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WO1990008649A1 - Tapis - Google Patents

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Publication number
WO1990008649A1
WO1990008649A1 PCT/CA1990/000034 CA9000034W WO9008649A1 WO 1990008649 A1 WO1990008649 A1 WO 1990008649A1 CA 9000034 W CA9000034 W CA 9000034W WO 9008649 A1 WO9008649 A1 WO 9008649A1
Authority
WO
WIPO (PCT)
Prior art keywords
mat
layer
boundary
curing
rubber
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CA1990/000034
Other languages
English (en)
Inventor
William Jolliffe
Steve Mandich
Kazuhide Obukuro
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
MRP ELASTOMERICS Inc
Original Assignee
MRP ELASTOMERICS Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by MRP ELASTOMERICS Inc filed Critical MRP ELASTOMERICS Inc
Publication of WO1990008649A1 publication Critical patent/WO1990008649A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/0057—Producing floor coverings
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C13/00—Pavings or foundations specially adapted for playgrounds or sports grounds; Drainage, irrigation or heating of sports grounds
    • E01C13/08—Surfaces simulating grass ; Grass-grown sports grounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3017—Floor coverings
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/02—Natural macromolecular compounds or derivatives thereof
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/068—Polyurethanes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/10—Particulate form, e.g. powder, granule
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/20—Cured materials, e.g. vulcanised, cross-linked

