WO2021133282A1

WO2021133282A1 - A composite material formed by a polyurea coating applied to a recycled polyurethane material and production method thereof

Info

Publication number: WO2021133282A1
Application number: PCT/TR2019/051253
Authority: WO
Inventors: Emir TEMİZKAN; Gülden EROĞLU; Huseyin DELİGÖZ
Original assignee: Safaş Saf Plasti̇k Sanayi̇ Ve Ti̇caret Anoni̇m Şi̇rketi̇
Priority date: 2019-12-24
Filing date: 2019-12-30
Publication date: 2021-07-01
Also published as: EP4081568A1

Abstract

The invention relates to a composite material (10) comprising a polyurethane base material 2 of 55 to 94 wt% and a coating (1) of 6 to 45 wt% provided to all surfaces of the said base material (2) and a binder of 11 to 19 wt%. The produced composite material (10) is waterproof, anti-bacterial, anti-static, nonslip, resistant to impacts, has high tear and tensile strength, high abrasion resistance, high chemical resistance and is suitable for outdoor conditions.

Description

A COMPOSITE MATERIAL FORMED BY A POLYUREA COATING APPLIED TO A RECYCLED POLYURETHANE MATERIAL AND PRODUCTION METHOD THEREOF

Technical Field of the Invention

The invention relates to obtaining a composite material by coating a recycled polyurethane material with a polyurea in order to be used as a flooring material.

State of the Art

Today, there is a great variety of materials used as flooring materials. These are composite materials obtained from recycled rubber, untreated rubber, EPDM coating, cork sheathing, EVA foam, wood flooring, closed cell PVC foam, nitrile rubber, polypropylene, PVC tube system, fiber (such as grass, coconut, cane, reed) mats, fabric or cotton mats, sponge rubber, fabric reinforced neoprene, corrugated asphalt patterned concrete, PVC flooring, woven rattan mat, polyvinyl mat and combinations thereof. However, majority of these are not suitable for exterior flooring. Additionally, the products used as exterior coating materials impact-proof and anti-injury materials are limited. Rubber material is generally preferred as an exterior flooring to prevent injuries caused by impacts from the ground due to falls and slippage. Waterproofing and hygiene is particularly important in places where children are active such as playgrounds and where animals are in contact. Recycled rubber used as flooring material is not able to provide these properties.

In patents of state of the art with numbers TR 2016/19143, TR 2011/08809, TR 2010/06408 and TR 2007/09142 rubber floorings are described. Recycled rubber is preferred for the materials used to be cost effective. Recycled rubber is formed by grinding used rubbers into small pieces and then bonding said small pieces together with a binder. The rubber mixed with a binder is shaped in a mold at a certain temperature. The waterproofing of this rubber material is not very good due to the gaps formed on the surface caused by the production method and it also has no anti bacterial properties due to bacterial growth. In other patents of the state of the art with numbers US 20060156663 A1, US 20020155274, US 20060032175 A1, US 6212838 B1, US2013/0084427 A1, TR 2016/11342, TR 2014/13219 and TR 2013/09868, composite materials were obtained by combining layers formed of different materials for decorative purposes or for outdoor use. However, in said documents, impact-proof, abrasion and chemical resistant and anti-bacterial composite materials are not discussed.

When patent documents of the state of the art with numbers PCT/TR2008/000115, US 20080242794 A1 and US 2010009385 are examined, it is seen that the anti-bacterial property of the composite materials are provided by using anti-microbial, silver and anti-bacterial zeolite.

In other patents of the state of the art with numbers US 7611772 B2, CN 202544330 U, CN 2025443284, US 20060046068 A1, US 20050287293 A1, WO 2006037026 A2, KR 20140066618 A, WO 2012 162641 A2 and TR 2010/05467, it is aimed to protect the coated material against abrasion, corrosion, impact and weather conditions by applying polyurea coating on a floor. In said patents, polyurea coating is directly applied to a floor. Another patent of the state of the art no. US6026769 relates to coating the inner wall of the mold with polyurea before producing a polyurethane foam in the mold and then producing a polyurethane foam therein and incorporating recycled polystyrene pieces therein during the foam production. In another patent of the state of the art with number US2013/084427 A1, polyurea or polyurethane coating is provided to the lower and upper surfaces of closed cell elastomeric (PVC or nitrile rubber) mattress.

