NZ747961A - Pu flooring production for a sports field - Google Patents
Pu flooring production for a sports fieldInfo
- Publication number
- NZ747961A NZ747961A NZ747961A NZ74796117A NZ747961A NZ 747961 A NZ747961 A NZ 747961A NZ 747961 A NZ747961 A NZ 747961A NZ 74796117 A NZ74796117 A NZ 74796117A NZ 747961 A NZ747961 A NZ 747961A
- Authority
- NZ
- New Zealand
- Prior art keywords
- component
- reaction mixture
- water
- amount
- polyurethane
- Prior art date
Links
- 238000009408 flooring Methods 0.000 title claims abstract description 42
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 14
- 229920002635 polyurethane Polymers 0.000 claims abstract description 183
- 239000004814 polyurethane Substances 0.000 claims abstract description 183
- 239000011541 reaction mixture Substances 0.000 claims abstract description 161
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 149
- 238000006243 chemical reaction Methods 0.000 claims abstract description 96
- 229920005830 Polyurethane Foam Polymers 0.000 claims abstract description 93
- 239000000203 mixture Substances 0.000 claims abstract description 64
- IQPQWNKOIGAROB-UHFFFAOYSA-N [N-]=C=O Chemical compound [N-]=C=O IQPQWNKOIGAROB-UHFFFAOYSA-N 0.000 claims abstract description 56
- 229920001730 Moisture cure polyurethane Polymers 0.000 claims abstract description 49
- 238000002156 mixing Methods 0.000 claims abstract description 33
- 239000007788 liquid Substances 0.000 claims abstract description 27
- 239000011496 polyurethane foam Substances 0.000 claims abstract description 22
- LFSYUSUFCBOHGU-UHFFFAOYSA-N 1-isocyanato-2-[(4-isocyanatophenyl)methyl]benzene Chemical compound C1=CC(N=C=O)=CC=C1CC1=CC=CC=C1N=C=O LFSYUSUFCBOHGU-UHFFFAOYSA-N 0.000 claims abstract description 16
- UPMLOUAZCHDJJD-UHFFFAOYSA-N Diphenylmethane p,p'-diisocyanate Chemical compound C1=CC(N=C=O)=CC=C1CC1=CC=C(N=C=O)C=C1 UPMLOUAZCHDJJD-UHFFFAOYSA-N 0.000 claims abstract description 16
- 239000007787 solid Substances 0.000 claims abstract description 14
- 238000007711 solidification Methods 0.000 claims abstract description 9
- 229920005903 polyol mixture Polymers 0.000 claims abstract description 5
- 150000003077 polyols Chemical class 0.000 claims description 100
- 229920005862 polyol Polymers 0.000 claims description 97
- 239000010457 zeolite Substances 0.000 claims description 63
- 239000006260 foam Substances 0.000 claims description 52
- 229920000642 polymer Polymers 0.000 claims description 43
- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims description 27
- 239000000463 material Substances 0.000 claims description 27
- 239000002808 molecular sieve Substances 0.000 claims description 16
- JIABEENURMZTTI-UHFFFAOYSA-N 1-isocyanato-2-[(2-isocyanatophenyl)methyl]benzene Chemical compound O=C=NC1=CC=CC=C1CC1=CC=CC=C1N=C=O JIABEENURMZTTI-UHFFFAOYSA-N 0.000 claims description 14
- 238000007789 sealing Methods 0.000 claims description 14
- 239000011248 coating agent Substances 0.000 claims description 13
- 238000000576 coating method Methods 0.000 claims description 13
- 239000004615 ingredient Substances 0.000 claims description 12
- 125000005442 diisocyanate group Chemical group 0.000 claims description 10
- 239000000853 adhesive Substances 0.000 claims description 7
- 230000001070 adhesive Effects 0.000 claims description 7
- 238000004026 adhesive bonding Methods 0.000 claims description 6
- 125000003118 aryl group Chemical group 0.000 claims description 5
- 101700000038 mpas Proteins 0.000 claims description 4
- 239000004567 concrete Substances 0.000 claims description 2
- 239000002689 soil Substances 0.000 claims description 2
- 239000002023 wood Substances 0.000 claims description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 53
- 229910002092 carbon dioxide Inorganic materials 0.000 description 53
- 125000001261 isocyanato group Chemical group *N=C=O 0.000 description 36
- 239000003981 vehicle Substances 0.000 description 33
- 239000003054 catalyst Substances 0.000 description 30
- KWYUFKZDYYNOTN-UHFFFAOYSA-M potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 27
- 239000000126 substance Substances 0.000 description 26
- 238000000034 method Methods 0.000 description 25
- 239000007789 gas Substances 0.000 description 21
- 239000000654 additive Substances 0.000 description 15
- -1 hydrogen compound Chemical class 0.000 description 15
- 239000010410 layer Substances 0.000 description 14
- 238000007664 blowing Methods 0.000 description 11
- 239000004604 Blowing Agent Substances 0.000 description 9
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Natural products NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 9
- 150000001875 compounds Chemical class 0.000 description 9
- 239000000376 reactant Substances 0.000 description 9
- JOYRKODLDBILNP-UHFFFAOYSA-N ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 8
- 238000011065 in-situ storage Methods 0.000 description 8
- 150000002513 isocyanates Chemical class 0.000 description 8
- 238000005187 foaming Methods 0.000 description 7
- 150000001412 amines Chemical class 0.000 description 6
- KIQKWYUGPPFMBV-UHFFFAOYSA-N diisocyanatomethane Chemical compound O=C=NCN=C=O KIQKWYUGPPFMBV-UHFFFAOYSA-N 0.000 description 6
- 239000000178 monomer Substances 0.000 description 6
- 239000004202 carbamide Substances 0.000 description 5
- 210000004027 cells Anatomy 0.000 description 5
- 150000002009 diols Chemical class 0.000 description 5
- 238000001035 drying Methods 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- 239000000945 filler Substances 0.000 description 5
- 238000006116 polymerization reaction Methods 0.000 description 5
- 230000036632 reaction speed Effects 0.000 description 5
- 229920001228 Polyisocyanate Polymers 0.000 description 4
- 239000004721 Polyphenylene oxide Substances 0.000 description 4
- 239000001569 carbon dioxide Substances 0.000 description 4
- 238000011049 filling Methods 0.000 description 4
- 230000001965 increased Effects 0.000 description 4
- 229920005906 polyester polyol Polymers 0.000 description 4
- 229920000570 polyether Polymers 0.000 description 4
- 239000005056 polyisocyanate Substances 0.000 description 4
- 230000002829 reduced Effects 0.000 description 4
- 239000004094 surface-active agent Substances 0.000 description 4
- 239000004698 Polyethylene (PE) Substances 0.000 description 3
- URGAHOPLAPQHLN-UHFFFAOYSA-N Sodium aluminosilicate Chemical compound [Na+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O URGAHOPLAPQHLN-UHFFFAOYSA-N 0.000 description 3
- QTBSBXVTEAMEQO-UHFFFAOYSA-N acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- 239000002253 acid Substances 0.000 description 3
- 230000000386 athletic Effects 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 3
- 239000003995 emulsifying agent Substances 0.000 description 3
- 238000004880 explosion Methods 0.000 description 3
- 239000008187 granular material Substances 0.000 description 3
- 238000009499 grossing Methods 0.000 description 3
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 229910052674 natrolite Inorganic materials 0.000 description 3
- 239000000049 pigment Substances 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- 239000004606 Fillers/Extenders Substances 0.000 description 2
- 229910000503 Na-aluminosilicate Inorganic materials 0.000 description 2
- 229920002323 Silicone foam Polymers 0.000 description 2
- NXMOWTFIUDDXIT-UHFFFAOYSA-L [7,7-dimethyloctanoyloxy(dioctyl)stannyl] 7,7-dimethyloctanoate Chemical compound CC(C)(C)CCCCCC(=O)O[Sn](CCCCCCCC)(CCCCCCCC)OC(=O)CCCCCC(C)(C)C NXMOWTFIUDDXIT-UHFFFAOYSA-L 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 2
- JYIBXUUINYLWLR-UHFFFAOYSA-N aluminum;calcium;potassium;silicon;sodium;trihydrate Chemical compound O.O.O.[Na].[Al].[Si].[K].[Ca] JYIBXUUINYLWLR-UHFFFAOYSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- VTYYLEPIZMXCLO-UHFFFAOYSA-L calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 2
- 239000007795 chemical reaction product Substances 0.000 description 2
- 229910001603 clinoptilolite Inorganic materials 0.000 description 2
- 238000001246 colloidal dispersion Methods 0.000 description 2
- 230000001276 controlling effect Effects 0.000 description 2
- 229920001971 elastomer Polymers 0.000 description 2
- 239000004872 foam stabilizing agent Substances 0.000 description 2
- 239000004088 foaming agent Substances 0.000 description 2
- 238000005755 formation reaction Methods 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 229910052500 inorganic mineral Inorganic materials 0.000 description 2
- 239000008258 liquid foam Substances 0.000 description 2
- 239000011707 mineral Substances 0.000 description 2
- 229920005749 polyurethane resin Polymers 0.000 description 2
- GOOHAUXETOMSMM-UHFFFAOYSA-N propylene oxide Chemical compound CC1CO1 GOOHAUXETOMSMM-UHFFFAOYSA-N 0.000 description 2
- 230000001681 protective Effects 0.000 description 2
- 230000000979 retarding Effects 0.000 description 2
- 230000000630 rising Effects 0.000 description 2
- 239000000429 sodium aluminium silicate Substances 0.000 description 2
- 235000012217 sodium aluminium silicate Nutrition 0.000 description 2
- 239000008259 solid foam Substances 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 230000003068 static Effects 0.000 description 2
- 230000001960 triggered Effects 0.000 description 2
- DNIAPMSPPWPWGF-GSVOUGTGSA-N (-)-propylene glycol Chemical compound C[C@@H](O)CO DNIAPMSPPWPWGF-GSVOUGTGSA-N 0.000 description 1
- 229960003563 Calcium Carbonate Drugs 0.000 description 1
- WNCYAPRTYDMSFP-UHFFFAOYSA-N Calcium aluminosilicate Chemical compound [Al+3].[Al+3].[Ca+2].[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O.[O-][Si]([O-])=O WNCYAPRTYDMSFP-UHFFFAOYSA-N 0.000 description 1
- 210000000497 Foam Cells Anatomy 0.000 description 1
- 241000233866 Fungi Species 0.000 description 1
- 229920002521 Macromolecule Polymers 0.000 description 1
- 229920000426 Microplastic Polymers 0.000 description 1
- DGTNSSLYPYDJGL-UHFFFAOYSA-N Phenylisocyanate Chemical compound O=C=NC1=CC=CC=C1 DGTNSSLYPYDJGL-UHFFFAOYSA-N 0.000 description 1
- 229920001451 Polypropylene glycol Polymers 0.000 description 1
- 239000004972 Polyurethane varnish Substances 0.000 description 1
- 229960004063 Propylene glycol Drugs 0.000 description 1
- 210000004915 Pus Anatomy 0.000 description 1
- 238000006640 acetylation reaction Methods 0.000 description 1
- 238000007259 addition reaction Methods 0.000 description 1
- 230000000996 additive Effects 0.000 description 1
- 229910001579 aluminosilicate mineral Inorganic materials 0.000 description 1
- 229910052908 analcime Inorganic materials 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000000404 calcium aluminium silicate Substances 0.000 description 1
- 235000012215 calcium aluminium silicate Nutrition 0.000 description 1
- 229940078583 calcium aluminosilicate Drugs 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- UNYSKUBLZGJSLV-UHFFFAOYSA-L calcium;1,3,5,2,4,6$l^{2}-trioxadisilaluminane 2,4-dioxide;dihydroxide;hexahydrate Chemical compound O.O.O.O.O.O.[OH-].[OH-].[Ca+2].O=[Si]1O[Al]O[Si](=O)O1.O=[Si]1O[Al]O[Si](=O)O1 UNYSKUBLZGJSLV-UHFFFAOYSA-L 0.000 description 1
- KXDHJXZQYSOELW-UHFFFAOYSA-N carbamate Chemical compound NC(O)=O KXDHJXZQYSOELW-UHFFFAOYSA-N 0.000 description 1
- KXDHJXZQYSOELW-UHFFFAOYSA-M carbamate Chemical group NC([O-])=O KXDHJXZQYSOELW-UHFFFAOYSA-M 0.000 description 1
- 125000002843 carboxylic acid group Chemical group 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 239000004359 castor oil Substances 0.000 description 1
- 235000019438 castor oil Nutrition 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 230000001413 cellular Effects 0.000 description 1
- 229910052676 chabazite Inorganic materials 0.000 description 1
- 230000005591 charge neutralization Effects 0.000 description 1
- 230000001427 coherent Effects 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 230000000875 corresponding Effects 0.000 description 1
- 230000003247 decreasing Effects 0.000 description 1
- 230000001419 dependent Effects 0.000 description 1
- 238000003795 desorption Methods 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 230000002708 enhancing Effects 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 238000007667 floating Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 230000000855 fungicidal Effects 0.000 description 1
