POLYURETHANE COMPOSITE MATERIALS

• US 20070225419A1
• Filed: 03/26/2007
• Published: 09/27/2007
• Est. Priority Date: 03/24/2006
• Status: Abandoned Application

• Current Assignee: Century-Board USA, LLC
• Original Assignee: Century-Board USA, LLC
• Inventors: Brown, Wade H.
• Application Number:
  US11/691,438
• Publication Number:
  US 20070225419A1
• Time in Patent Office: Days
• US Class Current: 524/430
• CPC Class Codes: B29C 45/0001 characterised by the choice of material
• CPC Class Codes: B29C 48/022 characterised by the choice of material
• CPC Class Codes: B29C 48/07 Flat, e.g. panels
• CPC Class Codes: B29C 48/285 Feeding the extrusion material to the extruder
• CPC Class Codes: B29C 48/2886 of fibrous, filamentary or filling materials, e.g. thin fibrous reinforcements or fillers
• CPC Class Codes: B29C 48/29 in liquid form
• CPC Class Codes: B29C 48/297 at several locations, e.g. using several hoppers or using a separate additive feeding
• CPC Class Codes: B29C 48/395 using screws surrounded by a cooperating barrel, e.g. single screw extruders
• CPC Class Codes: B29C 48/402 the screws having intermeshing parts
• CPC Class Codes: B29C 48/405 Intermeshing co-rotating screws
• CPC Class Codes: B29C 48/54 with additional forward-feeding elements
• CPC Class Codes: B29C 48/55 having reverse-feeding elements
• CPC Class Codes: B29C 48/56 having grooves or cavities other than the thread or the channel
• CPC Class Codes: B29C 48/57 provided with kneading disc-like elements, e.g. with oval-shaped elements
• CPC Class Codes: B29C 48/575 provided with elements of a generally circular cross-section for shearing the melt, i.e. shear-ring elements
• CPC Class Codes: B29C 48/63 having sections without mixing elements or threads, i.e. having cylinder shaped sections
• CPC Class Codes: B29C 48/67 having incorporated mixing devices not provided for in groups B29C48/52 - B29C48/66
• CPC Class Codes: B29C 48/834 Cooling
• CPC Class Codes: B29K 2049/00 Use of polyacetylene or cyanic ester resins, i.e. polymers having one or more carbon-to-carbon triple bonds or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/0005 : containing compounding ingredients releasing, lubricating or separating agents B29C33/56, fibers B29K2105/08, B29K2105/12; fillers B29K2105/16, recycled material B29K2105/26
• CPC Class Codes: B29K 2105/0014 : Catalysts
• CPC Class Codes: B29K 2105/0032 : Pigments, colouring agents or opacifiyng agents
• CPC Class Codes: B29K 2105/0044 : Stabilisers, e.g. against oxydation, light or heat
• CPC Class Codes: B29K 2105/005 : Heat sensitisers or absorbers
• CPC Class Codes: B29K 2105/06 : containing reinforcements, fillers or inserts
• CPC Class Codes: B29K 2105/12 : of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B29K 2105/16 : Fillers
• CPC Class Codes: B29K 2709/00 : Use of inorganic materials not provided for in groups B29K2703/00 - B29K2707/00, for preformed parts, e.g. for inserts
• CPC Class Codes: C04B 14/22 : Glass ; Devitrified glass
• CPC Class Codes: C04B 18/08 : Flue dust , i.e. fly ash
• CPC Class Codes: C04B 26/16 : Polyurethanes
• 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 18/36 : Hydroxylated esters of higher fatty acids
• CPC Class Codes: C08G 18/4045 : Mixtures of compounds of group C08G18/58 with other macromolecular compounds
• CPC Class Codes: C08G 18/4804 : Two or more polyethers of different physical or chemical nature
• CPC Class Codes: C08G 18/7657 : containing two or more aromatic rings
• CPC Class Codes: C08G 18/7671 : containing only one alkylene bisphenyl group
• CPC Class Codes: C08G 2101/00 : Manufacture of cellular products
• CPC Class Codes: C08G 2110/0083 : prepared using water as the sole blowing agent
• CPC Class Codes: C08J 2201/03 : Extrusion of the foamable blend
• CPC Class Codes: C08J 2375/04 : Polyurethanes
• CPC Class Codes: C08J 5/10 : characterised by the additives used in the polymer mixture
• CPC Class Codes: C08J 9/125 : Water, e.g. hydrated salts
• CPC Class Codes: C08K 3/00 : Use of inorganic substances as compounding ingredients
• CPC Class Codes: C08K 3/013 : Fillers, pigments or reinforcing additives
• CPC Class Codes: C08K 3/04 : Carbon
• CPC Class Codes: C08K 7/10 : Silicon-containing compounds
• CPC Class Codes: C08K 7/14 : Glass
• CPC Class Codes: C08L 75/04 : Polyurethanes
• CPC Class Codes: C08L 75/08 : from polyethers
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

