Polyurethane Sports Flooring Foam Lane Bonding
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Solution Overview
Problem
Existing polyurethane flooring for sports grounds faces challenges in maintaining a consistent foam structure and surface smoothness due to varying temperature and humidity conditions during installation, leading to uneven surfaces and irregular foam thickness.
Innovation Solution
A method and apparatus for producing polyurethane flooring that applies the foam in multiple lanes, with process parameters determined by environmental data, using a froth foam process and incorporating additives to control curing time, ensuring adjacent lanes bond firmly and maintain a predefined foam morphology across temperature and humidity variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If polyurethane foam is applied in multiple lanes under varying environmental conditions, then the installation can proceed across large surfaces, but the foam structure becomes uneven and curing time varies
Solution Approach 1:
The polyurethane reactive components are divided into multiple segments (isocyanate component and polyol component) that are mixed in controlled proportions. The application process is segmented into multiple lanes with controlled timing between lanes, allowing each segment to be applied with precise process parameters while maintaining overall consistency across the large surface area
Solution Approach 2:
The patent dynamically adjusts process parameters (mixing ratios, application timing, lane intervals) based on measured environmental conditions (temperature, humidity). This allows the foam structure consistency to be maintained across varying environmental conditions by changing the parameters of the polyurethane reaction process in real-time
2Strength
If the first lane is applied and allowed to cure before applying the second lane, then proper bonding can be achieved, but the curing time becomes too long causing surface damage
Solution Approach 1:
The first lane is applied with preliminary control of its curing process by adjusting process parameters (temperature, humidity control, catalyst amounts) so that it reaches an optimal bonding state before the second lane is applied. This preliminary action ensures that the first lane is ready for bonding without requiring excessive curing time that would expose the surface to damage risks
Solution Approach 2:
The patent implements feedback control where environmental conditions (temperature, humidity) are continuously measured and used to adjust the timing and process parameters for subsequent lane applications. This feedback mechanism ensures that the bonding strength is optimized while minimizing the total curing time by adapting to actual environmental conditions rather than using fixed time intervals
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 solution ensures a consistent, smooth, and resilient polyurethane flooring with controlled curing time, adapting to changing environmental conditions, resulting in a uniform and durable athletic track or playground surface.
Implementation Method 1
The polyurethane is produced by reacting an isocyanate component with a polyol component
Implementation Method 2
mixing the foam for the polyurethane flooring by mixing the isocyanate component and the polyol component using a froth foam process
Data Source
AI summary
A method for producing polyurethane flooring includes providing polyurethane reactive components including a isocyanate component and a polyol component, determining environmental data, determining process parameters for mixing the polyurethane reactive components, wherein the process parameters depend on the environmental data, mixing the foam for the polyurethane flooring by mixing the isocyanate component and the polyol component using a froth foam process with the process parameters, applying a first lane of the liquid foam to a ground, applying a second lane of the liquid foam to the ground, wherein a side edge of the second lane gets in contact with a side edge of the first lane, wherein the process parameter are determined so that the foam of the first lane is not cured before applying the foam of the second lane. Furthermore, the invention relates to an apparatus and a system for producing a polyurethane flooring.