ARTICLES OF MANUFACTURE, METHODS, AND PROCESSES FOR REDUCING VOLATILE ORGANIC COMPOUNDS EMISSION USING COATINGS

Abstract

Systems, methods, and a coating for coating a material containing Volatile Organic Compounds (VOC). The coating is generally in the chemical family of polymeric isocyanates and is characterized as a Mixture, specifically an Aromatic Isocyanate Pre-polymer. Embodiments of the coating 204 are 100% solids; have a density at 20 C. (68 F.) of 1.3 g/cm3 (10.85 lbs/gal); with a viscosity, dynamic at 20 C. (68 F.) of 2,000 mPas. The formulation contains Polymerics Diphenylmethane Diisocyanate; 4,4-methylenediphenyl diisocyanate (CAS #101-68-8); Pigment powder; Ultraviolet blockers; Ultraviolet absorbers; and Microbeadlet encapsulated esters.

Claims

1. A coating comprising: an aromatic isocyanate pre-polymer mixture comprising: polymerics diphenylmethane diisocyanate; 4, 4-methylenediphenyl diisocyanate; ultraviolet blockers; ultraviolet absorbers; and microbeadlet encapsulated esters.

2. The coating of claim 1 further comprising pigment powder.

3. The coating of claim 1 wherein the coating is substantially 100% solids that have a density at 20 C. (68 F.) of 1.3 g/cm.sup.3 (10.85 lbs/gal).

4. The coating of claim 3 wherein the coating has a viscosity, dynamic at 20 C. (68 F.) of 2,000 mPas.

5. A system to reduce photochemical reactions of organic materials, the system comprising: an organic material containing Volatile Organic Compounds (VOC) that is covered by: a first layer comprising: an aromatic isocyanate pre-polymer mixture; and a second layer, applied over at least a portion of the first layer, the second coating comprising: the aromatic isocyanate pre-polymer mixture; and a catalyst.

6. The system of claim 5 wherein the aromatic isocyanate pre-polymer mixture comprises: polymerics diphenylmethane diisocyanate; 4, 4-methylenediphenyl diisocyanate; ultraviolet blockers; ultraviolet absorbers; and microbeadlet encapsulated esters.

7. The system of claim 5 wherein the aromatic isocyanate pre-polymer mixture comprises pigment powder.

8. The system of claim 5 wherein the catalyst comprises ethyhexanoic, 2-potassium salt.

9. The system of claim 5 wherein the catalyst comprises 2, 2-dimorpholinodiethlyether.

10. The system of claim 5 wherein the catalyst comprises 2, 2-oxybisethanol.

11. The system of claim 5 wherein the catalyst comprises organic solvents.

12. The system of claim 5 wherein the aromatic isocyanate pre-polymer mixture locks-in VOC from reaching the surface of the organic material by chemically bonding with the organic material.

13. A method for coating materials comprising Volatile Organic Compounds (VOC) the method comprising: mixing a substrate containing Volatile Organic Compounds (VOC) and a coating; adding a catalyst and mixing again; and curing and drying the coated substrate.

14. The method of claim 13 wherein the coating comprises: polymerics diphenylmethane diisocyanate; 4, 4-methylenediphenyl diisocyanate; ultraviolet blockers; ultraviolet absorbers; and microbeadlet encapsulated esters.

15. The method of claim 13 wherein the coating comprises pigment powders.

16. The method of claim 13 wherein the catalyst comprises ethyhexanoic, 2-potassium salt.

17. The method of claim 13 wherein the catalyst comprises 2, 2-dimorpholinodiethlyether.

18. The method of claim 13 wherein the catalyst comprises 2, 2-oxybisethanol.

19. The method of claim 13 wherein the catalyst comprises organic solvents.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIG. 1 is a schematic illustration of multi-layered organic material encapsulated to reduce VOC emissions in accordance with disclosed embodiments.

[0023] FIG. 2 is a schematic flowchart illustrating methods of application of a coating on a substrate in accordance with disclosed embodiments.

[0024] While the disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

[0025] Disclosed embodiments include a chemical coating that helps reduce outgassing (vapor effluents), liquid leaching and micro-particulates from being released from the surface of the rubber under normal atmospheric conditions.

[0026] For embodiments intended to meet the above-described environmental conditions, the coating can be thick or nanometer thin, have high elongation, be hard and abrasion resistant, impervious to water ingress (WVTR), resistant to high and low temperatures, resistant to chemicals, resistant to heat, UV passivating, prevent gas permeation, and be unaffected by acids and organic solvents, among others. The herein disclosed embodiments meet these, and other, requirements.

[0027] The herein disclosed embodiments are effective because of, among other things, the change of the microstructure change that happen during the coating process at the surface of the candidate substance. The effectiveness of the herein disclosed embodiments is also a combination of the way the microstructural changes are accomplished at the surface as well as the composition of the microstructure itself as evidenced by microstructural analysis using surface and structural materials analysis.

[0028] Surface analysis includes particle analysis and identification, such as the elemental analysis of solid samples, detection of impurities and identification of physical and chemical defects. Surface sensitive analyses also include thin film analysis, depth profiling, penetration studies, and purity studies. It also provides analytical expertise to support chemical coating development, forensics, troubleshooting, quality control and failure analysis. Precision analytical technologies are required to assess product quality and to determine the escape of trace level impurities which may present a risk to human health or the environment.

