Noise-Absorbing Surfacing Material Using Polyurethane Encapsulation
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Solution Overview
Problem
Conventional rubber surfacings used in playgrounds and public spaces lack durability and wear resistance, and while they provide good impact absorption, they are not effective in reducing noise and impact.
Innovation Solution
A novel surfacing material is developed by combining ground SBR rubber with a ground mineral aggregate, such as silica, and encapsulating them with a polyurethane resin. This configuration enhances noise absorption, durability, and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional rubber surfacing is used, then impact absorption is good, but durability and wear resistance are poor
Solution Approach 1:
The patent creates a composite material combining ground SBR rubber granules (40-50 wt%), ground aggregate (38-42 wt%), and polyurethane resin (10-20 wt%). This composite structure integrates the impact absorption properties of rubber with the durability and wear resistance of aggregate and resin, resolving the contradiction between softness and strength.
2Object-affected harmful factors
If conventional rubber surfacing is used, then ease of repair is good, but noise absorption is poor
Solution Approach 1:
The patent utilizes the porous structure of ground rubber granules and aggregate particles within the resin matrix to create noise-absorbing voids. The interconnected pore structure allows sound waves to penetrate and dissipate energy, providing excellent noise absorption while maintaining the material's repairability through the flexible resin binder.
3Object-affected harmful factors
If asphalt surfacing is used, then durability is good, but noise and impact absorption is poor
Solution Approach 1:
The patent develops a composite material that merges the durability characteristics of asphalt-like aggregate-resin structures with the noise and impact absorption properties of rubber granules. The multi-phase composite structure allows simultaneous achievement of hardness for durability and softness for absorption.
4Strength
If more polyurethane resin is added to encapsulate rubber granules, then durability improves, but noise absorption may deteriorate
Solution Approach 1:
The patent optimizes the polyurethane resin content to a specific range (10-20 wt%) to achieve the right balance between durability and noise absorption. This parameter optimization ensures sufficient resin for encapsulation and binding while maintaining enough void space and rubber content for effective noise absorption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The new surfacing material exhibits improved noise absorption and reduced noise levels compared to traditional asphalt, while maintaining durability and wear resistance comparable to conventional rubber surfacings.
Implementation Method 1
The second component typically comprises a polyurethane resin. Polyurethane resins have a wide range of uses due to their rapid solidification and high adhesion to different types of surfaces.
Implementation Method 2
These two components are mixed at a time immediately prior to the application of the surfacing so that, once the material has been applied to the desired surface, a step of curing the resin takes place, providing stability and durability to the granulated rubber.
Implementation Method 3
the new material exhibits improved noise and impact absorption characteristics compared to a conventional surfacing, such as for example asphalt
Data Source
AI summary
The invention relates to a material for noise-absorbing surfacing, which comprises a mixture of a first component (A) and a second component (B), characterized in that the first component (A) comprises 40-50 wt% ground SBR rubber with a size less than 6 mm, 38-42% ground mineral aggregate with a size less than 8 mm, 10-20% polyurethane resin, and 3-4% glycol, the ground SBR rubber granules and the ground mineral granules being encapsulated by the polyurethane resin; and the second component (B) comprises 50-56% isocyanate and 38-45% polyether polyol. The invention also relates to a method for producing a material for noise-absorbing surfacing, characterized in that it comprises producing the first component, which comprises the step of encapsulating the ground SBR rubber granules and the ground mineral aggregate granules using the polyurethane resin by means of a mixer; and producing the second component, which comprises the step of introducing the isocyanate and the polyether polyol into a reactor at a temperature of between 50-80°C.