# US 10,870,128 B2 · Using a polyol mixture comprising PBD for creating a PU-based artificial turf

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- Number: US 10,870,128 B2
- Document ID: US10870128B2
- Status: Granted
- Kind: B2
- Application number: 16/009,733
- Filed: 2018-06-15
- Published: 2018-10-11
- Granted: 2020-12-22
- Earliest claimed: 2016-03-18
- Assignees: Advanced Polymer Technologies Corp.
- Applicants: Advanced Polymer Technologies Corp.
- Inventors: Stephan Sick; Frank Lucarelli; Axel Hinrichs; Andreas Schulze-Ising
- Web page: https://patentgrep.com/patent/US10870128B2

## CPC

- E01C 13/08: Surfaces simulating grass {; Grass-grown sports grounds (grass-like surfaces for skiing E01C13/12)}
- B05D 1/26: performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
- B05D 3/02: by baking {(B05D3/04 takes precedence)}
- C08G 18/4063: {Mixtures of compounds of group C08G18/62 with other macromolecular compounds}
- C08G 18/42: Polycondensates having carboxylic or carbonic ester groups in the main chain
- C08G 18/4825: {Polyethers containing two hydroxy groups (C08G18/4833 - C08G18/5096 take precedence)}
- C08G 18/6208: {Hydrogenated polymers of conjugated dienes}
- C08G 18/7671: {containing only one alkylene bisphenyl group}
- D06N 7/0071: {characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing}
- B05D 2503/00: Polyurethanes
- D06N 2203/068: Polyurethanes
- D10B 2401/06: Load-responsive characteristics
- D10B 2505/202: Artificial grass
- Y10T 428/23979: Particular backing structure or composition
- Y10T 428/23986: With coating, impregnation, or bond
- Y10T 428/23993: Composition of pile or adhesive
- 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)
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- D06N: WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

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.

## Claims

### Claim 1

A method of manufacturing an artificial turf, the method comprising:
creating a fluid polyurethane mass, the creating including 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 artificial turf fiber protrudes to a front side of the carrier and that a second portion of the artificial turf fiber is located at a back side of the carrier, wherein the carrier includes perforations; and
adding the fluid polyurethane mass on the back side of the carrier, the fluid polyurethane mass thereby incorporating the second portion of the artificial turf fiber and penetrating the carrier via the perforations to reach the front side of the carrier for incorporating at least a portion of the first portion of the artificial turf fiber; and
hardening the fluid polyurethane mass on the back side of the carrier.

### Claim 2 (depends on 1)

The method of claim 1, the polybutadiendiol having an amount of 0.5-10% by weight of a combination of the first polyol and the isocyanate.

### Claim 3 (depends on 1)

The method of claim 1, the polybutadiendiol having a number average molecular weight in a range of 1000 g/mol to 6000 g/mol.

### Claim 4 (depends on 1)

The method of claim 1, the polybutadiendiol being a hydrated polybutadiendiol.

### Claim 5 (depends on 1)

The method of claim 1, the first polyol being free of polybutadiendiol.

### Claim 6 (depends on 5)

The method of claim 5, the first polyol further comprising the polyester polyol.

### Claim 7 (depends on 1)

The method of claim 1, further comprising adding a wetting agent to a mixture comprising the first and/or second polyols and/or comprising the isocyanate.

### Claim 8 (depends on 7)

The method of claim 7, the wetting agent being a surfactant having an amount of 0.01% to 1.0% by weight of a combination of the first and second polyols and the isocyanate.

### Claim 9 (depends on 1)

The method of claim 1, further comprising adding a pale oil to a mixture comprising the first and second polyols and/or comprising the isocyanate, the pale oil being added in an amount of 0.5% to 4%, by weight of a combination of the first and second polyols and the isocyanate.

### Claim 10 (depends on 1)

The method of claim 1, the fluid polyurethane mass having a density of more than 1000 g/l.

### Claim 11 (depends on 1)

The method of claim 1, wherein incorporating the artificial turf fiber into the carrier comprises: tufting the artificial turf fiber into the carrier; or weaving the artificial turf fiber into the carrier.

### Claim 12 (depends on 1)

The method of claim 1, wherein the artificial turf fiber is a bundle of monofilaments.

### Claim 13 (depends on 1)

The method of claim 1, wherein the artificial turf fiber is a hydrophobic polyolefin fiber.

### Claim 14 (depends on 1)

The method of claim 1, the hardening of the fluid polyurethane mass comprising:
heating the polyurethane mass on the back side of the carrier to a temperature of 70-140° C.

### Claim 15 (depends on 1)

The method of claim 1, further comprising generating the artificial turf fiber, the generating comprising:
generating a polymer mixture;
extruding the polymer mixture into a monofilament;
quenching the monofilament;
reheating the monofilament; and
stretching the reheated monofilament to form the monofilament into the artificial turf fiber.

### Claim 16 (depends on 2)

The method of claim 2, wherein the polybutadiendiol has an amount of 1.0-9.0% by weight of said combination of the first polyol and the isocyanate.

### Claim 17 (depends on 16)

The method of claim 16, wherein the polybutadiendiol has an amount of 4.0-8.0% by weight of said combination of the first polyol and the isocyanate.

### Claim 18 (depends on 3)

The method of claim 3, wherein the polybutadiendiol has a number average molecular weight in a range of 1500 g/mol to 4500 g/mol.

### Claim 19 (depends on 5)

The method of claim 5, wherein the first polyol is a polycarbonate polyol, a polycaprolactone polyol, a propylene oxide based polyol, a polypropylene polyol, a polysulfide polyol, a polyether glycol, or a mixture of one or more of said polyols.

### Claim 20 (depends on 8)

The method of claim 8, wherein the surfactant has an amount of 0.05-0.15% by weight of said combination of the first and second polyols and the isocyanate.

### Claim 21 (depends on 7)

The method of claim 7, wherein the wetting agent is a surfactant having an amount of 0.8%-1.2% by weight of a combination of the first and second polyols and the isocyanate.

### Claim 22 (depends on 9)

The method of claim 9, wherein the pale oil is added in an amount of 0.7% to 1.2% by weight of the combination of the first and second polyols and the isocyanate.

### Claim 23 (depends on 10)

The method of claim 10, wherein the fluid polyurethane mass has a density in a range of 1100 g/l-1500 g/l.

### Claim 24 (depends on 23)

The method of claim 23, wherein the fluid polyurethane mass has a density in a range of 1200 g/l-1400 g/l.