In other patents of the state of the art with numbers US3401128, US5817703 and US6136870, a recycled polyurethane foam is obtained by mixing the polyurethane scraps obtained from the wastes formed after flexible polyurethane foam production and pressing under a certain level of temperature and pressure and keeping for a certain period of time. In said documents only recycled flexible polyurethane foam is obtained, composite materials obtained from polyurea coating are not discussed. In patent no. TR 2015/11236, products manufactured from polyurethane sponge and derivatives are coated with polyurea in order to be used as furniture components. In said patent, seating furniture produced with different manufacturing methods (armchairs, chairs, sofa sets, beanbags, stools, benches, winged chairs, office chairs, cinema chairs, deck chairs, etc.), cushions, pillows, upholstery and seats of motor vehicles, seating furniture and upholstery used in watercraft, seats of work and agricultural machinery, train and tram seats, toys, children's playgrounds, decorative wall and ceiling coating panels, parts of fitness and sports equipment which come into contact with the human body, screens, portable partition walls, decorative and accessory products are manufactured using polyurethane sponge and derivatives and the surfaces of said products are coated with polyurea. Undoubtedly, this patent about a polyurea polyurethane composite material is the most similar invention to the present invention. However, said invention does not have sufficient properties to prevent injuries caused by hard floors (stone, soil, asphalt and concrete floor). Additionally, the obtained final product does not have the required strength for use in outdoor conditions and the area of use and physical properties of the obtained final product is very different from the area of use of the present invention. In the patent, polyurea coated on the sponge is a very thin layer and it is used as textile material, thereby making the final product easy to clean.

Said composite material in the patent no. TR 2017/05714 is not suitable in terms of its poor anti-static and nonslip properties. The anti-static and nonslip properties of said material should be improved. To sum up, there is a need for developing a composite material which does not exist in the current state of the art and which has high tear-tensile strength, high chemical resistance, high tear and tensile strength, high abrasion resistance, high chemical resistance, waterproof, anti-bacterial, anti-static, nonslip and hygienic properties. As a result, it is easy to clean, resistant to impacts, and in compliance with the outdoor conditions.

Technical Problems to be Solved by the Invention

The objective of the invention is to develop a composite material having high tear- tensile strength, high chemical resistance, high abrasion resistance, high chemical resistance, high slip resistance, high impact resistance, hygienic, waterproof, anti bacterial, easy to clean, anti-static properties and is in compliance with the outdoor conditions by coating a recycled flexible polyurethane base material with another polyurea coating material in order to be used as a flooring material.

In the present invention, a composite material is obtained by spraying the polyurea coating material to at least one surface of the flexible polyurethane material.

Another objective of the invention is to produce a flooring material with high added value with the polyurethane foam produced by recycling the wastes formed during the continuous slabstock open cell flexible polyurethane foam material production. In the present invention a waterproof, anti-bacterial, anti-static, nonslip, resistant-to-outdoor conditions recycled flexible polyurethane foam is obtained by pressing the scraps formed by grinding wastes of polyurethane foam material and then coating all of the surfaces of the foam with polyurea material. In the present invention, these properties are obtained by providing a polyurea coating to the exterior surface of the polyurethane material.

The anti-static property of the composite material of the present invention is provided by using anti-static agents and its slip resistance is developed by using slip resistant agents. The anti-static property of the composite material obtained with the present invention prevented the electrostatic behavior and eliminated the discomfort caused by this electrostatic charge. Additionally, the slip resistance of the composite material used as the flooring material is improved by introducing certain filler therein.

Description of the Drawings

Figure 1. Three dimensional perspective view of the composite material formed by coating the all of the surfaces of the base material with polyurea material.

Figure 2. Three dimensional perspective view of the composite material formed by coating only the upper surface of the flat-cut base material with polyurea material. Figure 3. Three dimensional perspective view of the composite material formed by coating only the upper surface of the interlocking base material with polyurea material. Figure 4. Schematic view of the method for producing base material.