Polymeric composite materials, particularly highly filled polyurethane composite materials are described herein. Such highly filled polyurethane composite materials may be formed by reaction and extrusion of one or more polyols, one or more di- or poly-isocyanates, and from about 45 to about 85 weight percent of inorganic filler such as fly ash. Certain polyols, including plant-based polyols can be used. Certain composite materials also contain chain extenders and/or crosslinkers. The polyurethane composite material may also contain fibers such as chopped or axial fibers which further provide good mechanical properties to the composite material. Shaped articles containing the polyurethane composite material have been found to have good mechanical properties, such that the shaped articles are suitable for building applications.

Claims

1. A polyurethane composite material comprising:

a polyurethane formed by reaction of a reaction mixture of;

one or more monomeric or oligomeric poly- or di-isocyanates; and

at least one plant-based polyol; and

about 40 to about 85 weight percent of an inorganic filler, wherein the inorganic filler comprises coal ash.

2. The polyurethane composite material of claim 1, wherein the material comprises about 65 to about 75 weight percent of the inorganic filler.

3. The polyurethane composite material of claim 1, wherein the material comprises about 60 to about 85 weight percent of the inorganic filler.

4. The polyurethane composite material of claim 1, wherein the material comprises fly ash.

5. The polyurethane composite material of claim 1, wherein the coal ash comprises a mixture of bottom ash and fly ash.

6. The polyurethane composite material of claim 1, wherein the material additionally comprises one or more selected from the group consisting of chain extenders, cross linkers, and combinations thereof.

7. The polyurethane composite material of claim 1, wherein the material additionally comprises a chain extender.

8. The polyurethane composite material of claim 7, wherein the chain extender is one or more selected from the group consisting of ethylene glycol, glycerin, 1,4-butane diol, trimethylolpropane, glycerol, sorbitol, and combinations thereof.

9. The polyurethane composite material of claim 7, wherein the chain extender is a diamine chain extender.

10. The polyurethane composite material of claim 7, wherein the material comprises glycol extenders.

11. The polyurethane composite material of claim 1, wherein the material in the form of a shaped article.

12. The polyurethane composite material of claim 11, wherein the shaped article is selected from the group consisting of roofing material, siding material, carpet backing, synthetic lumber, building panels, scaffolding, cast molded products, decking material, fencing material, marine lumber, doors, door parts, moldings sills, stone, masonry, brick products, post signs, guard rails, retaining walls, park benches, tables slats, and railroad ties.

13. A solid surface article comprising a portion, wherein the portion comprises polyurethane composite material of claim 1.

14. A method of forming a polyurethane composite material, the method comprising:

providing at least one plant based polyol;

providing at least one poly or di-isocyanate;

providing about 45 to about 85 weight percent of an inorganic filler; and

extruding the at least one plant-based polyol, the at least one poly or di-isocyanate, and the inorganic filler, to produce a composite material.

15. The method of claim 14, wherein the composite material comprises about 65 to about 75 weight percent of the inorganic filler.

16. The method of claim 14, wherein the composite material comprises about 60 to about 85 weight percent of the inorganic filler.

17. The method of claim 14, wherein the inorganic filler comprises fly ash.

18. The method of claim 14, further comprising placing the extruded mixture in a mold.

19. The method of claim 18, further comprising shaping the extruded mixture in the mold.

20. The method of claim 19, wherein the mold is formed by one or more belts of a forming device.

21. The method of claim 14, further comprising mixing the at least one plant-based polyol with a solvent

22. The method of claim 21, wherein the solvent comprises about to 2 to about 10 wt % of one or more solvents selected from the group consisting of pentane, hexane, carbon tetrachloride, trichloroethylene, methylene chloride, chloroform, methyl chloroform, perchloroethylene, and ethyl acetate.