Described herein is a 3D spacer fabric reinforced composite, a process for producing it, a method of using it in footwear, and a footwear including it.

A method for preparing a novel waterborne polyurethane foam layer for synthetic leather is disclosed. The method includes first preparing a charged cellulose nanofiber by using a wood pulp as a raw material; meanwhile, subjecting a polyisocyanate, a macromolecular diol, a hydrophilic chain extender and a small molecular chain extender to a polyaddition reaction and an acid-base neutralization reaction in sequence, to obtain a cationic or anionic waterborne polyurethane; adding the charged cellulose nanofiber and a certain amount of a crosslinking agent to the oppositely charged ionic waterborne polyurethane emulsion, stirring the resulting mixture, forming a bimolecular layer at the gas/liquid interface by a self-assembly of the cellulose nanofiber and waterborne polyurethane nanoparticles through electrostatic interactions to obtain a stable Pickering foam; using the stable Pickering foam as a template, drying and solidifying to obtain the waterborne polyurethane foam layer for synthetic leather.

A closed loop recycling process of manufacturing a foam part includes dispersing a filler material recycled from an additive manufacturing (AM) process in at least one foam reactant and pouring or injecting the at least one foam reactant with the filler material into a mold and forming the foam part. The foam part has a foam matrix with between 2.5 wt. % and 30 wt. % of the filler material. The filler material can be a recycled powder from a selective laser sintering process that is not graded (i.e., sized) before being dispersed in the at least one foam reactant. For example, the recycled powder can be a recycled polyamide 12 (rPA12) powder with an average particle diameter of less than 100 micrometers. Also, the least one foam reactant can be a polyol reactant and an isocyanate reactant such that a polyurethane foam matrix with recycled rPA12 filler material is formed.

The invention relates to a process for producing polyurethanes using a component A comprising a polyhydrazide, a polysemicarbazide, a polysulfonyl hydrazide and/or carbodihydrazide, in particular a polyhydrazide, wherein the component A is employed in the form of a mixture C which further comprises a component B comprising a dispersion medium.

To provide a polyether polyol having a high degree of freedom in the design of a polyurethane foam, and capable of providing a polyol system solution excellent in storage stability. A polyether polyol having a polyoxyalkylene chain consisting of oxyalkylene units, and having a degree of unsaturation of at most 0.020 meq/g, a hydroxy value of from 1 to 80 mgKOH/g, a content of oxyethylene units of from 0 to 50 mass %, and a content of ultra-high molecular weight components which have molecular weights of from 12 to 46 times the number average molecular weight of at most 1,000 mass ppm. The number average molecular weight is a molecular weight as calculated as polystyrene measured by gel permeation chromatography (GPC) method, and the content of ultra-high molecular weight components is a value measured by high performance liquid chromatography (HPLC) method using a charged aerosol detector (CAD).

Composites having a polymer or natural leather skin layer and a polyurethane foam layer are made in a molding process. The polyurethane foam layer is made from a foam formulation that includes certain polyester polyols. The presence of the polyester polyol improves flow characteristics of the foam formulation. The foam so produced has unexpectedly low quantities of VOCs.

A foamable polyurethane resin composition includes a polyisocyanate material, a polyol material, water, and a catalyst. The polyisocyanate material contains 1,4-H.sub.6XDI; the polyol material contains crystalline PTMEG and noncrystalline PTMEG and/or PPG; the total amount of the crystalline PTMEG, the noncrystalline PTMEG, and PPG is 90% by mass or more with respect to the total amount of the polyol material; and a ratio of the crystalline PTMEG is 60% by mass or more and 90% by mass or less with respect to the total amount of the crystalline PTMEG, the noncrystalline PTMEG, and PPG.

A foamable polyurethane resin composition includes a polyisocyanate material, a polyol material, water, and a catalyst. The polyisocyanate material contains 1,4-H.sub.6XDI; the polyol material contains crystalline PTMEG and noncrystalline PTMEG and/or PPG; the total amount of the crystalline PTMEG, the noncrystalline PTMEG, and PPG is 90% by mass or more with respect to the total amount of the polyol material; and a ratio of the crystalline PTMEG is 60% by mass or more and 90% by mass or less with respect to the total amount of the crystalline PTMEG, the noncrystalline PTMEG, and PPG.

Polyurethane foams are made by curing a reaction mixture that contains an aromatic polyisocyanate, at least one isocyanate-reactive material having an average functionality of at least 2 and an equivalent weight of at least 200 per isocyanate-reactive group, at least one blowing agent, at least one surfactant and at least one catalyst, at least one cyclic 1,3-diketone compound, at least one aminoalcohol or alkylhydroxylamine and an alkali metal, phosphonium or ammonium sulfite. Foams so produced emit low levels of formaldehyde, acetaldehyde, acrolein and propionaldehyde.

Polyurethane foams are made by curing a reaction mixture that contains an aromatic polyisocyanate, at least one isocyanate-reactive material having an average functionality of at least 2 and an equivalent weight of at least 200 per isocyanate-reactive group, at least one blowing agent, at least one surfactant and at least one catalyst, a polyethyleneamine mixture having a number average molecular weight of 175 to 450 and an alkali metal, phosphonium or ammonium sulfite. Foams so produced emit low levels of formaldehyde, acetaldehyde, acrolein and propionaldehyde.