Figure 5. Schematic view of the method for producing coating material. Figure 6. Schematic view of the method for producing composite material.

Description of the References in the Drawings The parts in the figures are numbered separately and the elements corresponding to these numbers are provided below.

10. Composite material

1. Coating

2. Base material 100- Method for producing base material

200- Method for producing coating material 300- Method for producing composite material

Detailed Description of the Invention

The composite material 10 of the invention comprises a base material 2 and a coating provided to at least one surface, preferably all surfaces (including upper, lower and side surfaces) of said base material with the spraying method. Said base material 2 is a polyurethane material in the preferred embodiment of the invention but in practice is not limited thereto. Although polyurethane material is preferably a foam, it is not limited thereto in practice. The base material 2 is flexible and its elasticity is between 30% and 40% according to ASTM D3574-D standards. The base material 2 comprises at least one polyurethane foam waste (i.e. waste or scrap material, not shown in the figures) and a binder (not shown in the figures). Base material 2 has a flexible structure and base material 2 is obtained by recycling the polyurethane foam wastes (waste material) formed after the continuous slabstock flexible polyurethane foam material with a binder. Therefore, the recycled base material 2 with high density (150-250 kg/m³) is obtained by grinding the wastes formed after production of flexible polyurethane foam into small pieces, mixing them with a binder. In the preferred embodiment of the invention, polyurea coating 1 material is applied to at least one or all surfaces of the obtained recycled base material 2 with the spraying method.

Although said coating 1 is a polyurea material in the preferred embodiment of the invention, it is not limited thereto in practice. Production of polyurethane foam is performed in a mold as batch molded or continuous slabstock using a carrier and a tunnel. These two methods are very different from each other and there are various patents on the subject. In the invention, base material 2 is obtained by using the waste products from the products obtained by the continuous slabstock production method.

Composite material 10 is cost efficient due to using recycled base material 2. In the invention, the polyurethane base material 2 may have a thickness of 1 cm to 20 cm, preferably 2 cm to 10 cm, more preferably 3 cm to 7 cm. Additionally, the coating 1 used in the invention may have a thickness of 0.5 mm to 7 mm, preferably 1 mm to 3 mm. The composite material 10 comprises 55 to 94 wt% base material 2 and 6 to 45 wt% of coating 1. As the polyurea coating 1 material used in the invention is a costly material, its weight ratio in the composite material 10 of the present invention is low. The composite material 10 of the present invention, a composite material 10 which is robust, durable, flexible, waterproof, anti-static, nonslip, chemical resistant, resistant to external conditions and anti-bacterial is obtained with the polyurea coating 1 material applied to the polyurethane base material 2 surfaces with the spraying method.

Using recycled base material 2 in the composite material 10 of the present invention is important in terms of making use of polyurethane foam wastes. In an embodiment of the invention, the base material 2 comprises 80 to 90 wt% of polyurethane foam waste and 10 to 20 wt% of binder. In another embodiment of the invention, base material 2 obtained by recycling flexible polyurethane foam wastes is 55 to 94 wt%. Thus, the obtained composite material 10 is cost efficient.

A binder and polyurethane foam wastes are mixed in a mixing unit and a recycled flexible polyurethane base material 2 is obtained by pressing this by introducing steam to the system. In an embodiment of the invention, recycled base material 2 obtained from polyurethane foam wastes are cut into pieces of desired size and before it is laid on the floor, the entire surface is coated with the polyurea coating 1 material with the spraying method (Figure 1). In another embodiment of the invention, flexible polyurethane base material 2 is produced as flat-cut (Figure 2). In another embodiment of the invention, an interlocking flexible polyurethane base material 2 is produced. Composite material 10 is formed by coating only the upper surface with the polyurea coating 1 material after placing the polyurethane base material as shown in Figure 2 and Figure 3. In the embodiments shown in Figure 2 and Figure 3, sealing is provided by placing the polyurethane base material 2 in a wall-to-wall way on the floor and coating with the polyurea coating 1 until the end of the wall. Since the polyurethane base material 2 used in the composite material 10 is obtained by mixing and pressing the grinded polyurethane foam wastes (scraps) with the binder during production, it has a very high density compared to the standard flexible polyurethane sponges (15-65 kg/m³). In addition to having a high elasticity, the obtained polyurethane base material 2 continues to have the properties of the polyurethane foam from which it is recycled as well as being of high density. High density (150-250 kg/m³) prevents formation of problems such as precipitation in the final composite material 10 to be formed.

