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Filled polymer composite and synthetic building material compositions

  • US 7,794,817 B2
  • Filed: 12/22/2005
  • Issued: 09/14/2010
  • Est. Priority Date: 01/23/2004
  • Status: Active Grant
First Claim
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1. A building material comprising:

  • a polyurethane formed from reactants comprising;

    at least one isocyanate selected from the group consisting of monomeric di-isocyanates, monomeric poly-isocyanates, oligomeric di-isocyanates and oligomeric poly-isocyanates, wherein the isocyanate comprises between about 6 wt % and about 20 wt %, based on the total weight of the composite material;

    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, wherein the first polyol comprises between about 6 wt % and about 18 wt %, based on the total weight of the composite material;

    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 59.0 mg KOH/g, and wherein the second polyol comprises less than about 10 wt %, based on the total weight of the composite material, and wherein the second polyol comprises between about 5 wt % and about 20 wt %, based on the total weight of the first and second polyols being 100 wt %;

    water, wherein the water comprises less than about 0.5 wt %, based on the total weight of the composite material;

    one or more catalysts, wherein the polyurethane matrix is less rigid than a second polyurethane that would be formed by the reaction of the first polyol and the at least one isocyanate in the absence of the second polyol; and

    an inorganic particulate material component, wherein the inorganic particulate material component comprises between 60 wt % and 72 wt %, based on the total weight of the composite material, and wherein the inorganic particulate material component comprises particles with a particle size distribution between about 0.0625 in. and about 325 mesh.

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