CN1665677A - Moisture transpiration composite and products therefrom - Google Patents

Abstract

A formed hydrophilic urethane polymer foam composite HF with particles 3 up to 0.1% by weight of superabsorbent polymer and selectively other additives to enable collected moisture to move from an area of high humidity to an area of lower humidity, having a urethane polymer foam layer formed into a sized and shaped matrix, having interconnected strands 4 and filaments 1 of the urethane polymer and sized and shaped interstitial gaps and spaces 2, said particles 3 of superabsorbent polymer dispersed in, on and through said interconnected strands and filaments in spaced relationship and the sized and shaped interstitial air gaps 2 to provide improved capillarity in the formed foam matrix enhance transpiration and also multi-layered embodiments including at least one of said formed foam composites 5 to transpire collected moisture and enable evaporation of the transpired moisture.

Description

Moisture transpiration composites and products produced therefrom

Cross-references to related applications

This application is a continuation-in-part of U.S. Application 10/146237, filed May 15, 2002, entitled "Footwear with Hydrophilic Foam Lining to Enhance Breathability" 60/293335, filed May 24, 2001, and for all rights to the corresponding invention shown, disclosed and claimed herein, the Partial continuation applications will rely on these pre-existing applications.

Background technique

The present invention relates generally to materials and methods for improving the movement of water vapor migration through textiles and other products, and more particularly to materials and methods derived from body coverings such as outerwear, clothing, shoes, helmets, hats, other The lateral movement or transpiration and removal of moisture, especially bodily fluids, in confined spaces formed by clothing, appliances and accessories, wherein the removal of the generated moisture such as sweat provides lower humidity, lower temperature and improves this A comfort zone inside a body covering.

Manufacturers of body coverings such as garments, shoes, etc. strive to improve the comfort of their products in order to encourage the use of these products. It is a known fact that the human body responds negatively to the high humidity associated with high temperatures. ASHRAE provides a comfort index graph that compares temperature and humidity in relation to human comfort. The U.S. NAVAL FLIGHT SURGEONS MANUAL presents numerous papers on the effect of excess heat on physiological body changes due to protective clothing, outerwear, shoes, and other fabrics. In most cases, problems arise by not allowing the human thermoregulatory system to function.

The body's normal method of temperature regulation is through sweating when it senses an increase in temperature. Normal evaporation then converts the sweat into water vapor, which in turn burns heat and cools the body. The minimization of evaporation renders this method useless, and outside of the thermal comfort index data mentioned above, most people feel uncomfortable. The operation of the human body's normal thermoregulation methods is best understood by comparing how it feels during a hot day due to elevated ambient temperature and high humidity to a day with the same temperature and low humidity.

Any body covering such as outerwear, clothing, shoes, helmets, or other garments or appliances can affect the production and evaporation of sweat while the body feels an increase in temperature. Sweating will be reduced in any confined environment within which the dew point is reached. As understood by those skilled in the art, the dew point is the point at which the air in a confined environment is saturated with water vapor and the moisture condenses out of the air in the form of water droplets in such a confined environment. Where covering the body and skin with a body covering restricts or minimizes perspiration and evaporation, the same is true within clothing, shoes or helmets, backpacks or appliances that create a confined space or microenvironment attached to the body Appear. Efforts to minimize discomfort within the microenvironment include improved airflow, membranes to pass water vapor, siphons to accumulate moisture, phase change materials, and other techniques.

The ability of textiles, fabrics or other materials used to allow water vapor escaping from the body (as opposed to condensed water droplets of moisture) to reach the ambient atmosphere is an assessment of the aforementioned body coverings such as outerwear, shoes, helmets, appliances, accessories, etc. An important factor in the comfort of products and so on. The more efficiently a textile, fabric or other material covering the body allows this water vapor to reach the surrounding air, the more breathable the textile, fabric or other material is considered to be. Thus, the term "breathability" in textiles is a measure of the migration of water vapor through a textile, fabric or other material, rather than its air permeability or windproof characteristics. Conventional textiles specially designed for the ^intended purpose of this invention and other The breathability of the material was deemed acceptable.

There is a great deal of prior art on this aspect of water vapor in the field of the invention, and teachings on absorbency, water vapor permeability, siphoning to remove condensed vapor, membranes, and improvements in Technology for comfort zones within clothing and footwear. For example, reference may be made to US Patent Nos. 5,128,082, 5,260,345 and 5,331,728.

However, one of the continuing problems associated with body coverings such as outerwear, clothing, shoes, helmets and other garments or appliances, accessories, backpacks, etc. is to provide means and methods to overcome moisture generated due to heat, i.e., in Condesend water and trapped air collected within the microenvironment created by the enumerated body coverings as described above. These problems all cause discomfort and act as breeding grounds for bacteria and various physical ailments.

Accordingly, many devices, methods and techniques have been attempted to improve the breathability of body coverings such as garments, clothing, shoes, helmets and other garments, appliances and accessories, that is, to establish sufficient circulation, transpiration or migration to enable Move trapped moisture, i.e. condensed water droplets of moisture, water vapor and entrapped air from the internal microenvironment formed by such body coverings, utensils and accessories to the ambient air outside the body covering and enable the surrounding air to Movement from the outside into the interior microenvironment formed by the body covering displaces moisture, water vapor and trapped air for cooling and improved comfort and increased durability of the body covering.

For example, U.S. Patent Nos. 5,763,335 and 6,025,287 disclose a hydrophilic polyurethane foam polymer with 0.6% superabsorbent polymer for forming a layered lining material (layered lining material), and a method of making the same for collecting and transpiration of water or moisture from the microenvironment. The composite materials and layered liner materials disclosed in these patents absorb moisture and convert it to a gel within the layered liner material, which is then removed or opened to expose the microenvironment Moisture trapped within the gel can be allowed or allowed to evaporate after exposure to ambient ambient atmosphere.

In the present invention, new formulations and methods for preparing hydrophilic polyurethane polymer foam composites having limited amounts of superabsorbent polymer particles, surfactants and optionally and selected Other additives which eliminate and prevent the gel formation or gel blocking and evaporation mechanisms of said prior art patents '335 and '287. The new formulation and method is achieved by modifying and optimizing the orientation of superabsorbent polymer particles on, in and in interconnected strands, filaments and polymerized hydrophilic polyurethanes in formed foams. The size and shape of the randomly distributed interstitial air gaps within the composite composite matrix to significantly enhance the absorption of moisture and/or water vapor transversely to the length or x-direction and width or y-direction of the shaped foam matrix rate and physical movement or transpiration to enable moisture and/or water vapor to move from areas of high humidity to areas of low humidity where moisture and moisture vapor can be eliminated by evaporation and satisfactorily introduced by Cooler atmospheric air displaces moisture and wet vapor.

According to the present invention, formed hydrophilic polyurethane polymer foam composites (formed hydrophilic polyurethane polymer foam composites) and products, in addition to having improved absorption and transpiration characteristics, when compared with prior art materials developed for the same purpose, formed The surface condition of the product and the layers of the material also remains relatively dry.

