Energy-attenuating polyurethanes

Claim 2

A non-liquid, energy-absorbing polyurethane resulting from the process which comprises reacting a mixture of linear and branched polyols, a polyisocyanate and, optionally, a blowing agent, under polyurethane-forming conditions at an isocyanate index of from about 65 to about 85.

Claim 3

The polyurethane of claim 1 wherein the polyol comprises a mixture of at least one relatively high molecular weight polyol possessing two or three hydroxyl groups and having an equivalent weight of from about 500 to about 1500 and at least one relatively low molecular weight polyol possessing at least three hydroxyl groups and having an equivalent weight of from about 60 to about 200, the equivalent weight of the polyol mixture being from about 200 to about 1200 and the ratio of relatively high molecular weight to the ratio of relatively low molecular weight polyol equivalents being from about 1:0.8 to about 1:3.5.

Claim 4

The polyurethane of claim 2 possessing a Shore "00" hardness of from about 15 to about 85 and the average equivalent weight of the polyol mixture is from about 200 to about 800.

Claim 5

The polyurethane of claim 2 wherein at least one polyol in the mixture is a polyether polyol derived from the reaction of at least one 1,2-alkylene oxide and at least one starter compound possessing at least one reactive hydrogen atom.

Claim 6

The polyurethane of claim 4 wherein the polyether polyol is derived from the reaction of at least one 1,2-alkylene oxide selected from the group consisting of ethylene oxide, propylene oxide, butylene oxide and at least one starter compound selected from the group consisting of water, ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,4-butylene glycol, 2,3-butylene glycol, 1,6-hexanediol, 1,8-octanediol, neopentylene glycol, 1,4-bis-hydroxymethyl cyclohexane, 2-methyl-1,3-propanediol, glycerol, trimethylol propane, 1,2,6-hexanetriol, penetaerythritol, mannitol, sorbitol, methyl glucoside, sucrose, resorcinol, hydroquinone, 1,1,3-tris-(hydroxyphenyl) propane, ammonia, ethylene diamine, tetramethylene diamine, hexamethylene diamine, diethylene triamine, ethanolamine, diethanolamine, triethanolamine, aniline, phenylene diamine, 2,4-diaminotoluene, 2,6-diaminotoluene, polyphenylpolymethylene-polyamine and phenolformaldehyde resin.

Claim 7

The polyurethane of claim 4 wherein the polyether polyols is a polymer/polyol.

Claim 8

The polyurethane of claim 2 wherein at least one polyol in the mixture is a polyester polyol derived from the reaction of at least one polyhydric alcohol with at least one polyvalent carboxylic acid and/or anhydride thereof.

Claim 9

The polyurethane of claim 7 wherein the polyhydric alcohol is at least one member of the group consisting of ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,4-butylene glycol, 2,3-butylene glycol, 1,6-hexanediol, 1,8-octanediol, neopentylene glycol, cyclohexane dimethanol, (1,4-bis-hydroxymethylcyclohexane), 2-methyl-1,3-propane diol, glycerol, trimethylol propane, 1,2,6-hexanetriol, trimethylol propane, 1,2,6-hexane triol, trimethylol ethane, pentaerythritol, quinitol, mannitol, sorbitol, methyl glucoside, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycol, dipropylene glycol, polypropylene glycol, dibutylene glycol and polybutylene glycol and the polyvalent carboxylic acid and/or anhydride thereof is at least one member of the group consisting of succinic acid, adipic acid, suberic acid, azelaic acid, sebacic acid, phthalic acid, isophthalic acid, trimellitic acid, phthalic acid anhydride, tetrahydrophthalic acid anhydride, hexahydrophthalic acid anhydride, tetrachlorophthalic acid anhydride, endomethylene tetrahydrophthalic acid anhydride, glutaric acid anhydride, maleic acid, maleic acid anhydride, fumaric acid, dimeric fatty acid, trimeric fatty acid, terephthalic acid dimethyl ester and terephthalic acid-bis-glycol ester.

