# US 10,865,284 B2 · Floor pavement structure with gel layer > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,865,284 B2 - Document ID: US10865284B2 - Status: Granted - Kind: B2 - Application number: 16/474,294 - Filed: 2017-12-28 - Published: 2019-11-07 - Granted: 2020-12-15 - Earliest claimed: 2016-12-28 - Assignees: Advanced Polymer Technology, Inc. - Applicants: Advanced Polymer Technology Corp. - Inventors: Stephan Sick; Frank Luccarelli; Wesley Baum; Andreas Schulze-Ising - Web page: https://patentgrep.com/patent/US10865284B2 ## CPC - E01C 13/065: {at least one in situ layer consisting of or including bitumen, rubber or plastics} - A43B 13/04: Plastics, rubber or vulcanised fibre - B32B 9/00: Layered products comprising a {layer of a} particular substance not covered by groups B32B11/00 - B32B29/00 - B32B 9/005: {comprising one layer of ceramic material, e.g. porcelain, ceramic tile (layered products with at least two ceramic layers composed mainly of ceramic B32B18/00)} - B32B 27/06: as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)} - B60R 13/02: {Internal} Trim mouldings {; Internal} Ledges; Wall liners {for passenger compartments}; Roof liners (B60R13/01 takes precedence {; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18}) - C08G 18/10: Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step - C08G 18/36: Hydroxylated esters of higher fatty acids - C08G 18/4854: {Polyethers containing oxyalkylene groups having four carbon atoms in the alkylene group} - C08G 18/7621: {being toluene diisocyanate including isomer mixtures} - C08G 18/7671: {containing only one alkylene bisphenyl group} - C08G 65/33348: {containing isocyanate group} - C08J 3/075: Macromolecular gels - C08J 7/042: {with two or more layers, where at least one layer of a composition contains a polymer binder} - C08K 5/0016: {Plasticisers} - C08K 5/09: Carboxylic acids; Metal salts thereof; Anhydrides thereof - C08L 75/00: Compositions of polyureas or polyurethanes; Compositions of derivatives of such polymers - C09D 7/65: macromolecular (C09D7/41-C09D7/48 take precedence) - C09D 175/04: Polyurethanes - E04F 15/12: Flooring or floor layers made of masses in situ, e.g. seamless magnesite floors, terrazzo {gypsum floors}(inorganic or bituminous masses C04B; organic plastic masses C08L) - E04F 15/225: {Shock absorber members therefor} - C08G 2220/00: Compositions for preparing gels other than hydrogels, aerogels and xerogels - C08J 2375/04: Polyurethanes - C08J 2423/16: Ethene-propene or ethene-propene-diene copolymers - C08J 2433/08: Homopolymers or copolymers of acrylic acid esters - C08J 2475/04: Polyurethanes - C08L 2205/06: having improved processability or containing aids for moulding methods - C08L 2207/324: Liquid component is low molecular weight polymer - E01C: CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR (forming roads or like surfaces by compacting or grading snow or ice E01H) - A43B: CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR - C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) - C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09) - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) - C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D) - E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B) ## Abstract A floor pavement structure includes a top layer that seals the floor pavement structure and a PU gel layer. The PU gel layer includes a solid and a liquid component and is positioned between a base material and the top layer. The solid component is a polyurethane polymer matrix. The liquid component is a plasticizer. ## Claims ### Claim 1 A floor pavement structure comprising: a top layer that seals the floor pavement structure; and a polyurethane (PU) gel layer comprised of a solid component and a liquid component between a base material and the top layer, the solid component being a polyurethane polymer matrix, the liquid component being a plasticizer. ### Claim 2 (depends on 1) The floor pavement structure of claim 1, wherein the top layer is configured to seal the floor pavement structure such that water as well as the plasticizer is prevented from penetrating and crossing the top layer. ### Claim 3 (depends on 1) The floor pavement structure of claim 1, wherein the plasticizer is a vegetable oil, a derivative of a vegetable oil, a mixture of vegetable oils, or a mixture of vegetable oil derivatives. ### Claim 4 (depends on 1) The floor pavement structure of claim 1, wherein the plasticizer comprises: at least three fatty acids respectively bound by an ester bound to an alcohol molecule backbone, the plasticizer being a triglyceride. ### Claim 5 (depends on 1) The floor pavement structure of claim 1, wherein the top layer comprises an acrylic emulsion comprising pigments and sand. ### Claim 6 (depends on 1) The floor pavement structure of claim 1, wherein the base material comprises