Conventional testing of the MVTR of the improved shaped hydrophilic polyurethane polymer foam composites and products according to the present invention is 5 times higher than the above acceptable MVTR of such prior art materials developed for the same purpose. Effectively, this means that the shaped foams and products of the present invention will remove 5 times the amount of moisture from confined spaces or microenvironments, such as within shoes, helmets, coats, gloves, or under shoulder pads, knee pads, or the harness of a backpack. Air is transported to areas of lower humidity for evaporation, thereby overcoming the discomfort caused by this condition and improving the comfort and use of these body coverings. Additionally, it has been found that the improved shaped foam composite material significantly reduces or eliminates bacterial buildup and unpleasant odors.

Contents of the invention

Thus, one aspect of the present invention encompasses shaped hydrophilic polyurethane polymer foam composites and products having particles of at least one superabsorbent polymer, a sufficient amount of surfactant, and optionally other additives to enable moisture Moving from an area of high humidity to an area of lower humidity such as the surrounding ambient atmosphere, the composite materials and products include at least one polyurethane polymer foam layer formed into a sized and shaped matrix that is There are interconnected single yarns and filaments and interstitial gaps or spaces within the formed polyurethane polymer, and particles in the at least one superabsorbent polymer of up to 0.1% are generally sufficiently spaced to disperse in the interstitial gap. In, on and in even single yarns, filaments and interstitial gaps and spaces sized and randomly distributed to enhance the absorption and transpiration of collected moisture from areas of high humidity to areas of lower humidity within, and said shaped polyurethane foam layer connected to said lower humidity region in such a way as to allow the absorbed and collected moisture to evaporate from said substrate into the surrounding ambient atmosphere.

Another aspect of the present invention provides the above-described shaped hydrophilic polyurethane polymer foam composites and products, such as sheet stock of various thicknesses, having at least one superabsorbent material uniformly distributed therein and present in a certain proportion. Particles of polymers to avoid gel-blocking in shaped composites and products, but employing said shaped composites and products to allow maximum moisture evaporation through the use of one or more of the following additives: Anionic, cationic, amphoteric and amphiphilic surfactants; humectants such as glycerin; solid fillers such as wollastonite, feldspar, calcium carbonate, sodium bicarbonate; fibers such as cellulose, polyester, glass fibers and optionally and optionally Traces of colorants, fungicides and fragrances.

Another aspect of the invention provides multilayer products having various combinations of fabrics, films, and other substrates for attachment to shaped hydrophilic polyurethane polymer foam composites, such as sheet blanks of various thicknesses, said composites Particles having uniformly distributed therein at least one superabsorbent polymer in a proportion to avoid gel blocking, but employing said composite to allow composites along shaped composites and including such shaped hydrophilic polyurethane foams as described above The longitudinal x-axis and width y-axis of the multilayer product of material have the greatest moisture transpiration.

Another aspect of the present invention provides multilayer products having various combinations of fabrics, films, and other substrates for attachment to the above-described shaped hydrophilic polyurethane polymer foam composites, such as sheet blanks of various thicknesses, wherein the An impermeable moisture barrier film is bonded or adhesively secured to one side of the multilayer product to prevent moisture from flowing through the multilayer product in the transverse or z-direction perpendicular to the longitudinal lines of the multilayer product.

Another aspect of the present invention provides multilayer products having various combinations of fabrics, films, and other substrates for attachment to the above-described shaped hydrophilic polyurethane polymer foam composites, such as sheet blanks of various thicknesses, wherein the An impermeable moisture barrier film bonded or cohesively secured to one side of a multilayer product, optionally or alternatively allowing or preventing excessive moisture flow in the transverse or z direction perpendicular to the longitudinal lines of the multilayer product layer product.

In another aspect, the invention also relates to a boot comprising an upper portion and a sole portion, wherein the upper portion and the sole portion are connected together. So as to determine the micro-environmental space for the user's feet. Preferably, the upper end portion has, on the inner surface, one of the aforementioned multilayer combinations comprising at least one of the inventive shaped hydrophilic polyurethane polymer foam composites containing up to 0.1% superabsorbent polymer particles. Layer, wherein said at least one shaped foam layer of a liner or multi-layer liner communicates with the ambient atmosphere in a lower humidity area, such as on the outside of the footwear.

Another aspect of the present invention provides footwear having one of the above-described liners or multi-layer combinations having the shaped hydrophilic polymers of the present invention containing up to 0.1% superabsorbent polymer particles. At least one layer of the polyurethane polymer foam composite, the liner or one of the multilayer combinations is so attached within the footwear as to allow trapped moisture, water vapor and trapped air to pass from the microenvironment inside the footwear to the footwear Ambient air outside the boot is exchanged to increase the breathability of the boot and create lower humidity, lower heat in the micro-environment inside the boot, and provide greater overall comfort for the user of the boot.

Another aspect of the present invention provides footwear made of waterproof material having a moisture vapor permeable membrane therein, said footwear having one of the above-mentioned liners or multilayer combinations, said liner or multilayer combination One having at least one layer of the shaped hydrophilic polyurethane polymer foam composite of the present invention containing up to 0.1% superabsorbent polymer particles, one of said pads or multilayer combinations being so attached in the boot as to allow Collected moisture, water vapor, and trapped air are exchanged from the microenvironment inside the footwear with the ambient air outside the footwear to increase the breathability of the footwear and create a lower humidity, higher Low heat and provide greater overall comfort to the wearer of the footwear.

Another aspect of the present invention provides footwear having one of the above-mentioned liners or multilayer combinations polymerized from shaped hydrophilic polyurethane containing up to 0.1% superabsorbent polymer particles. made of a biofoam composite, one of the pads or multi-layer combinations is so attached within the footwear as to allow trapped moisture, water vapor, and trapped air to flow from the microenvironment inside the footwear to the environment outside the footwear. Air is exchanged to improve the breathability of footwear manufactured by conventional techniques, and when padding or multi-layer products are applied to footwear, it does not require changes in the shape, style and can be applied to all types of footwear Everyday sports and wearing footwear.

Yet another aspect of the present invention provides footwear having therein a waterproof, moisture-permeable membrane, and one of the above-mentioned liners or multilayer combination products, one of said liner or multilayer combination products comprising at most 0.1 % superabsorbent polymer particles formed hydrophilic foam composites, wherein the liner or multi-layer composite product is so connected in the footwear, so as to improve the inherent moisture vapor transmission rate (MVTR), to allow significant Increases the exchange of collected moisture, water vapor and trapped air from the microenvironment inside the footwear with the ambient air on the outside of the footwear, thereby providing lower humidity and lower heat in the microenvironment formed within the footwear , and to provide greater overall comfort to the user.

Description of drawings

Figure 1 shows a partial view of a cross-section of the matrix within a shaped hydrophilic polyurethane polymer foam layer of the present invention showing interconnected single yarns and filaments and interstices within the polyurethane polymer matrix prior to pressing or drying Interstices or spaces in which superabsorbent polymer particles are generally uniformly dispersed within, on and in the single yarns, filaments and interstitial spaces or spaces.

Figure 2 is an enlarged cross-sectional view taken along line 2-2 of one of the interconnected single yarns and filaments shown in Figure 1, showing the interplay of some dispersed superabsorbent polymer particles in a formed hydrophilic polymer foam layer In, on and in even single yarns and filaments.

Figure 3 shows a schematic cross-section of the appearance of a layer of a shaped hydrophilic polyurethane polymer foam product comprising superabsorbent polymer particles and a nonwoven fiber additive of the present invention, wherein in The interstitial spaces and spaces between the nonwoven fibers are filled with up to 0.1% superabsorbent polymer particles.

