Systems and methods for processing and dispensing filled multi-component materials

A process for forming a multi-component material comprising recycled ground rubber tire filler dispersed in a polymeric matrix, the process comprising the steps of:

• providing a first reactive component comprising a resin ingredient and a plurality of filler particles, wherein the filler particles comprise recycled ground rubber tire;
• providing a second reactive component comprising a curing agent capable of curing the resin ingredient to form a polymeric matrix;
• mixing the first reactive component and the filler in a first reservoir to provide a substantially homogeneous mixture;
• metering the first reactive component and the second reactive component using respective first and second pumping mechanisms to achieve a predetermined mix ratio of the first reactive component and the second reactive component, wherein during the step of metering, operating the first and second pumping mechanisms to provide a variation of curing agent mix ratio of up to about 350%;
• mixing the first reactive component and the second reactive component to form a polymerization mixture;
• and
• dispensing the polymerization mixture onto a surface to provide a fully-curable multi-component material.

A multi-component material dispensing system configured to deliver a fully-curable multi-component material comprising a mixture of a first reactive component and a second reactive component, the first reactive component comprising a resin ingredient and an elastic filler with a particle size of about 20 mesh or smaller size, and the second reactive component comprising a curing agent, the system comprising:

• a dispensing apparatus comprising first and second inlet ports, an outlet port and a mixing chamber in fluid communication with each of the first and second inlet ports and the outlet port;
• a mixing element at least partially disposed in the mixing chamber configured to mix the first reactive component and the second reactive component;
• a first reservoir configured to store the first reactive component and elastic filler, the first reservoir having a heating element configured to heat the first component and filler to a predetermined temperature while the first component and filler is stored in the reservoir and a mixer configured to mix the first reactive component and filler while the first reactive component and filler is stored in the reservoir;
• a second reservoir configured to store the second reactive component;
• a first pumping mechanism adapted to pump and meter the first reactive component and filler from the first reservoir to the first port of the dispensing apparatus, wherein the first pumping mechanism and the first reservoir are physically connected by a heated transfer line;
• and
• a second pumping mechanism adapted to pump and meter the second reactive component from the second reservoir to the second port of the dispensing apparatus;
• and
• a controller to regulate the output of the first and second pumping mechanisms to provide a variation of curing agent mix ratio of up to about 350%.