# US 2014/0193630 A1 · Systems and methods for processing and dispensing filled multi-component materials

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- Number: US 2014/0193630 A1
- Document ID: US20140193630A1
- Status: Published application
- Kind: A1
- Application number: 14/234,115
- Filed: 2011-07-21
- Published: 2014-07-10
- Earliest claimed: 2011-07-21
- Assignees: Rhino Linings Corporation
- Inventors: Russell Lewis; Mihai Solomon
- Web page: https://patentgrep.com/patent/US20140193630A1

## CPC

- B05B 11/1084: {each liquid or other fluent material being pumped by a separate pump}
- B01F 25/316: with containers for additional components fixed to the conduit
- B05C 17/00553: {with means allowing the stock of material to consist of at least two different components}
- B05C 17/00556: {with means for adjusting the proportions of the components}
- C08G 18/3203: {Polyhydroxy compounds}
- C08G 18/3225: {Polyamines}
- C08G 18/3271: {Hydroxyamines}
- C08L 21/00: Compositions of unspecified rubbers
- C08L 75/02: Polyureas
- C08L 75/04: Polyurethanes
- B05B: SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES (spray-mixers with nozzles B01F25/72; processes for applying liquids or other fluent materials to surfaces by spraying B05D)
- B01F: MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING (mixing paints B44D3/06)
- B05C: APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (spraying apparatus, atomising apparatus, nozzles B05B; plant for applying liquids or other fluent materials to objects by electrostatic spraying B05B5/08)
- C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)

## Abstract

Multi-component materials are substantially homogeneous and fully curable and comprise an elastic filler, an isocyanate curing agent, and a polyol resin ingredient that when combined produce a polymeric matrix, polyurethane and/or polyurea, having the filler dispersed therein. The material has a variation in polyisocyanate weight ratio of up to 350%. The filler is ground rubber tire particles sized 20 mesh or smaller. The mix weight ratio of the curing agent to resin ingredient is from about 40:100 to 140:100. The material is made and dispensed using a system configured to combine a heated mixture of the resin and filler with the curing agent at a desired variable mix ratio. A controller is used to provide the desired mix ratio and permits “on the fly” adjustment of the mix ratio while the resin and curing agent is being dispensed.

## Claims

### Claim 1

A substantially homogeneous fully curable multi-component material comprising:
a filler comprising an elastomeric material;
a first reactive component that is at least one polyisocyanate monomer; and
a second reactive component selected from the group consisting of at least one polyalcohol monomer, at least one polyamine monomer, and combinations thereof, that are capable of forming a polyurea, polyurethane or copolymer of polyurethane and polyurea by reacting with the polyisocyanate monomer;
wherein the multi-component material has a variation in polyisocyanate weight ratio of up to about 350%.

### Claim 2 (depends on 1)

The material as recited in claim 1 having a mix weight ratio of the first reactive component to the second reactive component from about 40:100 to 140:100.

### Claim 3 (depends on 1)

The material as recited in claim 1 wherein the filler comprises a hard material, and wherein the filler comprises 20% to 70% by weight of the total material.

### Claim 4 (depends on 3)

The material as recited in claim 3 having a mix weight ratio of the first reactive component to the second reactive component from about 20:100 to 70:100.

### Claim 5 (depends on 1)

The material as recited in claim 1, wherein the elastomeric filler comprises 5 to 70% ground rubber tire filler having a particle size of about 20 mesh or smaller.

### Claim 6 (depends on 1)

The material as recited in claim 1, further comprising a catalyst to promote polymer forming reaction of the first and second reactive components.

### Claim 7 (depends on 1)

The material as recited in claim 1, further comprising a blowing agent or entrained air to promote formation of a foamed product.

### Claim 8 (depends on 1)

A solid multi-component material comprising a polymeric matrix and elastic filler produced by polymerization of the material of claim 1, wherein the elastic filler comprises ground rubber tire.

### Claim 9 (depends on 8)

The solid multi-component material of claim 8, wherein the polymeric matrix comprises polyurethane or polyurea.

### Claim 10 (depends on 8)

The solid multi-component material of claim 8, which is produced by spraying the mixture onto a surface under conditions where polymerization occurs.

### Claim 11 (depends on 8)

The solid multi-component material of claim 8, which is a substantially solid layer between about 0.5 mm and 10 mm in average thickness.