As in the state of the art, polyurethane foam materials are produced in slabstocks in the invention. Said produced foam material are designed in desired sizes. Upper, lower and side parts of the polyurethane foam material are separated as waste. Therefore, wastes with varying sizes are obtained from the flexible polyurethane foam material and the base material 2 produced from said obtained wastes according to the method for producing base material 100 below:

- Obtaining small pieces by means of grinding process, i.e. scraps, from polyurethane foam wastes 101

- After mixing the obtained scraps with the binder in a predetermined amount in a mixing unit, transferring the mixture to the hopper for pressing 102

- Pressing the mixture of scraps and binder according to the desired density by means of the movable piston on the hopper where the mixture is located 103

- After introducing steam to the pressed mixture, keeping the mixture in the hopper for a predetermined period of time and obtaining the polyurethane base material 2 104

- Allowing the rebounded polyurethane base material 2 to rest for a predetermined period of time 105

- Cutting the base material 2 in the desired sizes 106

The amount of said binder in step 102 should be 5% to 25%, preferably 10% to 20% of the total amount. In the invention, TDI (80/20 2,4 toluene diisocyanate/2,6 toluene diisocyanate) or MDI (Diphenylmethane-4, 4-diisocyanate) pre-polymers having 10-25 of NCO % are used as the binder.

Said period of time in step 104 ranges from 10 minutes to 10 hours. This period of time preferably ranges from 30 min to 5 hours, more preferably from 1 to 2 hours.

The density of the polyurethane base material 2 obtained in step 104 ranges from 40 to 500 kg/m³, preferably from 100 to 400 kg/m³, more preferably from 150 to 250 kg/m³. The invention comprises 55 to 94 wt% of polyurethane base material 2.

Said period of time in step 105 ranges from 1 to 24 hours, preferably from 6 to 12 hours.

The coating 1 material to be used in the coating is obtained according to the method for producing coating material 200 below:

- Introducing at least one polyether amine and at least one chain extender of different molecular weights at a predetermined rate into one of the two tanks (tank A) 201

- If materials such as at least one pigment, at least one additive or at least one filler, introducing of such materials into the tank A 202

Introducing fillers such as calcite, aluminum hydroxide, lime into the tank A in order to increase slip resistance 203

- Preferably introducing dispersant agents into the tank A in order to prevent precipitation of introduced powder materials 204

- Introducing ionic fluids used as anti-static agents to the mixture in the tank A in order to provide anti-static property 205

- Introducing MDI pre-polymers to one of the two tanks (tank B) of step 201 206

- Circulating the mixture materials in tank A and tank B separately and simultaneously heating them to a predetermined temperature by means of a heater 207

Composite material 10 is obtained according to the method for producing composite material 300 below by spraying coating 1 material obtained after step 207 onto the base material 2: - Applying the same pressure with a piston at a predetermined pressure to the mixture materials in the two separate tanks (tank A and tank B) 301

- Producing composite material 10 by applying the pressurized polyurea coating 1 on the base material 2 obtained in step 104 or 105 of method for producing base material 100 with the spraying method using a gun and spray machine 302

The amount of said chain extender in step 201 is 10-30 wt%, preferably 15-25 wt% of the amount of the mixture in tank A.

The amount of the pigment material in step 202 is 0.001-1 wt%, preferably 0.01-0.1 wt% of the amount of the mixture in tank A.

Said slip resistant agent in step 203 ranges between 1-10 wt%, preferably 3-7 wt% of the amount of the mixture in tank A.

The amount of said dispergent agent of step 204 is 0.01-1 wt%, preferably 0.1 -0.5 wt% of the amount of the mixture in tank A.

The amount of the anti-static agent in step 205 is 0.01-5 wt%, preferably 0.1-1 wt% of the amount of the mixture in tank A.

Said temperature in step 207 ranges from 70 to 80 °C.

