poor surface properties
Solution Approach 1:
The patent modifies the surface properties of polyolefin resins by controlling crystallinity (30-80%) and adding specific additives to change surface energy and morphology, enabling adequate bonding without sacrificing the mechanical durability that made polyolefins attractive in the first place
Solution Approach 2:
The invention creates a composite material system using polyolefin resin combined with specific additives and modifiers that provide both the desired mechanical strength and improved surface bonding properties, effectively combining the benefits of different material approaches
2Ease of manufacture
If polyolefin resin compositions are used to improve bonding and reduce cost, then manufacturing cost decreases and bonding improves, but resistance to stress whitening and cracking under cold conditions may worsen
Solution Approach 1:
The patent carefully controls the crystallinity parameter (30-80%) of the polyolefin resin to balance cold-weather flexibility and stress resistance while maintaining the cost and bonding advantages of polyolefin materials
Solution Approach 2:
The invention applies different properties to different aspects of the material: the bulk material provides cost-effectiveness and bonding capability, while the controlled crystallinity and additive package provide localized resistance to stress whitening and cracking in critical areas
3Duration of action of stationary object
If existing polymers are used to meet performance demands, then durability is improved, but recyclability and cost-effectiveness deteriorate
Solution Approach 1:
The patent employs polyolefin resins that are inherently more recyclable and cost-effective than traditional polymers, creating a material that can be produced economically and disposed of or recycled easily while still providing adequate durability for footwear applications
Solution Approach 2:
By optimizing the polyolefin resin composition and crystallinity parameters, the invention achieves a durability level sufficient for footwear applications while maintaining the inherent recyclability and cost advantages of polyolefin materials
Data Source
AI summary
A variety of plates for footwear are provided including a polyolefin resin. Sole structures and articles of footwear formed therefrom are also provided. Methods of making the polyolefin resin compositions, plates, sole structures, and articles of footwear are also provided. In some aspects, the polyolefin resin composition includes an effective amount of a polymeric resin modifier. The effective amount can be an amount effective to allow the resin composition to pass a flex test, and in particular to pass a flex test without significant change in abrasion loss. In some aspects, the resin composition also includes a clarifying agent to improve optical clarity of the plate. In some aspects, the plates include a textile disposed on one or both of a first side and the second side of the plate. The textile can provide for improved bonding of the plate to other components such as a chassis or an upper.