### Claim 12 (depends on 1)

A foamed multi-component material comprising a polymeric matrix and elastic filler produced by polymerization of the material of claim 1, wherein the elastic filler comprises ground rubber tire.

### Claim 13 (depends on 12)

The foamed multi-component material of claim 12, which is produced by spraying the material onto a surface under conditions where polymerization occurs.

### Claim 14

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.

### Claim 15 (depends on 14)

The method as recited in claim 14, wherein after the step of mixing, the polymerization mixture has a mix weight ratio of first reactive component to second reactive component from about 40:100 to 140:100.

### Claim 16 (depends on 14)

The method as recited in claim 14, wherein filler comprises a hard material, and wherein the filler comprises 20% to 70% by weight of the total material.

### Claim 17 (depends on 16)

The method as recited in claim 16, wherein after the step of mixing, the mix weight ratio of the first reactive component to the second reactive component from about 20:100 to 70:100.

### Claim 18 (depends on 14)

The method as recited in claim 14, wherein the polymerization mixture comprises 5 to 70% recycled ground rubber tire particles having a particle size of about 20 mesh or smaller.

### Claim 19 (depends on 14)

The method as recited in claim 14 wherein the reservoir containing the first reactive component is heated.

### Claim 20 (depends on 19)

The method as recited in claim 19 wherein the first reactive component is delivered to the first pumping mechanism via a heated supply line.

### Claim 21 (depends on 14)

The method as recited in claim 14 wherein the first and second pumping mechanisms are driven by different motors having a controlled speed to provide the desired variation in mix ratio.

### Claim 22 (depends on 14)

The method as recited in claim 14 where the mix weight ratio of the first and second reactive components is adjustable during the step of dispensing.

### Claim 23 (depends on 14)

The method as recited in claim 14 further comprising adjusting the first and second pumping mechanisms to provide a desired volumetric output of the multi-component material.

### Claim 24 (depends on 23)

The method as recited in claim 23 wherein the step of adjusting takes place after the step of metering to achieve the desired mix ratio.

### Claim 25 (depends on 14)

The method as recited in claim 14, wherein the step of dispensing comprises an application process selected from the group consisting of air spray, airless spray and extrusion.

### Claim 26 (depends on 14)

The method as recited in claim 14, wherein the first reactive component further comprises a hard filler, wherein the multi-component material is mixed at a predetermined mix ratio comprising between 20% to 80% resin by weight, between 5% to 70% hard filler by weight, and between 5% to 70% recycled ground rubber tire filler by weight.

### Claim 27 (depends on 26)

The method as recited in claim 26, wherein the hard filler has a smaller particle size than the recycled ground rubber tire filler.

### Claim 28

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%.

### Claim 29 (depends on 28)

The dispensing system as recited in claim 28 wherein the controller is configured to provide the variation of curing agent mix ratio while the multi-component material is being dispensed by the dispensing apparatus.

### Claim 30 (depends on 28)

The dispensing system as recited in claim 28, wherein the mixing element is a disposable static mixer.

### Claim 31 (depends on 28)

The dispensing system as recited in claim 28, further comprising two motors that are connected to drive respective first and second pumping mechanism, and wherein the controller regulates the speed of the two motors to provide speed ratio control.

### Claim 32 (depends on 28)

The dispensing system as recited in claim 28, wherein the mixing element has a proximal end and a distal end, the distal end extending partially out of the outlet port of the dispensing apparatus.

### Claim 33 (depends on 28)

The dispensing system as recited in claim 28, first and second reactive components are mixed to provide a polymerization mixture having a mix weight ratio of first reactive component to second reactive component from about 40:100 to 140:100.

### Claim 34 (depends on 28)

The dispensing system as recited in claim 28, wherein the multi-component material further comprises a hard filler material, and wherein the hard filler material comprises 20% to 70% by weight of the total material.

### Claim 35 (depends on 34)

The dispensing system as recited in claim 34 wherein the multi-component material has a mix weight ratio of the first reactive component to the second reactive component from about 20:100 to 70:100.

### Claim 36 (depends on 28)

The dispensing system as recited in claim 28, wherein the multi-component material comprises 5 to 70% of the elastic filler in the form of recycled ground rubber tire particles having a particle size of about 20 mesh or smaller.