The components in the separate tanks in step 207 react with each other as soon as they come together, so that the components do not contact until they reach the nozzle of the spray gun. Since the system sprays an equal volume of material, it is important that the two mixtures in separate tanks have similar viscosities at 70 to 80 °C.

The pressure in step 208 is between 16 to 20 bar.

Said composite material 10 in step 209 comprises 44 to 75 wt% polyurethane base material 2 waste, 11 - 19 wt% of binder and 6 to 45 wt% of polyurea coating 1 .

As the synthesis of polyurea coating 1 material is a very fast reaction, application to the base material 2 is performed with the spray system.

Amines used in polyurea coatings (1) are generally 2-functional polyether amines having a molecular weight of 2000 and 3-functional having a molecular weight of 5000. Two-functional and low molecular weight amines are used as chain extenders. MDI pre-polymer is determined according to the hardness of the polyurea coating 1 to be obtained and MDI pre-polymers having 10 of NCO % are used for soft coatings and those with 20 of NCO % are used for hard coatings. The invention is designed to prevent injury and wounding of humans and animals as a result of falls and slippage. In the present invention, a composite material 10 obtained by applying polyurea coating 1 on the recycled flexible polyurethane base material 2 is laid on the ground. While the recycled flexible polyurethane base material 2 on the inside provides layer flexibility, the polyurea coating 1 on the outside provides anti bacterial, anti-static, nonslip, resistance to outdoor conditions and physical strength properties to the composite material 10.

Exemplary Applications:

Used Chemicals

Grinded Flexible Polyurethane Base Material 2 Wastes - Scraps

Binder (TDI (80/20 2,4 toluene diisocyanate/2,6 toluene diisocyanate) or MDI

(Diphenylmethane-4, 4-diisocyanate) pre-polymers)

MDI Pre-polymers

PE-1 - 2-functional polyether amine with 2000 Dalton molecular weight PE-2 - 3-functional polyether amine with 5000 Dalton molecular weight Chain Extender Pigment

Slip resistant agent Dispersant agent Anti-static agent

Production of Recycled Flexible Polyurethane Base Material 2

Calculated flexible polyurethane foam particles (scraps) in accordance with the desired dimensions are introduced to the mixing unit. Binder is introduced to the system while the scraps are being mixed in the mixing unit, materials are transferred to the hopper that have a piston and a steam system after mixing for 15-30 minutes. The hopper is pressed with a piston into the predetermined size for the desired density of the recycled flexible polyurethane base material 2. During this operation, steam is introduced to the hopper. The recycled flexible polyurethane base material 2 is produced after 2 hours and is taken out left for rest. After curing is finished, the recycled flexible polyurethane base material 2 is cut into desired sizes. Application of Spray Polyurea Coating 1

PE-1 , PE-2, chain extender, pigment, slip resistant agent, dispersant agent, and anti static agent is introduced to a tank A in predetermined amounts. MDI pre-polymer is introduced to a tank B in a predetermined amount and heated to 75 °C with resistance by circulation. Heated mixtures in the tank A and tank B are sprayed with a spray gun at a pressure of between 16 to 20 bar. The mixtures in the two tanks meet at the nozzle of the gun and first curing is complete in 5-10 seconds after being applied to the surface.

MDI pre-polymer with high NCO % is used in order to obtain hard product and MDI pre polymer with low NCO % is used in order to produce soft product. If the requested product has the dimensions of 200x100x5 cm³, all surfaces of the recycled flexible polyurethane base material (2) can be coated with polyurea coating 1 and given to the customer as final product (figure 1). If the product is to be used for coating the floor of a certain area, in order to be more cost effective, the flat-cut (figure 2) or interlaced-cut recycled flexible base material 2 (figure 3) is placed on the application surface and the polyurea 1 (figure 2 and figure 3) spray application can be made at the place of use, thus forming the final product.