Figure 4 shows a diagrammatic cross-section of another embodiment of the shaped product of the invention having the shaped hydrophilic polyurethane polymer foam composite of the invention shown in Figure 3 with the use of moisture vapor permeable An adhesive is attached to the hydrophilic covering fabric.

Figure 5 shows a schematic cross-section of another embodiment of a shaped multilayer product of the present invention having the hydrophilic polyurethane polymer foam composite shown in Figure 3 with A hydrophilic cover fabric, and a hydrophobic waterproof cover fabric affixed to the outer surface, and preferably made of leather or leather-like material in connection with or associated with the operation.

Figure 6 shows a schematic cross-section of yet another embodiment of a shaped multilayer product of the present invention having the hydrophilic polyurethane polymer foam composite of the present invention shown in Figure 3 and a separate and unique form of cover material such as Fabrics or films to obtain or enable variable functional characteristics on either surface of the shaped composite in terms of moisture control and transpiration of collected moisture.

Figure 7 shows a schematic cross-section of a portion of a shaped multilayer product having the hydrophilic polyurethane polymer foam composite of the present invention shown in Figure 3, thereby illustrating the use of a water permeable adhesive to cover the fabric The warp and weft yarns are bonded to the forming composite.

Figure 8 shows a schematic cross-section of a portion of another form of relatively lightweight multilayer product having the shaped hydrophilic polyurethane polymer foam composite of the present invention without any nonwoven fiber additives. It is prepared by knife coating the foam composite onto release paper and bonding the woven fabric layer "in place" thereto.

Figure 9 shows a partial schematic cross-section of yet another version of a relatively lightweight multilayer product having the shaped hydrophilic polyurethane polymer foam composite of the present invention without any nonwoven fiber additives. It is formed by knife-coating the foam composite between lower and upper layers of release paper, bonded or secured "in place" to at least one surface of the shaped composite by means of a moisture-permeable adhesive, preferably a woven cover fabric prepared above.

Figure 10A is a longitudinal side view of a class of footwear lined with a multilayer shaped product having a woven fabric built or secured to the inner surface of the leather upper end portion of the footwear by a suitable impermeable adhesive And the longer part and the upper edge of the opening of the foot and the upper and edge of the tongue (tongue, tongue) part of the shoe, for communication with the environment.

Figure 10B is an enlarged section taken along line 10B-10B of Figure 10A.

Fig. 11 is a longitudinal cross-sectional view of the footwear shown in Fig. 10B.

FIG. 12 is a cross section taken along line 12 - 12 of FIG. 11 .

FIG. 13 is an enlarged cross section taken along line 13 - 13 of FIG. 12 .

Figure 14 is a schematic illustration of the theoretical differential flow of collected moisture droplets from an area of high humidity to an area of lower humidity through a shaped multilayer product having a hydrophilic polyurethane polymer foam composite of the present invention.

Detailed ways

In order to achieve the beneficial results of the present invention, it is necessary to formulate the polymeric aqueous mixture to provide a shaped foam layer or shaped composite, wherein the shaped foam composite matrix will have a high moisture vapor transmission rate, allowing the generated moisture (i.e. , condensed water vapor droplets collected within the microenvironment created by the exemplary body covering) physically move from wet places (i.e., areas of high humidity within the created microenvironment) to areas of low humidity , and then to a place where evaporation is allowed to remove said moisture.

The improved and shaped foam product is formulated by combining a limited amount of superabsorbent polymer particles comprising sufficient water, up to 0.1%, a surfactant to adjust the size of the open-cell cells or randomly distributed interstitial air gaps, An aqueous formulation of optional and selected other additives with at least one suitable polyurethane prepolymer to form a polymeric mixture which is deposited on a removable bottom paper on a moving carrier or transport system and topped with a removable top paper Covering the upper surface, moving the polymeric mixture on a carrier or transport system, and simultaneously sizing the individual normally annular cells into a predominantly elliptical shape that ultimately generates more x-y directional polyurethane polymer units Yarns and fibers for enhanced transpiration of collected moisture, removal of top and bottom release paper, and forming plies of polyurethane polymer foam composites through secondary secondary steps such as forming sheets, die cutting, etc., with Products for lining applications in various applications such as clothing, shoes, helmets, etc.

Such methods or processes for making layers of shaped foamed polyurethane polymer materials are described in US Patent Nos. 5,763,335 and 6,025,287, among others, and are well known to those skilled in the art and will therefore not be described more fully.

However, the shaped foam composites of the present invention differ in that within the matrix of the shaped foam, the shape, size and orientation of the interconnected single yarns and filaments and the interstitial spaces and gaps have been optimized for the collected moisture In the x-y direction, ie in the same longitudinal plane as the length and width of the shaped foam composite.

Additionally, however, the ratios of chemicals within the formulations of the shaped foam composites of the present invention have also been designed to prevent gel formation and blocking, as described in U.S. Patent 5,331,728 and Patents '335 and '287, while using This shaped foam composite maximizes absorbency, transpiration and breathability. Thus, the improved shaped foam composites of the present invention will absorb and transport moisture from areas of high humidity, such as microenvironments, to areas of lower humidity and where it can be evaporated.

In addition to the improved transpiration and evaporation achieved by the improved shaped foam composites of the present invention, it has also been found that the surface condition of the improved foam composites remains relatively dry when compared to conventional prior art absorbent materials. If a drop of water is placed on any surface of the modified shaped foam composite, as described below, and the drop is allowed to penetrate the surface, when the tissue is pressed onto the same area of that surface, it will not pick up any water, even when applied When pressure is applied to the paper towel.

In the conventional batch mixing process for formulating the shaped hydrophilic polyurethane polymer foam composites of the present invention, the aqueous mixture employs about 15% to 85% by weight of water, 0.05% to 0.1% by weight of at least one superabsorbent polymer, and optional and optional additives, and from 1% to 50% by weight of a hydrophilic polyurethane prepolymer to provide a polymeric mixture for forming a foam composite.

The superabsorbent polymers used in this formulation are preferably sodium polyacrylate/polyol polymers and copolymer absorbents, which are readily available in the commercial market in liquid, fibrous form, and are preferred for use herein, with Composites of particle size used for the purpose and application of the invention. Such superabsorbent polymers are described in US Patent Nos. 5,763,335 and 4,914,170.

Superabsorbent polymers are generally defined as having the ability to spontaneously absorb aqueous fluids while maintaining their respective integrity. In such superabsorbent polymers, the carboxyl groups on the polymer chains are solvated when in contact with aqueous fluids. As a result, these groups partially dissociate into negatively charged carboxylate anions. The polymer chain now contains a large number of similarly charged ionic groups that repel each other. The chain becomes larger in size and will absorb and retain an increasing amount of fluid.

In contrast to superabsorbents, conventional absorbents, including humectants, absorb liquid primarily by physical means, and will return to their original shape under the slightest stress or pressure. Thus, the preferred formulations for use in the present invention are limited combinations of superabsorbent polymers and humectants which allow the collected and absorbed moisture to move from areas of high humidity to areas of low humidity due to pressure differentials.

However, in order to obtain the inventive functional characteristics and advantageous results of the improved shaped foam composite, it is important that the amount of superabsorbent polymer used in the aqueous mixture during formulation must be limited, as described above. In this regard, the preferred amount will be 0.1% by weight of the mixture. Too much superabsorbent polymer tends to cause the trapped moisture to gel, as occurs in prior art formulations, and this will effectively slow down the desired transpiration of the trapped moisture and prevent the moved to areas of lower humidity.