- 239000000417 fungicide Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229910052677 heulandite Inorganic materials 0.000 description 1
- 150000002431 hydrogen Chemical class 0.000 description 1
- 125000004435 hydrogen atoms Chemical group [H]* 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 239000001023 inorganic pigment Substances 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 239000001034 iron oxide pigment Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 230000001264 neutralization Effects 0.000 description 1
- 238000006386 neutralization reaction Methods 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000012299 nitrogen atmosphere Substances 0.000 description 1
- IAYPIBMASNFSPL-UHFFFAOYSA-N oxane Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 230000000737 periodic Effects 0.000 description 1
- 229910001743 phillipsite Inorganic materials 0.000 description 1
- 239000010773 plant oil Substances 0.000 description 1
- 229920002959 polymer blend Polymers 0.000 description 1
- 229920003225 polyurethane elastomer Polymers 0.000 description 1
- 238000007781 pre-processing Methods 0.000 description 1
- 230000002028 premature Effects 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 235000013772 propylene glycol Nutrition 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 239000005871 repellent Substances 0.000 description 1
- 230000002940 repellent Effects 0.000 description 1
- 230000036633 rest Effects 0.000 description 1
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- 229910052678 stilbite Inorganic materials 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 150000003512 tertiary amines Chemical class 0.000 description 1
- YXFVVABEGXRONW-UHFFFAOYSA-N toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 1
- 230000001702 transmitter Effects 0.000 description 1
- 238000004642 transportation engineering Methods 0.000 description 1
- 150000003672 ureas Chemical class 0.000 description 1
Abstract
The invention relates to a method for producing a polyurethane flooring (129) for a sports field (136), the method comprising: - providing (502) reactive components for producing polyurethane, the reactive components comprising an A component (902) being a polyol mixture and a B component (904) being an isocyanate mixture and water (914), the B component comprising: o 2,2' Methyiendiphenyldiisocyanate (922); o diphenylmethane-2,4'-diisocyanate (924); o diphenylmethane-4,4'-diisocyanate (926); and o isocyanate prepolymer (932); - mixing (504) the reactive components for generating a liquid polyurethane reaction mixture (129); - applying (506) the polyurethane reaction mixture (128) to a ground (103) of the sports field before chemical reactions in the reaction mixture have generated a solid polyurethane foam, the polyurethane foam after its solidification to be used as the polyurethane flooring. g an isocyanate mixture and water (914), the B component comprising: o 2,2' Methyiendiphenyldiisocyanate (922); o diphenylmethane-2,4'-diisocyanate (924); o diphenylmethane-4,4'-diisocyanate (926); and o isocyanate prepolymer (932); - mixing (504) the reactive components for generating a liquid polyurethane reaction mixture (129); - applying (506) the polyurethane reaction mixture (128) to a ground (103) of the sports field before chemical reactions in the reaction mixture have generated a solid polyurethane foam, the polyurethane foam after its solidification to be used as the polyurethane flooring.
Description
Field of the invention
The invention relates to a method and system for producing a polyurethane flooring,
especially a polyurethane sports flooring.
Background and related art
Japanese patent application with application number 09248510 (KOBAYASHI
KENJI) describes the provision of an elastic paving material that has desired
cushion properties and elasticity for providing an elastic pavement. A material is
disclosed containing a soft foaming body chip in a foaming polyurethane resin
composed mostly of closed cells and having an expansion ratio of 1.05 to 2.0 times
and a density of 0.6 to 1.2 g/cm3. This material is applied on a bedrock to form a
lower layer. The foaming polyurethane resin is obtained when an inactive gas is
mechanically and uniformly mixed and dispersed, in the presence of a silicone foam
adjusting agent, into the mixture of a main agent composed mainly of an urethane
prepolymer having an isocyanate group at its terminal and a hardening agent
comprising an active hydrogen compound, an inorganic filler, a catalyst, and other
assistants.
The German patent application DE 102008054962 A1 relates to a process for the
production of elastic laminates, in which a polyurethane binder containing a
prepolymer containing isocyanate groups is mixed with a granulate of a cellular
polyurethane elastomer and optionally further plastic granules and an excess of
water. Thereby, at least 20% by weight of water, based on the weight of prepolymer
containing isocyanate groups, is added to the polymer mixture.
US patent US005558917A relates to a polyisocyanate based on polymethylene
poly(phenylisocyanate) and to a process for the production of a polyurethane
backing on a substrate using this polyisocyanate to produce the polyurethane
backing. The polyisocyanate has a functionality of less than about 2.4, an
isocyanate group content of 25 to 30%, and a urethane content of from about 2 to
6%, and comprises polymethylene poly(phenylisocyanate) from about 5 to 25% of
4,4'-methylene bis(phenyloisocyanate), and from about 20 to 50% of 2,2'- and 2,4'-
methylene bis(phenyl-isocyanate).
James & Wells Ref: 310446NZ
US patent US005596063A relates to a process for the preparation of CFC-free,
flexible polyurethane foams or molded foams by reacting A) liquid polyisocyanate
mixtures containing bonded urethane groups and having a content of NCO groups
of from 20 to 30% by weight, B) relatively high-molecular-weight polyhydroxyl
compounds.
Floorings for sport grounds, for example for an athletic track or safety playground,
are commonly made of polyurethane.
Floorings for sport grounds are typically installed by unrolling a pre-fabricated PU
roll mat at its destination and gluing the PU mat down to the floor with a
polyurethane adhesive. The production of the PU mat within a manufacturing plant
may comprise performing a chemical reaction that quickly, typically within minutes,
generates a foamed, solid PU layer. The pre-fabricated PU roll is produced in a
sport ground factory and is transported – potentially via long distances – to the sport
area where it shall be installed. After the PU roll mat is rolled out, the edges of the
lanes need to be connected with each other and need to be sealed to prevent the
forming of open crevices between the lanes.
Summary
It is an objective of the present invention to provide for an improved method and
system for producing a polyurethane (PU) flooring for a sports field as specified in
the independent claims. Embodiments of the invention are given in the dependent
claims. Embodiments of the present invention can be freely combined with each
other if they are not mutually exclusive.
In one aspect, the invention relates to a method for producing a polyurethane
flooring for a sports field. The method comprises:
- providing reactive components for producing polyurethane, the reactive
components comprising an A component being a polyol mixture and a B
component being an isocyanate mixture and water, the B component comprising:
o 2,2’ Methylendiphenyldiisocyanate in an amount of 0,1%-3,2% of
the B-Component;
o diphenylmethane-2,4’-diisocyanate;
o diphenylmethane-4,4’-diisocyanate; and
James & Wells Ref: 310446NZ
o isocyanate prepolymer in an amount of 54%-70% of the B-
component;
- mixing the reactive components for generating a liquid polyurethane reaction
mixture; thereby, chemical reactions are triggered that will slowly generate
polyurethane and CO2 gas, whereby the CO2 gas causes the reaction mixture
and the polyurethane polymers contained therein to foam;
- applying the polyurethane reaction mixture to a ground of the sports field before
chemical reactions in the reaction mixture have generated a solid polyurethane
foam, the polyurethane foam after its solidification to be used as the polyurethane
flooring.
Said features may be beneficial for multiple reasons: using water as a further
reactive component allows generating an in-situ PU foam from a slowly reacting PU
reaction mixture that can be directly applied on the ground of the sports field. Thus,
the costs associated with transporting pre-fabricated PU roll to the place of
destination can be avoided or at least reduced. Water is abundantly available and
the other two reactive components consume less volume per weight unit than a pre-
fabricated, foamed PU roll. Thus, transportation and handling costs are reduced.
Moreover, the reaction of the reactive components generates the PU and, at the
same time, CO2 in sufficient amount to act as a foam blowing agent for generating
the foam. Using a B component with a specific mixture of MDI monomers
(comprising a combination of 2,2’ Methylendiphenyldiisocyanate, diphenylmethane-
2,4’-diisocyanate and diphenylmethane-4,4’-diisocyanate) and an isocyanate
prepolymer generated from said monomers may have the advantage that said
specific reaction mixture has been observed to react with the A component and the
water comparatively slowly. It is assumed – without being bound to any particular
theory – that sterical properties of the MDI monomers, in particular the 2,2’
Methylendiphenyldiisocyanate, reduce the reaction speed with the OH groups of the
A component. Thus, the process of PU polymer generation is retarded, leaving the
competing reaction between water and the ingredients of the B component enough
time to generate CO2 bubbles which blow the reaction mixture for creating a PU
foam instead of a non-foamed PU mass.
James & Wells Ref: 310446NZ
Typically, the reaction of the reactive components and thus, the foam generation,
begins in a reaction tank upon mixing the reactive components in said tank and
continues after the PU reaction mixture was applied on the ground for several
minutes or even several hours. The amount of water and/or the amount and type of
catalysts or other substances is chosen thus that the speed of foam generation
corresponds to the speed of the chemical reaction that forms the PU. This means
that CO2 is generated at least until the majority of the educts that could react to
generate the PU foam have in fact been transformed into the PU foam. This may
ensure that the foam has been transformed into a solid PU foam before it collapses
due to a reduced amount of CO2 bubbles acting as a foam blowing agent.
Typically, the reaction mixture is applied to the ground within 15 minutes,
preferentially within one minute, after its generation. Although foam generation
starts immediately and the reaction mixture already comprises some CO2 bubbles
when applied to the ground, the reaction mixture at this moment in time is still best
characterized as a (viscous) liquid. While the chemical reactions for generating the
CO2 gas and the PU polymers continue, the PU liquid having been applied on the
ground becomes more and more viscous and finally transforms into a solid foam
phase.
In a further beneficial aspect, the PU reaction mixture can be applied to the ground
directly without the necessity to add an additional adhesive layer between the PU
layer and the ground. This is because the in-situ generated foam is at least right
after its application on the floor sufficiently liquid to penetrate into small cracks of the
ground, thereby mechanically fixing the PU floor when the PU has completely
solidified.
In a further beneficial aspect, no additional leveling layer between the ground and
the flooring layer is necessary to compensate for surface irregularities of the ground.
This is because the applied PU reaction mix and the resulting PU foam will fill
depressions and indentations of the ground and will equalize when applied to a
sufficient amount on the ground.
In a further beneficial aspect, no additional step for sealing or connecting edges of
adjacent lanes is necessary as multiple adjacent lanes may simply be applied on the
floor before the foam has solidified. In this case, the non-solidified foam of the
James & Wells Ref: 310446NZ
adjacent lanes will automatically unify to form a connected, seamless sport floor.
