Filled polyurethane composites with lightweight fillers

• US 10,030,126 B2
• Filed: 06/05/2015
• Issued: 07/24/2018
• Est. Priority Date: 06/05/2015
• Status: Active Grant

• Current Assignee: Westlake Royal Building Products Incorporated
• Original Assignee: Boral Ip Holdings (Australia) Pty Limited (Seven Group Holdings Limited)
• Inventors: Kumar, Amitabha, Ai, Li, Hill, Russell L.
• Primary Examiner(s): Cain, Edward J
• Application Number:
  US14/893,838
• Publication Number:
  US 20170114211A1
• Time in Patent Office: 1,145 Days
• Field of Search: 523218, 523219
• CPC Class Codes: C04B 14/12 Expanded clay
• CPC Class Codes: C04B 14/14 Minerals of vulcanic origin granite C04B14/048
• CPC Class Codes: C04B 14/16 porous, e.g. pumice
• CPC Class Codes: C04B 14/185 expanded
• CPC Class Codes: C04B 14/204 expanded
• CPC Class Codes: C04B 14/24 porous, e.g. foamed glass
• CPC Class Codes: C04B 14/28 of calcium
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 14/46 Rock wool ; Ceramic or silicate fibres C04B14/40, C04B14/42 take precedence
• CPC Class Codes: C04B 16/0625 Polyalkenes, e.g. polyethylene
• CPC Class Codes: C04B 16/0633 Polypropylene
• CPC Class Codes: C04B 16/065 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 16/0658 Polyacrylonitrile
• CPC Class Codes: C04B 16/0683 Polyesters, e.g. polylactides
• CPC Class Codes: C04B 16/0691 Polyamides; Polyaramides
• CPC Class Codes: C04B 16/08 porous, e.g. expanded polystyrene beads or microballoons
• CPC Class Codes: C04B 18/24 Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 18/248 from specific plants, e.g. hemp fibres
• CPC Class Codes: C04B 18/26 Wood, e.g. sawdust, wood shavings
• CPC Class Codes: C04B 20/002 Hollow or porous granular materials
• CPC Class Codes: C04B 20/0048 : Fibrous materials
• CPC Class Codes: C04B 20/0076 : characterised by the grain distribution
• CPC Class Codes: C04B 20/10 : Coating or impregnating roofing granules E04D7/005
• CPC Class Codes: C04B 20/1051 : Organo-metallic compounds; Organo-silicon compounds, e.g. bentone
• CPC Class Codes: C04B 20/1059 : Pigments or precursors thereof
• CPC Class Codes: C04B 2111/00586 : Roofing materials
• CPC Class Codes: C04B 2111/28 : Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 2111/52 : Sound-insulating materials
• CPC Class Codes: C04B 26/16 : Polyurethanes
• CPC Class Codes: C04B 38/10 : by using foaming agents C04B38/02 takes precedenceor by using mechanical means, e.g. adding preformed foam
• CPC Class Codes: C08G 18/18 : containing secondary or tertiary amines or salts thereof
• CPC Class Codes: C08G 18/4018 : Mixtures of compounds of group C08G18/42 with compounds of group C08G18/48
• CPC Class Codes: C08G 18/4208 : containing aromatic groups
• CPC Class Codes: C08G 18/7671 : containing only one alkylene bisphenyl group
• CPC Class Codes: C08K 13/04 : Ingredients characterised by their shape and organic or inorganic ingredients
• CPC Class Codes: C08K 2201/005 : Additives being defined by their particle size in general
• CPC Class Codes: C08L 75/04 : Polyurethanes
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

Polyurethane composites and methods of preparation are described herein. The polyurethane composites can comprise (a) a polyurethane formed by the reaction of (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and (ii) one or more polyols, (b) a particulate filler having a bulk density of 1 g/cm³ or greater, (c) optionally a fiber material, and (d) a lightweight filler having a bulk density from 0.01 g/cm³ to less than 1 g/cm³. In some examples, the lightweight filler can be selected from expanded perlite, expanded clay, foamed glass, and combinations thereof. Articles such as building materials comprising the polyurethane composites are also disclosed.