Because surfactants function to control the size of the cells or randomly distributed interstitial spaces or air gaps within the shaped foam composite matrix, the surfactants are added to the aqueous mixture during the formulation process. This in turn affects capillary action which is the enhancement of the moisture trapped in, on and within the superabsorbent polymer particles distributed in the interconnected single yarns and filaments in any of the formed foam composite matrices of the present invention major factor in moving between. The use of surfactants to modify surface conditions is well known in the art. Typically, ethylene oxide and propylene oxide surfactants are commercially available under the trade name or designation PLURONIC from BASF. Where small sized interstices or open cells are desired, use 2% by weight of PLURONIC L 62 in the aqueous mixture. In cases where large size interstices or open cells are desired, use 5% by weight of PLURONIC F88 in the aqueous mixture.

Similarly, hydrophilic polyurethane prepolymers are also commercially available and known to those skilled in the art from U.S. Patent Nos. John Wiley & Sons, New York, N.Y. Publishing, Polyurethane`s Chemistry and Technology by J.H.Saunders and K.C. Frisch, Vol.XVI Part 2, High Polymer Series, "Foam Systems", pp. 7-26 and "Procedure for the Preparation of Polymers General methods for the preparation and formulation of such polymers are found on page 26 et seq. A preferred hydrophilic polyurethane prepolymer for use in the present invention is sold under the trade name BIPOL 6 by Mace Adhesives and Coatings, another is sold under the trade name HYPOL by the Dow Chemical Company, and another is sold by Lendall Manufacturing Incorporated sells it under the tradename PREPOL. These prepolymers are suitable for use in the present invention due to their strongly hydrophilic character, reasonable cost and equilibrium moisture content of 5-45% at relative humidity of 50%-90%.

In the formation of multilayer products having a base layer and cover layer of a hydrophilic polyurethane polymer foam composite and layers of other materials; such cover or other layers may be woven, nonwoven, water permeable, waterproof , natural or synthetic fabrics and fibers, and will be selected according to the function or application for a given multilayer product. Such functions or applications affecting the choice of cover layer or other layers meet without limitation such as abrasion resistance, tensile strength, elongation, flame retardancy, moisture vapor transmission, insulation, aesthetics, feel, density, thickness and use in various other characteristics of applications and uses.

Additionally, cover or other layers may be attached or disposed on opposing surfaces of the base layer of the shaped foam composite of the present invention, and may be bonded, laminated, or adhered to the base layer of the shaped foam composite as desired or preferred.

Bonding can be achieved "in situ" by attachment to polymerized moisture during formation of the shaped foam composite.

Adhesive bonding is well known in the art. When an adhesive is used to attach a cover or other layer to the surface of the base layer of the shaped foam composite, it is also desirable to allow moisture to pass through the adhesive, and preferred adhesives will include heat activated reticulated bonds Web adhesives such as those sold commercially by Bostic, Middleton, MA under the trademark or phrase SPA 111, and other equivalent hot melt dot matrix (dot matrix) coating materials.

Referring to the drawings, Figures 1 and 2 of the drawings show partial schematic representations of interconnected single yarns and filaments (generally designated 1 ) in cross-section of a shaped hydrophilic polyurethane foam composite HF of the present invention. The individual yarns and filaments 1 within the shaped foam composite are interconnected in part such that there are interstitial spaces (generally designated 2 ) defining randomly distributed air spaces throughout the shaped foam body. Thus, as shown, individual yarns and filaments 1 are not separated from each other by a single air gap 2 . Thus, within this type of foam, several single yarns or filaments 1 can be interconnected to each other by a thin-walled membrane of a hydrophilic polyurethane polymer. Those skilled in the art will recognize such shaped foam composites as open cell foams. Furthermore, and important to the invention, these figures show that a maximum of 0.1% superabsorbent polymer particles (generally marked 3) are bound or present in the single yarns and filaments 1 .

During the formulation and processing of the ingredients described above to provide the improved shaped foam composite HF, the superabsorbent polymer particles 3 shown in Figures 1 and 2 of the accompanying drawings are distributed in discrete relationship to each other. This spacing between individual superabsorbent polymer particles limits or effectively eliminates gel formation or gel blocking as defined by the prior art. It has been found that if the superabsorbent polymer particles are not in contact with each other, when they swell upon absorbing moisture, they will prevent gel formation and the condensed water vapor and droplets of collected moisture will transpire through the formed foam composite without Gel sticks. In addition, such spacing reduces the absorption capacity or rate of absorption of the individual particles. This spacing is controlled by the ratio of the amount of superabsorbent polymer particles to the amount of hydrophilic prepolymer added to the mixture.

Conventional prior art polyurethane polymer foams are also subject to migration, inhomogeneity and collapse when wetted. The superabsorbent polymer in the present invention is immobilized within the interconnected single yarns, filaments and interstitial gaps or air spaces within the formed hydrophilic polyurethane foam composite matrix, as shown in Figures 1 and 2, the present invention allows moisture to flow along the single yarns and filaments from one particle of superabsorbent polymer to the next and prevents the formed foam composite matrix from collapsing.

Although this does not increase transpiration, it increases the saturation of the absorbed moisture collected and, due to the increased saturation of the droplets of collected moisture within the formed foam matrix, transpiration or flow from areas of high humidity occurs through pressure differentials to an area of lower humidity.

Enhanced transpiration by varying the cell size, shape and size of the interstitial gaps and air gaps that are randomly established between the interconnected single yarns and filaments to provide the capillary action differential that is required to meet within the formed foam composite The different viscosities of the droplets of moisture collected by the superabsorbent polymer.

Capillary action is a function of the size and shape of the interstitial gaps and air gaps within the formed polyurethane polymer foam composite matrix. Those skilled in the art will appreciate and know that the smaller the size of the gap or air space, the better capillary action will be established to enhance transpiration of collected moisture from areas of high humidity.

Changes in capillary action are obtained by adding surfactants when formulating aqueous mixtures, and during processing of hydrophilic polyurethane polymer foam composites, by compression in forming polymeric foam layers, and/or during processing of hydrophilic polyurethane polymer foam composites. Water polymer foam composite process by changing the temperature. Those skilled in the art will appreciate that capillary action affects both the absorption and the rate of transpiration of condensed droplets of collected moisture.

A further embodiment of the shaped polyurethane polymer foam composite is obtained by adding a fiber network or cut fiber material. Fibrous webs and chopped fiber materials can be natural or synthetic fibers, and either hydrophilic or hydrophobic. Examples of such fibers are cellulose, polyester and glass fibers.

Figure 3 of the accompanying drawings shows this embodiment of the invention and is used to create a sheet blank of shaped hydrophilic polyurethane polymer foam composite that can be used for many purposes and as other multilayer products of the invention at least one layer of . Formulation and Processing In this embodiment, the natural or synthetic nonwoven fibrous web or material is added during formulation at a rate of 0.5% to 5% by weight of the aqueous mixture. Therefore, when making shaped hydrophilic polyurethane polymer foam composites, the woven or nonwoven fibrous web or material 4 has the same characteristics as shown in Figures 1 and 2 of the accompanying drawings completely filled with hydrophilic polyurethane foam and superabsorbent Polymer filled gaps.