The automated connection of adjacent PU mixture or PU foam lanes reliably
protects against the generation of cracks at adjacent edges of two lanes which could
allow water to penetrate and damage the floor.
Combining a B component comprising a “reaction-retarded” MDI mixture and a
corresponding prepolymer with water as a further reactive component allows that
two competing reactions (a “blowing reaction” generating CO2 bubbles and a
“gellation reaction” generating the PU polymer) are slowly executed in parallel,
whereby the CO2 gas generation is sufficient to blow the polyurethane or at least
prevent the collapse of the PU at least as long as the gellation reaction continues.
Thus, embodiments of the invention may allow generating PU floorings for sports
ground in a quicker, less labor intensive manner. Embodiments of the invention may
allow generating huge, seamless sport floors that automatically compensate for
surface irregularities in the ground, firmly attach to the ground without any adhesive
layer.
Contrary to non-foamed floors, embodiments of the invention may allow producing
floors for sport fields which are cushioning and elastic.
Non-foamed floors have been observed to get hard and brittle in particular at low
temperatures. Embodiments of the invention allow providing a foamed PU-based
sports field that cushions any force applied on the ground by more than 35%. Thus,
a force of 100 Newton applied on the floor is cushioned to a force of 65 Newton by
the PU-based, in-situ foamed sports field according to embodiments of the
invention.
The mixture of the reactive components which in addition may comprise one or
more additives such as catalysts, pigments, fillers, etc, is also referred to as reaction
mixture. As the foaming and PU generation process starts immediately upon
generation of the reaction mixture, this reaction mixture can also be referred to as
(liquid) “PU foam” although the majority of the educts in the reaction mixture may
not have reacted into PU or CO2 yet.
In a further beneficial aspect, no machines for mechanically foaming a PU-reaction
mixture are required as the PU formation according to embodiments of the invention
James & Wells Ref: 310446NZ
is based on adding water to the reaction mixture. This may be beneficial as
machines for mechanically foaming PU are expensive and/or may often not be
available.
In a further beneficial aspect, the method according to embodiments of the invention
has been observed to be applicable in a wide temperature range, in particular in a
range of 5°C - 40°C, and thus can be used for generating PU floorings for outdoor
sport fields in many different climate zones and in a wide temperature range. Thus,
this method is particularly suited for generating PU-based flooring for outdoor sport
fields. In comparison, state of the art, factory-plant based approaches for generating
PU-based foamed sport field floorings are based on a comparatively narrow and
high temperature range. Typically, PU foam generated in a factory (with a reaction
mixture that lacks water) has completed the foaming process with 6 minutes at
180°C cushioning temperature. To the contrary, the foam generated according to
embodiments of the invention solidifies not earlier than 30 minutes, or even not
before one to several hours and is “cured” (“completely hardened”) after about some
days or even one week. Thus, embodiments of the invention use a “reaction-
retarded” reaction mixture for generating foamed PU.
According to embodiments, the amount of the water and the amount of the 2,2’
methylenediisocyanate is chosen such that one hour after the mixing of the reactive
components, more than 60% of the water has reacted to CO2 and more than 50%
of the NCO groups of component B have reacted with hydroxyl groups of the polyol
of the component B into the solid polyurethane foam. Typically, the generation of the
solid PU foam may be completed not before 30 minutes after mixing the reactive
components together. Thus, the reaction speed of the specific reaction mixture is
retarded and allows applying multiple lanes of a PU reaction mixture in situ that will
automatically solidify in a time interval that allows applying multiple parallel lanes
while the reaction mixture is still liquid.
According to embodiments, di-n-octyltin neodecanoate is added as a catalyst to the
reaction mixture for catalyzing a polyaddition reaction of the polyol and the B
component. The amount of the catalyst is in the range of 0,0008 % to 0.0011% by
weight of a combination of the A component and the water.
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The appropriate amount of 2,2’ methylenediisocyanate and water can easily be
determined by performing some preliminary tests with various amounts of 2,2’
methylenediisocyanate in the B component and the premix used for creating the B
component and various amounts of water in the range of 0,1-1,5 % by weight of the
A component, in particular 0,4-0,6 % by weight of the A component.
The 2,2’ methylenediisocyanate monomer and a prepolymer in the B component
created from the above specified mixture of MDI monomers has been observed to
have a strong impact on the reaction velocity of the PU reaction mixture. The
optimum amount of said monomer and of the water may depend on the
particularities of the type of polymer of the A component, of the particularities and
amounts of other MDI monomers and the premix-polymer, if any. The amount of
water will typically be in the above specified range and the optimum amount of 2,2’
methylenediisocyanate may easily be determined by using a particular amount of
water, e.g. 0,5% of the A component and then testing the reaction velocity for
various amounts of the 2,2’ methylenediisocyanate.
According to embodiments, the water is added to the reaction mixture as a
compound of the A component.
According to embodiments, the water is added in an amount of 0,1% - 1,5% by
weight of the A component, more preferentially in an amount of 0,4 to 0,6 % by
weight of the A component, e.g. 0,5 % by weight of the A component. 0,5 % of the A
component typically correspond to 0,2 % to 0,3 % of the total reaction mixture. This
may be advantageous as said amount of water will be able to generate a sufficient
amount of CO2 gas to blow up the PU reaction mixture into a PU foam before the
PU solidifies. Thus, a highly elastic PU foam may be generated.
Typically, the A component comprises the polyol and a plurality of other
substances, e.g. additives, which typically do not contribute more than a few percent
to the total A component. As the polyol and the water do not react with each other,
they can be provided as a polyol-water mixture in a single container. Using an A
component that already comprises water may ease the handling of the reaction
educts and may ease the creation of the reaction mixture. Alternatively, the water
and the A component are respectively provided in a separate container, e.g.
separate boxes or bottles, and are added, together with the B component, to a
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reaction tank for providing the mixture of the reactive components. In some
examples, the container comprising the B component or the A component is used
as a reaction tank.
According to embodiments, the water is added to the reaction mixture and/or to the
A component in a free, non-zeolitbound form. Thus, a manufacturer of the A
component or a company that adapts a standard A component to the requirements
of artificial turf industry may add water in the above specified amount range to the A
component. This may ease the handling at the sport fields site because only two
reaction components, the A component and the B component have to be mixed with
each other. The A component may already comprise an appropriate amount of
water (which will not react with the polyol of the A component but will react with the
isocyanate groups of the monomers, MDI-polymers and of the prepolymer of the B
component). Thus, the handling of the reaction components at the sports facility
may greatly be facilitated.
According to embodiments, the method comprises adding a molecular sieve
material to the A component to adsorb and remove any moisture from the A
component. For example, the molecular sieve material can be a 3 Å molecular sieve
material.
According to some embodiments, the molecular sieve material is a zeolite of a first
type, e.g. a zeolite adapted to absorb large amounts of water quickly and adapted to
desorb the water only very slowly. For example, the first zeolite can be a sodium
aluminosilicate, e.g.: Na12Al12Si12O48·27H2O, zeolite A, Na16Al16Si32O96·16H2O,
Na12Al12Si12O48·q H2O, Na384Al384Si384O1536·518H2O.
Optionally, if the water is added to the reaction mixture as an ingredient of the A
component, the water is added after the moisture was removed from the A
component. Removing the moisture from the A component may be beneficial as it
ensures that the water that is later added to the A component or to the reaction
mixture as a further reaction component for producing the CO2 gas is present in the
reaction mixture exactly in the specified amount. The amount of water may be
critical, because if the amount of water would be too high, many CNO groups would
react into CO2 gas without forming PU, thereby resulting in a PU foam whose
resilience and mechanical durability is limited. If the amount of water would be too
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low, the amount of CO2 gas generated would not suffice to generate an elastic PU
foam.
According to some examples, the molecular sieve material is removed from the A
component before a defined amount of water is (intentionally) added to the A
component or the reaction mixture. This may ensure that the molecular sieve
material does not absorb the water that is deliberately added to the component A or
to the reaction mixture to generate the CO2 foam. Alternatively, the molecular sieve
material is added to the A component exactly up to an amount where it is completely
soaked with the moisture contained in the A component. For example, the state of a
molecular sieve material may easily be identified by a color change of the molecular
sieve material upon having absorbed water up to the capacity of the molecular sieve
material and the adding of the molecular sieve material to the A component may be
stopped immediately after having observed that newly added molecular sieve
material keeps its color as all moisture in the A component has already been
absorbed. According to other examples, the amount of molecular sieve material that
needs to be added to absorb the moisture in the ingredients of the A component is
determined empirically and/or heuristically. For example, the A component may
comprise a particular plant oil as extender, a particular polyol and a particular filling
material and the amount of molecular sieve material that is able to completely
absorb the moisture in said ingredients of the A component may be determined
heuristically and/or empirically. For example, in case a particular type of A
component typically comprises 0,4% of water as moisture, a first zeolite may be
added to the A component in an amount of 1% by weight of the A component, the
first zeolite being able to absorb water in an amount of up to 40% of its own weight.
Then, a further zeolite may be added that is soaked with a defined amount of water,
whereby the defined amount of water is desorbed and released slowly to react with
other components of the reaction mixture. Thus, in some embodiments, the water
that is used as a reactive component of the reaction mixture is added by means of a
second zeolite. In these embodiments, the water used as reaction component is
also referred to as “further water” as is may not be identical to an undefined amount
of water (“moisture”) that may be contained in other reaction mixture components.
According to embodiments, the B component comprises a mixture of monomers and
polymers respectively comprising one or more NCO groups. The polyol of the A
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component comprises one or more OH groups. The NCO groups in the B
component and the OH groups in the A component (without the water) have an
NCO/OH molar ratio in the range of 1.14:1 to 1.18:1, e.g. in the range of 1.15:1 to
1.17:1. This ratio may help to ensure that an appropriate amount of NCO groups
can react with the water to generate the CO2 as a foaming agent and an
appropriate amount of NCO groups can react with the polyol of the A component to
generate the PU polymer. For example, the totality of MDI monomers, the MDI
polymer and the prepolymer in the B component and the polyol in the A component
may have an NCO/OH molar ratio of 1.16:1. This means that in the reaction mixture
there are 116 NCO groups (provided by the B component) per 100 OH groups
(provided by the polyol of the A component lacking any water). This means that the
surplus 16 NCO groups can react with the water to form CO2 gas bubbles acting as
the foam blowing agent. Thus, the OH groups of the water and of the polyol
“compete” for the NCO groups of the B component, and CO2 is generated until
there is either no more water that can be released from a zeolite or until there is no
more isocyanate in the reaction mixture.
According to embodiments, the method further comprises adding a catalyst for
catalyzing a polyaddition reaction of the A component and the B component. The
catalyst is added to the reaction mixture in an amount that catalyzes the generation
of the solid polyurethane foam at a speed that prevents the generation of the solid
polyurethane foam before at least 30 minutes has lapsed since the generation of the
reaction mixture. Typically, this amount of the catalyst is about half of the amount of
said catalyst that is used for generating PU foam mats in an artificial turf
manufacturing plant. This may be further ensure that the generation of the PU
polymers is retarded and a PU foam is generated rather than an un-foamed PU
mass.
For example, the catalyst for the polyaddition reaction can be di-n-octyltin
neodecanoate in an amount of 0,0008 % to 0.0011% by weight of a combination of
the A component and the water, e.g. 0,001 % by weight of the A component and the
water. The catalyst may be an ingredient of the A component or added separately
when generating the reaction mixture. Alternatively, the catalyst may be di-butyl-tin-
dilaureat or an amine catalyst, in particular a tertiary amine catalyst. Examples of
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amine catalysts are PolyCat DBU and PolyCat 4. Preferentially, the amine catalyst
is added to an amount equal to or less than half of the amount of amine catalyst
used for generating PU for artificial turf in a manufacturing plant, whereby the
specific amount of the catalyst may depend from the respective type of catalyst
used.
