Extrusion of polyurethane composite materials

• US 9,139,708 B2
• Filed: 02/14/2014
• Issued: 09/22/2015
• Est. Priority Date: 03/24/2006
• Status: Active Grant

• Current Assignee: EM Resources LLC
• Original Assignee: Boral Ip Holdings LLC (Seven Group Holdings Limited)
• Inventors: Brown, Wade H.
• Primary Examiner(s): WOLLSCHLAGER, JEFFREY MICHAEL
• Application Number:
  US14/180,805
• Publication Number:
  US 20140155504A1
• Time in Patent Office: 585 Days
• Field of Search: None
• US Class Current: 1/1
• 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

Methods of extruding polyurethane composite materials are described. One method includes introducing at least one polyol and inorganic filler to a first conveying section of the extruder, transferring the at least one polyol and inorganic filler to a first mixing section of an extruder, mixing the at least one polyol and the inorganic filler in the first mixing section, transferring the mixed at least one polyol and inorganic filler to a second conveying section of the extruder, introducing a di- or poly-isocyanate to the second conveying section, transferring the mixed at least one polyol and inorganic filler and the di- or poly-isocyanate to a second mixing section, mixing the mixed at least one polyol and inorganic filler with the di- or poly-isocyanate in the second mixing section of the extruder to provide a composite mixture, and transferring the composite mixture to an output end of the extruder. Other related methods are also described.

Claims

1. A method of forming a polymeric composite material in an extruder, the method comprising:

introducing at least one polyol and inorganic filler to a first conveying section of the extruder, wherein the inorganic filler comprises about 60 to about 85 weight percent of the polymeric composite material;

transferring the at least one polyol and inorganic filler to a first mixing section of an extruder;

mixing the at least one polyol and the inorganic filler in the first mixing section;

transferring the mixed at least one polyol and inorganic filler to a second conveying section of the extruder;

introducing a di- or poly-isocyanate to the second conveying section, wherein the ratio of the di- or poly-isocyanate to the at least one polyol, based on equivalent weight, is about 0.5;

1 to about 1.5;

1;

transferring the mixed at least one polyol and inorganic filler and the di- or poly-isocyanate to a second mixing section;

mixing the mixed at least one polyol and inorganic filler with the di- or poly-isocyanate in the second mixing section of the extruder to provide a composite mixture; and

transferring the composite mixture to an output end of the extruder,

wherein the method further comprises introducing fibrous material in the second conveying section or in a third conveying section, the third conveying section being located between the second mixing section and a third mixing section.

2. The method of claim 1, wherein the extruder is a twin screw extruder.

3. The method of claim 1, wherein the inorganic filler is fly ash.

4. The method of claim 1, wherein the first conveying section comprises one or more transfer screws.

5. The method of claim 1, wherein the first mixing section comprises a slotted screw.

6. The method of claim 1, wherein the first mixing section comprises a lobal screw.

7. The method of claim 1, wherein the first mixing section comprises a lobal screw and a slotted screw.

8. The method of claim 1, wherein the second conveying section comprises a transfer screw.

9. The method of claim 1, wherein the second mixing section comprises a reverse screw.

10. The method of claim 9, wherein the reverse screw comprises a reverse slotted screw.

11. The method of claim 1, further comprising adding one or more components of the composite mixture in the first conveying section of the extruder, the one or more components being selected from the group consisting of a catalyst, a surfactant, and a blowing agent.

12. The method of claim 11, further comprising blending the one or more components with the at least one polyol prior to introduction to the first conveying section.

13. The method of claim 1, further comprising mixing the mixed at least one polyol and inorganic filler and the di- or poly-isocyanate in the third mixing section subsequent to the second conveying section and prior to the second mixing section.

14. The method of claim 13, wherein the third mixing section comprises a reverse screw.

15. The method of claim 1, wherein the method further comprises introducing fibrous material in the second conveying section, and mixing the fibrous material with the mixed at least one polyol and inorganic filler and the di- or poly-isocyanate in the second mixing section.

16. The method of claim 1, wherein the inorganic filler comprises a particulate inorganic filler.

17. A method of forming a polymeric composite material in an extruder, the method comprising:

introducing at least one polyol, inorganic filler, and one or more additional components to a first conveying section of the extruder, wherein the inorganic filler comprises about 60 to about 85 weight percent of the polymeric composite material, wherein the one or more additional components is selected from the group consisting of a catalyst, a surfactant, and a blowing agent, wherein the extruder is a twin screw extruder, and wherein the first conveying section comprises one or more transfer screws;

transferring the at least one polyol, the inorganic filler, and the one or more additional components to a first mixing section of an extruder, wherein the first mixing section comprises a lobal screw;

mixing the at least one polyol, the inorganic filler, and the one or more additional components in the first mixing section;

transferring the at least one polyol, the inorganic filler, and the one or more additional components to a second conveying section of the extruder, wherein the second conveying section comprises a transfer screw;

introducing a di- or poly-isocyanate and a fibrous material to the second conveying section, wherein the ratio of the di- or poly-isocyanate to the at least one polyol, based on equivalent weight, is about 0.5;

1 to about 1.5;

1;

transferring the at least one polyol, the inorganic filler, the one or more additional components, the di- or poly-isocyanate, and the fibrous material to a second mixing section, wherein the second mixing section comprises a reverse screw;

mixing the mixed at least one polyol, the inorganic filler, the one or more additional components, the di- or poly-isocyanate, and the fibrous material in the second mixing section of the extruder to provide a composite mixture; and

transferring the composite mixture to an output end of the extruder.