Claims

1. A composite comprising:

(a) a polyurethane formed by the reaction of

(i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and

(ii) one or more polyols;

(b) from 35% to 75% by weight, based on the total weight of the composite, of a particulate filler having a bulk density of 1 g/cm³ or greater; and

(c) from 4% to 20% by weight, based on the total weight of the composite, of a lightweight filler having a bulk density of from 0.01 g/cm³ to less than 1 g/cm³, wherein the lightweight filler is chosen from expanded volcanic ash, expanded perlite, pumicite, expanded vermiculite, expanded clay, foamed glass, soybean hulls, rice hulls, seeds, seed husks, chopped straw, expanded polystyrene beads, scoria, and combinations thereof;

wherein the composite has a density of from 2 lb/ft³ to 37 lb/ft³; and

wherein the composite has flexural strength of 1000 psi or greater as measured by ASTM C1185-08 (2012).

2. The composite of claim 1, wherein the lightweight filler has a bulk density of from 0.05 g/cm³ to 0.6 g/cm³.

3. The composite of claim 1, wherein the lightweight filler includes expanded perlite, expanded clay, foamed glass, or a combination thereof.

4. The composite of claim 1, wherein the lightweight filler has an average particle size diameter of from 0.01 micron to 2 mm.

5. The composite of claim 1, wherein the particulate filler comprises fly ash.

6. The composite of claim 5, wherein the fly ash is present in an amount of from 50% to 75% by weight, based on the total weight of the composite.

7. The composite of claim 1, wherein the weight ratio of the lightweight filler to the particulate filler is from 1:

10 to 1;

1.

8. A building material comprising the composite of claim 1.

9. The composite of claim 1, where the density is from 10 lb/ft³ to 35 lb/ft³.

13. The composite of claim 1, wherein the polyurethane is present in an amount of from 15% to 40%, by weight, based on the total weight of the composite.

14. The composite of claim 13, further comprising from 4% to 8% by weight, based on the total weight of the composite, of a fiber material.

17. The composite of claim 1, wherein the composite has a handleability of 9 in-lb/in or greater as measured by ASTM C1185-08 (2012).

19. The composite of claim 3, wherein the particulate filler includes fly ash.

10. A method of making a polyurethane composite comprising:

(a) mixing

(1) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof,

(2) one or more polyols,

(3) 35% to 75% by weight, based on the total weight of the mixture, of a particulate filler having a bulk density of 1 g/cm³ or greater, and

(4) 4% to 20% by weight, based on the total weight of the mixture, of a lightweight filler having a bulk density of from 0.01 g/cm³ to less than 1 g/cm³ to form a mixture, wherein the lightweight filler is chosen from expanded volcanic ash, expanded perlite, pumicite, expanded vermiculite, expanded clay, foamed glass, soybean hulls, rice hulls, seeds, seed husks, chopped straw, expanded polystyrene beads, scoria, and combinations thereof;

(b) allowing the one or more isocyanates and the one or more polyols to react in the presence of the particulate filler and the lightweight filler to form the polyurethane composite having

(1) a density of from 2 lb/ft³ to 37 lb/ft³, and

(2) flexural strength of 1000 psi or greater as measured by ASTM C1185-08 (2012), and

wherein the mixture is free of a blowing or foaming agent other than water.

11. The method of claim 10, wherein the mixture further comprises a catalyst.

12. The method of claim 10, wherein the mixture contains less than about 0.5 wt % water.

15. The method of claim 10, wherein the mixture is processed at a temperature of from 200°

F. to 500°

F.

16. The method of claim 10, wherein the mixture does not comprise a catalyst.

18. The method of claim 10, wherein the polyurethane composite has a handleability of 9 in-lb/in or greater as measured by ASTM C1185-08 (2012).

20. The method of claim 10, wherein the particulate filler includes fly ash, and wherein the lightweight filler includes expanded perlite, expanded clay, foamed glass, or a combination thereof.