Claim 10

The polyurethane of claim 2 wherein at least one polyol in the mixture is a polyester polyol derived from a lactone.

Claim 11

The polyurethane of claim 9 wherein the lactone is epsilon-caprolactone.

Claim 12

The polyurethane of claim 2 wherein at least one polyol in the mixture is a hydroxyl-terminated polybutadiene.

Claim 13

The polyurethane of claim 2 wherein at least one polyol in the mixture is selected from the group consisting of polythioether, polyacetal, polycarbonate, polyester amide, hydroxyl-terminated diene polymer, polyhydroxy compound possessing the urethane group, polyhydroxy compound possessing the urea group, modified naturally occurring polyol, carbohydrate, addition product of alkylene oxide with phenol-formaldehyde resin and addition product of alkylene oxide with urea-formaldehyde resin.

Claim 14

The polyurethane of claim 2 wherein at least one polyol in the mixture is a relatively low molecular weight trimethylol propane-propylene oxide adduct and at least one other polyol in the mixture is a relatively high molecular weight polypropylene glycol.

Claim 15

The polyurethane of claim 2 wherein at least one polyol in the mixture is a relatively low molecular weight trimethylol propane-propylene oxide adduct and at least one other polyol in the mixture is a relatively high molecular weight hydroxyl-terminated polybutadiene.

Claim 16

The polyurethane of claim 2 wherein the polyisocyanate is at least one member of the group consisting of ethylene diisocyanate, 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate, 1,12-dodecane diisocyanate, cyclobutane-1,3-diisocyanate, cyclohexane-1,3-diisocyanate, cyclohexane-1,4-diisocyanate, 1-isocyanato-3,3,5-tri- methyl-5-isocyanato methyl cyclohexane; 2,4-hexahydrotolyl- ene diisocyanate, 2,6-hexahydrotolylene diisocyanate, hexahydro-1,3-diisocyanate, 1,4-phenylene diisocyanate, perhydro-4,4'-diphenylmethane diisocyanate, 4,4'-diphenylmethane diisocyanate, 1,3-diisocyanate, 1,4-phenylene diisocyanate, 2,4- tolylene diisocyanate, 2,6-tolylene diisocyanate, diphenylmethane-2,4'-diisocyanate, 4,4'-diisocyanate, naphthylene-1,5-diisocyanate, triphenylmethane-4,4',4"-triisocyanate, polyphenylpolymethylene polyisocyanate, polyisocyanate possessing the carbodiimide group, polyisocyanate possessing the allophanate group, polyisocyanate possessing the isocyanurate group, polyisocyanate possessing the urethane group, polyisocyanate possessing the urea group and polyurethane possessing the biuret group.

Claim 17

The polyurethane of claim 2 wherein a chain extending agent is reacted with the mixture of polyols, polyisocyanate and optional blowing agent, said chain extending being at least one member of the group consisting of ethylene glycol, 1,3-propylene glycol, 1,3-butylene glycol, 1,4-butanediol, butenediol, butynediol, amylene glycol, neopentylene glycol, 1,4-phenylene-bis-(beta-hydroxyethyl) ether, 1,3-phenylene-bis-(beta- hydroxyethyl) ether, bis-(hydroxymethyl)-cyclohexane, 1,6 hexanediol, diethylene glycol, dipropylene glycol, N-phenyldiethanolamine, N-phenyldiisopropanolamine, ethanolamine, diethanolamine, 2-hydroxyethyl-N-amino benzene, ethylene diamine, propylene diamine, butylene diamine, hexamethylene diamine, cyclohexylene diamine, phenylene diamine, tolylene diamine, xylyene diamine, 3,3'-dichlorobenzidene, 3,3'-dinitrobenzidine, 4,4'-methylene-bis(2-chloraniline), 3,3-dichloro-4,4'-biphenylene diamine, 2,6-diamino pyridine, 4,4'-diamino diphenylmethane, hydrazine, N,N'-dimethyl hydrazine, 1,6-hexamethylene-bis-hydrazine, carbodihydrazide, adipic acid dihydrazide, oxalic acid dihydrazide, isophthalic acid dihydrazide, thiodipropionic acid dihydrazide, tartaric acid dihydrazide, 1,3-phenylenedisulfonic acid dihydrazide, omega-aminocaproic acid dihydrazide and bis-hydrazine carbonic ester of a glycol.