Definitions

  • This invention relates to mats and the process for producing the mats.
  • the invention has particular application to resilient mats for use as artificial turf and as floor coverings, and to mats utilising recycled rubber material as a constituent thereof.
  • Convention artifical turf matting as used, for example for playing surfaces typically comprises an upper turf carrying sheet affixed to a substrate.
  • the upper sheet is often formed of plastic grass, typically thin strips of plastic material, tufted into a flexible backing of, for example, polyurethane. To retain the grass in the sheet and to provide additional strength a secondary backing sheet may also be provided.
  • This turf carrying sheet is then glued to a substrate, normally a resilient flexible rubber sheet.
  • the process of glueing the turf sheet to the substrate is normally carried out manually, with operators spreading a layer of glue over the substrate and then laying the other turf sheet over the glue coated surface. When spreading the glue, care must be taken to provide a uniform thickness over the surface such that the resulting bond is uniform.
  • Artificial turf is most frequently used in outdoor locations and may, therefore, be subject to large variations in temperature. As the upper turf sheet and the rubber backing often have difference coefficients of expansion, the join between the two must withstand the forces experienced when the components of the mat expand and contract at differing rates. Also, where the artificial turf is used, for example, to provide a driving surface on a golf range, the grass layer will be subject to considerable abuse and must, therefore, be fixed securely to the backing to prevent separation.
  • a mat comprising a first layer including a first material and a second layer including a second material and a third material. At the boundary between the two layers there is chemical bonding between the first material and the second material.
  • the first layer may be relatively thin and may form an upper surface of the mat.
  • the second layer may be relatively thick and resilient to provide a lower substrate for the mat.
  • the third material may be formed of granules bound together by the second material.
  • a process for producing a mat comprising the steps: providing a first layer having a first side and including a first material; coating the first side of the first layer with a second layer including a second material and a third material; and curing the second material to form a boundary between the first and second layers at which the first material and the cured second material are chemically bonded together.
  • the curing of the second material may be carried out in the presence of a catalyst.
  • a mat comprising granules of rubber dispersed in a polymeric binding.
  • Figure 1 is a sectional view of an artificial turf mat in accordance with the present invention.
  • Figure 2 is a side view of apparatus for use in producing the mat of Figure 1.
  • Figure 1 of the drawings illustrates a mat 10 of artificial turf. It will be noted that the mat comprises three identifiable layers: a first or upper layer 12 which contains the artificial grass 14; a second or lower layer 16 in the form of a resilient substrate; and an intermediate layer 18.
  • the upper layer 12 is formed of a polyurethane sheet carrying tufts of artificial grass 14 in the form of thin olefin strips.
  • the upper layer 12 will be formed of two layers of polyurethane, a first layer 12A into which the grass 14 is tufted, and a second layer 12B applied to the rear surface of the first layer to assist in retaining the grass and to provide greater mechanical strength.
  • the lower layer 16 is formed of a mixture of granules of rubber 17 dispersed throughout a polyurethane binder 19. The process of producing the layer 16 will be described later.
  • the intermediate layer 18 is formed of polyurethane which is crosslinked to the polyurethane in the upper and lower layers 12, 16.
  • crosslinking between the layers 12, 16, 18 provides a substantially unitary mat.
  • the upper layer 12 is provided in the form of a turf mat 21 on a reel 20 from which the mat 21 may be dispensed, with the grass 14 extending downwardly.
  • the raw material for the lower layer 16 is granulated rubber 23, conveniently from shredded scrap tires, urethane 25 and a catalyst 27.
  • the rubber 23 is contained in a feedstock hopper 22, from which it is transferred into a batch weight hopper 24 by a suitable conveyor, in this case an 18' length, 6" diamater screw auger conveyor 26.
  • a suitable conveyor in this case an 18' length, 6" diamater screw auger conveyor 26.
  • the batch weight hopper 24 is mounted on scales 28 which may be set to deactivate the conveyor 26 when a desired weight of rubber has been deposited in the hopper 24.
  • the rubber is released into a ribbon mixer 30 which includes a further inlet through which the urethane 25 and catalyst 27 may be introduced.
  • a separate mixer 32 is also provided for containing only urethane and catalyst.
  • Measured amounts of rubber, urethane and catalyst are introduced into the mixers 30, 32 where they are mixed for a predetermined time sufficient to disperse the urethane and catalyst throughout the rubber and thoroughly mix the urethane and catalyst, respectively. While the mixing operation proceeds, a length of mat 21 from the reel 20 is pulled across a screet table 36 above which the mixers 30, 32 and the batch weight hopper 24 are mounted. The urethane and catalyst mix are then released from the mixer 32, through an outlet 38 onto the turf, where the polyurethane and catalyst mix are spread evenly over the mat by a screet blade 40. Generally, the volume of urethane and catalyst mix released will be sufficient to completely coat the rear surface of the turf mat 21. The volume required will vary depending on the surface finish of the mat, a rough or irregular surface requiring a greater volume of urethane and catalyst mix. This relatively thin layer will eventually form the intermediate layer 18.
  • the rubber, urethane and catalyst mix is released from the mixer 30 through outlet 42 onto the turf mat and the urethane and catalyst mix layer.
  • the screet blade 40 is raised slightly and used to level the mix to form an even coating. The thicker layer will eventually form the lower layer of the finished mat.
  • the coated turf is then moved to the right (as seen in Figure 2) between the platens 44, 46 of a hydraulic press 48.
  • the platens 44, 46 of the press illustrated are oil heated, self-lubricating and the press is capable of producing 100 psi over 6912 square inches (96" long x 72" wide).
  • the hydraulic system 50 and the oil heater 52 of the press 48 are shown as separate units. It should also be noted that the trailing edges 54, 56 of the platens 44, 46 are unheated.
  • the coated turf mat 21 is compressed and heated in the press 48 to compress and cure the urethane in the urethane and catalyst mix and the rubber, urethane and catalyst mix, and to compress the mixes to a predetermined degree.
  • the urethane polymerizes such that a first boundary 58 (Figure 1) is created between the turf mat 21 and the urethane and catalyst mix, now the polyurethane intermediate layer 18.
  • a first boundary 58 Figure 1
  • the temperatures to which the platens 44, 46 are heated are chosen so as not to damage the turf mat 21, particularly the grass 14 which is normally more susceptible to heat damage.
  • the pressures are chosen so as not to damage the mat 21.
  • the platens 44, 46 are separated and the resulting mat pulled onto a cutting table 62, where the mat is cut to size.
  • the unheated edges 54, 56 of the platens slow the curing operation at the trailing edge of the mat 21 such that the cured layers 16, 18 appear as continuous layers along the length of the finished mat 10. While the cutting operation is taking place, subsequent trailing portions of the mat 21 may be subject to curing in the press 48, or being coated on the screet table 36.
  • the properties of the substrate 16 may be varied by using different sizes of rubber granules and different forms or densities of urethane.
  • the rubber used may be from 200 mesh up to outsize (3/8" diameter).
  • the proportions of rubber to urethane may be varied, the mix including up to 50% weight urethane. Curing time is governed by the proportion of catalyst present, the use of the intermediate layer of urethane between the upper and lower layers also serving to accelerate the bonding process between the layers.
  • 1404.6 ozs. of 5 mesh rubber granules is mixed with 20 ozs. of Vibrathane B843C urethane and 5.4 ozs. of Triethenolamine for three minutes. The mix is then spread over a polyurethane mat 60" wide by 60" long. The mat and mix are then placed in a press and subject to compression of 47 psi for between platens heated to 92° C 6 minutes.
  • the resulting layer is 3'4" thick.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Road Paving Structures (AREA)

