Filled polymer composite and synthetic building material compositions
First Claim
1. A polymer 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 comprising a polyether polyol, the first polyol having a first hydroxyl number in the range of 365 mg KOH/g to 395 mg KOH/g; and
(c) a second polyol comprising a polyether polyol, the second polyol having a second hydroxyl number in the range of 33.8 mg KOH/g to 37.2 mg KOH/g, or from 56.2 mg KOH/g to 59.0 mg KOH/g, and forming the polyurethane, 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 wherein the second polyol is between about 5 wt % and about 20 wt %, based on the total weight of the first and second polyols being 100 wt %; and
(2) 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 60 to 72 wt %, based on the total weight of the composite material.
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Accused Products
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.
284 Citations
43 Claims
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1. A polymer composite material, comprising:
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(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 comprising a polyether polyol, the first polyol having a first hydroxyl number in the range of 365 mg KOH/g to 395 mg KOH/g; and (c) a second polyol comprising a polyether polyol, the second polyol having a second hydroxyl number in the range of 33.8 mg KOH/g to 37.2 mg KOH/g, or from 56.2 mg KOH/g to 59.0 mg KOH/g, and forming the polyurethane, 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 wherein the second polyol is between about 5 wt % and about 20 wt %, based on the total weight of the first and second polyols being 100 wt %; and (2) 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 60 to 72 wt %, based on 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, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39)
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40. A polymer composite material comprising:
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(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 comprising a polyether polyol, the first polyol having a first hydroxyl number in the range of 365 mg KOH/g to 395 mg KOH/g; and (c) a second polyol comprising a polyether polyol, the second polyol having a second hydroxyl number in the range of 33.8 mg KOH/g to 37.2 mg KOH/g, or 56.2 mg KOH/g to 59 mg KOH/g, and forming the polyurethane, 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 wherein the second polyol is between about 5 wt % and about 20 wt %, based on the total weight of the first and second polyols being 100 wt %; and (2) 60 to 72 wt % of an inorganic particulate material, based on the total weight of the composite material. - View Dependent Claims (41, 42, 43)
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Specification