The fibrous material may be either natural or man-made synthetic material and enhances the transpiration activity of the composite and the tensile strength of the shaped foam composite and thus is ideal for forming a base sheet blank (generally designated 5), the base sheet The blank also serves as a layer within the multilayer product of the present invention shown and described below.

Thus, in the two-layer embodiment of the invention shown in Figure 4 of the accompanying drawings, there is a shaped layer of hydrophilic polyurethane polymer foam composite, i.e. as described in the embodiment of the invention shown in partial section in Figure 3 Sheet blank 5 of variable thickness and density. This can be done by varying the hydrophilic polyurethane prepolymer, water, up to 0.1% superabsorbent polymer, up to 70% humectant, sufficient surfactant as a function of the desired application and fiber web or chopped fiber material ratio to obtain. The second layer 6 of covering fabric is secured to the opposite surface of the blank sheet 5 by means of any permeable type of adhesive for friction, aesthetics and other conditions that the application or use may require. The adhesive may be permeable or impermeable as a function of or depending on the application or use of the particular layered product.

Where the cover fabric is secured to the surface of the sheet blank 5 in contact with the collected moisture, the cover fabric must allow the collected moisture to pass through the shaped hydrophilic polyurethane polymer foam composite A sheet blank 5 in which the material foam composite material is connected to the covering material is defined. The adhesives used to fix or bond this covering fabric 6 to the sheet blank 5 of shaped foam composite are of the open reticulated hot melt type or of the lattice deposition type, all of which are shown in Figure 7 of the accompanying drawings.

Another product is shown in Figure 5 of the accompanying drawings in a multilayer embodiment of the invention. Again, a formed composite layer of hydrophilic polyurethane polymer foam, ie a sheet blank 5 of variable thickness and density according to an embodiment of the invention shown in partial section in FIG. 3 . This can be achieved by varying the proportions of hydrophilic polyurethane prepolymer, water, humectant, superabsorbent polymer up to 0.1%, and fibrous web or chopped fiber material. A first hydrophilic cover fabric 8 is then fixed to the moisture contacting surface of the formed foam composite layer 5 by means of a permeable type adhesive. Similarly, a waterproof hydrophobic cover fabric 9 is secured to the other surface of the formed foam composite layer 5 by any suitable means.

In this embodiment, the base shaped composite material layer of the sheet blank 5 is operatively connected around the leather or leather-like material such as 10 and arranged so that the shaped foam composite material layer is at one end of the leather or leather-like layer of material 10a extending around, thereby allowing at least one end of the shaped foam composite layer 5 to communicate with the surrounding environment surrounding the embodiment. This will promote transpiration of the collected moisture along the x-y length and width planes of the sheet blank layer 5 from areas of high humidity to areas of lower humidity, ie the surrounding air. If the leather or leather-like material is waterproof, the waterproof covering fabric layer may be omitted.

Similarly, in the embodiment shown in Figure 6 of the drawings, a shaped foam composite layer of the sheet blank material 5 shown in Figures 3, 4 and 5 is provided. This layer is formulated in the same way to provide a sheet blank 5 of variable thickness and density (as a function of application and use). Combinations and variations of separate and distinct fabrics and films may be used to cover respective opposing surfaces of the shaped foam composite to provide variable characteristics to respective opposing sides of the layers of the sheet blank 5 . Thus, a covering fabric 11 is provided on the moisture contacting surface and a further covering fabric 12 is provided on the side remote from the moisture contacting surface of the sheet blank layer.

In some cases, the application or use does not want the condensed droplets of collected moisture to transpire through the composite of the formed foam sheet blank in the "z" direction perpendicular to the composite thickness of the sheet blank. In this case, an impermeable moisture barrier membrane 9 is bonded to the side of the composite material opposite the cover fabric, as shown in Figure 5 of the accompanying drawings.

Various combinations of fabrics, films, and other substrates can be attached to the shaped polyurethane polymer foam composite 5 . For example, another embodiment of the present invention requires that the shaped foam composite should be secured or bonded to "leather" or leather-like material in order to increase the absorption, transpiration and vaporization characteristics of eg shoes made from such shaped foam composite. Component foam roll goods with bonded waterproof membrane, such as sheet blank 5 and cover layer 6 in Figure 4, are punched into curved shapes larger than the size and shape of the shoe upper. The leather upper part 10' is then glued to the waterproof membrane side of the leather upper part 10, as shown in FIG. Excess foam composite material can then be rolled on the outer edge of the shoe upper, thereby exposing the foam material to the outside or ambient atmosphere while still communicating with the shoe interior. In operation, moisture from the interior of the shoe then transpires along the "x-y" length and width plane of the shaped polyurethane polymer foam composite and, when exposed to the ambient atmosphere, will evaporate through the open end of the sheet blank 5, All of these are shown in Figure 5 of the accompanying drawings.

In Figure 6, another shaped, sized multilayer product of the present invention has a first covering fabric 11 whose outer surface 11a is in a relatively dense and compact position with condensed droplets of moisture collected therein. Areas of higher pressure are interconnected. Covering fabric 12 is bonded, joined, laminated or bonded on the opposite or inner surface 11b to the second layer of shaped polyurethane polymer foam composite 5 of the sheet blank described above. On the side 5a of the shaped foam composite away from the cover fabric 11, the inner surface 12a of the second layer of woven, nonwoven, natural or synthetic material is bonded, connected, laminated or bonded to said side 5a . The outer surface 12b of the natural or synthetic material 12 communicates with a lower density and lower pressure low humidity area such as the ambient atmosphere.

During operation and use, the first cover fabric layer 11 communicates with areas of maximum condensed droplets of moisture and water vapor collected therein. The superabsorbent polymer is integrally and generally uniformly dispersed in the matrix of the formed polyurethane polymer foam composite layer and the single yarns act to draw out and absorb the collected moisture droplets and water vapor and render them From the areas of high density and high humidity transpiration via the cover fabric 11 to the areas of low density and low humidity represented by the layer of shaped foamed composite material 5 and the third layer of natural and synthetic material.

Figure 7 is a partial cross-sectional view of a hydrophilic polyurethane polymer foam composite with a cover fabric bonded thereto, showing the cover fabric at 6, 8, 9, 10 and 11 in Figures 3, 4 and 6, respectively A more detailed manner of bonding to the sheet blank base 5. It shows the warp and weft fibers of the cover woven fabric at 13 and 14 intercommunicating with a water permeable adhesive 15 and attached to the sheet blank base 5 .

Functional operation using the techniques taught here is to physically use the high moisture vapor transmission rate provided by the sheet blank base 5 to move unwanted trapped moisture from one place to another. The sheet blank base 5 may or may not require a covering material. If cover material is required, the composite material requires a means of bonding, joining, laminating or bonding the cover material to the sheet blank base 5 as shown in Figures 4, 5, 6 and 7 of the accompanying drawings.

The covering material comprises at least one water permeable, waterproof man-made, synthetic, fabric membrane or film. The chosen covering material is anticipated by the function it will perform. That is, as an example, the covering material is characterized to satisfy abrasion, tensile strength, elongation, flame retardancy, moisture vapor transmission, insulation, aesthetics, feel, density, thickness, and the like. 4, 5, 6 and 7 above show combinations of covering materials on opposite sides of a sheet blank base 5 comprising a plurality of different cover material.

