Polyurethanes derived from highly reactive reactants and coal ash

• US 9,481,759 B2
• Filed: 08/12/2010
• Issued: 11/01/2016
• Est. Priority Date: 08/14/2009
• Status: Active Grant

• Current Assignee: Westlake Royal Building Products Incorporated
• Original Assignee: Boral Ip Holdings LLC (Seven Group Holdings Limited)
• Inventors: Herrington, Ronald M., Jian, Kengqing, Hill, Russell L.
• Primary Examiner(s): COONEY, JOHN M
• Application Number:
  US12/855,368
• Publication Number:
  US 20110086931A1
• Time in Patent Office: 2,273 Days
• Field of Search: 521/99, 521/122, 521/123, 521/170, 521/172, 521/173, 521/174, 524/65, 524/443, 524/705, 524/789, 528/74.7, 528/80, 528/85
• US Class Current: 1/1
• CPC Class Codes: C04B 14/022 Carbon
• CPC Class Codes: C04B 14/043 Alkaline-earth metal silicates, e.g. wollastonite
• CPC Class Codes: C04B 14/048 Granite
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 14/368 Baryte
• CPC Class Codes: C04B 14/38 Fibrous materials; Whiskers
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 14/46 Rock wool ; Ceramic or silicate fibres C04B14/40, C04B14/42 take precedence
• CPC Class Codes: C04B 16/06 fibrous
• CPC Class Codes: C04B 18/0409 Waste from the purification of bauxite, e.g. red mud
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 22/064 of the alkaline-earth metals
• CPC Class Codes: C04B 22/145 Gypsum from the desulfuration of flue gases
• CPC Class Codes: C04B 26/16 Polyurethanes
• CPC Class Codes: C04B 38/02 by adding chemical blowing agents
• CPC Class Codes: C08G 18/4288 modified by higher fatty oils or their acids or by resin 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 18/7664 containing alkylene polyphenyl groups
• CPC Class Codes: C08G 2110/0008 : flexible
• CPC Class Codes: C08G 2110/0025 : rigid
• CPC Class Codes: C08G 2110/0066 : ≥ 150kg/m3
• CPC Class Codes: C08G 2110/0083 : prepared using water as the sole blowing agent
• 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 at least one isocyanate and at least one polyol, and coal ash (e.g., fly ash). The composite materials are highly reactive systems such as through the use of highly reactive polyols, highly reactive isocyanates, or both. 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 at least one isocyanate, at least one polyol, coal ash, and a catalyst.

Claims

1. A method of preparing a composite material, comprising:

mixing

(1) at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates and mixtures thereof,

(2) at least one polyol wherein the at least one polyol includes 70% or more of one or more first polyols, wherein each first polyol comprises a polyester or polyether polyol comprising 75% or more primary hydroxyl groups based on the total number of hydroxyl groups in the polyester or polyether polyol, wherein at least one of the one or more first polyols comprises an aromatic polyol,

(3) coal ash, and

(4) a catalyst

to produce a mixture; and

allowing the at least one isocyanate and the at least one polyol in the mixture to react in the presence of the coal ash and catalyst to form the composite material, wherein the mixture exhibits a cream time of at least 15 seconds and a wet tack free time of 125 seconds or less, as measured by ASTM 7487-08,

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

2. The method of claim 1, wherein the aromatic polyol comprises an aromatic polyester polyol.

3. The method of claim 1, wherein the mixture exhibits a wet tack free time of 90 seconds or less, as measured by ASTM 7487-08.

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

5. The method of claim 1, wherein the at least one isocyanate, the at least one polyol, the coal ash, and the catalyst are mixed in an extruder.

6. The method of claim 1, wherein the mixture is allowed to react in a continuous forming system.

7. The method of claim 1, wherein the at least one polyol includes from 70% to 85% of or more of one or more first polyols.

