Filled polyurethane composites and methods of making same

• US 8,846,776 B2
• Filed: 08/12/2010
• Issued: 09/30/2014
• Est. Priority Date: 08/14/2009
• Status: Active Grant

• Current Assignee: EM Resources LLC
• Original Assignee: Boral Ip Holdings LLC (Seven Group Holdings Limited)
• Inventors: Herrington, Ronald M., Jian, Kengqing
• Primary Examiner(s): Leonard, Michael L
• Application Number:
  US12/855,380
• Publication Number:
  US 20110086934A1
• Time in Patent Office: 1,510 Days
• Field of Search: 528/48, 528/74.5, 528/76, 528/80, 528/85, 521/122, 521/123, 521/172, 521/173, 521/177
• US Class Current: 521/177
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 26/16 Polyurethanes
• CPC Class Codes: C04B 38/0067 characterised by the density of the end product
• CPC Class Codes: C04B 38/02 by adding chemical blowing agents
• CPC Class Codes: C08G 18/36 Hydroxylated esters of higher fatty acids
• CPC Class Codes: C08G 18/6662 with compounds of group C08G18/36 or hydroxylated esters of higher fatty acids of C08G18/38
• CPC Class Codes: C08G 2101/00 Manufacture of cellular products
• CPC Class Codes: C08K 11/005 Waste materials, e.g. treated or untreated sewage sludge
• CPC Class Codes: C08K 3/04 Carbon
• CPC Class Codes: C08L 75/04 Polyurethanes
• CPC Class Codes: Y02W 30/91 Use of waste materials as fillers for mortars or concrete

Abstract

Composite materials and methods for their preparation are described herein. The composite materials include a polyurethane made from the reaction of an isocyanate and a mixture of polyols, and coal ash (e.g., fly ash). The mixture of polyols comprises at least two polyols including a high hydroxyl number polyol having a hydroxyl number greater than 250 and comprising from about 1% to about 25% by weight of the total polyol content used to form the polyurethane, and a low hydroxyl number polyol having a hydroxyl number of 250 or lower. The coal ash is present in amounts from about 40% to about 90% by weight of the composite material. Also described is a method of preparing a composite material, including mixing an isocyanate, a mixture of at least two polyols, coal ash (e.g., fly ash), and a catalyst.

Claims

1. A rigid composite material comprising:

a polyurethane formed by the reaction of an isocyanate selected from the group consisting of diisocyanates, polyisocyanates and mixtures thereof, and at least two polyols, the at least two polyols comprising;

a high hydroxyl number polyol selected from the group consisting of polyether polyols and polyester polyols, the high hydroxyl number polyol having a hydroxyl number greater than 250 and having 75% or greater primary hydroxyl groups, wherein the high hydroxyl number polyol includes an aromatic polyester polyol and wherein the high hydroxyl number polyol comprises from about 1% to about 25% by weight of the total polyol content used to form the polyurethane, and

a low hydroxyl number polyol selected from the group consisting of polyether polyols and polyester polyols, the low hydroxyl number polyol having a hydroxyl number of 250 or lower; and

from about 40% to about 90% by weight coal ash,

wherein the composite material has a density of 5 lb/ft³ or greater.

2. The composite material of claim 1, wherein the coal ash is fly ash.

3. The composite material of claim 1, wherein the high hydroxyl number polyol includes a plant-based polyol and/or the low hydroxyl number polyol includes a plant-based polyol.

4. The composite material of claim 1, wherein the low hydroxyl number polyol includes castor oil.

5. The composite material of claim 1, wherein the low hydroxyl number polyol includes castor oil and the high hydroxyl number polyol includes a soybean oil-based polyol.

6. The composite material of claim 5, wherein the soybean oil-based polyol is formed by the reaction of a soybean oil and a polyester.

7. The composite material of claim 6, wherein the soybean oil and polyester based polyol is prepared using recycled polyester.

8. The composite material of claim 1, wherein the high hydroxyl number polyol comprises from about 1% to about 15% by weight of the total polyol content used to form the polyurethane.

9. The composite material of claim 1, wherein the polyurethane component has a total environmental content of greater than 35%.

10. The composite material of claim 1, wherein the polyurethane component has a total environmental content of greater than 40%.

11. The composite material of claim 1, wherein the polyurethane component has a total environmental content of greater than 45%.