Bonding, either by complete "in situ" formation or by joining or bonding cover sheets or other layers of material to the shaped polyurethane polymer foam composite, is performed by conventional techniques well known to those skilled in the art.

Similarly, flame lamination, which joins cover sheets or other layers of material to the layers of the base blank sheet 5 of the shaped polyurethane polymer foam assembly, is also well known to those skilled in the art.

Adhesive bonding to the sheet blank base can be accomplished by conventional bonding methods known to those skilled in the art. Where the adhesive is intended to bond to the cover material and also allow moisture to pass through the adhesive, it has been found that a preferred adhesive will comprise a heat activated reticulated adhesive similar to SPA111 which achieves Hot melt adhesives and matrix coating adhesives available from BOSTIC, Middleton, MA, and equivalents.

Hydrophilic polyurethane prepolymers are liquid systems that form carbon dioxide and amines when reacted with water. The amine produces polymerization of the polyurethane prepolymer, thereby forming a solid foamed polymer, while the carbon dioxide creates air bubbles within the formed polymer. Using process controls, including temperature and surfactants that vary the surface tension within the reaction, and adjusting the volume fraction of the formulation, we have been able to create combinations of cell size, pore volume, hydrophilicity, moisture absorption, and evaporation to maximize Moisture transpiration, as shown in the Examples and Tables described below.

Conventional polyurethane yarns and fibers described as hydrophilic allow transpiration of water only along the surface of such yarns and fibers or by capillary action.

The hydrophilic polyurethane prepolymer chemistry within the present invention differs from conventional polyurethanes by its hydrophilic polyurethane polymer components. This hydrophilic polyurethane polymer component allows the polyurethane polymer single yarns and filaments of the foam matrix to absorb water into the backbone of each single yarn and fiber for use with surfactants, absorbents, wetting agents or dispersed in The chopped fiber material contacts within the foam matrix.

Thus, the rate of transpiration is increased by the hydrophilic polyurethane prepolymer used in the shaped foam composite formulations of the present invention.

The exposed inventive embodiment (shown in Figure 5) regarding the sheet blank base material 5 shows that the sheet blank material is a thin matrix wrapped around a leather object 10 with a small surface area exposed to the external environment. This design can be altered to increase the volume ratio of the exposed sheet blank base 5 relative to the internal surface area. The moisture transpiration volume in the "x-y" length and width plane or direction is related to the density of the sheet blank base 5 . For example, a 0.061 inch thick sheet stock base material tested with the standard MVTR cup test transpires 1.61 g of moisture/hour. The same product compressed to a thickness of 0.049 inches transpired 0.335 g moisture/hour during processing. This shows that a 20% reduction in thickness results in approximately 80% reduction in transpiration rate.

In FIG. 8, another multi-shape embodiment of the present invention is shown forming a lightweight sheet blank of polyurethane polymer foam composite 50, which is formed by scraping the polyurethane polymer foam composite 50 with a doctor blade on a bottom release paper. Coating the polymeric mixture, and bonding a cover fabric "in situ" to the polymeric mixture to provide a shaped product, are produced in the process of formulating a shaped polyurethane polymer foam composition.

Thus, the lightweight sheet blank of the shaped polyurethane polymer foam composite typically has superabsorbent polymer particles uniformly dispersed among the material singles 51 and filaments 52 of the shaped foam composite 50, such as at 53 . Cover fabric 54 is bonded or joined to the upper surface of shaped foam composite 50 during the formulation and polymerization process described above. Another layer of woven or nonwoven material or composite material 55 may be bonded, connected, laminated or bonded to the lower surface of shaped foam composite 50 .

A still further embodiment of the present invention is shown in FIG. 9, which differs from FIG. 8 only in that the covering fabric 54 Adhesively bonded to the upper surface of the shaped foam composite 50 .

Figures 10A and 10B illustrate another embodiment of the invention for a footwear (generally designated 60) made of any conventional natural or synthetic material, the footwear having upper ends connected to each other Portion 61 and sole portion 62 to define a receiving space 63 for the foot. An access opening 63a communicates with a foot receiving space 63, and a collar 64 is formed around the access opening. Upper portion 61 is separated by tongue member 65 so that when upper portion 61 is folded higher than the assembled position of tongue portion 65, the side edges of upper portion, such as 61a, communicate with the surrounding atmosphere on the outside of shoe 60.

Multilayer liner 66 comprising at least one layer of sheet blank base 5 as described above and as shown in FIGS. And/or by stitching, not shown, the multilayer liner 66 is secured to the inner surface of the upper end portion 61 .

A multi-layer product having a shaped hydrophilic polyurethane foam composite, such as those shown in FIG. Protective lining layer (socking layer) (when the footwear is in use, it is in contact with the user's foot). The multi-layer lining 66 is so fixed or bonded to the inner surface 61a of the leather or leather-like material of the upper end portion 61 by an adhesive 68 that it extends beyond the tongue portion 65 and the collar 64 of the boot 60, As a result the side edges 5 a and the protective lining layer 67 communicate with the ambient air outside the boot 60 . This enables moisture collected within the foam layer of the liner or multi-layer liner 26 to migrate or transpire from the interior of the boot 20 through both the open side edge 5a and the protective liner layer to the exterior of the shoe when the boot is in use. in the surrounding air. Thus, providing a more efficient mechanism for moisture vapor transmission rate (MVTR) transpiration not only along the x-y axis or longitudinal line of the foam layer, but also transversely across the protective liner layer of liner 66 . In addition, ambient air will also enter the footwear through the formed foam composite layer or liner 66 and protective liner layer 67 to displace evaporated moisture, thereby: improving the MVTR and breathability of the footwear, transporting moisture from The moisture and trapped air inside the footwear are collected and replaced with ambient air to cool the interior of the footwear and make it more comfortable for the user.

The above mentioned shoes lined with the multilayer product or liner of the shaped foam composite material shown in Figures 3, 4, 5, 6 and 7 and described above were tested against conventional shoes of the same type, wherein male subjects aged 30 years were used. The subjects walked for 2 hours and 45 minutes at a time on a human-powered treadmill with a 15-minute rest between each walk. Air temperature and humidity readings inside the shoe were also monitored, and the perceived comfort index (PCT) was determined with the help of ASHRE data. The results are shown in Table 1 below.

Table 1

regular shoes Shoes with formed foam composite lining Test cycle 1 Temperature °F 80 79.2 Relative humidity 74 62 PCT 83 81 Test cycle 2 Temperature °F 81.91 78.2 Relative humidity 77 73 PCT 88 80

From this test it follows that a shoe construction with such a multi-layer product or liner containing the shaped foam composite of the invention reduces the relative humidity in the microenvironment of the footwell within the shoe and significantly affects the perceived comfort index (Perceived Comfort Index, PCT). At higher temperatures, the decrease in PCT was more pronounced, as can be seen by comparing test cycle 1 and test cycle 2.

The perceived comfort index is how people interpret the combination of heat and high humidity. Within the temperature range inside the shoe, the lower the PCT, the more comfortable people feel.

Figures 11, 12 and 13 are further schematic views of another type of footwear showing an upper end portion 71 made of leather and a sole portion 72 defining a foot receiving space 73 having a foot entry edge 73a and tongue-shaped region 71a. The multilayer shaped polyurethane polymer foam product (generally designated 74) of the present invention comprises a shaped polyurethane polymer foam composite 75 formulated as described above attached or lined to the interior surface of upper end portion 71.