Claim 18

The polyurethane of claim 2 containing at least one additive selected from the group consisting of filler, pigment, surfactant, plasticizer and, where said polyurethane is a foam, a foam stabilizer.

Claim 19

The polyurethane of claim 1 possessing a Shore "00" hardness according to ASTM D2240 of from about 15 to about 85.

Claim 20

The polyurethane of claim 18 possessing a Shore "00" hardness according to ASTM D2240 of from about 30 to about 75.

Claim 21

The polyurethane of claim 1 possessing a resilience according to Zwick Rebound Pendulum DIN 53512 of from about 25% or less.

Claim 22

The polyurethane of claim 20 possessing a resilience according to Zwick Rebound Pendulum DIN 53512 of from about 20% or less.

Claim 23

The polyurethane of claim 1 possessing a ball rebound resilience according to ASTM D3574-H of from about 20% or less.

Claim 24

The polyurethane of claim 22 possessing a ball rebound resilience according to ASTM D3574-H of from about 15% or less.

Claim 25

The polyurethane of claim 1 possessing a tear resistance according to ASTM D3574-F of at least about 5 PLI.

Claim 26

The polyurethane of claim 24 possessing a tear resistance according to ASTM D3574 of at least about 7 PLI.

Claim 27

An article fabricated from the polyurethane of claim 1.

Claim 28

An article fabricated from the polyurethane of claim 2.

Claim 29

The article of claim 27 which is a shoe sole insert

Claim 30

The article of claim 27 which is a dynamic energy absorption device.

Claim 31

The article of claim 29 which is a vibration energy absorption device.

Claim 32

A process for preparing a non-liquid, energy-absorbing polyurethane which comprises reacting a mixture of linear and branched polyols, a polyisocyanate and, optionally, a blowing agent, under polyurethane-forming condition at an isocyanate index of from bout 65 to abut 85.

Claim 33

A process for preparing a non-liquid, energy-absorbing polyurethane which comprises reacting a mixture of linear and branched polyols, a polyisocyanate and, optionally, a blowing agent, under polyurethane-forming condition at an isocyanate index of from bout 65 to abut 85.

Claim 34

The process of claim 31 wherein the polyol comprises a mixture of at least one relatively high molecular weight polyol possessing two or three hydroxyl groups and having an equivalent weight of from about 500 to about 1500 and at least one relatively low molecular weight polyol possessing at least three hydroxyl groups and having an equivalent weight of from about 60 to about 200, the equivalent weight of the polyol mixture being from about 200 to about 1200 and the ratio of relatively high molecular weight to the ratio of relatively low molecular weight polyol equivalents being from about 1:0.8 to about 1:3.5.

Claim 35

The process of claim 32 wherein the resulting polyurethane possesses a Shore "00" hardness of from about 15 to about 85 and the average equivalent weight of the polyol mixture is from about 200 to about 800.

Claim 36

The process of claim 32 wherein at least one polyol in the mixture is a polyether polyol derived from the reaction of at least one 1,2-alkylene oxide and at least one starter compound possessing at least one reactive hydrogen atom.