Abstract

Le procédé décrit, qui sert à fabriquer un tapis unitaire (10) composé d'au moins deux couches distinctes, consiste à prévoir une première couche (12) en forme de feuille présentant une première face et contenant un premier matériau, à revêtir la première face de la feuille avec une seconde couche (16) contenant un deuxième matériau (19), un troisième matériau (17) et un catalyseur, et à vulcaniser le second matériau pour former une limite entre les couches (12, 16) au niveau de laquelle se produit une liaison chimique entre le premier matériau et le deuxième matériau. Les premier et deuxième matériaux peuvent être constitués par des matériaux polymères et le troisième matériau peut être constitué par du caoutchouc granulaire. Le tapis qui en résulte (10) peut être utilisé comme surface de jeu pour sols et autres surfaces similaires.
PCT/CA1990/000034 1989-02-01 1990-02-01 Tapis Ceased WO1990008649A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US30469089A 1989-02-01 1989-02-01
US304,690 1989-02-01

Publications (1)

Publication Number Publication Date
WO1990008649A1 true WO1990008649A1 (fr) 1990-08-09

Family

ID=23177570

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CA1990/000034 Ceased WO1990008649A1 (fr) 1989-02-01 1990-02-01 Tapis

Country Status (2)

Country Link
AU (1) AU5030690A (fr)
WO (1) WO1990008649A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1996022413A1 (fr) * 1995-01-19 1996-07-25 Ekotex S.R.O. Revetement de sol auto-adhesif et son procede de fabrication
EP1008447A3 (fr) * 1998-12-09 2001-05-16 The Dow Chemical Company Procédé pour la préparation de rembourrages en matériau cellulaire comprenant un laminé TPU
CN102197949A (zh) * 2010-03-23 2011-09-28 旭聚企业股份有限公司 利用回收废弃物为材料的方块型地毯及其制法
WO2016055414A1 (fr) * 2014-10-07 2016-04-14 Kölbl Engineering und Consulting GmbH Tapis ou bande

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1388208A (en) * 1971-12-09 1975-03-26 Bayer Ag Substrates for use in soil free cultivation
DE2540193A1 (de) * 1975-09-10 1977-03-24 Walter Koepsell Aus zerschnitzeltem gummi und bindemittel bestehende platten und verfahren zur herstellung derselben
US4037013A (en) * 1975-11-07 1977-07-19 Dayco Corporation Carpet underlay comprising foamed scrap particles
DE3017899A1 (de) * 1979-05-17 1980-11-27 Oesterr Heraklith Ag Verfahren zur herstellung von pur- gebundenen gummigranulatmatten

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1388208A (en) * 1971-12-09 1975-03-26 Bayer Ag Substrates for use in soil free cultivation
DE2540193A1 (de) * 1975-09-10 1977-03-24 Walter Koepsell Aus zerschnitzeltem gummi und bindemittel bestehende platten und verfahren zur herstellung derselben
US4037013A (en) * 1975-11-07 1977-07-19 Dayco Corporation Carpet underlay comprising foamed scrap particles
DE3017899A1 (de) * 1979-05-17 1980-11-27 Oesterr Heraklith Ag Verfahren zur herstellung von pur- gebundenen gummigranulatmatten

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1996022413A1 (fr) * 1995-01-19 1996-07-25 Ekotex S.R.O. Revetement de sol auto-adhesif et son procede de fabrication
EP1008447A3 (fr) * 1998-12-09 2001-05-16 The Dow Chemical Company Procédé pour la préparation de rembourrages en matériau cellulaire comprenant un laminé TPU
CN102197949A (zh) * 2010-03-23 2011-09-28 旭聚企业股份有限公司 利用回收废弃物为材料的方块型地毯及其制法
WO2016055414A1 (fr) * 2014-10-07 2016-04-14 Kölbl Engineering und Consulting GmbH Tapis ou bande

Also Published As

Publication number Publication date
AU5030690A (en) 1990-08-24

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