8. The method of claim 1, wherein the at least one polyol includes 75% or more of one or more first polyols.

9. The method of claim 8, wherein the at least one polyol includes greater than 90% of or more of one or more first polyols.

10. The method of claim 1, wherein one or more of the first polyols have a primary hydroxyl number, defined as the hydroxyl number multiplied by the percentage of primary hydroxyl groups based on the total number of hydroxyl groups in the polyol, of greater than 250 mg KOH/g.

11. The method of claim 1, wherein the one or more first polyols each have a primary hydroxyl number, defined as the hydroxyl number multiplied by the percentage of primary hydroxyl groups based on the total number of hydroxyl groups in the polyol, of greater than 250 mg KOH/g.

12. The method of claim 1, wherein one or more of the first polyols has a primary hydroxyl number of greater than 280 mg KOH/g.

13. The method of claim 12, wherein one or more of the first polyols has a hydroxyl number of greater than 300 mg KOH/g.

14. The method of claim 13, wherein one or more of the first polyols has a hydroxyl number of greater than 350 mg KOH/g.

15. The method of claim 1, wherein each first polyol when replacing the polyols used in the standard polyurethane formulation of the Brookfield Viscosity Test produces a Brookfield viscosity of over 50,000 mPa·

s in less than 225 seconds.

16. The method of claim 15, wherein each first polyol when replacing the polyols used in the standard polyurethane formulation of the Brookfield Viscosity Test produces a Brookfield viscosity of over 50,000 mPa·

s in less than 200 seconds.

17. The method of claim 16, wherein each first polyol when replacing the polyols used in the standard polyurethane formulation of the Brookfield Viscosity Test produces a Brookfield viscosity of over 50,000 mPa·

s in less than 175 seconds.

18. The method of claim 1, wherein the at least one isocyanate, the at least one polyol, at least one catalyst, the coal ash, and any other components used to form the polyurethane when mixed together and used as the polyurethane in the Brookfield Viscosity Test produces a Brookfield viscosity of over 50,000 mPa·

s in less than 225 seconds.

19. The method of claim 1, wherein the at least one isocyanate, at least one polyol, at least one catalyst, and any other non-filler additives when mixed together in the amounts used in the polyurethane without fly ash and any other fillers produce a surface temperature rise in a cup test of at least 120°

F.

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

21. The method of claim 1, wherein the coal ash is fly ash.

22. The method of claim 1, wherein the coal ash comprises from about 60% to about 85% by weight of the mixture.

23. The method of claim 1, further comprising mixing a crosslinker with the at least one isocyanate, the at least one polyol, the coal ash, and the catalyst.

24. The method of claim 23, wherein the crosslinker includes glycerin.

25. The method of claim 1, further comprising mixing fibers with the at least one isocyanate, the at least one polyol, the coal ash, and the catalyst.

26. The method of claim 1, wherein the at least one polyol further includes one or more second polyols, wherein each second polyol comprises 50% or less primary hydroxyl groups based on the total number of hydroxyl groups in the second polyol.

27. The method of claim 26, wherein one or more of the second polyols have a primary hydroxyl number, defined as the hydroxyl number multiplied by the percentage of primary hydroxyl groups based on the total number of hydroxyl groups in the polyol, of less than 200 mg KOH/g.

28. The method of claim 27, wherein one or more of the second polyols have a primary hydroxyl number, defined as the hydroxyl number multiplied by the percentage of primary hydroxyl groups based on the total number of hydroxyl groups in the polyol, of less than 150 mg KOH/g.

29. The method of claim 1, further comprising mixing a silicone surfactant with the at least one isocyanate, the at least one polyol, the coal ash, and the catalyst.

30. The method of claim 1, wherein the catalyst comprises an amine-containing catalyst.

31. The method of claim 1, wherein the composite material comprises a building material.

32. The method of claim 31, wherein the building material is selected from the group consisting of siding material, carpet backing, building panels, and roofing material.