Multi-layered structures and uses thereof

#The disclosure relates to multi-layered structures, including multi-layered structures used in gas-filled bladders, cushioning devices, and vulcanized articles, such as vehicle tires.

#Multi-layered structures having excellent fluid (gas or liquid) barrier properties are needed for constructing gas-filled bladders, cushioning devices, tires, and other structures. The multi-layered structures need to have low gas transmission rates for nitrogen or other gases. Thermoset and thermoplastic polymers are used in these applications because of their excellent flexibility. Thermoplastic polymers, including thermoplastic polyurethanes (“TPUs”), have desirable characteristics because their scraps can be reclaimed, melted or ground, and reused to produce new thermoplastic articles. Although thermoset materials sometimes lack the recyclability advantage, in some instances, they can be useful in achieving a well-balanced set of physical and mechanical properties for applications as footwear, sporting equipment, and vehicle tires.

#FIG. 1 is a side elevational view of an athletic shoe with a portion of the midsole cut-a-way to expose a cross-sectional view.

#FIG. 2 is a bottom elevational view of the athletic shoe of FIG. 1 with a portion cut-a-way to expose another cross-sectional view.

#FIG. 3 is a section view taken along line 3-3 of FIG. 1.

#Aspects of the present disclosure relate to a multi-layered structure. The multi-layered structure includes a core layer having a first side and a second side and a first cap layer having a cap layer first side and a cap layer second side. The first side of the first cap layer is in direct contact with the first side of the core layer. The first cap layer includes a blended material, where the blended material includes at least one thermoplastic material and at least one rubber compound. In an aspect, the rubber compound can be uncured or partially cured. In some examples, the cap layer can bond (e.g., covalently) to another layer (e.g., a rubber layer) that is adjacent and directly in contact with the first cap layer.

#In some aspects, the multi-layered structure further includes a second cap layer having a second cap layer first side and a second cap layer second side. The second cap layer first side is in direct contact with the second side of the core layer. The second cap layer can comprise, consist essentially of, or consist of a thermoplastic material, as the term is defined herein. When the multi-layered structure further includes a second cap layer, the second cap layer can include the same or different thermoplastic material as that of the first cap layer.

#In some aspects, the multi-layered structure includes a core layer including a multi-layer polymeric material. In some examples, the multi-layer polymeric material is a composite of alternating thermoplastic materials and barrier microlayers or layers of a first thermoplastic material and a second thermoplastic material, where a layer of the second thermoplastic material has a lower gas permeability than a layer of the first thermoplastic material. In some aspects, the layer of the second thermoplastic material has an average thickness of about 0.1 microns to about 50 microns. In some aspects, the multi-layer polymeric material includes ethylene-vinyl alcohol copolymer layers.