The multi-layer shaped foam product 74 is secured using a suitable adhesive and is arranged relative to the inner surface of the shoe so as to form a first collar (generally designated 74a) around the tongue-shaped area on the boot 70, and on the side of the foot. A second collar 74b is formed around the entry edge 73a. Thus, the multilayer shaped foam product 74 of the present invention enables the microenvironment of a highly dense and high humidity portion within the shoe with collected droplets of moisture and moisture vapor to be less dense and low humidity on the outside of the boot 70. The areas communicate, and for the reasons listed above with respect to the formed hydrophilic polyurethane polymer foam composite, transpiration of moisture occurs, resulting in improved comfort conditions in the microenvironment of the foot receiving space 73 within the boot 70.

To better understand the improved moisture transpiration caused by the shaped foam composites of the present invention, Figure 14 shows a cross-sectional view of a sized and shaped multi-layer embodiment product, generally designated 80, There is a woven cover fabric layer 81 whose outer surface 81a communicates with denser areas of high humidity where moisture and water vapor collect within the microenvironment, such as a shoe, as shown in FIGS. 10A and 11 . The inner surface 81b of the cover fabric 81 is bonded, laminated or bonded to the surface of a shaped hydrophilic polyurethane polymer foam composite 82 formulated according to various formulations described herein and in the Examples described below. on the adjacent surface 82a of the second substrate. In particular, the second layer 82 of the shaped foam composite has been formulated with a humectant additive such as glycerin to enhance moisture transpiration.

14 shows that the natural or synthetic material of the third nonwoven or woven layer 83 on the opposite face or side 82b of the base layer of the shaped foam composite 82 also has bonding, lamination or bonding to the shaped foam composite. The inner surface 83a on the opposite face or side 82b of the matrix of material 82 . The opposite or outer surface 83b of said third layer 83 of material communicates with a region of low density or low humidity, such as the atmosphere.

Although the outer surface 81a of the cover layer of the fabric 81 is located in the area where the collected moisture and water vapor is greatest and the humidity is high, the formed hydrophilic polyurethane polymer foam composite matrix layer acts to attract and absorb the collected water. act so that it moves laterally from an area of high densification and high humidity or collected water through the first cover layer 80 to a base layer of shaped foam composite 82 and a third layer 83 of natural or synthetic material of low densification or low humidity area.

With further reference to FIG. 14 , the flow rate of the collected moisture droplets DW through the first cover layer 81 is relatively high. Thus, the diameter of the droplet expands to almost 2 times the diameter when the droplet travels to the adjacent surface 82a of the second layer of shaped foam composite material of the present invention.

The individual yarns and filaments in the formed hydrophilic polyurethane polymer foam composite matrix layer 82 in which the superabsorbent polymer is integrally and generally uniformly dispersed in, on and in the individual yarns and filaments are hydrophilic, to the action of eliciting and absorbing water droplets DW and expecting it to transpire from the denser and higher humidity region through the first fabric cover layer to the base layer represented by the matrix layer of shaped foam composite material 82 and the third layer 83 of natural or synthetic material in areas of low humidity.

The purely large amount of collected moisture does not increase the transpiration of the water droplet DW, since the collected moisture does not confer any capacity to the existing surrounding conditions.

The movement of the droplet through the matrix of the formed foam composite layer 82 is slightly reduced and then greatly increased as it transpires through the third layer 83 of natural and synthetic materials and evaporates into the adjacent atmosphere in a region of low density and low humidity. Increase.

Transpiration, ie movement, occurs due to pressure differences or capillary action.

Capillary action is a function of the size and shape of the interstitial gaps and air spaces within the formed foam composite matrix.

The size of the interstitial gaps and air spaces within the shaped foam composite matrix is adjusted by the volume of surfactant in the aqueous mixture used in the polymerization process to form the hydrophilic polyurethane polymer foam composite of the present invention as described above and shape.

The following examples are given as specific illustrations of the invention. It should be understood, however, that the invention is not limited to the specific details set forth in the examples. In the examples, as well as in the remainder of the specification, all parts and percentages are by weight unless otherwise indicated.

Example 1

Prepare the aqueous phase by mixing in the following order of addition:

Pluronic(BASF)F88 .3% solution 93.36%

Foley Fluff(Buckeye Cellulose) 1.54

Glycerin (Emery 916) 3.07

Pluronic(BASF)L62 1.29

Superabsorbent (Stockhausen AP 80-HS) 0.10

Guar Gum (Alpha-Chem) 0.64

The aqueous phase was then added to and mixed with 33 wt% Dow Chemical Hypol Prepolymer. The mixed composition was cast on a silicone release paper and covered with a second sheet of the same (release paper). The thickness of the resulting foam reaction was controlled by a spacer and top cover plate clamped to the bench. After about 8 minutes of emergence and curing, the foam composite was removed and dried in an oven. The foam components were then laminated to K2 fabric supplied by Hub Fabric using heat activated web adhesive from Bostic.

Example 2

As in Example 1, an aqueous phase was prepared comprising:

Pluronic(BASF)F88 1% solution 37.88%

Calcium carbonate (Noah Technologies) 54.43

Glycerin (Emery 916) 7.59

Superabsorbent (Stockhausen AP 80-HS) 0.1

The aqueous phase was then added to and mixed with the above 27.5% Prepolymer. The mixture was poured between two spacers on release paper, as in Example 1, and 1/4 thickness of 2.5 (ounces/yard ² ) oz./sq.yd. Ester nonwoven fibers (available from Carr-Lee) were placed on the liquid mixture. Then add a piece of release paper, to the top of the rising foam nonwoven, bonded. In this example, the thickness of the spacer is 1/8 (obtained by pressing 1/4 thickness of nonwoven fibers), so as to correspond to the desired 1/8 thickness of the final composite material. The composite is shown in FIGS. 3 , 4 , 5 , 6 and 7 . It is well known to those skilled in the art that various cell sizes, hydrophilicity, water retention and water siphonage can be adjusted by means of various surfactants, absorbents and/or fillers added to the water phase, such as:

Surfactant absorbent filler Nonionic polyethylene oxide man-made chopped fiber ion polyvinylpyrrolidone mineral both sexes clay Cellulose Fiber

test

The Moisture Vapor Transmission Rate (MVTR) of the insole material (Cambrelle® pad) described in the prior art on Duratex foam was tested by a recognized Quality Assurance Procedure. The product prepared by the invention exceeds the industrial standard of 600-4000g water/m ² /24h@40°C. The results in Table 1 show the results in the length x direction and the width y direction along the longitudinal plane of the formed hydrophilic polyurethane polymer foam composite layer; Table 2 shows the results in the z direction transverse or perpendicular to the longitudinal plane. Testing found that the lower density and thinner samples exemplified in the preferred formulation (Example 2) also exceeded the MVTR of the prior art.