concrete, asphalt, sand, stone, wood, or clay. ### Claim 7 (depends on 1) The floor pavement structure of claim 1, wherein the top layer is a polyurethane layer comprising EPDM granules, the pavement structure lacking a barrier layer. ### Claim 8 (depends on 1) The floor pavement structure of claim 1, further comprising: a polyurethane layer between the gel layer and the top layer or between the gel layer and a barrier layer, if any. ### Claim 9 (depends on 1) The floor pavement structure of claim 1, wherein at least a fraction of the plasticizer is covalently bound to the polyurethane polymer matrix, or wherein 55% to 65% by weight of the gel layer consists of the plasticizer. ### Claim 10 (depends on 9) The floor pavement structure of claim 9, wherein the fraction of the plasticizer that is covalently bound to the polyurethane polymer matrix is a vegetable oil with one or more functional groups in at least one of its fatty acid chains, the functional group having reacted with an isocyanate in a polyurethane reaction mixture to form the covalent bonds with the polyurethane polymer matrix. ### Claim 11 (depends on 1) The floor pavement structure of claim 1, further comprising: a barrier layer between the gel layer and the top layer, the barrier layer configured to prevent the plasticizer from leaving the gel layer in the direction from the base material to the top layer. ### Claim 12 (depends on 11) The floor pavement structure of claim 11, the barrier layer being a layer of synthetic resin, the synthetic resin including acrylic latex, styrolbutadien, or a combination of acrylic latex and carboxylated styrolbutadien. ### Claim 13 (depends on 11) The floor pavement structure of claim 11, wherein the barrier layer comprises ethylene glycol as a compatibilizer configured to promote adhesion of the top layer to the gel layer. ### Claim 14 (depends on 11) The floor pavement structure of claim 11, wherein the top layer has a height of 100 μm-2 mm, 200 μm-1000 μm, or 400 μm 500 μm; the barrier layer has a height of 5 μm-300 μm, 20 μm-200 μm, or 50 μm 100 μm; the gel layer has a height of 1 mm-4 mm, 1.5-3.5 mm, or about 2 mm; or a primer layer has a height of 5 μm-500 μm, 50 μm-300 μm, or 100 μm-150 μm. ### Claim 15 A method of constructing a floor pavement structure, the method comprising: applying a polyurethane (PU) reaction mixture comprising a plasticizer on top of a base material; letting the applied reaction mixture form a PU gel layer comprising a solid component and a liquid component, the solid component being a polyurethane polymer matrix, the liquid component being the plasticizer; and after the formation of the PU gel layer, applying a top layer that seals the floor pavement structure on top of the PU gel layer. ### Claim 16 (depends on 15) The method of claim 15, wherein the top layer is configured to seal the floor pavement structure such that water as well as the plasticizer is prevented from penetrating and crossing the top layer. ### Claim 17 (depends on 15) The method of claim 15, further comprising: applying a primer layer on the base material; optionally, before the primer has dried, applying silica sand or other forms of granules having a size of silica sand on the primer layer so as to increase a surface roughness of the primer layer; and after the primer layer has dried, performing the application of the PU reaction mixture on top of the primer layer. ### Claim 18 (depends on 15) The method of claim 15, further comprising: after the applied reaction mixture has finished forming the PU gel layer, applying a barrier layer on top of the gel layer; and the application of the top layer comprising: after the barrier layer has solidified, applying the top layer on top of the barrier layer. ### Claim 19 (depends on 15) The method of claim 15, wherein the plasticizer is a chemical derivative of a vegetable oil, and the method further comprises: generating the plasticizer, the generating comprising: increasing a number of unsaturated carbon bonds in the fatty acids of the vegetable oils; or adding at least one hydroxyl group, at least one amino group, or both at least one hydroxyl group and at least one amino group to at least one of the fatty acid chains of the vegetable oil. ### Claim 20 (depends on 15) The method of claim 15, wherein the plasticizer being a chemical derivative of vegetable oil, and the method further comprises: generating the plasticizer, the generating comprising: reacting a plurality of triglyceride molecules in a transesterification reaction into poly-ester molecules, the poly-ester molecules respectively comprising at least three fatty acids, wherein in the transesterification reaction a glycerol component of the triglyceride molecules is replaced by another carbon atom backbone component that comprises at least four carbon atoms; and using the poly-ester molecules as the plasticizer or as a component of the plasticizer.