FILLED POLYMER COMPOSITE AND SYNTHETIC BUILDING MATERIAL COMPOSITIONS
First Claim
1. A polymer composite material comprising:
- a polyurethane formed by reaction of a mixture comprising;
a poly- or di-isocyanate;
a first polyol comprising a polyether polyol, the first polyol having a first molecular weight in the range of 400 to 481, the first polyol being more rigid relative to the second polyol; and
a second polyol comprising a polyether polyol or a polyester polyol, the second polyol having a second molecular weight which is greater than the first molecular weight and falling in the range of 500 to 3000 and being more flexible relative to the first polyol, wherein the second polyol is about 5 wt % to about 20 wt % of the total weight of the first and second polyols; and
wherein the polyurethane is less rigid than a second polyurethane that would be formed by the reaction of the first polyol and the poly- or di-isocyanate in the absence of the second polyol; and
an inorganic particulate material comprising one or more of fly ash, bottom ash, particulate glass and granite tailings dispersed in the polymer matrix, the inorganic particulate material being about 60 wt % to about 72 wt % of the total weight of the composite material.
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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.
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Citations
20 Claims
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1. A polymer composite material comprising:
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a polyurethane formed by reaction of a mixture comprising; a poly- or di-isocyanate; a first polyol comprising a polyether polyol, the first polyol having a first molecular weight in the range of 400 to 481, the first polyol being more rigid relative to the second polyol; and a second polyol comprising a polyether polyol or a polyester polyol, the second polyol having a second molecular weight which is greater than the first molecular weight and falling in the range of 500 to 3000 and being more flexible relative to the first polyol, wherein the second polyol is about 5 wt % to about 20 wt % of the total weight of the first and second polyols; and wherein the polyurethane is less rigid than a second polyurethane that would be formed by the reaction of the first polyol and the poly- or di-isocyanate in the absence of the second polyol; and an inorganic particulate material comprising one or more of fly ash, bottom ash, particulate glass and granite tailings dispersed in the polymer matrix, the inorganic particulate material being about 60 wt % to about 72 wt % of the total weight of the composite material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A polymer composite material, comprising:
a polyurethane formed by reaction of a mixture comprising; a poly- or di-isocyanate; a first polyol comprising a polyether polyol, the first polyol having a first molecular weight; a second polyol comprising a polyether polyol or a polyester polyol, the second polyol having a second molecular weight greater than the first molecular weight, wherein the second molecular weigh is in the range of 500 to 3000, wherein the second polyol is about 5 wt % to about 20 wt % of the total weight of the first and second polyols; and wherein the polyurethane is less rigid than a second polyurethane that would be formed by the reaction of the first polyol and the one or more monomeric or oligomeric poly- or di-isocyanates in the absence of the second polyol; and an inorganic particulate material, the inorganic particulate material being about 60 to about 74 wt % of the total weight of the composite material.
Specification