Filled polymer composite and synthetic building material compositions

• US 20050163969A1
• Filed: 01/23/2004
• Published: 07/28/2005
• Est. Priority Date: 01/23/2004
• Status: Active Grant

• Current Assignee: Westlake Royal Building Products Incorporated
• Original Assignee: Century-Board USA, LLC
• Inventors: Brown, Wade
• Granted Patent: US 7,763,341 B2
• Time in Patent Office: Days
• US Class Current: 428/151
• CPC Class Codes: B29C 39/16 between endless belts
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 18/06 Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 26/16 Polyurethanes
• CPC Class Codes: C04B 38/0067 characterised by the density of the end product
• CPC Class Codes: C04B 38/02 by adding chemical blowing agents
• CPC Class Codes: C08G 18/0895 Manufacture of polymers by continuous processes C08G18/0838 takes precedence
• CPC Class Codes: C08G 18/4816 mixtures of two or more polyetherpolyols having at least three hydroxy groups
• CPC Class Codes: C08G 2110/0066 ≥ 150kg/m3
• CPC Class Codes: C08G 2110/0083 prepared using water as the sole blowing agent
• CPC Class Codes: C08J 2375/08 from polyethers
• CPC Class Codes: C08J 5/04 Reinforcing macromolecular compounds with loose or coherent fibrous material
• CPC Class Codes: C08J 5/043 with glass fibres
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08L 2203/14 used for foams
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/24438 Artificial wood or leather grain surface
• CPC Class Codes: Y10T 428/24479 including variation in thickness

Abstract

The invention relates to composite compositions having a matrix of polymer networks and dispersed phases of particulate or fibrous materials. The polymer matrix contains a polyurethane network formed by the reaction of a poly- or di-isocyanate and one or more saturated polyether or polyester polyols, and an optional polyisocyanurate network formed by the reaction of optionally added water and isocyanate. The matrix is filled with a particulate phase, which can be selected from one or more of a variety of components, such as fly ash particles, axially oriented fibers, fabrics, chopped random fibers, mineral fibers, ground waste glass, granite dust, or other solid waste materials. The addition of water can also serve to provide a blowing agent to the reaction mixture, resulting in a foamed structure, if such is desired.

Claims

1. A polymer matrix composite material, comprising:

(1) a polyurethane formed by reaction of a reaction mixture, comprising;

(a) one or more monomeric or oligomeric poly- or di-isocyanates;

(b) a first polyol selected from the group consisting of polyether polyols and polyester polyols, having a first molecular weight; and

(c) an optional second polyol selected from the group consisting of polyether polyols and polyester polyols, having a second molecular weight lower than the first molecular weight; and

(2) an optional polyisocyanurate formed by reaction of a monomeric or oligomeric poly- or di-isocyanate with water which has been optionally added to the reaction mixture;

(3) an inorganic particulate material.

2. The polymer matrix composite material of claim 1, wherein the material is foamed.

3. The polymer matrix composite material of claim 1, further comprising one or more inorganic fibers disposed throughout the polymer matrix.

4. The polymer matrix composite material of claim 1, further comprising axially oriented fiber rovings disposed on, in, or beneath the surface of the composite.

5. The polymer matrix composite material of claim 1, wherein the second polyether polyol is present in an amount between 0 and about 20 wt % of the first polyether polyol.

6. The polymer matrix composite material of claim 1, wherein the inorganic particulate material is present in an amount ranging between about 45 wt % and about 80 wt %, based on the total weight of the composition.

7. The polymer matrix composite material of claim 1, wherein the inorganic particulate material is a fly ash, bottom ash, or particulate glass.

8. The polymer matrix composite material of claim 1, wherein the inorganic particulate material has a particle size distribution ranging from about 0.0625 in. to below about 325 mesh.

9. The polymer matrix composite material of claim 1, wherein the inorganic particulate material contains less than about 0.5 wt % water.

10. An synthetic lumber, comprising the polymer matrix composite material of claim 1;

wherein the composite material comprises a relatively porous material and a relatively non-porous toughening layer disposed on and adhered to the porous material.

11. The synthetic lumber of claim 10, having a size and shape corresponding to that of commercially available lumber products.

13. The synthetic lumber of claim 11, wherein the synthetic lumber comprises at least on surface that has been embossed or impressed with a pattern.

14. The synthetic lumber of claim 13, wherein the pattern comprises a simulated wood grain.

15. A method of producing a polymer matrix composite, comprising:

(1) mixing a first polyether polyol having a first molecular weight and a second polyether polyol having a second molecular weight higher than the first molecular weight with one or more catalysts, water, and optional surfactant,

(2) optionally introducing reinforcing fibrous materials into the mixture;

(3) introducing inorganic filler into the mixture;

(4) introducing poly- or di-isocyanate into the mixture; and

(5) allowing the exothermic reaction to proceed without forced cooling except to control runaway exotherm, thereby forming a polymer matrix composite.

16. The method of claim 15, further comprising extruding the mixture or the polymer matrix composite through a die.

17. The method of claim 16, wherein at least a portion of the mixing or reaction, or both occurs in an extruder.

18. The method of claim 15, further comprising molding the polymer matrix composite into a desired shape.

19. The method of claim 16, further comprising forming the polymer matrix composite into a synthetic lumber.

20. The method of claim 19, wherein the forming comprises shaping the polymer matrix composite into a size and shape suitable for synthetic lumber.

21. The method of claim 20, wherein the forming further comprises embossing or impressing at least one surface of the polymer matrix composite with a pattern.

22. The method of claim 15, wherein the one or more catalysts comprise a skin-forming catalyst.

23. The method of claim 22, wherein the skin-forming catalyst comprises an organic tin compound.

24. The method of claim 15, wherein the one or more catalysts comprise a gelation catalyst.

25. The method of claim 24, wherein the gelation catalyst comprises an amine.

26. The method of claim 15, further comprising introducing axially oriented fiber rovings into the polymer matrix composite.

27. The method of claim 26, wherein the fiber rovings are introduced on, in, or beneath the surface of the composite.