Using the catalyst(s) in the above specified amount ranges for controlling the speed
of the gellation reaction may be advantageous as the catalyst ensures that the
chemical reaction for generating the PU foam will terminate within several hours,
e.g. six hours after having applied the PU reaction mixture on the ground, but will
typically not terminate within the first 10 minutes after applying the mixture on the
ground. Thus, the reaction speed of generating PU by connecting NCO groups of
molecules of the B component with OH groups of the polyol is controlled to ensure
that the PU polymer is neither generated too fast (too fast means: at a speed that
would cause the flooring to be less elastic because the majority of the water is still
absorbed by a zeolite and when the PU is generated and solidified, thereby causing
the not yet solidified PU to collapse as the small amount of CO2 generated at that
early state is not enough to generate a PU foam) nor too slow (too slow means: at a
speed that would cause the flooring to be less elastic because the PU may solidify
in a late state when the majority of the water has already reacted into CO2 bubbles
that have left the reaction mixture when the PU foam solidifies).
According to embodiments, the method further comprises adding a second zeolite to
the reaction mixture. The second zeolite is soaked with the water (that is used as
reactive component of the reaction mixture and that is also referred to as “further
water” as it may be supplied in addition to or instead of an amount of water that is
already contained as “moisture” in one of the reaction components) and is adapted
to desorb at least 20% of the water to the reaction mixture within 60 minutes after
creation of the reaction mixture. The combination of a first and a second zeolite and
a defined amount of water added in free form to the reaction mixture may ensure
that the amount of water that is added can be determined and controlled highly
accurately, resulting in a high reproducibility of the properties, in particular the
elasticity, of the resulting PU foam.
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Adding a second zeolite that slowly releases water into the reaction mixture may be
particularly advantageous in case of high ambient temperatures an additional
amount of water is provided that slowly but continuously reacts with the isocyanates
to generate CO2 bubbles acting as foaming agent. By choosing the appropriate
amount and type of second zeolite, the CO2 production can be boosted to
counteract the decreased viscosity and increased PU polymerization speed for
multiple hours. While the first zeolite that may be used for drying the reactive
components may be a zeolite that strongly absorbs water and that releases water
only very slowly or not at all, the second zeolite is typically a zeolite that
continuously desorbs a significant portion of its bound water, e.g. 20% or more,
within 30 to 60 minutes after having been added to the reaction mixture.
According to embodiments, the method further comprises acquiring a temperature
of the ground of the sports field. For example, the apparatus or vehicle used for
applying the liquid PU reaction mixture on the sports ground may comprise a
thermometer or may comprise a data processing unit connected to the internet and
being configured for retrieving current temperature data for the sports field from a
weather service. The apparatus or device may comprise, for example, a GPS
module allowing the apparatus or device to automatically determine the current
location of the apparatus or device and to retrieve current weather data for the
sports field from one or more weather services via the internet. The amount of the
second zeolite depends on the measured ambient temperature. The higher the
temperature, the higher the amount of the second zeolite with its adsorbed (further)
water that is added to the reaction mixture. An appropriate amount can be
determined for each specific combination of an A component and a B component
experimentally, e.g. in some preparatory text runs under different temperatures.
This may be advantageous as said features may allow adopting the method to very
hot areas, e.g. Dubai or other states having similar climatic conditions. Typically, the
method as described herein can be applied on a very wide temperature area.
However, in case the temperature of the ground and the ambient temperature is
very high, two effects occur which may – if not compensated by appropriate
countermeasures – result in the generation of a PU foam with low elasticity (not
enough CO2 bubbles were present during solidification). One effect is that with
growing temperature, the PU reaction mixture is less viscous. Thus, the CO2
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bubbles reach the surface of the PU reaction mix much faster and have a shorter
resting time within the PU reaction mixture and thus also have a shorter time to act
as blowing agent. In a second aspect, the speed of the addition reaction between
the polyol in the A component and the isocyanate molecules in the B component
increases with an increase of the temperature of the reaction mix.
Thus, as a consequence of a high ambient temperature, the majority of PU
polymers may have formed before a sufficient amount of CO2 gas could be
generated that rests in the reaction mixtures long enough to allow for the creation of
a flexible solid foam. By adding water that is continuously released by the second
zeolite, said two accelerating effects on the reaction can be compensated: the water
is released slowly and continuously, thereby ensuring that throughout the generation
of the PU polymer a sufficient amount of CO2 gas is generated in the mixture. The
type and amount of the second zeolite is chosen such that the zeolite continues
releasing water at least as long as the chemical reaction that generates urethane
linkages continues. For example, the second zeolite can be a hydrated Clinoptilolite
zeolite, a potassium aluminosilicate, a calcium aluminosilicate, a sodium
aluminosilicate, etc. Preferably, the second zeolite has a high water absorption
capacity and/or a fast water desorption rate.
According to some examples, the method further comprises acquiring a current
temperature at a current time and a future temperature at a future time of the ground
of the sports field. For example, the current time could be measured by a
thermometer of the vehicle or apparatus that applies the PU reaction mixture and/or
could be retrieved from a weather service via the internet and a network interface of
said vehicle or apparatus. Likewise, the future temperature could be retrieved from
said weather service by sending current location information, e.g. GPS data, from
the apparatus or vehicle to the internet service. The future time for which the future
temperature is predicted and received is typically in the range of 2-24 hours later
than the current time. Selectively in case the current and the future temperature are
in a range of 5°C to 40°C, the reaction mixture as described herein without adding
any further zeolite bound water may be applied. However in case the current
temperature or future temperature exceeds 30°C, adding the second zeolite with the
zeolite-bound water to the reaction mixture may be beneficial and help to ensure
that a sufficient amount of CO2 is generated during the polyaddition reaction. At
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least in case the current or future temperature exceeds or is predicted to exceed
40°C, the second zeolite that is soaked with water to its capacity is added to the
reaction mixture to increase the amount of CO2 gas generated.
According to embodiments, the method comprises generating the B component by:
- creating an MDI premix comprising:
o 2,2’ Methylendiphenyldiisocyanate in an amount of 0,3%-7% by weight of the
MDI premix, preferably in an amount of 4%-7% by weight of the MDI premix;
o diphenylmethane-2,4’-diisocyanate in an amount of 10%-35% by weight of
the MDI premix;
o diphenylmethane-4,4’-diisocyanate in an amount of 10%-45% by weight of
the premix; and
o MDI-polymers consisting of two or more of said diisocyanate monomers in
an amount of 0%-30% by weight of the MDI premix;
- mixing the MDI premix 940 and a premix polyol for letting the MDI premix
components and the premix polyol generate the B component, the B component
comprising:
o an aromatic isocyanate prepolymer; and
o unreacted educts of the premix and the premix polyol.
Then, the components of the B component premix are allowed to react with each
other (which may typically achieved already at room temperature and/or in
accordance with standard techniques known in PU polymer chemistry to generate
prepolymers of the B component) to generate the B component. The resulting B
component comprises an aromatic isocyanate prepolymer generated from the
educts in the MDI premix and the premix polyol. The prepolymer is generated in an
amount of 54 – 70 % by weight of the B component and unreacted educts of the
premix and of the premix polyol in an amount of 30 - 46 % by weight of the B
component. The relative amounts of the MDI monomers (2,2’ Methylen-
diphenyldiisocyanate, diphenylmethane-2,4’-diisocyanate and diphenylmethane-
4,4’-diisocyanate) typically does not change significantly during this reaction. Some
of the monomers react with each other to form an “MDI polymer” which may also be
contained in the MDI premix. The monomers and the MDI polymer will react with the
premix polymer, e.g. a polyether polyol to form the prepolymer, also referred herein
as premix product, which is an ingredient of the B component.
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The premix polyol, i.e., the polyol used for generating the prepolymer, can be the
same type of polyol as the polyol of the A component. However, it is possible that a
different polyol are used which preferentially have a similar molecular weight. For
example, the premix polyol can be a polyether polyol and the polyol of the A
component can be a polyethylene.
The above given amount ranges have been observed as being particularly suited for
generating an in-situ PU foam over a broad temperature range of 5°C to 40°C in a
controlled and reaction-retarded manner.
According to embodiments, the NCO content of the B component being between
1.5% and 18% by weight of the B component, in particular between 9% and 14%,
e.g. 10% by weight of the B component.
According to embodiments, the MDI premix comprises a mixture of isocyanate
monomers and optionally the MDI polymer and is used, for generating the
isocyanate prepolymer. The MDI premix comprises the 2,2’ Methylendiphenyldiiso-
cyanate in an amount of 1,0 to 7 % by weight of the MDI premix. This particular
amount of the 2,2’ Methylendiphenyldiisocyanate has been observed to be
particularly effective in retarding the reaction speed of the PU polymerization.
According to embodiments, the NCO content of the B component is the weight ratio
of unreacted MDI monomers (2,2’ Methylendiphenyldiisocyanate, diphenylmethane-
2,4’-diisocyanate and diphenylmethane-4,4’-diisocyanate) and the MDI polymer to
the total weight of the B component, i.e., a measure of the isocyanate content of the
B compound that can be used for generating PU.
Using a B component whose prepolymer has the above specified NCO content
and/or which comprises the above specified amount of 2,2’ MDI monomer is
particularly advantageous as this combination results in a retardation of the
generation of the foamed PU that allows to apply the reaction mixture on the ground
without risking an immediate explosion of the reaction mixture and without a volume
expansion of the reaction mixture that would prevent the controlled application of the
reaction mixture to the ground.
According to embodiments, the B component comprises an isomeric mixture of the
three above mentioned MDI monomers, an MDI based polymer, a premix polymer
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(said four compounds are also referred to as “B component educts”) and a NCO
terminal prepolymer generated from two or more of said four components
(“products”). About 40% by weight of the resulting B component may comprise said
four unreacted educts and about 60% of the B component may consist of a reaction
product of said educts in the form of a prepolymer.
The expression “substance mixture M having an NCO content of Z %” as used
herein refers to the function “Z= (weight of unreacted NCO-monomers and MDI
polymer x 100%)/ total weight of the substance mixture M.
Polyurethane prepolymers are formed by combining an excess of diisocyanate
monomers with a premix polyol. One of the NCO groups of the diisocyanate
monomers reacts with one of the OH groups of the premix polyol. The other end of
the polyol reacts with another diisocyanate. The resulting prepolymer has an
isocyanate group on both ends. The prepolymer is a diisocyanate itself, and it reacts
like a diisocyanate but with several important differences. When compared with the
original diisocyanate, the prepolymer has a greater molecular weight, a higher
viscosity, a lower isocyanate content by weight (%NCO), and a lower vapor
pressure. Prepolymers can be made under controlled conditions in a manufacturing
plant. A dry nitrogen atmosphere protects isocyanates from atmospheric moisture
and protects polyols from oxidation.
The above mentioned isomeric MDI monomer mixture and the relative amounts of
polyol-OH groups and NCO groups of the monomers that react into a prepolymer
having the above mentioned NCO content may be advantageous as these factors
result in a comparatively high viscosity of the prepolymer. The high viscosity and the
steric properties of the prepolymer result in a retardation of the PU foam generation
that allows adding water to the reaction mixture without triggering an immediate,
significant volume expansion or explosion by the generated water. In a further
beneficial aspect, the increased viscosity of the prepolymer that is part of the B
component may be able to slow down the escaping of the gas bubbles from the
reaction mixture. Typically, a catalyst is not used in prepolymer reactions. The
prepolymer may be generated by stirring and heating the above mentioned MDI
monomer mixture to approximately 60°C. The polyol is then added at a slow rate to
keep the MDI mixture liquid and control the exotherm. The progress of the
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reaction can be monitored by periodic measurements of %NCO and viscosity. The
amount of isocyanate and polyol needed to form a prepolymer with a given %NCO
may be computed from the polyol equivalent weight X, the isocyanate equivalent
weight Y and N as the desired % NCO of the prepolymer (as a fraction). If 1
equivalent each of the premix polyol and isocyanate (provided in the form of MDI
monomers) is mixed, a 0 %NCO prepolymer will result. By increasing the relative
amount of MDI monomers relative to the polyol, a %NCO that is larger than 0 can
be obtained.