[0029] The herein disclosed embodiments have demonstrated reduction of VOC emission in outdoor environments by over 90% which is typically much more effective compared to other conventional methods of reducing/containing VOCs in outdoor environments.

[0030] The herein disclosed embodiments also enable the production of a large amount of color rubber mulch of excellent quality that can be used for various purposes both indoors and outdoors.

[0031] Chemical, physical and mechanical, and toxicological tests were extensively carried out to confirm both the efficacy and also to ensure that the coating/polymer complies with global and industrial exacting specifications.

[0032] VOC tests and analysis included VOC Evaporative Emission testing, identification of VOC's, identification and quantification of residual solvents, odor analysis, and identification of trace off-gas products using chromatography and/or thermal desorption. In addition to the VOCs themselves, the tests included non-volatile content, aqueous mixtures, non-aqueous mixtures, content of VOCs, solids content, specific gravity, and trace analysis.

[0033] Surface and structural materials analysis includes microstructural characterization of materials, including polymers, films, coatings, metals, plastics and contaminants. Surface analysis includes particle analysis and identification, such as the elemental analysis of solid samples, detection of impurities and identification of physical and chemical defects. Surface sensitive analyses also include thin film analysis, depth profiling, penetration studies, and purity studies.

[0034] The herein disclosed embodiments have tested with various kinds of rubber mulch (mulch-like chip, crumb, flour and/or flake-shaped rubber particles), with different surface areas. In all cases, the herein disclosed embodiments showed low temperature stability (even 60 C.); thermal stability even at above normal temperatures, water resistance, no outgassing detected (comparing weight loss compared to existing alternatives), no aging (due to its elastomeric characteristics), no ultraviolet/weather/color fade detected, no chemical absorption under normal use, and no observable effects from prolonged ozone exposure.

[0035] FIG. 1 is a schematic illustration of a system 100 for a multi-layered organic material that has been encapsulated to reduce VOC emissions in accordance with disclosed embodiments. As shown, layer 102 is the organic layer, such as shredded tires and synthetic rubber. Layer 104 is a transition layer (e.g., layer 1) which has been chem-mechanically applied to insulate the organic layer 102 from direct contact with natural elements which could lead to photochemical degradation. Layer 106 (e.g., layer 2) is a coating that encapsulates the transition layer 104 locking any potential gasses that could have been produced from the organic layer 102 that could be in the transition layer 104 from being emitted into the atmosphere. This coating layer 106 is mechanically applied on top of the transition layer 104. The thickness of this coating layer 106 varies from several nanometers to micrometers depending on the thickness of the transition layer 104.

[0036] FIG. 2 is a schematic flowchart illustrating methods 200 of application of a coating on a substrate in accordance with disclosed embodiments. As shown, at 202 the substrate to be coated, such as rubber mulch, or other organic material, and the coating 204 are mixed together at 206. In some embodiments, the coating 204 may be colored or otherwise pigmented to result in a colored coating (e.g., water blue, grass green, oxide red, nut brown, and the like). In some embodiments, mixing at 206 may take place in a controlled mixing environment, such as a sealable mixing tank or the like, and is carried out until the desired coverage and consistency is achieved.

[0037] Once a desired consistency is achieved, a curing/drying agent or catalyst 210 may be added to the mixture of the substrate 202 and coating 204 as indicated at 212. Additional mixing of the substrate 202, coating 204, and catalyst 210 may also occur at 212 to ensure appropriate mixing is achieved.

[0038] As indicated at 214 the coated material is then cured and dried. Additional heating is not required for drying; however, some embodiments may employ additional heating, air-circulation, or the like to facilitate curing and drying.

[0039] As indicated at 216 post-drying procedures, such as packaging, labeling, and the like, may be implemented. At 218 the coated material (and, if desired, colored) may then be applied in the desired manner (e.g., used a mulch, as a sports field covering, or the like).

[0040] Embodiments of the coating 204 are described as follows. The chemical composition of coating 204 is generally in the chemical family of polymeric isocyanates and labeled according to the Globally Harmonized System (GHS). The coating 204 chemical characterization is as a Mixture, specifically an Aromatic Isocyanate Pre-polymer. Embodiments of the coating 204 are 100% solids; have a density at 20 C. (68 F.) of 1.3 g/cm.sup.3 (10.85 lbs/gal); with a viscosity, dynamic at 20 C. (68 F.) of 2,000 mPas. The formulation contains Polymerics Diphenylmethane Diisocyanate; 4,4-methylenediphenyl diisocyanate (CAS #101-68-8); Pigment powder; Ultraviolet blockers; Ultraviolet absorbers; and Microbeadlet encapsulated esters.

[0041] Embodiments of the catalyst 210 are described as follows. As noted above, catalyst 210 is used to complete the deposition cycle 212 and is introduced as a liquid when the mixture of solid pieces/particles (e.g., mulch) is uniformly coated and dry to the touch as indicated at 212. The catalyst 210 formulation is labeled according to the GHS and it is characterized as a Mixture. The Formulation contains Ethyhexanoic, 2-Potassium Salt; 2, 2-Dimorpholinodiethlyether; 2, 2-Oxybisethanol; and Organic Solvents.

[0042] Although various embodiments have been shown and described, the present disclosure is not so limited and will be understood to include all such modifications and variations are would be apparent to one skilled in the art.