Methods for manufacturing articles of footwear are provided. In various aspects, the methods comprise utilizing additive manufacturing methods with foam particles. In some aspects, the additive manufacturing methods comprise increasing the temperature of a plurality of foam particles with actinic radiation under conditions effective to fuse a portion of the plurality of foam particles comprising one or more thermoplastic elastomers. Increasing the temperature of the foam particles can be carried out for one or multiple iterations. The disclosed methods can be used to manufacturer articles with sub-regions that exhibit differing degrees of fusion between the foam particles, thereby resulting in sub-regions with different properties such as density, resilience, and/or flexural modulus. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

Methods for manufacturing articles of footwear are provided. In various aspects, the methods comprise utilizing additive manufacturing methods with foam particles. In some aspects, the additive manufacturing methods comprise increasing the temperature of a plurality of foam particles with actinic radiation under conditions effective to fuse a portion of the plurality of foam particles comprising one or more thermoplastic elastomers. Increasing the temperature of the foam particles can be carried out for one or multiple iterations. The disclosed methods can be used to manufacturer articles with sub-regions that exhibit differing degrees of fusion between the foam particles, thereby resulting in sub-regions with different properties such as density, resilience, and/or flexural modulus. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

A polyurethane, in particular a thermoplastic polyurethane, is obtainable or obtained by reacting at least a polyisocyanate composition and a polyol composition. The polyol composition contains at least one polyester diol or polyether diol, having a number-average molecular weight in the range from 500 to 3000 g/mol, and at least one polysiloxane having two terminal isocyanate-reactive functionalities selected from a thio group, a hydroxyl group, and an amino group. A process can be used for preparing this polyurethane, and a molded body containing the polyurethane is useful. Foam beads based on polyurethane can be obtained or obtainable from the polyurethane, and a process can be used for producing foam beads. Corresponding bead foams are useful.

A modified expanded bead that includes an expanded bead which includes a specific base polymer (β) and a coating layer which includes a specific base polymer (α). The coating layer covers at least part of an outer surface of the expanded bead. The melting point Tα of the base polymer (α) and the melting point Tβ of the base polymer (β) satisfy a relationship of 0≤Tα−Tβ≤20. When the modified expanded bead is cut into two halves along a cutting plane to form two half portions and thereafter one of the two half portions is cut along planes perpendicular to the cutting plane to form ten small pieces, outermost pieces among the ten small pieces have a xylene-insoluble content (B) which is less than a xylene-insoluble content (A) in the half portion and the xylene-insoluble content (A) is 10-80% by mass.

A modified expanded bead that includes an expanded bead which includes a specific base polymer (β) and a coating layer which includes a specific base polymer (α). The coating layer covers at least part of an outer surface of the expanded bead. The melting point Tα of the base polymer (α) and the melting point Tβ of the base polymer (β) satisfy a relationship of 0≤Tα−Tβ≤20. When the modified expanded bead is cut into two halves along a cutting plane to form two half portions and thereafter one of the two half portions is cut along planes perpendicular to the cutting plane to form ten small pieces, outermost pieces among the ten small pieces have a xylene-insoluble content (B) which is less than a xylene-insoluble content (A) in the half portion and the xylene-insoluble content (A) is 10-80% by mass.

A process can be used for producing a thermoplastic polyurethane, where the process at least involves converting at least one isocyanate composition and a polyol composition, to obtain a prepolymer having isocyanate groups, and reacting the resulting prepolymer with at least one chain extender. The at least one isocyanate composition contains an isocyanate selected from naphthylene 1,5-diisocyanate (NDI), diphenylmethane 4,4′-diisocyanate (MDI), p-phenyl diisocyanate (PPDI), o-tolidine diisocyanate (TODI), ethylene diphenyl diisocyanate (EDI), or mixtures thereof. The polyol composition contains a polytetrahydrofuran or a derivative thereof. A thermoplastic polyurethane obtained or obtainable by such a process is useful, and a foamed pellet material can be produced containing such a thermoplastic polyurethane. The foamed pellet material of the invention can be used for production of a molded article.

The present invention relates to expanded thermoplastic polyurethane beads, a preparation method for same, and an application thereof. The expanded thermoplastic polyurethane beads consists of components of the following parts by weight: 100 parts of a thermoplastic polyurethane, 1-10 parts of a cell size stabilizer, and 1-35 parts of a melt viscosity modifier. The preparation method for the expanded thermoplastic polyurethane beads is also disclosed. The bead is produced by employing a volatile blowing agent to immerse the thermoplastic polyurethane, comprising the pore size stabilizer and the melt viscosity modifier, in an aqueous suspension, and is then followed by the foaming process. Utilization of the expanded thermoplastic polyurethane beads of the present invention allows for preparation of a foam product. The expanded thermoplastic polyurethane beads prepared per the present invention has uniform cell sizes and a high product yield. At the same time, the expanded thermoplastic polyurethane bead provides a great sintering performance even at a relatively low vapor pressure, a molded foam product has a small deformation, a low dimensional shrinkage ratio relative to a mold, great dimensional stability, and an aesthetically appealing appearance.

The present invention relates to expanded thermoplastic polyurethane beads, a preparation method for same, and an application thereof. The expanded thermoplastic polyurethane beads consists of components of the following parts by weight: 100 parts of a thermoplastic polyurethane, 1-10 parts of a cell size stabilizer, and 1-35 parts of a melt viscosity modifier. The preparation method for the expanded thermoplastic polyurethane beads is also disclosed. The bead is produced by employing a volatile blowing agent to immerse the thermoplastic polyurethane, comprising the pore size stabilizer and the melt viscosity modifier, in an aqueous suspension, and is then followed by the foaming process. Utilization of the expanded thermoplastic polyurethane beads of the present invention allows for preparation of a foam product. The expanded thermoplastic polyurethane beads prepared per the present invention has uniform cell sizes and a high product yield. At the same time, the expanded thermoplastic polyurethane bead provides a great sintering performance even at a relatively low vapor pressure, a molded foam product has a small deformation, a low dimensional shrinkage ratio relative to a mold, great dimensional stability, and an aesthetically appealing appearance.

An expanded polypropylene resin particle is obtained from a base material resin having a melting point of 140° C. to 150° C., wherein the base material resin includes a polypropylene resin A including 3 weight % to 15 weight % of 1-butene and having a melting point of 130° C. to 140° C.; and a polypropylene resin B having a melting point of 145° C. to 165° C., and wherein the expanded polypropylene resin particle has an average cell diameter of 100 μm to 340 μm.

An expanded polypropylene resin particle is obtained from a base material resin having a melting point of 140° C. to 150° C., wherein the base material resin includes a polypropylene resin A including 3 weight % to 15 weight % of 1-butene and having a melting point of 130° C. to 140° C.; and a polypropylene resin B having a melting point of 145° C. to 165° C., and wherein the expanded polypropylene resin particle has an average cell diameter of 100 μm to 340 μm.