It is expected the polyurea coating 1 , which is one of the components of the composite material 10, is resistant to impacts (according to the ASTM D-1709-15 standards), the elasticity thereof is 15-30 % (according to the ASTM D-3574 standards), the shore A hardness value thereof is 60-80 (according to the ASTM D 2240-05 standards), the water absorption value thereof is below 2% (according to the ASTM D 570-98 standards), the tensile strength thereof is 20-40 N/mm (according to the ASTM D638- 10 standards), the tear strength thereof is 15-25 N/mm (according to the ASTM D638- 10 standards), the maximum tension thereof is 5-15 MPa (according to the ASTM D638-10 standards), is anti-static, slip resistant and resistant to all chemicals except for strong acids in the chemical resistance test (according to the ASTM D-543-06 standards). In the microbiology laboratory of Uludag University, two different bacteria were tested in anti-bacterial test according to ASTM 2149A and the composite material was found to be anti-bacterial. The results are provided on Table 1. Table 1. Anti-bacteriality Test

Bacteria Reduction (24 hours)

Stphylococcus Aureus Escherichia

Coli

% Log % Log

C -0.10 07.49 49

Recycled Flexible Polyurethane Foam 10.62 0.04 277.01 0.58

The anti-static property is tested according to the ASTM D257-75 standards, materials with electrical resistance in the range of 10⁹-10¹² ohms/square are anti-static materials. The electrical resistance test performed at Istanbul University Chemical Engineering Department showed that the composite material 10 had anti-static properties. The results are provided on Table 2. The anti-static property which was not provided in the previous composite (EX-KOMP) was provided.

Table 2. Electrical Resistance Values

Slip resistance is important as the composite material 2 is to be used as a flooring material. When the literature is examined, it is seen that slip resistance is determined by applying the TSE CEN / TS 16165 Annex B (Determination of Slip Resistance of Pedestrian Surfaces - Ramp Test), BS 7976-2 (Pendulum Test (Determination of Slip Resistance)) and TS EN 14231 (Natural Stones - Test Methods - Determination of Slip Resistance with Pendulum Test Equipment) standards for ceramic tiles. However, as these standards are for smooth and hard surfaces, it was thought that they might not yield accurate results for polyurea coatings. Therefore, the produced composite material was sent to a farm to be tested as a cow bed and it was seen that the cows did not slip thereon. Additionally, as it is a soft surface, the animals were comfortable and they were not injured after falling, thus it was observed that milk yield increased.

The composite material produced with the present invention is a product suitable for many years to be used in interior and exterior conditions with its high impact resistance, waterproof property, chemical resistance and anti-bacterial properties in addition to being able to prevent damages caused by falling due to having a certain level of flexibility.

Application of the Invention to the Industry

Everything described in the detailed description of the invention is the same as application to the industry. The recycled flexible polyurethane base material 2 portion of the composite material 10 described above will be produced in-house as described above. All surfaces of recycled flexible polyurethane base material 2 cut in certain sizes can be coated with polyurea coating 1 . In the case of application to large areas, the recycled flexible polyurethane base material 2, which is cut in certain sizes or is interlocked, is laid in the application area and the polyurea coating 1 is applied onto the recycled flexible polyurethane base material 2 laid on the floor, thereby the composite material 10 is obtained. The important point here is that the recycled flexible polyurethane base material 2 is laid on the whole surface without leaving any gaps and the application applied to the area until the wall limits. Otherwise, there might be some problems regarding sealing.

As the polyurea coating 1 used in the composite material 10 has high resistance and high elasticity, it prevents animals’ feet from digging into the ground by flexing when it is used as an animal bed in an embodiment of the invention. Thus, the material is not damaged due to its resistance. The elasticity of the composite material 10 is also one of the reasons preventing slipping. Additionally, fillers introduced to the composite material 10 such as calcite, aluminum hydroxide and lime act as an anti-slip agent and reinforces the resistance of the composite material 10 to slipping.

As the composite material 10 will be used in areas which include humans and animals, it is important for the composite material 10 to exhibit anti-static properties in terms of utility. In products which do not show anti-static properties, static electricity accumulates due to friction and this causes electric shocks and disturb the beings in contact. For this reason, the anti-static property of the composite material 10 is provided by introducing anti-static agents therein.

