Polyolefin-based resins, sole structures, and articles of footwear and sporting equipment formed therefrom

Abstract

Resin compositions composed of a polyolefin copolymer, a polymeric resin modifier, and a thermoplastic vulcanizate (TPV) are provided herein. A variety of sole structures for footwear, including plates, are provided including the polyolefin-based resin compositions described herein. Articles of footwear formed therefrom are also provided. Methods of making the polyolefin-based resin compositions, plates, sole structures, and articles of footwear and sporting equipment are also provided.

We claim: 
     
         1 . An article of footwear comprising an upper and a sole structure, wherein the sole structure comprises a polyolefin-based resin composition comprising a polyolefin copolymer, a polymeric resin modifier, and a thermoplastic vulcanizate (TPV). 
     
     
         2 . The article of footwear of  claim 1 , wherein the article includes a bond between the sole structure and the upper, and wherein the bond between the sole structure and the upper forms a bite line between the sole structure and the upper. 
     
     
         3 . The article of footwear of  claim 1 , wherein the article further comprises a toe bumper, the toe bumper straddles the bite line at least in the forefoot portion of the upper, and the toe bumper is bonded to the upper, to the plate, or to both the upper and the plate. 
     
     
         4 . The article of footwear of  claim 3 , wherein the toe bumper straddles the bite line at least in the forefoot portion of the upper. 
     
     
         5 . The article off footwear of  claim 1 , wherein the polyolefin copolymer comprises a plurality of repeat units, with each of the plurality of repeat units individually derived from an alkene monomer having about 1 to about 6 carbon atoms. 
     
     
         6 . The article of footwear of  claim 1 , wherein the polymeric resin modifier comprises about 10 percent to about 15 percent ethylene repeat units by weight based upon a total weight of the polymeric resin modifier. 
     
     
         7 . The article of footwear of  claim 1 , wherein the TPV comprises a crosslinked elastomer dispersed in a thermoplastic phase. 
     
     
         8 . The article of footwear of  claim 7 , wherein the TPV comprises a EPDM rubber dispersed in a thermoplastic phase, optionally wherein the thermoplastic phase comprises polypropylene. 
     
     
         9 . The article of footwear of  claim 7 , wherein the crosslinked elastomer of the TPV includes a cured polyolefin rubber. 
     
     
         10 . The article of footwear according to  claim 3 , wherein the toe bumper comprises a second resin composition including a thermoplastic elastomer. 
     
     
         11 . The article of footwear according to  claim 10 , wherein the second resin composition comprises one or more styrene copolymers, optionally wherein the one or more styrene copolymers comprises a SBS copolymer or a SEBS copolymer. 
     
     
         12 . The article of footwear according to  claim 10 , wherein the second resin composition is a thermoplastic elastomeric second resin composition, and wherein the thermoplastic elastomeric second resin composition is thermally bonded to the polyolefin-based resin composition of the sole structure, or to the upper, or to both the polyolefin-based resin composition of the sole structure and the upper. 
     
     
         13 . The article of footwear of  claim 1 , wherein the sole structure comprises a second resin composition. 
     
     
         14 . The article of footwear of  claim 13 , wherein the second resin composition comprises a polyolefin that is different from the polyolefin copolymer of the polyolefin-based resin composition. 
     
     
         15 . The article of footwear of  claim 14 , wherein the polyolefin of the second resin composition is a polyolefin chosen from polypropylene, polypropylene-polyethylene copolymers, copolymers of ethylene and higher olefins, or a blend thereof. 
     
     
         16 . The article of footwear of  claim 13 , wherein in the sole structure, the second resin composition comprises a thermoplastic elastomeric polyester polyurethane, a thermoplastic polyether polyurethane, or any combination thereof. 
     
     
         17 . The article of footwear of  claim 13 , wherein the sole structure comprises a second element, and wherein the second element comprises the second resin composition. 
     
     
         18 . The article of footwear of  claim 17 , wherein the second element comprises a traction element, a chassis, a textile, or any combination thereof. 
     
     
         19 . The article of footwear of  claim 18 , wherein the sole structure has a first side and a second side, wherein the first side is configured to be ground-facing. 
     
     
         20 . The article of footwear of  claim 19 , wherein the first side of the sole structure includes a plurality of traction elements, wherein one or more of the plurality of traction elements are integrally formed in the sole structure, and wherein the one or more of the plurality of traction elements comprise the polyolefin-based resin composition.