PBD-Modified PU Backing for Water-Stable Artificial Turf
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Solution Overview
Problem
Artificial turf fibers face issues with mechanical wear, UV resistance, thermal cycling, and chemical interactions, leading to a short lifespan and loss of playing characteristics due to weak adhesion between hydrophobic polyolefin fibers and hydrophilic polyurethane backings, which can delaminate and swell when exposed to water.
Innovation Solution
A method involving the creation of a polyurethane (PU) backing using a polyaddition reaction with polybutadiene diol (PBD) to increase hydrophobicity and stability, enhancing the attachment of hydrophobic fibers through Van-der-Waals forces and preventing delamination, while maintaining mechanical strength and resistance to water exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If polyurethane backing is used to fix artificial turf fibers, then the backing provides structural support and fiber fixation, but the hydrophilic polyurethane has weak adhesion to hydrophobic polyolefin fibers and delaminates when exposed to water
Solution Approach 1:
The invention changes the chemical composition parameters of the polyurethane by incorporating polybutadiene diol (PBD) segments, which alter the surface properties from hydrophilic to more hydrophobic. This parameter change in the polymer structure enables stronger adhesion to hydrophobic polyolefin fibers through improved compatibility and prevents delamination when exposed to water.
Solution Approach 2:
The invention creates a composite polyurethane material combining traditional polyurethane components with polybutadiene diol segments. This composite structure integrates the structural support properties of polyurethane with the hydrophobic characteristics of PBD, achieving both strong fiber adhesion and water resistance simultaneously.
2Strength
If polybutadiene diol is added to increase hydrophobicity, then the adhesion to hydrophobic fibers improves, but the polyurethane may become more susceptible to chemical degradation
Solution Approach 1:
The invention carefully controls the concentration and molecular weight parameters of polybutadiene diol incorporation to optimize the balance between hydrophobicity and chemical stability. By adjusting these parameters, the formulation achieves enhanced Van-der-Waals forces for fiber attachment while maintaining resistance to chemical degradation and saponification.
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 PU-based backing strongly fixes hydrophobic fibers, increases resistance to tuft withdrawal forces, and maintains performance under various environmental conditions, including water exposure, by creating a hydrolytically stable and more hydrophobic polyurethane variant that prevents swelling and saponification.
Implementation Method 1
the attachment of the PU to the fiber via Van-der-Waals forces is increased
Implementation Method 2
the creation comprising reacting first and second polyols with an isocyanate
Implementation Method 3
the PU is made more hydrophobic and the attachment of the PU to the fiber via Van-der-Waals forces is increased
Data Source
Figure 1~2
Figure 3~4
Figure 5a~6b
AI summary
The invention relates to a method of manufacturing an artificial turf (600, the method comprising: - creating (102) fluid polyurethane mass (210), the creation comprising reacting first and second polyols with an isocyanate, ▪the first polyol being a polyether polyol and/or a polyester polyol having at least 2 hydroxyl groups per molecule, the second polyol being polybutadiendiol; ▪the isocyanate comprising isocyanate monomers, isocyanate polymers or isocyanate prepolymers or a mixture thereof, the isocyanate monomers, isocyanate polymers and the isocyanate prepolymers having two or more isocyanate groups per molecule; - incorporating (104) an artificial turf fiber (501) into a carrier (308) such that a first portion (302) of the fiber protrudes to the front side of the carrier and that a second portion (506) of the fiber is located at the back side of the carrier; and - adding (106) the fluid polyurethane mass on the back side of the carrier; and - hardening (108) the fluid polyurethane mass.