For example, the B component may have a viscosity (that is mainly determined by
the type of prepolymer which again depends on the type and amount of the MDI
monomers) of 2500 – 3500, preferentially 3200mPas /25°C. This may be
advantageous as this viscosity may ensure that the CO2 bubbles rest for a
sufficiently long time interval in the PU reaction mixture to allow for the generation of
a flexible PU foam. Polyols of the desired viscosity are available commercially.
According to embodiments, the 2,2’ methylendiphenyldiisocyanate is comprised in a
mixture of isocyanate monomers used for generating the B component to an amount
of 1,0 to 7 % by weight of said mixture. Said mixture is also referred herein as
“premix”, “MDI premix” or “pre-mixture”. This amount of the particular monomer 2,2’
methylendiphenyldiisocyanate has been observed to be particularly effective in
retarding the reaction speed of the polyaddition reaction that creates the PU
polymer.
According to some embodiments, the polyol of the A component being a primary
hydroxyl terminated diol of the molecular weight 1000- 4000 Dalton. For example,
said polyol may be polyethylene (PE).
According to embodiments, the polyol of the A component has a viscosity of 2500 to
3500 mPas/25°C. This may be advantageous as this viscosity may ensure that the
CO2 bubbles rest for a sufficiently long time interval in the PU reaction mixture to
allow for the generation of flexible PU foam. Polyols of the desired viscosity are
available commercially.
In accordance with some examples, at least the B component and the A component
are held separately in an apparatus or vehicle. For example, the apparatus or
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vehicle may comprise a first tank for the A component including the water and may
comprise a second tank for the B component. Alternatively, the water may be stored
not as part of the A component but as a separate reaction component in a third tank.
In some examples, all reactive components are held in the apparatus or vehicle in a
predetermined temperature range and are pumped in a prefixed ratio through a
static mixer before being applied on the ground.
For example, the ground can be concrete, soil or wood or any other kind of material.
The reaction mixture is applied to the ground directly in the absence of an adhesive
layer. An adhesive layer may not be necessary as the reaction mixture is sufficiently
fluid to infiltrate depressions and wells and to level out depressions and other
irregularities of the ground (“floating floor”).
According to embodiments, applying the reaction mixture to the ground comprises
applying a first lane of the reaction mixture to the ground. Before the foam of the first
lane has solidified, a second lane of the reaction mixture is applied to the ground
such that a side edge of the second lane is in contact with a side edge of the first
lane. Thus, multiple parallel lanes of the reaction mixture may be applied which
intermix at the lane edges in a highly viscous but liquid state automatically. This may
allow the foam of the first and second lane to intermix at the contact edges of the
lanes before the foam of both lane solidifies. Thus, no additional working step for
sealing or gluing the different lanes to each other is necessary. In some examples, a
water-proof coating is applied directly on multiple lanes without a preceding step of
attaching the two lanes to each other.
According to embodiments, the reaction mixture is applied to the ground by a
vehicle or by an apparatus carried by a user. The method further comprises
automatically determining the position and/or the speed of the vehicle or apparatus
used for applying the reaction mixture to the ground; and automatically adjusting the
type and/or quantity of reactive components mixed together to generate the reaction
mixture in dependence on the position and the speed of the vehicle or the user
carrying the apparatus. For example, the amount of reactive components mixed
together in a given time minute may be automatically adapted to the movement
speed of the person or the vehicle, thereby ensuring that a constant volume of the
liquid PU reaction mixture is applied per area unit of the sports field ground. The
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total amount of PU reaction mixture per area unit may depend on the particular
requirements of the sports field regarding e.g. elasticity of the flooring. Typically, the
solidified PU foam will have a thickness of about 1 to 5 cm.
According to embodiments, the method comprises applying, after the applied
polyurethane foam has solidified or hardened, a sealing coating. The sealing coating
preferentially covers multiple lanes of the polyurethane ground. The application of
the sealing coating comprises skipping any operation for gluing adjacent lanes to
each other (as known from prior art methods which apply prefabricated patches of
artificial turf.
In a further aspect, the invention relates to a system for producing a polyurethane
flooring for a sports field as specified in the independent system claim.
For instance, the system comprises an A component, a B component and water.
The A component is a polyol mixture. The B component is an isocyanate mixture.
The water may be added separately or as part of the A component. In any case, the
water and the B- component are stored in different containers. The system further
comprises a mixer for mixing the A component, the B component and the water for
generating a liquid polyurethane reaction mixture and a nozzle. The nozzle is
coupled to the mixer for applying the polyurethane reaction mixture to a ground of
the sports field before chemical reactions in the reaction mixture have generated a
solid polyurethane foam. After its solidification, the polyurethane foam is to be used
as the polyurethane flooring of the sports field. The composition of the reactive
components and the reaction mixture may correspond to any of the embodiments
and examples described herein, including the embodiments and examples
presented for the method of generating the PU based flooring.
In a further aspect, the invention relates to a portable apparatus comprising said
system. For example, the apparatus may comprise at least two separate containers
or tanks for storing the A component and the B component separately. Optionally,
the apparatus may comprise a thermometer or a network interface for receiving
temperature and weather data from a remote weather service, and/or may comprise
a GPS module for automatically determining the position and/or velocity of the
apparatus. Said data may be used automatically for determining the amount of
reactants mixed together per time unit, the amount of the second zeolite soaked
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with water to be added to the reaction mixture, if any, and to determine if the
application of the PU foam should be postponed due to heavy rainfall (drizzle rain
will in many cases not preclude the application of the PU reaction mixture).
In a further aspect, the invention relates to a vehicle comprising said system. The
vehicle can be, for example, a paving machine.
For example, the first and second containers may be boxes, bottles or other forms
of containers which comprise the reactants, and optional additive substances such
as catalysts, fungicides, flame retardants, pigments, filler materials or the like. At
least the A component and the B component are contained in different containers to
prevent a premature start of the reaction. The reaction tank may comprise the
nozzle as an integral part or may, alternatively, be coupled to the nozzle via a duct
such that the PU foam generated in the reaction tank upon mixing the reactive
components is applied to the ground via the duct and via the nozzle. For example,
the first and second containers can be an integral part of an apparatus or vehicle
comprising the reaction tank and the nozzle. Alternatively, the first and second
containers are separate, mobile containers, e.g. transport containers, which are
merely used as carriers for providing the educts such that the educts can be added
to the reaction tank manually.
According to some examples, all reactive components can be stored in a reaction
tank of the apparatus or vehicle and can be pumped in a predefined ratio through a
static mixer before being applied on the ground. The first and second containers and
the nozzle can be coupled to the reaction tank of the apparatus or vehicle via a
respective duct. It is also possible that the reaction tank lacks a mixer. In this case,
a user has to manually mix the reaction components. Optionally, the reaction tank or
the apparatus comprising it may be actively heated and/or cooled to have a
predetermined temperature in the range is between 5° C and 45° C, more
preferentially between 10° C and 25 °C, or is selectively used in case the
environment temperature is within said temperature range.
The solidification and curing of the applied PU reaction mixture typically takes 30
minutes to several hours and is performed at the environmental temperatures which
preferentially should be in the range of 5-45°C.
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In a further aspect, the invention relates to a PU flooring of a sports field
manufactured by a method according to any one of the embodiments and examples
described herein.
According to embodiments, the position and/or the speed of the vehicle or
apparatus used for applying the foam to the ground is measured, e.g. by a GPS
device contained in or coupled to the vehicle or apparatus, and the process
parameters (e.g. mixing speed, foam output per time unit amount of educts used
and added to the reaction mixture per time unit) and the type and quantity of
components (e.g. A component, water, B component, catalyst, etc.) are adjusted
depending on the position and the speed of the vehicle or the user carrying the
apparatus. Thus, the PU foam output may automatically and dynamically be
adjusted e.g. in dependence on the movement speed of the vehicle or the user
carrying the PU foam application apparatus. This may ensure that the PU foam is
applied evenly and homogeneously on the ground of the sport field irrespective of
the (variable) movement speed of a user.
According to embodiments, the method further comprises mixing rubber granulates
into the foam before applying the foam to the ground. The rubber granules may
further increase the elasticity of the ground and may provide for a pleasant, natural
haptic of the generated PU-based sport field.
According to embodiments, the method further comprises: applying, after the
polyurethane foam has solidified or hardened, a sealing coating. The sealing coating
preferentially covers multiple lanes of the polyurethane ground. The application of
the sealing coating comprises skipping any operation for gluing adjacent lanes to
each other. This “gluing/adhesive” step for attaching PU-edges of different lanes to
each other can be avoided as the not yet solidified PU foam masses of the two
lanes automatically intermix when they are brought in contact with each other. Thus,
the step of applying the sealing coating can be performed as soon as the PU form
has completely hardened, typically within one or a few days. The sealing coating
improves the water resistance of the PU foam. For example, the sealing coating
may be a PU varnish.
In a further beneficial aspect, embodiments of the invention are robust against rain
even before the PU foam has solidified, at least in respect to drizzling or normal
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rain. This is because rain falling on the surface of the non-yet solidified PU foam
automatically results in the creation of a protective PU film that prevents the rain
from reaching inner regions of the PU foam. The surface may have become rough
due the rain drops. However, according to embodiments, this the surface of the
solidified PU foam on the ground of the sport field can easily be smoothed by
grinding off the rough surface generated by the rain drops and then sealing the
smoothed surface.
Thus, in a further beneficial aspect, the reactants used for PU foam generation
according to embodiments of the invention are chosen such that the PU generation
is retarded: even a direct contact with water, e.g. with rain drops, does not lead to
an explosion of the reaction mixture (as would be the case with standard reaction
mixtures used for quickly generating PU foam in a factory hall).
“Polyurethanes” (PU) as used herein are any type of polymer containing a urethane
linage. The urethane linkage (carbamate group) is -NH-CO-O-. PUs are formed by
reacting isocyanates with compounds that have an active hydrogen, such as diols,
that contain hydroxyl-groups, typically in the presence of a catalyst. Since there are
many compounds containing active hydrogens and many different diisocyanates,
the number of polyurethanes that can be synthesized is also large. The specific
properties of the polyurethane can be tailored to a specific need by combining the
appropriate compounds. Polymers are macromolecules made up of smaller, repeating
units known as monomers. Generally, they consist of a primary long-chain
backbone molecule with attached side groups.
A “vehicle” as used herein is a self-propelled, commonly wheeled, machine that is
manually or automatically controlled and that is used for applying PU reaction
mixture on a ground of a sport field. For example, the vehicle may be a paving
machine comprising a reaction tank, two or more tanks for the educts and a nozzle
for applying the generated PU reaction mixture on the ground. At the moment of
applying the PU reaction mixture, the PU reaction mixture may already comprise
some products, i.e., PU polymers, but the majority of PU polymers are generated
after having applied the reaction mixture on the ground.
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An “apparatus” as used herein is a portable device that can be carried by a user and
used to apply the foam generated in the reaction tank to the ground. Typically, the
apparatus is used for in-situ PU foam generation for smaller sport fields.
An “sport field”, “pitch” or “sports ground” as used herein is an indoor or outdoor
playing area for various sports, e.g. soccer, tennis, hand ball, sprint races and
others.