Claim 37

The process of claim 34 wherein the polyether polyol is derived from the reaction of at least one 1,2-alkylene oxide selected from the group consisting of ethylene oxide, propylene oxide, butylene oxide and at least one starter compound selected from the group consisting of water, ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,4-butylene glycol, 2,3-butylene glycol, 1,6-hexanediol, 1,8-octanediol, neopentylene glycol, 1,4-bis-hydroxymethyl cyclohexane, 2-methyl-1,3-propanediol, glycerol, trimethylol propane, 1,2,6-hexanetriol, penetaerythritol, mannitol, sorbitol, methyl glucoside, sucrose, resorcinol, hydroquinone, 1,1,3-tris(hydroxyphenyl) propane, ammonia, ethylene diamine, tetramethylene diamine, hexamethylene diamine, diethylene triamine, ethanolamine, diethanolamine, triethanolamine, aniline, phenylene diamine, 2,4-diaminotoluene, 2,6-diaminotoluene, polyphenylpolymethylene-polyamine and phenolformaldehyde resin.

Claim 38

The process of claim 34 wherein the polyether polyols is a polymer/polyol.

Claim 39

The process of claim 32 wherein at least one polyol in the mixture is a polyester polyol derived from the reaction of at least one polyhydric alcohol with at least one polyvalent carboxylic acid and/or anhydride thereof.

Claim 40

The process of claim 37 wherein the polyhydric alcohol is at least one member of the group consisting of ethylene glycol, 1,2-propylene glycol, 1,3 -propylene glycol, 1,4-butylene glycol, 2,3-butylene glycol, 1,6-hexanediol, 1,8-octanediol, neopentylene glycol, cyclohexane dimethanol, (1,4-bis-hydroxymethylcyclohexane), 2-methyl-1,3-propane diol, glycerol, trimethylol propane, 1,2,6-hexanetriol, trimethylol propane, 1,2,6-hexane triol, trimethylol ethane, pentaerythritol, quinitol, mannitol, sorbitol, methyl glucoside, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycol, dipropylene glycol, polypropylene glycol, dibutylene glycol and polybutylene glycol and the polyvalent carboxylic acid and/or anhydride thereof is at least one member of the group consisting of succinic acid, adipic acid, suberic acid, azelaic acid, sebacic acid, phthalic acid, isophthalic acid, trimellitic acid, phthalic acid anhydride, tetrahydrophthalic acid anhydride, hexahydrophthalic acid anhydride, tetrachlorophthalic acid anhydride, endomethylene tetrahydrophthalic acid anhydride, glutaric acid anhydride, maleic acid, maleic acid anhydride, fumaric acid, dimeric fatty acid, trimeric fatty acid, terephthalic acid dimethyl ester and terephthalic acid-bis-glycol ester.

Claim 41

The process of claim 32 wherein at least one polyol in the mixture is a polyester polyol derived from a lactone.

Claim 42

The process of claim 39 wherein the lactone is epsilion-caprolactone.

Claim 43

The process of claim 32 wherein at least one polyol in the mixture is a hydroxyl-terminated polybutadiene.

Claim 44

The process of claim 32 wherein at least one polyol in the mixture is selected from the group consisting of polythioether, polyacetal, polycarbonate, polyester amide, hydroxyl-terminated diene polymer, polyhydroxy compound possessing the urethane group, polyhydroxy compound possessing the urea group, modified naturally occurring polyol, carbohydrate, addition, product of alkylene oxide with phenol-formaldehyde resin and addition product of alkylene oxide with urea-formaldehyde resin.

Claim 45

The process of claim 32 wherein at least one polyol in the mixture is a relatively low molecular weight trimethylol propane-propylene oxide adduct and at least one other polyol in the mixture is a relatively high molecular weight polypropylene glycol.

Claim 46

The process of claim 32 wherein at least one polyol in the mixture is a relatively low molecular weight trimethylol propane-propylene oxide adduct and at least one other polyol in the mixture is a relatively high molecular weight hydroxyl-terminated polybutadiene.

