Using a polyol mixture comprising PBD for creating a PU-based artificial turf
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Solution Overview
Problem
Artificial turf surfaces face challenges in maintaining mechanical strength, resistance to water, and durability due to weak Van-der-Waals forces between hydrophobic fibers and hydrophilic polyurethane backings, leading to fiber detachment and delamination under mechanical and environmental stress.
Innovation Solution
A method involving the creation of a hydrophobic polyurethane backing by reacting polyether or polyester polyols with polybutadiene diol and isocyanate, which increases the hydrophobicity of the polyurethane, enhances mechanical fixation of hydrophobic fibers, and prevents delamination by forming chemical bonds, while also being resistant to water and chemical degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional polyurethane is used, then initial bonding is achieved, but delamination occurs under mechanical and environmental stress over time
Solution Approach 1:
The invention modifies the chemical structure parameters of polyurethane by introducing polybutadiene polyol with specific functionality (1.5-2.5) and vinyl content (30-70 wt%), which changes the bonding mechanism from weak physical adsorption to strong chemical bonding, preventing delamination under stress
Solution Approach 2:
The invention replaces the unstable, short-lived physical bonding mechanism with a durable, long-lasting chemical bonding mechanism through polybutadiene polyol, which maintains bond strength throughout the entire service life of the artificial turf (5-15 years)
2Reliability
If hydrophobic polyolefin fibers are used, then fiber durability and chemical resistance are improved, but bonding to polyurethane backing deteriorates due to weak Van-der-Waals forces
Solution Approach 1:
The invention changes the surface energy and chemical composition parameters of the polyurethane backing by adding polybutadiene polyol, creating a surface that is chemically compatible with hydrophobic polyolefin fibers, enabling strong bonding without compromising fiber durability
Solution Approach 2:
The invention creates a more homogeneous interface between the hydrophobic fiber and polyurethane backing by incorporating polybutadiene polyol, which has chemical properties intermediate between polar polyurethane and non-polar polyolefin, reducing interfacial incompatibility
3Reliability
If polybutadiene polyol is added to polyurethane, then adhesion to hydrophobic fibers and resistance to delamination are improved, but manufacturing complexity increases
Solution Approach 1:
The invention extracts the bonding function from the bulk polyurethane matrix and concentrates it in the polybutadiene polyol component, which reacts specifically with isocyanate to form strong bonds, simplifying the overall formulation while achieving enhanced performance
Solution Approach 2:
The polybutadiene polyol serves multiple functions simultaneously: it provides hydrophobicity for fiber compatibility, creates chemical bonding sites through isocyanate reaction, and maintains polyurethane matrix structure, reducing the need for multiple separate additives
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 results in a polyurethane-based artificial turf backing that firmly fixes hydrophobic fibers, resisting tuft withdrawal forces and maintaining structural integrity under various environmental conditions, including water exposure, thereby extending the lifespan and performance of the turf.
Implementation Method 1
reacting polyether or polyester polyols with polybutadiene diol and isocyanate, which increases the hydrophobicity of the polyurethane
Implementation Method 2
prevents delamination by forming chemical bonds
Implementation Method 3
weak Van-der-Waals forces between hydrophobic fibers and hydrophilic polyurethane backings
Implementation Method 4
reacting first and second polyols with an isocyanate
Data Source
AI summary
A method of manufacturing an artificial turf includes creating fluid polyurethane mass. The creation including reacting first and second polyols with an isocyanate. The first polyol is a polyether polyol and/or a polyester polyol having at least 2 hydroxyl groups per molecule, the second polyol being polybutadien diol. The isocyanate including 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. The method further includes 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, adding the fluid polyurethane mass on the back side of the carrier, and hardening the fluid polyurethane mass.