A “zeolite” as used herein is a substance, e.g. a microporous aluminosilicate
mineral, which has the capability of absorbing water and releasing the absorbed
water gradually over a period of time typically comprising multiple minutes, hours or
even days. According to embodiments, a first zeolite is used for drying the reaction
components, in particular the A component, and a second zeolite is added to the
reaction mixture for slowly releasing absorbed water. The released water can act as
a reaction partner in a chemical reaction with a B component that creates CO2 gas.
Zeolites have a porous structure that can accommodate a wide variety of cations,
such as Na+, K+, Ca2+, Mg2+ and others. These positive ions are rather loosely
held and can readily be exchanged for others in a contact solution. In some
embodiments, naturally occurring Zeolites are used. In other embodiments, zeolites
are used that are industrially produced. Some of the more common mineral zeolites
are analcime, chabazite, clinoptilolite, heulandite, natrolite, phillipsite, and stilbite.
An example mineral formula is: Na2Al2Si3O10·2H2O, the formula for natrolite.
Naturally occurring zeolites are rarely pure. For this reason, industrially produced
zeolites are preferentially used due to their uniformity and purity.
An “NCO/OH molar ratio” or “isocyanate index” as used herein is the ratio of the
reactive groups of the polyol of the A component and the B component used in a
polymerization reaction to generate polyurethane. For an isocyanate, the reactive
group is -N=C=O (NCO). The reactive group for a polyol is -O-H (OH). Typically,
when generating polyurethane in a factory, the molar ratio of NCO and OH is one or
very close to one, e.g. 1,02. Embodiments of the invention use a highly unusual,
high NCO/OH molar ratio. This high ratio may allow generating a large amount of
CO2 upon an isocyanate reacting with water to form an –NH2 group and a CO2
molecule. This reaction is performed in the mixture of reactive components in
parallel and in competition to the polymerization reaction that connects the
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isocyanate molecules and the polyol molecules to form the PU. Thus, the
isocyanate index is the ratio of the equivalent amount of isocyanate used relative to
the theoretical equivalent amount times 100. The theoretical equivalent amount is
equal to one equivalent isocyanate per one equivalent OH group of the polyol.
Depending on the molecular weight of the polyol and of the isocyanate used, this
isocyanate index can be obtained by mixing different parts by weight of the polyol
and the isocyanate and respective components.
When reacting an isocyanate in one or more polyols to form a polyurethane, one
NCO group reacts with one OH group. When the number of NCO groups equals the
number of OH groups, a stoichiometric NCO:OH ratio of 1.0 is obtained. This ratio is
commonly referred to as the “index”. To determine the amount of isocyanate
required to react with a given polyol, the desired index (often 1), the isocyanate
equivalent weight and the weight fractions and equivalent weights of the polyols and
water to be added to the reaction mixture is taken into account.
An “isocyanate component” or “B component” as used herein is a substance or
substance mixture comprising at least an isocyanate and optionally further
substances, e.g. one or more different isocyanates or additives.
A “polyol component” or “A component” as used herein is a substance or substance
mixture comprising at least one polyol, e.g. a diol, and optionally further substances,
e.g. one or more different polyols and/or additives. Optionally, the A component may
also comprise the water used as educt in the blowing reaction to produce the CO2
to act as the blowing agent when generating the PU foam.
A “foam” as used herein is a colloidal dispersion of a gas in a liquid or solid medium.
At the moment when the foam is applied on the ground, the foam is a colloidal
dispersion of gas in a liquid medium, e.g. a liquid, viscous reaction mixture
comprising all necessary educts for generating PU and for continuously generating
CO2 until PU generation has completed. At least a small fraction of the liquid
reaction mixture may have already reacted into PU at the moment of applying the
liquid PU foam on the ground, whereby the remaining fraction of the reaction
mixture may not yet have reacted into PU. The gas may be, for example, CO2
generated by a reaction of water with the B component. The remaining fraction may
react into PU within the next few, e.g. 6 hours after having applied the liquid foam on
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the ground, whereby the CO gas bubble production continues until said reaction has
completed.
The “hydroxyl number” is the number of milligrams of potassium hydroxide required
to neutralize the acetic acid taken up on acetylation of one gram of a chemical
substance that contains free hydroxyl groups. The hydroxyl value is a measure of
the content of free hydroxyl groups in a chemical substance, usually expressed in
units of the mass of potassium hydroxide (KOH) in milligrams equivalent to the
hydroxyl content of one gram of the chemical substance.
Brief description of the drawings
In the following embodiments of the invention are explained in greater detail, by way
of example only, making reference to the drawings in which:
Figure 1 depicts the application of in-situ generated PU foam on a sport field
ground;
Figure 2 depicts an athletic track comprising multiple lanes;
Figure 3 depicts the automatic intermixing of adjacent PU foam lanes;
Figure 4 depicts three fresh PU foam lanes;
Figure 5 depicts a paving machine that applies PU foam on the ground;
Figure 6 is a flowchart of a method of generating a PU-based flooring of a
sports ground;
Figure 7 depicts the gellation reaction for generating PU;
Figure 8 depicts the blowing reaction for generating CO2 as the blowing agent;
Figure 9 depicts the composition of the A component and of the B component.
Detailed description
Figure 1 depicts the application of in-situ generated PU reaction mixture 128 on a
sport field ground 103. A user 102 carries a portable apparatus 101 comprising a
reaction tank 154 with a mixer 156 that is coupled to a nozzle 124 via a duct. The
system comprises a first container 160 with a B component and a second container
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162 for the A component. In the depicted example, the A component comprises an
exactly defined amount of water, while all other substances of the A component may
have been dried in a pre-processing step with the help of a first zeolite. The amount
of water and the type and amount of polyol and isocyanates are chosen such that a
sufficient amount of CO2 is continuously generated in a blowing reaction for
boosting the generation of the PU foam. Optionally, the reaction mixture comprises
a second zeolite with absorbed water for boosting the blowing reaction in case the
ambient temperature is high. The first and second containers can be coupled
directly to the mixer 156 or can be coupled indirectly to the mixer via the reaction
tank 154. In other examples, the first and second containers may simply be
transport containers which are not coupled to the reaction tank and are merely used
for transporting the reactants and for filling the reactants into the reaction tank. The
viscosity of the PU reaction mixture 128 generated by the blowing reaction and the
gellation reaction that happen in parallel may depend on the specific composition of
the reaction mixture in the reaction tank 154. Preferentially, the viscosity is low
enough to allow self-levelling of the viscous liquid PU reaction mixture or PU foam
128 into a plane PU foam layer that slowly solidifies into a foamed PU based
flooring 129 of a sport field. Thus, uneven ground surfaces, damaged areas and
hollows in the ground are filled by the PU foam and an even PU foam layer is
generated that solidifies after some hours to form the PU based, elastic flooring of
the sport field. However, the viscosity should be high enough to retain the CO2
bubbles to allow the PU foam to build.
The PU foam is allowed to dry and solidify completely. Depending on the
temperature and other weather conditions, complete solidification is typically
accomplished within 1 to 15 hours after the mixing of the reactive components, e.g.
between 6 to 10 hours after the mixing of the reactive components.
The water can be contained in a separate container or can be part of the A
component contained in the second container. The A component, the B component
and the water may be provided in a step 502 of a method shown in Fig. 6. For
example, said substances can be provided by a user who adds said substances to
the first or second containers or who adds said substances directly in the reaction
container.
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In step 504 the mixer mixes all components of the reaction mixture, i.e., all reactive
components for producing polyurethane foam and optionally one or more of the
additives and/or filler materials mentioned above. By mixing the A component, the B
component and the water, chemical reactions, in particular a gellation reaction that
generates PU polymers and a blowing reaction that generates CO2 as a blowing
agent are triggered which in effect result in the generation of PU foam.
The composition of the reaction mixture, in particular the amount of water and the
MDI monomers in the B component are chosen such that the formation of CO2 is
performed at the same time as the urethane polymerization (gellation) is occurring.
The carbon dioxide is generated by reacting isocyanate with the water.
When the mixer has mixed the reaction mixture homogeneously, the reaction
mixture starts generating PU polymers and CO2 gas bubbles and is referred to as
“PU liquid” or “liquid PU reaction mixture” although the chemical reactions for
generating the PU foam may immediately start and may immediately generate some
CO2 bubbles. The PU reaction mixture is transported from the mixer to a nozzle 124
and is applied directly on the floor of a sport field. The user 102 may apply multiple
lanes of the PU reaction mixture to generate the PU flooring for a larger area.
Preferentially, the PU reaction mixture is applied on an outdoor ground, but it is also
possible to apply the method for generating indoor sport field floorings. In solidified
and dried state, the PU foam 129 is used as the polyurethane flooring of the sport
field.
Optionally, the solidified PU layer 129 can be coated with a protective and water
repellent layer 127 (“coating”), e.g. for increasing the resistance of the flooring to
heat, UV light, rain, fungi and other factors (see Fig. 1b) and/or to give the flooring a
desired color.
Figure 4 shows one embodiment of a PU flooring of a sport field comprising multiple
lanes and figure 3 depicts the automatic intermixing of adjacent PU foam lanes.
The ground 103 to be applied with a polyurethane flooring is a rectangular sports
field 136 with a length 138 and a width 140. The ground 103 may be prepared, e.g.
concreted and/or leveled, or unprepared. The user 102 may use a portable
apparatus 101 as shown in Fig. 1a or a vehicle 100 as shown in Fig. 5 for applying a
lane of the liquid foam 128 having a width 142 which is smaller than the width 140 of
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the sports ground 136. Therefore, the PU reaction mixture is applied to the ground
103 in lanes 144, 146, 148, wherein adjacent lanes 144, 146, 148 are in contact with
each other. The foam of a second lane 146 which is applied after the foam of a first
lane 144 immediately intermixes with and generates a coherent mass with the foam
of the first lane 144 (see figure 3) so that a side edge 150 of the first lane 144 is in
contact with the side edge 152 of the second lane 146. The side edge 130 would
contact the side edge of lane 148 once said lane is applied on the ground.
In case a vehicle is used, the vehicle may comprise a levelling unit 126 and an
injection unit 126. The levelling unit is wider in shape than the injection unit 124 so
that the levelling unit 126 can smooth the transition from the first lane 144 to the
second lane 146.
Figure 2 schematically shows a second embodiment of a method for applying foam
for a polyurethane flooring to a ground 103 of an athletic track comprising multiple
lanes. In this embodiment, the sport field is an oval track field. The user with the
apparatus 101 or with the vehicle 100 moves around the field applying the PU
reaction mixture 128 that slowly starts to foam. The second lane 146 connects at the
starting point of the first lane 144, whereby the apparatus or vehicle moves radially
inwards so that the path of motion of the apparatus 100 is spiral.
Independently from the geometry in which the reaction mixture is applied to the
ground, the foam/mixture of the first lane 144 should be in a liquid state when
applied the adjacent second lane 146. If the foam 128 of the first and the second
lanes 144, 146 are both liquid respectively not cured, the foam of both lanes 144,
146 is mixed up in the contact zone and/or bond firmly together to improve a
continuous polyurethane flooring. Furthermore, the user 102 can use a levelling unit
126 of the vehicle or a mechanical tool to smooth the PU foam to produce an even
and smooth surface 129.
Therefore, the method comprises applying the foam of the second lane 146 before
the foam of the first lane 144 solidifies (is cured). Especially in hot, dry climate
conditions and floorings with large expansions it is important to start applying the
second lane shortly, preferentially within 30 minutes or one hour after having
generated the first lane, to prevent that the curing process may have started before
the second lane is applied to the ground 103.
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To avoid an early curing process, the components of the reaction mixture used for
generating the PU foam and the process parameters of the mixing process can be
customized to the environmental conditions.
Distributing various sensors 132 at different positions of the ground may have the
advantage that the environmental data of an unfavorably positioned sensor 132 can
be compensated for. For example, one sensor can be positioned in shadow so that
the temperature of this sensor is lower than the temperature of the remaining
ground. For example, the mixture can be customized such that the process
parameters enable the deposition of the foam using the worst measured
environmental conditions of the sensors. For example the highest measured
temperature. Alternatively, a map of the environmental data may be created and the
mixture and the process parameters are customized continuously on the basis of
this map and the current position of the apparatus 100.