Claim 47

The process of claim 32 wherein the polyisocyanate is at least one member of the group consisting of ethylene diisocyanate, 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate, 1,12-dodecane diisocyanate, cyclobutane-1,3-diisocyanate, cyclohexane-1,3-diisocyanate, cyclohexane-1,4-diisocyanate, 1-isocyanato- 3,3,5-trimethyl-5-isocyanato methyl cyclohexane; 2,4-hexahydrotolylene diisocyanate, 2,6-hexahydrotolylene diisocyanate, hexahydro-1,3-diisocyanate, 1,4-phenylene diisocyanate, perhydro-4,4'-diphenylmethane diisocyanate, 4,4'-diphenylmethane diisocyanate, 1,3-diisocyanate, 1,4-phenylene diisocyanate, 2-4-tolyelene dissocyanate, 2,6-tolylene diisocyanate, diphenylmethane-2,4'-diisocyanate, 4,4'-diisocyanate, naphthylene-1, 5-diisocyanate, triphenylmethane-4,4',4"-triisocyanate, polyphenyl-polymethylene polyisocyanate, polyisocyanate possessing the carbodiimide group, polyisocyanate possessing the allophanate group, polyisocyanate possesing the isocyanurate group, polyisocyanate possesing the urethane group, polyisocyanate possessing the urea group and polyurethane possessing the biuret group.

Claim 48

The process of claim 32 wherein a chain extending agent is reacted with the mixture of polyols, polyisocyanate and optional blowing agent, said chain extending being at least one member of the group consisting of ethylene glycol, 1,3-propylene glycol, 1,3-butylene glycol, 1,4-butanediol, butenediol, butynediol, amylene glycol, neopentylene glycol, 1,4-phenylene-bis-(betahydroxyethyl) ether, 1,3-phenylene-bis-(betahydroxyethyl) ether, bis-(hydroxymethyl)-cyclohexane, 1,6 hexanediol, diethylene glycol, dipropylene glycol, N-phenyl-diethanolamine, N-phenyldiisopropanolamine, ethanolamine, diethanolamine, 2-hydroxyethyl-N-amino benzene, ethylene diamine, propylene diamine, butylene diamine, hexamethylene diamine, cyclohexylene diamine, phenylene diamine, tolylene diamine, xylyene diamine, 3,3'-dichlorobenzidene, 3,3'-dinitrobenzidine, 4,4'-methylene-bis(2-chloraniline), 3,3-dichloro-4,4'-biphenylene diamine, 2,6-diamino pyridine, 4,4'-diamino diphenylmethane, hydrazine, N,N'-dimethyl hydrazine, 1,6-hexamethylene-bis-hydrazine, carbodihydrazide, adipic acid dihydrazide, oxalic acid dihydrazide, isophthalic acid dihydrazide, thiodipropionic acid dihydrazide, tartaric acid dihydrazide, 1,3-phenylenedisulfonic acid dihydrazide, omega-aminocaproic acid dihydrazide and bis-hydrazine carbonic ester of a glycol.

Claim 49

The process of claim 32 containing at least one additive selected from the group consisting of filler, pigment, surfactant, plasticizer and, where said polyurethane is a foam, a foam stabilizer.

Claim 50

The process of claim 31 wherein the resulting polyurethane possesses a Shore "00" hardness according to ASTM D2240 of from about 15 to about 85.

Claim 51

The process of claim 48 wherein the resulting polyurethane possesses a Shore "00" hardness according to ASTM D2240 of from about 30 to about 75.

Claim 52

The process of claim 31 wherein the resulting polyurethane possesses a resilience according to Zwick Rebound Pendulum DIN 53512 of from about 25% or less.

Claim 53

The process of claim 50 wherein the resulting polyurethane possesses a resilience according to Zwick Rebound Pendulum DIN 53512 of from about 20% or less.

Claim 54

The process of claim 31 wherein the resulting polyurethane possesses a ball rebound resilience according to ASTM D3574-H of from about 20% or less.

Claim 55

The process of claim 52 wherein the resulting polyurethane possesses a ball rebound resilience according to ASTM D3574-H of from about 15% or less.

Claim 56

The process of claim 31 wherein the resulting polyurethane possess a tear resistance according to ASTM D3574-F of at least about 5 PLI.

Claim 57

The process of claim 54 wherein the resulting polyurethane possesses a tear resistance according to ASTM D3574 of at least about 7 PLI.