Polyurethane composite materials

• US 8,138,234 B2
• Filed: 03/26/2007
• Issued: 03/20/2012
• Est. Priority Date: 03/24/2006
• Status: Expired due to Fees

• Current Assignee: EM Resources LLC
• Original Assignee: Century-Board USA, LLC
• Inventors: Brown, Wade H.
• Primary Examiner(s): HEINCER, LIAM J
• Application Number:
  US11/691,451
• Publication Number:
  US 20070225391A1
• Time in Patent Office: 1,821 Days
• Field of Search: 521/170, 521/172, 521/174, 521/122, 521/91, 521/92, 521/80
• US Class Current: 521/91
• CPC Class Codes: B29C 45/0001 characterised by the choice of material
• CPC Class Codes: B29C 48/022 characterised by the choice of material
• CPC Class Codes: B29C 48/07 Flat, e.g. panels
• CPC Class Codes: B29C 48/285 Feeding the extrusion material to the extruder
• CPC Class Codes: B29C 48/2886 of fibrous, filamentary or filling materials, e.g. thin fibrous reinforcements or fillers
• CPC Class Codes: B29C 48/29 in liquid form
• CPC Class Codes: B29C 48/297 at several locations, e.g. using several hoppers or using a separate additive feeding
• CPC Class Codes: B29C 48/395 using screws surrounded by a cooperating barrel, e.g. single screw extruders
• CPC Class Codes: B29C 48/402 the screws having intermeshing parts
• CPC Class Codes: B29C 48/405 Intermeshing co-rotating screws
• CPC Class Codes: B29C 48/54 with additional forward-feeding elements
• CPC Class Codes: B29C 48/55 having reverse-feeding elements
• CPC Class Codes: B29C 48/56 having grooves or cavities other than the thread or the channel
• CPC Class Codes: B29C 48/57 provided with kneading disc-like elements, e.g. with oval-shaped elements
• CPC Class Codes: B29C 48/575 provided with elements of a generally circular cross-section for shearing the melt, i.e. shear-ring elements
• CPC Class Codes: B29C 48/63 having sections without mixing elements or threads, i.e. having cylinder shaped sections
• CPC Class Codes: B29C 48/67 having incorporated mixing devices not provided for in groups B29C48/52 - B29C48/66
• CPC Class Codes: B29C 48/834 Cooling
• CPC Class Codes: B29K 2049/00 Use of polyacetylene or cyanic ester resins, i.e. polymers having one or more carbon-to-carbon triple bonds or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/0005 : containing compounding ingredients releasing, lubricating or separating agents B29C33/56, fibers B29K2105/08, B29K2105/12; fillers B29K2105/16, recycled material B29K2105/26
• CPC Class Codes: B29K 2105/0014 : Catalysts
• CPC Class Codes: B29K 2105/0032 : Pigments, colouring agents or opacifiyng agents
• CPC Class Codes: B29K 2105/0044 : Stabilisers, e.g. against oxydation, light or heat
• CPC Class Codes: B29K 2105/005 : Heat sensitisers or absorbers
• CPC Class Codes: B29K 2105/06 : containing reinforcements, fillers or inserts
• CPC Class Codes: B29K 2105/12 : of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B29K 2105/16 : Fillers
• CPC Class Codes: B29K 2709/00 : Use of inorganic materials not provided for in groups B29K2703/00 - B29K2707/00, for preformed parts, e.g. for inserts
• CPC Class Codes: C04B 14/22 : Glass ; Devitrified glass
• CPC Class Codes: C04B 18/08 : Flue dust , i.e. fly ash
• CPC Class Codes: C04B 26/16 : Polyurethanes
• CPC Class Codes: C04B 38/02 : by adding chemical blowing agents
• CPC Class Codes: C08G 18/0895 : Manufacture of polymers by continuous processes C08G18/0838 takes precedence
• CPC Class Codes: C08G 18/36 : Hydroxylated esters of higher fatty acids
• CPC Class Codes: C08G 18/4045 : Mixtures of compounds of group C08G18/58 with other macromolecular compounds
• CPC Class Codes: C08G 18/4804 : Two or more polyethers of different physical or chemical nature
• CPC Class Codes: C08G 18/7657 : containing two or more aromatic rings
• CPC Class Codes: C08G 18/7671 : containing only one alkylene bisphenyl group
• CPC Class Codes: C08G 2101/00 : Manufacture of cellular products
• CPC Class Codes: C08G 2110/0083 : prepared using water as the sole blowing agent
• CPC Class Codes: C08J 2201/03 : Extrusion of the foamable blend
• CPC Class Codes: C08J 2375/04 : Polyurethanes
• CPC Class Codes: C08J 5/10 : characterised by the additives used in the polymer mixture
• CPC Class Codes: C08J 9/125 : Water, e.g. hydrated salts
• CPC Class Codes: C08K 3/00 : Use of inorganic substances as compounding ingredients
• CPC Class Codes: C08K 3/013 : Fillers, pigments or reinforcing additives
• CPC Class Codes: C08K 3/04 : Carbon
• CPC Class Codes: C08K 7/10 : Silicon-containing compounds
• CPC Class Codes: C08K 7/14 : Glass
• CPC Class Codes: C08L 75/04 : Polyurethanes
• CPC Class Codes: C08L 75/08 : from polyethers
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete

