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Filled polymer composite and synthetic building material compositions

  • US 7,993,553 B2
  • Filed: 04/20/2006
  • Issued: 08/09/2011
  • Est. Priority Date: 01/23/2004
  • Status: Active Grant
First Claim
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1. A method of continuously forming a molded material comprising:

  • mixing a highly filled composite mixture in a multi-zone extruder essentially at room temperature and without adding heat, wherein the composite mixture comprises;

    a monomeric or oligomeric poly or di-isocyanate;

    a first liquid polyol having a first molecular weight and a second polyol having a second molecular weight higher than the first molecular weight, wherein the second liquid polyol comprises about 5 wt % to about 20 wt % of the total weight of the first and second polyols;

    wherein the first polyol has a viscosity in the range of about 480 cP to about 840 cP at 25°

    C., and the second polyol viscosity is in the range of about 480 cP to about 840 cP at 25°

    C.;

    a foaming agent;

    an inorganic particulate material comprising about 60 wt % to about 85 wt % of the composite mixture; and

    a catalyst;

    extruding the highly filled composite mixture through a die;

    molding the mixture in a forming system comprising;

    at least a first and a second opposed mold belt, each having an inner surface and an outer surface;

    at least a first and a second opposed endless belt spaced apart a distance, each having an inner surface and an outer surface, wherein the inner surface of the first belt is contactable with the outer surface of the first mold belt to move with and support the first mold belt during molding, and wherein the inner surface of the second belt is contactable with the outer surface of the second mold belt to travel with and support the second mold belt during molding;

    a mold cavity disposed between the inner surfaces of the at least two opposed mold belts; and

    removing the molded material from the mold cavity after sufficient time has passed for the mixture to cure or harden into the molded material, wherein the molded material comprises a density of at least about 30 lb/ft3.

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