Filled polymer composite and synthetic building material compositions
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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Abstract
The invention relates to composite compositions having a matrix of polymer networks and dispersed phases of particulate or fibrous materials. 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. A system for providing shape and/or surface features to a moldable material includes, in an exemplary embodiment, at least two first opposed flat endless belts spaced apart a first distance, with each having an inner surface and an outer surface.
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Citations
44 Claims
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1. A method of continuously forming a molded material comprising:
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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. - 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, 34, 35)
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29. A method of continuously forming a molded material comprising:
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forming a highly filled composite mixture in a continuous mixing device, wherein the composite mixture comprises; a monomeric or oligomeric poly or di-isocyanate; a first polyol having a first molecular weight; a second polyol having a second molecular weight lower than the first molecular weight, wherein the second 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 has a viscosity in the range of about 480 cp to about 840 cP at 25°
C.;a foaming agent; inorganic particulate material comprising about 60 wt % to about 85 wt % of the composite mixture; and a catalyst; wherein the exothermic reaction is allowed to proceed without additional heat and without forced cooling except to control runaway exotherm; passing the mixture through the exit of the continuous mixing device; molding the mixture in a forming system comprising; at least two opposed endless belts spaced apart a distance, each having an inner surface and an outer surface; a mold cavity defined at least in part by the inner surfaces of the at least two opposed endless 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. - View Dependent Claims (30, 31, 32, 33, 36, 37, 38, 39, 40, 41, 42, 43, 44)
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Specification