US4112176A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Ground rubber elastomeric composite useful in surfacings and the like, and methods
Assignee: U S Rubber Reclaiming Co Inc
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Filing: 1976-02-20
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Granted: 1978-09-05
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Expires: 1996-02-20
Abstract
Abstract There is provided a polyurethane ground rubber composite and a new method for formation and preparation thereof. The composite is suitable for use in laminated and other surfacing or as a surfacing and has excellent flexibility, resiliency, weatherability, and elastomeric qualities; and comprises particulate vulcanized rubber substantially coated on each particle with about 3 to about 8 microns, and in some instances about 3 to about 10 microns, of a cross-linked binder derived from an essentially solvent-free polymeric isocyanate prepolymer having a number average molecular weight of 800-4000, the cross-linking of the isocyanate prepolymer being accomplished by controlled reaction with water using an equivalent ratio of NCO/OH of 0.14/1 to 0.83/1 to form urea and buiret linkages, and providing a void content of 25-60 volume percent, so that the carbon dioxide generated by the water/isocyanate reaction can readily diffuse through the film and so that the vented carbon dioxide does not cause foaming of the composite; and methods of controlling the forming of the composite, the layering of the composite, and/or mixing it in situ.
Inventors
- 👤 Allen R. Bailey
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-07 22:18
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/16; B32B13/00; B32B13/04; B32B13/08; B32B15/00; B32B15/16; D; D06; D06N; D06N7/00; D06N7/0063; D06N7/0071; D06N7/0076; D06N7/0089; E; E01; E01C; E01C13/00; E01C13/06; E01C13/065; E01C13/08; E04; E04F; E04F15/00; E04F15/22; B32B2260/00; B32B2260/02; B32B2260/025; B32B2260/04; B32B2260/046; B32B2264/00; B32B2264/02; B32B2264/0207; B32B2307/00; B32B2307/10; B32B2307/50; B32B2307/56; D06N2203/00; D06N2203/02; D06N2203/06; D06N2203/068; D06N2205/00; D06N2205/10; D06N2205/20; Y; Y10; Y10T; Y10T428/00; Y10T428/23907; Y10T428/23979; Y10T428/25; Y10T428/254; Y10T428/29; Y10T428/2982; Y10T428/2991; Y10T428/2998; Y10T428/31504; Y10T428/31551; Y10T428/31569; Y10T428/31573; Y10T428/31583; Y10T428/31587; Y10T428/31598
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
108 words
A flexible resilient elastomeric composite composed of vulcanized rubber particles substantially coated and bonded with a cross-linked non-foamed binder consisting essentially of a solvent-free polymeric isocyanate prepolymer cross-linked by urea and biuret linkages and having an excess NCO content of 3-10% and a number average molecular weight between 800 and 4000, said cross-linking of the isocyanate prepolymer being accomplished by the controlled reaction fo prepolymer components in an equivalent ratio NCO/OH of 0.14/1 to 0.83/1; the film thickness of the prepolymer binder on the rubber particles being from about 3 microns to about 10 microns and the void content of the composition being between 25 and 60 percent.
Claim 2
Dependent Claim
108 words
A flexible resilient elastomeric composite composed of vulcanized rubber particles substantially coated and bonded with a cross-linked non-foamed binder consisting essentially of a solvent-free polymeric isocyanate prepolymer cross-linked by urea and biuret linkages and having an excess NCO content of 3-10% and a number average molecular weight between 800 and 4000, said cross-linking of the isocyanate prepolymer being accomplished by the controlled reaction fo prepolymer components in an equivalent ratio NCO/OH of 0.14/1 to 0.83/1; the film thickness of the prepolymer binder on the rubber particles being from about 3 microns to about 10 microns and the void content of the composition being between 25 and 60 percent.
Claim 3
Dependent Claim
19 words
A composition as in claim 1 wherein said film thickness is from about 3 microns of about 8 microns.
Claim 4
Dependent Claim
13 words
A surfacing comprising at least one layer of the composite of claim 1.
Claim 5
Dependent Claim
24 words
A surfacing as in claim 3 comprising, in addition to the layer of composite, one or more layers of metal, wood, or polymeric material.
Claim 6
Dependent Claim
20 words
The surfacing of claim 3 wherein the uppermost layer of the composite has a coat of an elastomeric polymeric sealer.
Claim 7
Dependent Claim
18 words
A laminated product comprising the composite of claim 1 bonded to a layer of carpeting, tile, or linoleum.
Claim 8
Dependent Claim
23 words
The composite as in claim 1 wherein the vulcanized rubber is dried to a controlled moisture content of 0.1 to 1.0 weight percent.
Claim 9
Dependent Claim
18 words
The composite as in claim 1 wherein the vulcanized rubber consists of particles of neoprene or nitrile rubber.
Claim 10
Dependent Claim
113 words
A flexible, resilient, elastomeric composite having a void content within the range of from 25-60% comprising 60-95 weight percent vulcanized rubber particles partially or wholly coated and bonded together by 5-40 weight percent of a cross-linking non-foamed binder consisting essentially of a solvent-free polymeric isocyanate prepolymer having urea and biuret cross-linkages; said prepolymer binder having a viscosity at 25° C. of 1,000-12,000 cps., containing 3-10% excess NCO, and having a number average molecular weight between 800-4000, said isocyanate prepolymer being crosslinked by the controlled reaction of said prepolymer with a stoichiometric excess of water in an equivalent ratio of NCO/OH 0.14/ 1 to 0.83/ 1 , to form said urea and biuret cross-linkages.