Slabstock flexible polyurethane foam is first produced as large blocks of 20 meters and later sized according to the customer demands. After production, the lower, upper and side surfaces of the base material 2 are trimmed and spared as waste. Additionally, the remains of the polyurethane foams cut in certain sizes according to the customer demands are also separated as a waste. These wastes are girinded into small pieces with a granulator. These pieces called scraps are sold at much lower prices than their cost. Thanks to the present invention, these scraps are used in the production of recycled flexible polyurethane base material 2 which is one of the components of the composite material 10 which is a product with high added value.

The invention is not limited to the above exemplary embodiments, and a person skilled in the art can readily put forward embodiments of the invention. These are considered within the scope of the invention as claimed by the accompanying claims.

Claims

1 - A composite material (10) comprising:

- a base material (2) and a coating (1) material; characterized by 55 to 94 wt% of base material (2) which is obtained by recycling polyurethane foam material wastes and 6 to 45 wt% of coating (1) material which is provided to at least one surface, preferably all surfaces of the said base material (2) with the spraying method, in order to produce a durable floor material which is waterproof, solid, durable, flexible, waterproof, anti bacterial, anti-static, nonslip, has high tensile and tear strength, resistant to impacts and resistant to outdoor conditions and chemicals.

2- A composite material (10) according to claim 1 , characterized in that it comprises a base material (2) comprising 44 to 75 % of polyurethane foam waste and 11 to 19 wt% of binder.

3- A composite material (10) according to claim 2, characterized in that it comprises a base material (2) with a thickness of 1 cm to 20 cm.

4- A composite material (10) according to claim 3, characterized in that it comprises a base material (2) with a thickness of 2 cm to 10 cm.

5- A composite material (10) according to claim 4, characterized in that it comprises a base material (2) with a thickness of 3 cm to 7 cm.

6- A composite material (10) according to claim 5, characterized in that it comprises a base material (2) comprising polyurethane foam material.

7- A composite material (10) according to claim 6, characterized in that it comprises a coating (1) with a thickness of 0.5 mm to 7 mm.

8- A composite material (10) according to claim 7, characterized in that it comprises a coating (1 ) with a thickness of 1 mm to 3 mm. 9- A composite material (10) according to claim 8, characterized in that it comprises a polyurea coating (1) material.

10- A composite material (10) according to claim 9, characterized in that it comprises 10 to 20 wt% of binder.

11- A composite material (10) according to claim 10, characterized in that it comprises a binder with TDI (80/20 2,4 toluene diisocyanate/2,6 toluene diisocyanate) or MDI (Diphenylmethane-4, 4-diisocyanate) pre-polymer comprising 10% to 25% NCO.

12- A method for producing base material (100) using wastes, comprising the steps of:

- Obtaining small pieces by means of grinding, i.e. scraps, from polyurethane foam wastes (101)

- After mixing the obtained scraps with the binder in a predetermined amount in a mixing unit, transferring the mixture to hopper for pressing (102)

- Pressing the mixture of scraps and binder according to the desired density by means of the movable piston on the hopper where the mixture is located (103)

- After introducing steam to the pressed mixture, keeping the mixture in the hopper for a predetermined period of time and obtaining the polyurethane base material (2) (104)

- Allowing the rebounded polyurethane base material (2) to rest for a predetermined period of time (105)

13- A method for producing base material (100) according to claim 12, characterized in that the amount of said binder in step 102 is 5% to 25% of the total amount.

14- A method for producing base material (100) according to claim 13, characterized in that the amount of said binder in step 102 is 10% to 20% of the total amount. 15- A method for producing base material (100) according to claim 14, characterized in that the said time in step 104 is between 10 minutes to 10 hours.

16- A method for producing base material (100) according to claim 15, characterized in that the said time in step 104 is between 30 minutes to 5 hours. 17- A method for producing base material (100) according to claim 16, characterized in that the said time in step 104 is between 1 to 2 hours.

18- A method for producing base material (100) according to claim 17, characterized in that the density of the polyurethane base material (2) obtained in step 105 is 40 to 500 kg/m³.

19- A method for producing base material (100) according to claim 18, characterized in that the density of the polyurethane base material (2) obtained in step 105 is 100 to 400 kg/m³.

20- A method for producing base material (100) according to claim 19, characterized in that the density of the polyurethane base material (2) obtained in step 105 is 150 to 250 kg/m³.

21- A method for producing base material (100) according to claim 20, characterized in that the said time in step 105 is between 1 to 24 hours.

