Microcellular polyurethane flexible foams having densities no greater than
0.3 g/cc which are suitable for use as lightweight shoe sole components
are produced with carbon dioxide in an amount such that the
polyurethane-forming mixture has a free rise density of from about 0.03
to about 0.3 g/cc. At least a portion of that carbon dioxide is dissolved
as a gas into one or both of the reaction components. The amount of
dissolved carbon dioxide must be such that the froth density of the
isocyanate and/or isocyanate-reactive component(s) in which the carbon
dioxide is dissolved will be from about 0.1 to about 0.8 g/cc. Additional
carbon dioxide may be formed by the reaction of water and isocyanate
during the polyurethane-forming reaction but the total amount of CO.sub.2
present should be controlled to ensure that the polyurethane-forming
mixture has a free rise density of from about 0.03 to 0.3 g/cc. Use of a
preferred isocyanate-reactive component in which a specified ratio of
diol to triol is satisfied makes it possible to use more water than had
been expected. Use of a preferred prepolymer makes it possible to produce
microcellular polyurethanes having good physical properties solely with a
diol. The product microcellular foams possess a uniform cell structure
and enhanced physical properties as compared to all water-blown foams of
the same basic formulation and density. The hardness of the foams is more
suitable for shoe sole, particularly midsole applications, than that of
the water-blown foams, despite the lower urea hard segment content of the
CO.sub.2 blown foams.