Furthermore, additional environmental data may be taken into account, for example
a weather forecast, a time of the day or the relative humidity. Due to the weather
forecast and the time of day a rising of the temperatures during the process may by
predicted in order to adapt the mixture and the process parameters to the rising
temperatures. For example, additional environmental data may be received from a
meteorological service.
The environmental data may be measured at the beginning of the process or
continuously in order to adjust the mixture and the process parameters continuously
to the environmental data. The environmental data may be stored to a memory of
the control unit 134. The stored data may be used to improve the prediction of
temperatures or to control the current mixing process.
In a further embodiment, the position and/or the speed of the apparatus 100 may be
determined by additional sensors. By this information, the control unit 134 may
calculate the time between applying the first and the second lanes, calculate the
required curing time and adapt the mixture and the process parameters of the foam.
Figure 5 depicts a system 100 in the form of a paving machine that applies PU
reaction mixture 128 on the ground as depicted in Fig. 1. The PU reaction mixture
128 consists essentially of two reactive components, A B component and an A
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component that may in addition comprise a defined amount of water as a further
reactive component. Depending on the desired properties of the flooring, various
polyurethane forming ingredients, for example chemical additives, compressed air
or other additives may be added. The composition and amount of the reactive
components and the additives, e.g. catalysts and/or a second zeolite soaked with
additional water to compensate high temperatures, may influence the speed of PU
polymer generation and/or the speed of CO2 production as well as mechanical
properties of the flooring, the resistance to climate conditions, the water absorbency,
the viscosity of the PU foam, the stability of the PU foam, the curing time, the color
or other characteristics of the flooring.
For example, the additives may comprise emulsifiers and/or foam stabilizers, e.g.
high sheer resistant silicone foam stabilizers. Catalysts might be used to moderately
enhance the reactivity of the mixture between the NCO terminal prepolymer and/or
the polymeric isocyanate on one hand and the polyol of the A component.
Moreover, pigments and UV stabilizers might be used.
The system 100 comprises tanks 160, 162 for the basic materials of the
polyurethane, wherein the first tank 160 contains the B component and the second
tank 162 contains the A component and the defined amount of water. Both tanks
160, 162 are connected with ducts 108, 110 to a mixing unit 156 in which the
components are mixed to a foam 128 for the polyurethane flooring. Each duct 108,
110 comprises a valve 112, 114 for dosing the amount of polyol respectively
isocyanate which flows from the respective tank 160, 162 to the mixing unit 156.
The ducts 108, 110 may comprise a supply unit, for example a pump. In the
example depicted in Fig. 5, the apparatus is a vehicle, but the portable apparatus
depicted in Fig. 1a could likewise comprise the same or functionally equivalent
components as described for the vehicle of Fig. 5.
Alternatively, the system 100 can comprise a further tank 116 comprising the
defined amount of water for the blowing reaction and/or comprising various
polyurethane forming ingredients. The further tank 116 is connected with a duct 118
to the mixing unit 156. The duct comprises a valve 120. The system 100 may
comprise various tanks for various additives depending on the desired number of
additives to be added to the foam 128 for the polyurethane flooring.
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The mixing unit 156 comprises means for producing a reaction mixture for
generating polyurethane foam. The mixing unit 106 is connected with a duct 122 to
an application unit 124 which is configured for applying the reaction mixture 128 to a
ground 103. The application unit 124 may comprise a various number of nozzles for
applying the mixture 128 to the ground 103. The nozzles may be spaced out evenly
over the entire width of the application unit 124. Alternatively, there may be a single
nozzle or a bundle of nozzles and a user may have to smoothly move the nozzle
from one side to the other to evenly spread the PU foam over the ground (see Fig.
1a).
Furthermore, the system 100 comprises a levelling unit 126 for levelling and
smoothing the applied mixture 128. The levelling unit 126 may be a scraper, which
is located in a drive direction 130 of the apparatus 100 behind the injection unit 124.
The levelling unit 126 is configured for smoothing the surface 129 of the applied
foam and or for taking up excess foam.
The vehicle comprises a driving unit 131 for driving the apparatus 100 in the drive
direction 130.
Furthermore, a sensor 132 for measuring environmental conditions may be provided
as part of the vehicle 100. The sensor 132 may be configured for measuring the air
temperature, the ground temperature, the relative humidity or other climate
conditions. Various sensors for determining various environmental data may be
provided.
The valves 112, 114, 120, the mixing unit 156, the application unit 124, the levelling
unit 126, the drive unit and the sensor 132 are connected to a control unit 134. The
control unit 134 is configured for receiving environmental data measured by the
sensor 132 and to control the valves 112, 114, 120, the mixing unit 106, the
application unit 124, the drive unit 131 and the levelling unit 126 depending on the
received environmental data.
The environmental data are measured by the sensor 132 and sent to the control unit
134. The control unit 134 controls the valves 112, 114, 120 so that the desired
mixture of polyol, isocyanate, water and additives is mixed. Furthermore, the
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amount of zeolite-bound water and/or the amount of catalysts or other process
parameters can be adjusted by controlling the mixing unit 156.
Furthermore, the control unit may take into account the geometry of the ground, the
planned path, respectively the length of each lane 144, 146, 148, the thickness of
the polyurethane flooring and the speed of the system 100 (vehicle or portable
apparatus) into the process of determination the mixture 128 in order to ensure that
the foam of a first lane 144 is not cured before the foam of the second lane 146 is
applied and/or to ensure that a sufficient amount of PU foam is applied to reach the
desired minimum thickness and elasticity of the PU flooring.
In the described embodiment, the sensor 132 is attached to the system 100 so that
the environmental conditions are measured at the position of the apparatus
100. Therefore, the mixture and the process parameters can be adapted
continuously to the current conditions so that a constant curing time of the PU foam
generated from the applied mixture 128 can be achieved.
Alternatively or in addition, stationary sensors can be used. Stationary sensors can
be positioned at various positions of the ground 103 in order to achieve the
environmental conditions in advance in order to customize the mixture of the foam
to these conditions. In these embodiments, the sensors 132 may be connected to
the control unit 134 by any wireless connection, for example a radio connection or a
WLAN-connection, whereby the sensor 132 comprises a transmitter and the control
unit 134 comprises a receiver.
Figure 6 is a flowchart of a method of generating a PU-based flooring of a sports
ground. The reactants, i.e., at least a polyol, an isocyanate and water and optionally
one or more additives are provided in step 502, e.g. by filling the reactants into
different containers 160, 162. The reactants and optionally one or more additives
are added and distributed to the different containers such that the substances in
each of the containers basically do not react with each other. Then, in step 504, an
automated mixing device or a mechanical mixer operated by a human is used for
mixing the reactants for triggering one or more chemical reactions, e.g. the gellation
reaction and the blowing reaction to generate PU polymers that are foamed by the
blowing agent CO2. The PU reaction mixture for chemically generating the PU foam
is applied to the ground of a sport field.
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After applying the polyurethane reaction mixture to the ground, the ground is
optionally smoothed and leveled to a predetermined roughness and level. In some
examples, the viscosity of the PU foam is small enough to allow self-levelling. After
the smoothing and levelling process, the polyurethane foam cures. Optionally, the
solidified, cured PU layer is coated with a further, protective layer 127. A separate
step to anneal edges of two adjacent lanes to each other is not necessary.
Again, the application may be performed fully automatically as described for
example for fig. 5 or can be performed semi-automatically by a user 102 using a
portable PU foam application apparatus.
Figure 7 depicts the gellation reaction for generating PU. In order to produce
polyurethane, a polyaddition reaction is performed. In this type of chemical reaction,
the isocyanate monomers and the prepolymer in the B component contain reacting
end groups. Specifically, a diisocyanate (OCN-R-NCO) is reacted with the polyol of
the A component represented here as a diol (HO-R-OH). The first step of this
reaction results in the chemical linking of the two molecules leaving a reactive
alcohol (OH) on one side and a reactive isocyanate (NCO) on the other. These
groups react further with other monomers to form a larger, longer molecule. This is
typically a rapid process which yields high molecular weight materials. Embodiments
of the invention may allow selecting the type and amount of the reactive
components and/or catalysts such that the reaction (gellation reaction) that
generates the PU polymers is retarded. The reaction is retarded such that basically
the PU polymer foam is built and solid after one or more hours, e.g. 1 to 10 hours
after the mixing of the reactive components.
Figure 8 depicts the blowing reaction for generating CO2 as the blowing agent. The
reaction to generate carbon dioxide involves water reacting with an isocyanate first
forming an unstable carbamic acid, which then decomposes into carbon dioxide and
an amine. The amine reacts with more isocyanate to give a substituted urea. Water
has a very low molecular weight, so even though the weight percent of water may
be small, the molar proportion of water may be high and considerable amounts of
urea produced. The urea is not very soluble in the reaction mixture.
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As water is present in the reaction mixture, the isocyanate reacts with water to form
an urea linkage and carbon dioxide gas and the resulting polymer contains both
urethane and urea linkages. This reaction is referred to as the blowing reaction.
Figure 9 illustrates the composition of the reaction mixture for generating PU foam
according to some embodiments of the invention. In the depicted embodiments, the
water is added to the reaction mixture as an ingredient of the A component 902.
In the following, four examples RM1-RM4 for a reaction mixture RM comprising
different amounts (specified in “parts by weight”) of an A component 902 and a B
component 904 will be given:
parts by parts by Hydroxyl number NCO NCO
weight A weight B of polyol of A content of index
component component component [mg B of RM
KOH/g A component
component]
RM1 100 80 96,24-109,74 10% 1,16
RM2 100 95 96,24-109,74 10% 1,16
RM3 100 60 96,24-109,74 14% 1,16
RM4 100 68 96,24-109,74 14% 1,16
For example, the polyol 906 may have a hydroxyl number of 155-180 mg KOH/g
polyol 906. As the polyol has a share of the A component of about 54 % by weight in
the depicted example, the hydroxyl number of the “complete” A component is
diluted/reduced in accordance with the share of the polyol in the A component.
Thus, according to the first example RM1, the isocyanate index of 1.16 is obtained
by mixing 100 parts by weight of the A component whose polyol 906 has a hydroxyl
number in a range of 155-180 mg KOH/g mg KOH/g with 80 parts by weight of the B
component having an NCO-content of 10% for generating the reaction mixture.
James & Wells Ref: 310446NZ
According to embodiments, the polyol 906 of the A component 902 is a
polyetherpolyols or a polyesterpolyol. The polyol can be branched. The polyol can
be a primary hydroxyl terminated diol. For example, the polyol 906 can have a
molecular weight of 1000- 4000 Dalton, e.g. 1190 Dalton. The polyol 906
preferentially has a viscosity of 2500-3500 mPas/25°C. According to some
examples, the polyol has an acid value of up to 3 and/or a density of 1,0 g/cm . The
acid value (or "neutralization number") is the mass of potassium hydroxide (KOH) in
milligrams that is required to neutralize one gram of the chemical substance. The
acid value is a measure of the amount of carboxylic acid groups in a chemical
compound, such as a fatty acid, or in a mixture of compounds. The polyol 906 can
be, for example, a polyetherpolyols, e.g. polypropyleneglycol. Polyetherpolyols may
be manufactured e.g. from propylenoxide and may have the advantage of
generating a PU with good coherence properties. Alternatively, the polyol can be a
polyesterpolyol which may have the advantage of generating a PU with good
adhesion properties (to the non-PU ground). The polyol can also be a mixture of
polyester-polyols and polyether polyols having the advantage of a good compromise
between adherence and coherence capabilities of the generated PU foam.
