SILANE-TERMINATED POLYURETHANE AND RUBBER COMPOSITE MATERIALS
Composite materials including rubber particles and silane-terminated polyurethane binders are disclosed.
1 . A composite material comprising:
rubber particles having an average particle size no larger than 500 microns; and a silane-terminated polyurethane binder.
2 . The composite material of claim 1 , comprising:
10-50 percent by weight rubber particles having an average particle size no larger than 500 microns; and
50-90 percent by weight silane-terminated polyurethane binder.
3 . The composite material of claim 1 , comprising:
35-50 percent by weight rubber particles having an average particle size no larger than 500 microns; and
50-65 percent by weight silane-terminated polyurethane binder.
4 . The composite material of claim 1 , wherein the rubber particles have an average particle size no larger than 50 microns.
5 . The composite material of claim 1 , wherein the composite material cures when exposed to atmospheric moisture, forming a solid composite material exhibiting tensile strength of at least 100 psi.
6 . The composite material of claim 1 , wherein the composite material cures when exposed to atmospheric moisture, forming a solid composite material exhibiting tensile strength of at least 200 psi.
7 . The composite material of claim 1 , wherein the composite material cures when exposed to atmospheric moisture, forming a solid composite material exhibiting percentage elongation of at least 60%.
8 . The composite material of claim 1 , wherein the composite material cures when exposed to atmospheric moisture, forming a solid composite material exhibiting percentage elongation of at least 100%.
9 . The composite material of claim 1 , wherein the composite material cures when exposed to atmospheric moisture, forming a solid composite material exhibiting tear resistance of at least 20 pil.
10 . The composite material of claim 1 , wherein the composite material cures when exposed to atmospheric moisture, forming a solid composite material exhibiting tear resistance of at least 30 pil.
11 . The composite material of claim 1 , wherein the rubber particles comprise rubber recycled from used tires.
12 . The composite material of claim 1 , wherein the rubber particles comprise cryogenically ground rubber recycled from used tires.
13 . The composite material of claim 1 , wherein the silane-terminated polyurethane binder comprises a reaction product of an amino-functional silane compound and a polyisocyanate, wherein the polyisocyanate comprises a reaction product of a polyether polyol and a diisocyanate.
14 . The composite material of claim 1 , further comprising a property modifier selected from the group consisting of carbon nanotubes and nylon fibers.
15 . The composite material of claim 1 , further comprising a silane curing catalyst.
16 . A cured article of manufacture comprising the composite material of claim 1 , the article of manufacture selected from the group consisting of: a running track; a wrestling mat; a play area mat; a floor or ground mat for humans or animals; a truck bed-liner mat; a landscaping article; a gasket; an article for sound abatement; a construction material; a speed bump; a bumper; a rail-road crossing pad; and a base for a traffic control device.
17 . A composite material comprising:
10-50 percent by weight rubber particles having an average particle size no larger than 400 microns; and
50-90 percent by weight silane-terminated polyurethane binder;
wherein the composite material cures when exposed to atmospheric moisture, forming a solid composite material exhibiting tensile strength of at least 100 psi, percentage elongation of at least 60%, and tear resistance of at least 20 pil; and
wherein the rubber particles comprise cryogenically ground rubber recycled from used tires.
18 . The composite material of claim 17 , wherein the rubber particles have an average particle size no larger than 50 microns, and wherein the composite material cures when exposed to atmospheric moisture, forming a solid composite material exhibiting tensile strength of at least 175 psi, percentage elongation of at least 90%, and tear resistance of at least 30 pil.
19 . A method of forming a composite material comprising:
combining rubber particles having an average particle size no larger than 500 microns and a silane-terminated polyurethane binder to form a composite mixture;
and curing the composite mixture to form the composite material,
20 . The method of claim 19 , wherein curing the composite mixture comprises exposing the composite mixture to atmospheric moisture.
21 . The method of claim 19 , wherein curing the composite mixture comprises exposing the composite mixture to a predetermined moisture level and temperature in a controlled temperature and humidity environment.
22 . The method of claim 19 , wherein the composite material formed by curing the composite mixture comprises 35-50 percent by weight rubber particles and 50-65 percent by weight silane-terminated polyurethane binder.
23 . The method of claim 19 , wherein the rubber particles have an average particle size no larger than 400 microns.
24 . The method of claim 19 , wherein the rubber particles have an average particle size no larger than 50 microns.
25 . The method of claim 19 , wherein the composite material formed by curing the composite mixture exhibits one or more material properties selected from the group consisting of tensile strength of at least 100 psi, percentage elongation of at least 60%, tear resistance of at least 20 pil, and combinations of any thereof.
26 . The method of claim 19 , wherein the composite material formed by curing the composite mixture exhibits one or more material properties selected from the group consisting of tensile strength of at least 200 psi, percentage elongation of at least 100%, tear resistance of at least 30 pil, and combinations of any thereof.
27 . The method of claim 19 , comprising:
combining cryogenically ground rubber particles recycled from used tires having an average particle size no larger than 400 microns and a silane-terminated polyurethane binder to form a composite mixture, the silane-terminated polyurethane binder comprising a reaction product of an amino-functional silane compound and a polyisocyanate, wherein the polyisocyanate comprises a reaction product of a polyether polyol and a diisocyanate; and curing the composite mixture to form the composite material.
28 . The method of claim 19 , further comprising combining a property modifier with the rubber particles and the silane-terminated polyurethane binder, the property modifier selected from the group consisting of carbon nanotubes and nylon fibers.