Table 1

x-y direction Cambrelle/Duratex this invention Improve% MVTRg/ ^m2 /24h 5056   10696 112 Table 2 Z direction 4018 5897 47

Example 3

To reduce the density of the foam composite described in Example 2, the formulation was changed to include:

Pluronic(BASF)F88 1% solution 89.11%

Sodium bicarbonate (Arm-Hammer) .90

Glycerin (Emery 916) 9.99

The aqueous phase was mixed with Dow Chemical Hypol in a 1:1 weight ratio. The mixed composition was cast on the leather surface, covered with release paper, and sized with spacers. After curing and drying, the fabric layers are thermally laminated with a web adhesive. This method is not used for the product shown in Figure 5, in that the covering fabric 9 is eliminated. This approach defines another embodiment which shows the versatility of the invention. The formulation change between Example 3 and Example 2 lowered the density of the foam from 15.61 lb./cu.ft. (pounds per cubic foot) to 10.91 lb./cu.ft., about 9%.

Example 4

A formulation was prepared as in Example 3 and spread on release paper. The paper was then pulled open by a knife from 0.005 to 0.375, leaving a continuous film thickness of foamed superabsorbent on the paper. Further develop the paper until the foam reacts but is still tacky. The cover fabric K2 (Hub Fabric) was then placed on the tacky surface, where in the absence of leaks it was glued to the polyurethane.

Example 5

A formulation as in Example 3 was prepared and processed as in Example 4. The cover fabric was replaced with a second layer of release paper, allowing the foam to cure within the top and bottom paper only. Once fully cured, remove the bottom paper and drive off residual water in the oven. The resulting foam sheet of the present invention can then be further processed by bonding it to a selected fabric, film or substrate with an adhesive. See Figure 9.

The formulations, processes, products, materials and applications described above are shown in order to exemplify the main embodiments. The present invention is a lightweight, flexible shaped polyurethane polymer foam composite, a moisture retaining material for use in multilayer products that transpires moisture from wet areas to dry areas.

The principles, preferred embodiments and implementations of this invention have been described in the foregoing specification. However, the invention as claimed herein should not be construed as limited to the particular forms disclosed, as these are considered illustrative, not limiting. Variations and changes may be made by those skilled in the art without departing from the spirit and scope of the invention as set forth in the claims that follow.

Claims (16)

1. shaping hydrophilic polyurethane polymer foamed composite, it comprises the limited amount additive that is selected from least a absorbent, super-absorbent polymer and the wetting agent in PEO and the PVP, at least a surfactant and chooses wantonly and select, so that improve the moisture transpiration of the environment of fine and close from height in high humility to the zone of hanging down fine and close and low humidity.

2. shaping hydrophilic polyurethane polymer foamed composite, it has for optimizing from the environment of high densification and high humility through its qualification matrix to gap the moisture moisture-holding capacity in the zone of low densification and low humidity and rising interconnection single thread, long filament and crack of preparing and space, and described composite is from comprising following product:

A. water, it comprises desired water, limited amount at least a absorbent, super-absorbent polymer and wetting agent and the Hdyrophilic polyurethane prepolymer that is selected from PEO and the PVP;

B. described water also comprises at least a anion, cation, both sexes and amphiphilic surfactant optional and that select; With

C. optional and select additive, it is selected from filler, weaves and non-woven chopped strand material, colouring agent, antiseptic and spices.

3. claim 1 or 2 shaping hydrophilic polyurethane polymer foamed composite, wherein filler material is selected from wollastonite, feldspar, calcium carbonate and sodium acid carbonate.

4. claim 1 or 2 shaping hydrophilic polyurethane polymer foamed composite, wherein fibrous material is selected from cellulose, polyester and glass fibre.

5. claim 1 or 2 shaping hydrophilic polyurethane polymer foamed composite, wherein filler material is selected from wollastonite, feldspar, calcium carbonate and sodium acid carbonate, and fibrous material is selected from cellulose, polyester and glass fibre.

6. the hydrophilic polyurethane polymer foamed composite of claim 1, wherein the moisture vapour transmission rate under 40 ℃ is at 600-20000g/m ²In the scope of/24h.

7. the shaping hydrophilic polyurethane polymer of claim 2, wherein:

A. absorbent is a particle form, and it mostly is 0.1wt% most, and intactly and usually be evenly dispersed between single thread, long filament and the crack of matrix within the gap and space, on and among; With

Gap and space absorb and transpiration with the moisture that improves in this shaping foamed composite according to certain size and shape manufacturing between b. described crack.

8. claim 1 or 2 shaping hydrophilic polyurethane polymer foamed composite, it has at least one the lip-deep covering fabric material that bonds to matrix, so that make moisture easily pass this covering fabric, and does not absorb described moisture.

9. the shaping hydrophilic polyurethane polymer foamed composite of claim 8 and covering fabric material, wherein use the bonding covering fabric material of adhesive of moisture permeable, and described adhesive is selected from netted adhesive, dot matrix adhesive and the flame crucible zone pressure adhesive of thermal activation.

10. the shaping Hdyrophilic polyurethane foamed composite of claim 9 and covering fabric material, it has at least one away from the surface that bonds to the covering fabric on another layer that is selected from the material in film and the film fabric, and collected moisture is rising to be arrived and the adjacent shaping foamed composite side in low humidity zone so that stop.

11. the multilayer Hdyrophilic polyurethane froth pulp of claim 8, wherein at least the moisture vapour transmission rate of one deck formed polyurethane froth bed under 40 ℃ at 600-20000g/m ²In the scope of/24h.

12. comprise the footwear boots of upper part and sole portion, wherein connect this upper part and sole portion, so that be user's pin restriceted envelope, thereby form the microenvironment of collected moisture, described upper part has the multilayer hydrophilic polyurethane polymer froth pulp of at least a absorbent that contains maximum 0.1wt%, and the wherein surrounding air intercommunication of multi-layered product and footwear boots outside, to improve the gas permeability in the footwear boots and to reduce humidity.

13. the footwear boots of claim 12, wherein the shaping hydrophilic polyurethane polymer foam multi-layered product in the upper part comprises at least a hydrophilic polyurethane polymer foamed composite, multi-layered product is through the microenvironment of described composite in the footwear boots and the intercommunication between the atmosphere on every side of described footwear boots outside, and described multi-layered product comprises and the cover layer of the described microenvironment intercommunication in described footwear boots, and this cover layer is a moisture permeable.

14. the footwear boots of claim 13, wherein multi-layered product so is fixed on the upper part, so that collected moisture and surrounding air are all along composite layer longitudinal propagation and the zone of laterally passing through the moisture permeable of covering fabric, so that collected moisture is replaced by surrounding air.

15. the footwear boots of claim 13, wherein the upper part has the space top edge on every side that is arranged in user's pin for the atmosphere intercommunication on every side with footwear boots outside, and multilayer hydrophilic polyurethane polymer product selectively and optionally is connected around the described top edge, so that the microenvironment of the open side edge of at least a hydrophilic polyurethane polymer foamed composite within it in the footwear boots and the intercommunication between the atmosphere on every side of described footwear boots outside, comprise and the covering fabric of described microenvironment intercommunication in described footwear boots that with described multi-layered product described covering fabric is a moisture permeable.

16. the footwear boots of claim 13, wherein the upper part has and its whole ligulate element that forms and design, so that with atmosphere intercommunication around the footwear boots outside, selectively and optionally be connected at least one inner surface of ligulate element with multilayer hydrophilic polyurethane polymer product, so that the outside intercommunication of open side edge and footwear boots, with allow collected moisture from the microenvironment of described footwear boots, to flow out and surrounding air in described foamed material enters the footwear boots.

Images