Using a polyol mixture comprising PBD for creating a PU-based artificial turf
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Solution Overview
Problem
Artificial turf fibers face issues with mechanical wear, UV resistance, thermal cycling, chemical interactions, and environmental conditions, leading to reduced durability and surface characteristics over time, especially due to weak Van-der-Waals forces between hydrophobic polyolefin fibers and hydrophilic polyurethane backings, and susceptibility to water-induced swelling and saponification.
Innovation Solution
A method involving the creation of a polyurethane (PU) backing by reacting polyether or polyester polyols with isocyanates, incorporating polybutadiendiol to increase hydrophobicity and stability, and using a wetting agent to enhance fiber fixation, resulting in a hydrolytically stable and strongly adhering PU backing that exhibits a 'stick-slip' effect for improved fiber retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyurethane backing is used to fix artificial turf fibers, then fiber fixation is achieved, but fiber pull-out occurs due to weak Van-der-Waals forces between hydrophobic polyolefin fibers and hydrophilic polyurethane
Solution Approach 1:
The patent modifies the chemical composition parameters of the polyurethane by incorporating polybutadiendiol (PBD) at specific ratios (0.1-10 wt%, preferably 0.5-5 wt%). This changes the surface properties of the PU from hydrophilic to more hydrophobic, increasing the Van-der-Waals forces between the backing and polyolefin fibers, thereby preventing fiber pull-out while maintaining fixation strength
Solution Approach 2:
The patent creates a composite polyurethane material combining traditional polyols with polybutadiendiol. This composite material integrates the adhesive properties of PU with the hydrophobic characteristics of PBD, achieving both strong fiber fixation and resistance to fiber pull-out through enhanced interfacial compatibility
2Ease of manufacture
If standard polyurethane is used for backing, then manufacturing is simple, but water causes swelling and saponification reducing durability
Solution Approach 1:
The patent modifies the chemical structure of polyurethane by incorporating polybutadiendiol, which changes the material's hydrolytic stability parameters. The PBD-containing PU exhibits reduced susceptibility to water-induced swelling and saponification, enhancing durability while maintaining manufacturability through standard polyaddition processes
Solution Approach 2:
The patent addresses the inherent vulnerability of polyurethane to water degradation by incorporating PBD, which introduces hydrophobic segments that counteract water attack. The modified PU converts the potential harm of water exposure into an opportunity for enhanced stability through improved hydrolytic resistance
3Reliability
If polybutadiendiol is added to increase hydrophobicity, then fiber adhesion improves, but manufacturing complexity increases
Solution Approach 1:
The patent optimizes the PBD content parameter within specific ranges (0.1-10 wt%, preferably 0.5-5 wt%) to achieve the desired hydrophobicity and fiber adhesion. By controlling this parameter, the patent balances performance improvement with manufacturing simplicity, avoiding excessive complexity while achieving enhanced fiber backing interaction
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 method provides a durable and long-lasting artificial turf with enhanced resistance to mechanical wear, UV exposure, and water, ensuring stable fiber fixation and improved surface characteristics by creating a hydrophobic PU backing that strongly adheres to hydrophobic fibers, reducing the risk of fiber pull-out and maintaining performance over extended use.
Implementation Method 1
Van-der-Waals forces between the fibers and the PU backing are weak and fibers may easily be pulled out of a PU backing when a tuft-withdrawal force is applied. By adding polybutadiendiol (PBD) in the reaction mixture used for creating the PU in a polyaddition reaction, the PU is made more hydrophobic and the attachment of the PU to the fiber via Vander-Waals forces is increased.
Implementation Method 2
By adding polybutadiendiol (PBD) in the reaction mixture used for creating the PU in a polyaddition reaction, the PU is made more hydrophobic
Implementation Method 3
adding the fluid polyurethane mass on the back side of the carrier, the polyurethane mass thereby incorporating at least the second portions of the fiber; and hardening the fluid polyurethane mass on the back side of the carrier
Data Source
AI summary
Method of manufacturing an artificial turf includes: creating fluid polyurethane mass, 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 an artificial turf fiber into a carrier such that a first portion of the fiber protrudes to the front side of the carrier and that a second portion of the fiber is located at the back side of the carrier; and adding the fluid polyurethane mass on the back side of the carrier; and hardening the fluid polyurethane mass.