Polyurethane composite materials

• US 8,299,136 B2
• Filed: 03/26/2007
• Issued: 10/30/2012
• Est. Priority Date: 03/24/2006
• Status: Active Grant

• Current Assignee: Westlake Royal Building Products Incorporated
• Original Assignee: Century-Board USA, LLC
• Inventors: Brown, Wade H.
• Primary Examiner(s): HEINCER, LIAM J
• Application Number:
  US11/691,449
• Publication Number:
  US 20080132611A1
• Time in Patent Office: 2,045 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 polyurethane composite material comprising:

a polyurethane formed by reaction of a reaction mixture of;

one or more monomeric or oligomeric poly- or di-isocyanates; and

a first polyol, which is a rigid polyol, having a first hydroxyl number in the range of about 320 mg KOH/g to about 600 mg KOH/g; and

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

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

water in an amount that provides a composite material having a density of about 30 lbs/ft³ to about 85 lbs/ft³;

wherein the mixture is substantially free of halogenated hydrocarbons;

wherein the ratio of the first polyol to the second polyol is about 3 to about 20;

about 40 to about 85 weight percent inorganic filler, wherein the inorganic filler comprises coal ash; and

reinforcing fiber having a length in the range of 0.125 inches to about 1 inch.

2. The polyurethane composite material of claim 1, wherein the material comprises about 65 to about 75 weight percent inorganic filler.

3. The polyurethane composite material of claim 1, wherein the material comprises about 60 to about 85 weight percent inorganic filler.

4. The polyurethane composite material of claim 1, wherein the material comprises about 65 to about 85 weight percent inorganic filler.

5. The polyurethane composite material of claim 1, wherein the material comprises fly ash.

6. The polyurethane composite material of claim 1, wherein the material comprises about 0.01 wt % to about 0.5 wt % of the at least one coupling agent.

7. A polyurethane composite material comprising:

a polyurethane formed by reaction of a reaction mixture comprising;

one or more monomeric or oligomeric poly- or di-isocyanates;

a first polyol, which is a rigid polyol, having a first hydroxyl number in the range of about 320 mg KOH/g to about 600 mg KOH/g; and

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

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

a blowing agent;

wherein the blowing agent is water, which is present at a concentration of less than about 0.4 % based upon the weight of the composite material;

wherein the ratio of the first polyol to the second polyol is about 3 to about 20;

about 60 to about 85 weight percent of an inorganic filler, based upon the weight of the composite material, wherein the inorganic filler comprises coal ash;

wherein the reaction mixture is substantially free of halogenated hydrocarbons;

an ultraviolet light stabilizer;

about 0.1 to about 10 weight percent of a reinforcing fiber based upon the weight of the composite material;

wherein the reinforcing fiber has a length in the range of 0.125 inches to about 1 inch;

wherein the composite material has a density of about 65 lbs/ft³ to about 85 lbs/ft³ .

8. The polyurethane composite material of claim 7, wherein the material comprises about 65 to about 75 weight percent of the inorganic filler.

9. The polyurethane composite material of claim 7, wherein the material comprises about 65 to about 85 weight percent of the inorganic filler.

10. The polyurethane composite material of claim 7, wherein the material comprises fly ash.

11. The polyurethane composite material of claim 7, wherein the material additionally comprises chopped fibers.

12. The polyurethane composite material of claim 11, wherein the chopped fibers comprises chopped fiber glass and chopped basalt fiber.

13. The polyurethane composite material of claim 7, further comprising axially oriented fiber rovings disposed on, in, or beneath the surface of the composite.

14. The polyurethane composite material of claim 7, wherein the reaction mixture further comprises at least one of ethylene glycol, 1,4-butane diol, trimethylolpropane, glycerol, and sorbitol.

15. The polyurethane composite material of claim 7, wherein the materially comprises a chain extender, the chain extender being an organic compound having two or more hydroxyl groups.

16. The polyurethane composite material of claim 7, wherein a chain extender is reacted with the one or more monomeric or oligomeric poly- or di-isocyanates.

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

providing a first polyol, which is a rigid polyol, having a first hydroxyl number in the range of about 320 mg KOH/g to about 600 mg KOH/g;

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

wherein the ratio of rigid polyol to flexible polyol is about 3 to about 20;

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

providing at least one poly or di-isocyanate;

providing about 45 to about 85 weight percent of an inorganic filler based upon the weight of the composite material;

providing a blowing agent consisting essentially of water at a concentration of less than about 0.4% based upon the weight of the composite material;

wherein the mixture is substantially free of halogenated hydrocarbons;

extruding the first polyol, the second polyol, the at least one poly or di-isocyanate, and the inorganic filler into an extruded mixture; and

containing the extruded mixture in a forming device;

wherein the resulting polyurethane composite material has a density in the range of about 30 lbs/ft³ to about 85 lbs/ft.

18. The method of claim 17, further comprising placing the extruded mixture in a mold.

19. The method of claim 18, further comprising shaping the extruded mixture in the mold.

20. The method of claim 19, wherein the mold is formed by one or more belts of a forming device.

21. The method of claim 17, further comprising mixing the at least one polyol with a solvent.

22. The method of claim 21, wherein the solvent comprises about to 2 to about 10 wt % of one or more solvents selected from the group consisting of pentane, hexane, and ethyl acetate.