22- A method for producing base material (100) according to claim 21 , the said time in step 105 is between 6 to 12 hours.

23- A method for producing a coating material (200) obtained according to the steps of:

- Introducing at least one polyether amine and at least one chain extender of different molecular weights at a predetermined rate to one of the two tanks (tank A and tank B (201)

- If materials such as at least one pigment, at least one additive or at least one filler, introducing of such materials into the tank A (202)

Introducing fillers such as calcite, aluminum hydroxide, lime into the tank A in order to increase slip resistance (203)

- Preferably introducing dispersant agents into the tank A in order to prevent precipitation of introduced powder materials (204)

- Introducing ionic fluids used as anti-static agents to the mixture in the tank A in order to provide anti-static property (205)

- Introducing MDI pre-polymers into tank B of step 201 (206) - Circulating the mixture materials in two separate tanks separately and simultaneously heating them to a predetermined temperature by means of a heater and circulation (207)

24- A method for producing coating material (200) according to claim 23, characterized in that the amount of said chain extender in step 201 is 10-30 wt% of the amount of the mixture in tank A.

25- A method for producing coating material (200) according to claim 24, characterized in that the amount of said chain extender in step 201 is 15-25 wt% of the amount of the mixture in tank A.

26- A method for producing coating material (200) according to claim 25, characterized in that the amount of pigment material in step 202 is 0.001-1 wt% of the amount of the mixture in tank A.

27- A method for producing coating material (200) according to claim 26, characterized in that the amount of pigment material in step 202 is 0.01-0.1 wt% of the amount of the mixture in tank A.

28- A method for producing coating material (200) according to claim 27, characterized in that the said slip resistant agent in step 203 is 1-10 wt% of the amount of the mixture in tank A.

29- A method for producing coating material (200) according to claim 28, characterized in that the said slip resistant agent in step 203 is 3-7 wt% of the amount of the mixture in tank A.

30- A method for producing coating material (200) according to claim 29, characterized in that the amount of said dispersant agent in step 204 is 0.01-1 wt% of the amount of the mixture in tank A.

31- A method for producing coating material (200) according to claim 30, characterized in that the amount of said dispersant agent in step 204 is 0.1 -0.5 wt% of the amount of the mixture in tank A. 32- A method for producing coating material (200) according to claim 31 , characterized in that the amount of anti-static agent in step 205 is 0.01-5 wt% of the amount of the mixture in tank A.

33- A method for producing coating material (200) according to claim 32, characterized in that the amount of anti-static agent in step 205 is 0.01-1 wt% of the amount of the mixture in tank A.

34- A method for producing coating material (200) according to claim 33, characterized in that the said temperature in step 207 is 70 to 80 °C.

35- A method for producing a composite material (300) obtained according to the steps of:

- Applying the same pressure with a piston at a predetermined pressure to the mixture materials in the two separate tanks (301)

- Producing composite material (10) by applying the pressurized polyurea coating (1) on the base material (2) obtained in step 104 or 105 of method for producing base material (100) with the spraying method using a gun and spray machine (302)

36- A method for producing coating material (200) according to claim 35, characterized in that the pressure value in step 301 is between 16 to 20 bar.

37- A coating (1) material according to any of the preceding claims with resistance according to the ASTM D-1709-15 standards.

38- A coating (1) material according to any of the preceding claims characterized in that it has an elasticity of 15% to 30% according to the ASTM D-3574 standards.

39- A coating (1) material according to any of the preceding claims characterized in that the shore A hardness value is 60 to 80 according to the ASTM D 2240-05 standards. 40- A coating (1) material according to any of the preceding claims characterized in that the water absorption value is below 2% according to the ASTM D 570-98 standards. 41- A coating (1) material according to any of the preceding claims characterized in that the tensile strength is 20 to 40 N/mm according to the ASTM D638-10 standards.

42- A coating (1) material according to any of the preceding claims characterized in that the tear strength is 15 to 25 N/mm according to the ASTM D638-10 standards.

43- A coating (1) material according to any of the preceding claims characterized in that the maximum tension is 5 to 15 MPa according to the ASTM D638-10 standards.