Claim 11
Dependent Claim
113 words
A flexible, resilient, elastomeric composite having a void content within the range of from 25-60% comprising 60-95 weight percent vulcanized rubber particles partially or wholly coated and bonded together by 5-40 weight percent of a cross-linking non-foamed binder consisting essentially of a solvent-free polymeric isocyanate prepolymer having urea and biuret cross-linkages; said prepolymer binder having a viscosity at 25° C. of 1,000-12,000 cps., containing 3-10% excess NCO, and having a number average molecular weight between 800-4000, said isocyanate prepolymer being crosslinked by the controlled reaction of said prepolymer with a stoichiometric excess of water in an equivalent ratio of NCO/OH 0.14/ 1 to 0.83/ 1 , to form said urea and biuret cross-linkages.
Claim 12
Dependent Claim
21 words
The composite as in claim 9 having an excess NCO content of 6-8% and a molecular weight of 2000 - 3000.
Claim 13
Dependent Claim
30 words
The composite as in claim 9 having a binder coating thickness of 7.5 - 8.5 microns and adapted for providing ear surfaces, crash barriers, shoe soles and unsupported sheet goods.
Claim 14
Dependent Claim
31 words
The composite as in claim 9, having a binder coating thickness of 3.5 to 40 microns and adapted for supported sheet goods, carpet backing, lamination, and space-filling composites and the like.
Claim 15
Independent Claim
97 words
A method of forming a flexible resilient and elastomeric composite which comprises substantially coating vulcanized rubber particles to a thickness of about 3 microns to about 10 microns; with a non-foaming cross-linked binder consisting essentially of a solvent-free polymeric isocyanate prepolymer having a number average molecular weight between 800 and 4000, cross-linking said prepolymer by a controlled reaction with water at an equivalent ratio of NCO/OH of 0.14/1 to 0.83/1 to form urea and biuret cross-linkages; said cross-linked coating having a void content of about 25 percent to 60 percent; and consolidating and bonding said coated particles.
Claim 16
Independent Claim
97 words
A method of forming a flexible resilient and elastomeric composite which comprises substantially coating vulcanized rubber particles to a thickness of about 3 microns to about 10 microns; with a non-foaming cross-linked binder consisting essentially of a solvent-free polymeric isocyanate prepolymer having a number average molecular weight between 800 and 4000, cross-linking said prepolymer by a controlled reaction with water at an equivalent ratio of NCO/OH of 0.14/1 to 0.83/1 to form urea and biuret cross-linkages; said cross-linked coating having a void content of about 25 percent to 60 percent; and consolidating and bonding said coated particles.
Claim 17
Independent Claim
80 words
The method of forming and spreading a layer of composite which comprises mixing 60-95 weight percent of crumb rubber with 5-40 weight percent of a cross-linking binder derived from an essentially solvent-free polymeric isocyanate prepolymer having a viscosity of 25° C. of 1,000-12,000 cps. and containing 3-10% excess NCO, spreading the layer in situ and curing said binder by absorption of atmospheric moisture by said prepolymer to form urea and biuret crosslinkages at an NCO/HO ratio of 0.14/1 to 0.83/1.
Claim 18
Independent Claim
80 words
The method of forming and spreading a layer of composite which comprises mixing 60-95 weight percent of crumb rubber with 5-40 weight percent of a cross-linking binder derived from an essentially solvent-free polymeric isocyanate prepolymer having a viscosity of 25° C. of 1,000-12,000 cps. and containing 3-10% excess NCO, spreading the layer in situ and curing said binder by absorption of atmospheric moisture by said prepolymer to form urea and biuret crosslinkages at an NCO/HO ratio of 0.14/1 to 0.83/1.
Claim 19
Independent Claim
89 words
A method of forming a surfacing which comprises applying on a base a layer of composite comprising 60-95 weight percent of crumb rubber with 5-40 weight percent cross-linking binder consisting essentially of a solvent-free polymeric isocyanate prepolymer having a viscosity at 25° C. of 1,000-12,000 cps. and containing 3-10% excess NCO, cross-linking said isocyanate prepolymer by the reaction with water, the ratio of NCO/OH being 0.14/1 to 0.83/being controlled to form substantially only urea and biuret linkages, and then sealing said exposed composite layer with a polymeric elastomeric coating.
Claim 20
Independent Claim
89 words
A method of forming a surfacing which comprises applying on a base a layer of composite comprising 60-95 weight percent of crumb rubber with 5-40 weight percent cross-linking binder consisting essentially of a solvent-free polymeric isocyanate prepolymer having a viscosity at 25° C. of 1,000-12,000 cps. and containing 3-10% excess NCO, cross-linking said isocyanate prepolymer by the reaction with water, the ratio of NCO/OH being 0.14/1 to 0.83/being controlled to form substantially only urea and biuret linkages, and then sealing said exposed composite layer with a polymeric elastomeric coating.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1981-09-04 | 1982-03-06 | 1982-09-05 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1985-09-04 | 1986-03-06 | 1986-09-05 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1989-09-04 | 1990-03-06 | 1990-09-05 | $7700.00 | Window Closed / Lapsed |