12. The composite material of claim 1, wherein the polyurethane component has a total environmental content of about 50%.

13. The composite material of claim 1, wherein the composite material has a total environmental content of greater than 75%.

14. The composite material of claim 1, wherein the composite material has a total environmental content of greater than 80%.

15. The composite material of claim 1, wherein the composite material has a total environmental content of greater than about 85%.

16. The composite material of claim 1, wherein the composite material is foamed.

17. The composite material of claim 1, further comprising glass fibers.

18. The composite material of claim 1, wherein the fly ash is from about 60% to about 85% by weight.

19. The composite material of claim 1, wherein the low hydroxyl number polyol has a hydroxyl number of lower than 180.

20. A building material comprising the composite material of claim 1.

21. The building material of claim 20, wherein the building material is selected from the group consisting of siding material, carpet backing, building panels, and roofing material.

22. The composite material of claim 1, wherein the low hydroxyl number polyol has a hydroxyl number of lower than 170.

26. The composite material of claim 1, wherein the composite material has a density of 20 lb/ft³ to 60 lb/ft³.

28. The composite material of claim 1, wherein the low hydroxyl number polyol comprises from about 75% to about 99% by weight of the total polyol content used to form the polyurethane.

23. A method of preparing a rigid composite material comprising:

mixing (1) an isocyanate selected from the group consisting of diisocyanates, polyisocyanates and mixtures thereof, (2) at least two polyols, the at least two polyols comprising (i) a high hydroxyl number polyol selected from the group consisting of polyether polyols and polyester polyols, the high hydroxyl number polyol having a hydroxyl number greater than 250 and having 75% or greater primary hydroxyl groups, wherein the high hydroxyl number polyol includes an aromatic polyester polyol and wherein the high hydroxyl number polyol comprises from about 1% to about 25% by weight of the total polyol content used to form the polyurethane, and (ii) a low hydroxyl number polyol selected from the group consisting of polyether polyols and polyester polyols, the low hydroxyl number polyol having a hydroxyl number of 250 or lower, (3) coal ash, and (4) a catalyst; and

allowing the isocyanate and the at least two polyols to react in the presence of the coal ash and catalyst to form the composite material,

wherein the amount of coal ash added in the mixing step comprises from about 40% to about 90% by weight of the composite material,

wherein the composite material has a density of 5 lb/ft³ or greater.

24. The method of claim 23, wherein the low hydroxyl number polyol has a hydroxyl number of lower than 180.

25. The method of claim 23, wherein the high hydroxyl number polyol, when replacing the polyol used in the standard polyurethane formulation of the Brookfield Viscosity Test, produces a Brookfield viscosity of over 50,000 cP in less than 225 seconds.

27. The method of claim 23, wherein the composite material has a density of 20 lb/ft³ to 60 lb/ft³.

29. The method of claim 23, wherein the low hydroxyl number polyol comprises from about 75% to about 99% by weight of the total polyol content used to form the polyurethane.

30. A method of preparing a rigid composite material comprising:

mixing (1) an isocyanate selected from the group consisting of diisocyanates, polyisocyanates and mixtures thereof, (2) at least two polyols, the at least two polyols comprising (i) a high hydroxyl number polyol selected from the group consisting of polyether polyols and polyester polyols, the high hydroxyl number polyol having a hydroxyl number greater than 250 and having 75% or greater primary hydroxyl groups, wherein the high hydroxyl number polyol comprises an aromatic polyester polyol and the high hydroxyl number polyol comprises from about 1% to about 25% by weight of the total polyol content used to form the polyurethane, and (ii) a low hydroxyl number polyol selected from the group consisting of polyether polyols and polyester polyols, the low hydroxyl number polyol having a hydroxyl number of 250 or lower, (3) coal ash, and (4) a catalyst; and

allowing the isocyanate and the at least two polyols to react in the presence of the coal ash and catalyst to form the composite material,

wherein the high hydroxyl number polyol, when replacing the polyol used in the standard polyurethane formulation of the Brookfield Viscosity Test, produces a Brookfield viscosity of over 50,000 cP in less than 225 seconds,

wherein the amount of coal ash added in the mixing step comprises from about 40% to about 90% by weight of the composite material, and

wherein the composite material has a density of 5 lb/ft³ or greater.