Abstract

Polymeric composite materials, particularly highly filled polyurethane composite materials are described herein. Such highly filled polyurethane composite materials may be formed by reaction and extrusion of one or more polyols, one or more di- or poly-isocyanates, and from about 45 to about 85 weight percent of inorganic filler such as fly ash. Certain polyols, including plant-based polyols can be used. Certain composite materials also contain chain extenders and/or crosslinkers. The polyurethane composite material may also contain fibers such as chopped or axial fibers which further provide good mechanical properties to the composite material. Shaped articles containing the polyurethane composite material have been found to have good mechanical properties, such that the shaped articles are suitable for building applications.

Claims

1. A method of forming a polyurethane composite material, the method comprising:

providing at least a first polyol having first hydroxyl number in the range of about 320 mg KOH/g to about 600 mg KOH/g; and

providing at least a second polyol having a second hydroxyl number which is at least about 20 mg KOH/g and is less than the first hydroxyl number;

wherein the ratio of first polyol to second polyol is about 3 to about 80;

wherein the first polyol and the second polyol are plant based polyester polyols; and

wherein the first polyol and the second polyol, when mixed together, have a viscosity of about 1500 cP or less at 20°

C.;

providing at least one poly or di-isocyanate;

providing an inorganic filler;

providing a blowing agent consisting essentially of about 0.1 wt % to about 0.4 wt % water based upon the weight of the composite material; and

mixing the first polyol, the second polyol, and the poly or di-isocyanate, the inorganic filler, and the blowing agent to form a reaction mixture, and extruding the reaction mixture into an extruded, foaming mixture; and

containing the extruded mixture in a mold; and

allowing the composite material to cure in the mold;

wherein substantially no halogenated hydrocarbons are added;

wherein the composite material comprises about 60 to about 85 weight percent of an the inorganic filler; and

wherein the composite material has a density in the range of about 30 lb/ft³ to about 80 lb/ft³.

2. The method of claim 1, wherein the weight ratio of the first polyol to the second polyol is about 4 to about 10.

3. The method of claim 1, wherein the weight ratio of the first polyol to the second polyol is about 5 to about 8.

4. The method of claim 1, wherein the extruded material comprises about 65 to about 75 weight percent of the inorganic filler.

5. The method of claim 1, wherein the inorganic filler comprises fly ash.

6. The method of claim 1, further comprising extruding a catalyst with the composite material.

7. The method of claim 6, wherein the catalyst is blended with the first and second polyols prior to mixing in the extruder.

8. A method of coating a solid surface article, the method comprising:

depositing a polyurethane composite material on a solid surface article, the polyurethane composite material comprising;

a reaction product of at least a first polyol, a second polyol, at least one di- or poly-isocyanate, and less than about 0.4% water by weight; and

about 60 to about 85 weight percent of an inorganic filler;

wherein the first polyol and the second polyol are plant-based polyester polyols;

wherein the ratio of the first polyol to the second polyol is about 3 to about 80;

shaping the polyurethane composite material on the solid surface article in a mold so that the material is restrained from expanding;

wherein substantially no halogenated hydrocarbons are added; and

curing the polyurethane composite material on the solid surface article;

wherein the composite material has a density in the range of about 30 lb/ft³ to about 80 lb/ft³.

9. The method of claim 8, wherein the solid surface article is a tile.

10. The method of claim 8, wherein the inorganic filler comprises fly ash.

11. The method of claim 8, wherein the polyurethane composite material comprises about 65 to about 75 weight percent of the inorganic filler.