In the following, the A component will be described in greater detail for
embodiments of the invention, whereby the “%” values are “% by weight of the A
component”:.
54% polyol 906, e.g. a polyethylene; according to embodiments, the polyol 906 of
the A component is a polyether polyol or a polyester polyol or a mixture thereof. It
has a hydroxyl number of 155-180 mg KOH/g /g polyol;
31 % filling material 908, e.g. calcium carbonate;
7,6% extender 910, e.g. castor oil;
0,5% water 914; preferably, the water is added in a very precise amount by
drying the other ingredients of the A component, e.g. with a first zeolite, and then
adding the defined water in free form and/or bound to a second zeolite;
7,4% further substances 912, e.g.:
o 4,5% inorganic and/or organic pigments 916, e.g. iron oxide pigments,
titandioxide, etc;
o 2,4 % of further substances 918, e.g. 0,001% catalyst of the PU polyaddition
reaction, e.g. Di-n-octyltinneodecanoat, 0,14% surfactants and emulsifiers,
James & Wells Ref: 310446NZ
remnants of the first zeolite used for drying the A component before adding
the water.
According to embodiments, the A component in addition comprises 0,5-2% of a
second zeolite soaked with water (the amount of filler material is adapted
accordingly). To prohibit an absorption of the additional water bound to the second
zeolite by the first zeolite, the first zeolite is either removed from the A component
after the drying process or is deactivated. Alternatively, the first zeolite is a zeolite
that absorbs water much slower than the second zeolite desorbs the water and that
also absorbs the water slower than the speed of the desorbed water reacting with
the B component to CO2. The second zeolite may be added to the reaction mixture
immediately before the PU reaction mixture is applied on the ground. Thus, the time
will not suffice for the first zeolite to absorb the additional water that is provided by
the second zeolite.
Surfactants and emulsifiers are used to emulsify the liquid components, regulate
foam cell size, and stabilize the cell structure to prevent collapse and surface
defects of the PU foam. Rigid foam surfactants are designed to produce very fine
cells and closed cell structures. Flexible foam surfactants are designed to stabilize
the reaction mass while at the same time maximizing open cell content to prevent
the foam from shrinking. Thus, the reaction mixture that is used for generating the
PU foam may in fact comprise a significant portion of additional substances for
modifying the viscosity and foam bubble properties, for colorizing the foam, for
acting as a filler or for other technical purposes.
According to embodiments, the B component 904 is created by reacting about 40
parts by weight of an MDI premix 940 with about 60 parts by weight of a premix
polyol 930. The premix polyol may be a polyetherpolyols. For example, the premix
polyol may have a molecular weight of about 2000 Dalton and a hydroxyl number in
the range of 30-160 mg KOH/g polyol, e.g. 55 mg KOH/g. In some example
embodiments, the premix polyol 930 and the polyol 906 of the A component can be
of the same type.
According to embodiments, the MDI premix 940 for generating the B component
comprises, before the premix polyol is added for generating the prepolymer:
James & Wells Ref: 310446NZ
• 0,3-7 % by weight of the MDI premix: 2,2’-Methylendiphenyldiisocyanate 922,
preferably in an amount of 4%-7% by weight of the MDI premix;
• 10-35 % by weight of the MDI premix: Diphenylmethane-2,4’-diisocyanate
924;
• 10-45 % by weight of the MDI premix: Diphenylmethane-4,4’-diisocyanate
926;
• 0-30 % by weight of the MDI premix: an MDI polymer 928 created by reacting
two or more of the monomers 922-926 with each other.
By adding and mixing the premix polyol 930 to the MDI premix, at least a fraction of
the totality of the educts 922-930 will react into a prepolymer 932, in this case an
aromatic isocyanate prepolymer. The prepolymer is comparatively viscous and has
a retarded reactivity in respect to polyols compared to “standard” prepolymers used
in PU generation reactions.
After the reaction of the premix polyol and the MDI monomers and the MDI polymer
has reached equilibrium, the resulting solution can be used as the B component.
The B component 904 comprises a mixture of unreacted educts 920 (MDI
monomers 922, 924, 926, optionally an MDI polymer 928 and the premix polyol 930)
and the prepolymer 932 as the reaction product of the chemical reactions that takes
place in the premix upon adding the premix polyol. Typically, about 62 % by weight
of the B component consists of the prepolymer 932 and about 38% by weight of the
B component consists of the unreacted educts 920.
Thus, in effect, according to embodiments, the B component comprises:
• 0,1-2,8 % by weight of the B-component: 2,2’-Methylendiphenyldiisocyanate
922;
• 10-20 % by weight of the B-component: Diphenylmethane-2,4’-diisocyanate
924;
• 10-25 % by weight of the B-component: Diphenylmethane-4,4’-diisocyanate
926;
• 0-16 % by weight of the B-component: an MDI polymer 928 created by
reacting two or more of the monomers 922-926 with each other.
• 62 % by weight of the B-component: aromatic isocyante- prepolymer, e.g.
(1,2-Propanediol, polymer with 1-isocyanato(4-
James & Wells Ref: 310446NZ
isocyanatophenyl)methylbenzene, 1,1-methylenebis 4-isocyanatobenzene,
methyloxirane and oxirane)
The B component has, according to some examples, has a viscosity of 3200
mPas/25°C. In some examples, the isocyanate has a density of 1,15 g/cm3.
James & Wells Ref: 310446NZ
Claims (21)
1. A method for producing a polyurethane flooring (129) for a sports field (136), 5 the method comprising: - providing (502) reactive components for producing polyurethane, the reactive components comprising an A component (902) being a polyol mixture and a B component (904) being an isocyanate mixture and water (914), the B component comprising: 10 o 2,2’ Methylendiphenyldiisocyanate (922) in an amount of 0,1%- 3,2% of the B-Component; o diphenylmethane-2,4’-diisocyanate (924); o diphenylmethane-4,4’-diisocyanate (926); and o an isocyanate prepolymer (932) in an amount of 54%-70% of the 15 B-component; - mixing (504) the reactive components for generating a liquid polyurethane reaction mixture (129); - applying (506) the polyurethane reaction mixture (128) to a ground (103) of the sports field before chemical reactions in the reaction mixture have 20 generated a solid polyurethane foam, the polyurethane foam after its solidification to be used as the polyurethane flooring.
2. The method of any one of the preceding claims, the water (914) being added 25 in an amount of 0,1 – 1,5 % by weight of the A component, in particular in an amount of 0,4% - 0,6% by weight of the A component.
3. The method of any one of the preceding claims, the water (914) being added to the reaction mixture as an ingredient of the A component.
4. The method of any one of the preceding claims, the water (914) being added to the reaction mixture and/or to the A component in a free, non-zeolitbound form. James & Wells Ref: 310446NZ
5. The method of any one of the preceding claims, further comprising: - adding a molecular sieve material to the A component to adsorb and remove any moisture from the A component; - optionally, if the water (914) is added to the reaction mixture as an 5 ingredient of the A component, adding the water (914) after the moisture was removed from the A component.
6. The method of claim 5, the molecular sieve material being a first zeolite. 10
7. The method of any one of the previous claims, the B component (904) comprising a mixture of monomers (922-926) and polymers (932) respectively comprising one or more NCO groups, the polyol (906) of the A component comprising one or more OH groups, the NCO groups in the B component and the OH groups in the polyol of the A component having an NCO/OH molar ratio 15 in the range of 1.14:1 to 1.18:1, in particular in the range of 1.15:1 to 1.17:1.
8. The method of any one of the previous claims, further comprising: - adding a second zeolite to the reaction mixture, the second zeolite being 20 soaked with the water and being adapted to desorb at least 20% of the water to the reaction mixture within 60 minutes after creation of the reaction mixture.
9. The method of claim 8, further comprising: 25 - acquiring a temperature of the ground (103) of the sports field; wherein the amount of the second zeolite depends on the measured ambient temperature, wherein the higher the temperature, the higher the amount of the second zeolite with its adsorbed water that is added to the reaction mixture.
10. The method of any one of the previous claims, further comprising generating the B component by: - creating an MDI premix (940)comprising: James & Wells Ref: 310446NZ o 2,2’ Methylendiphenyldiisocyanate (922) in an amount of 0,3 %-7% by weight of the MDI premix, preferably in an amount of 4%-7% by weight of the MDI premix; o diphenylmethane-2,4’-diisocyanate (924) in an amount of 10%- 5 35% by weight of the MDI premix; o diphenylmethane-4,4’-diisocyanate (926) in an amount of 10%- 45% by weight of the premix; and o MDI-polymers (930) consisting of two or more of said diisocyanate monomers (922, 924, 926) in an amount of 0%-30% by weight of 10 the MDI premix; - mixing the MDI premix 940 and a premix polyol (930) for letting the MDI premix components and the premix polyol 930 generate the B component, the B component comprising: o an aromatic isocyanate prepolymer (932); and 15 o unreacted educts of the premix and the premix polyol.
11. The method of any one of the previous claims, the NCO content of the B component being between 1.5% and 18% by weight of the B component.
12. The method of claim 11, the NCO content of the B component being between 9% and 14%, e.g. 10% by weight of the B component.
13. The method of any one of the previous claims, wherein the polyol (906) of the A component has a viscosity of 2500 to 3500 mPas/25°C.
14. The method of any one of the previous claims, wherein the ground is made of 30 concrete, soil or wood and wherein the reaction mixture is applied to the ground (103) directly in the absence of an adhesive layer.
15. The method of any one of the previous claims, wherein the application of the reaction mixture to the ground (103) comprises: James & Wells Ref: 310446NZ - applying a first lane (144) of the reaction mixture to the ground; - before the foam of the first lane has solidified, applying a second lane (146) of the reaction mixture (128) to the ground such that a side edge of the second lane is in contact with a side edge of the first lane.
16. The method of any of the previous claims, wherein the reaction mixture is applied to the ground by a vehicle (100) or by an apparatus (101) carried by a user (102), the method further comprising: - automatically determining the position and/or the speed of the vehicle or 10 apparatus used for applying the reaction mixture to the ground; and - automatically adjusting the type and/or quantity of reactive components mixed together to generate the reaction mixture in dependence on the position and the speed of the vehicle or the user (102) carrying the apparatus.
17. The method according to any one of the previous claims, further comprising: applying, after the applied polyurethane foam has solidified or hardened, a sealing coating (127), the sealing coating preferentially covering multiple lanes (144, 146, 148) of the polyurethane ground, thereby skipping any operation for 20 gluing adjacent lanes to each other.
18. A system for producing a polyurethane flooring (128) for a sports field (136), the system comprising: - an A component (902) being a polyol mixture; 25 - a B component (904) being an isocyanate mixture and comprising: o 2,2’ Methylendiphenyldiisocyanate (922) in an amount of 0,1%- 3,2% of the B-Component; o diphenylmethane-2,4’-diisocyanate (924); o diphenylmethane-4,4’-diisocyanate (926); and 30 o isocyanate prepolymer (932) in an amount of 54%-70% of the B- Component, - water (914), the water and the B- component being stored in different containers; James & Wells Ref: 310446NZ - a mixer for mixing (504) the A component, the B component and the water for generating a liquid polyurethane reaction mixture; and - a nozzle (124) coupled to the mixer for applying (506) the polyurethane reaction mixture (128) to a ground (103) of the sports field before 5 chemical reactions in the reaction mixture have generated a solid polyurethane foam, the polyurethane foam after its solidification to be used as the polyurethane flooring.
19. A portable apparatus (101) comprising the system of claim 18.
20. A vehicle (100) comprising the system of claim 18.
21. A polyurethane flooring (129) of a sports field (136) manufactured by a method 15 according to any one of the previous claims 1-17.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP16177333.8 | 2016-06-30 |
Publications (1)
Publication Number | Publication Date |
---|---|
NZ747961A true NZ747961A (en) |
Family
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