Inorganic polymer/organic polymer composites and methods of making same

• US 9,745,224 B2
• Filed: 10/05/2012
• Issued: 08/29/2017
• Est. Priority Date: 10/07/2011
• Status: Active Grant

• Current Assignee: Westlake Royal Building Products Incorporated
• Original Assignee: Boral Ip Holdings (Australia) Pty Limited (Seven Group Holdings Limited)
• Inventors: Hill, Russell L., Majors, Russ
• Primary Examiner(s): Choi, Ling
• Assistant Examiner(s): Grinsted, Ronald
• Application Number:
  US14/345,508
• Publication Number:
  US 20140349104A1
• Time in Patent Office: 1,789 Days
• Field of Search: 428323, 4283191, 428446, 4284255, 427403
• CPC Class Codes: B05D 7/52 Two layers
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 2250/02 2 layers
• CPC Class Codes: B32B 2250/24 All layers being polymeric
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2375/00 Polyureas; Polyurethanes
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: C04B 18/08 Flue dust , i.e. fly ash
• CPC Class Codes: C04B 20/002 Hollow or porous granular materials
• CPC Class Codes: C04B 20/0048 Fibrous materials
• CPC Class Codes: C04B 2103/10 Accelerators; Activators
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 22/062 of the alkali or alkaline-earth metals
• CPC Class Codes: C04B 24/04 Carboxylic acids; Salts, anhydrides or esters thereof
• CPC Class Codes: C04B 24/06 containing hydroxy groups
• CPC Class Codes: C04B 28/006 containing mineral polymers, e.g. geopolymers of the Davidovits type
• CPC Class Codes: C04B 7/02 Portland cement
• CPC Class Codes: Y02P 40/10 : Production of cement, e.g. improving or optimising the production methods; Cement grinding
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/24999 : Inorganic
• CPC Class Codes: Y10T 428/31598 : Next to silicon-containing [silicone, cement, etc.] layer

Abstract

Inorganic polymer/organic polymer composites and methods for their preparation are described herein. The inorganic polymer/organic polymer composites comprise a first layer comprising an inorganic polymer and a second layer adhered to the first layer comprising an organic polymer. The inorganic polymer is formed by reacting, in the presence of water, a reactive powder, an activator, and optionally a retardant. The reactive powder comprises 85% by weight or greater fly ash and less than 10% by weight portland cement. Also described herein are building materials including the composites.

Claims

1. An inorganic polymer/organic polymer composite, comprising:

a first layer comprising an inorganic polymer formed by reacting in the presence of water;

a reactive powder comprising 85% by weight or greater fly ash, based on the total weight of the reactive powder and less than 10% by weight portland cement, based on the total weight of the reactive powder; and

an activator; and

a second layer adhered to the first layer comprising an organic polymer and from 40% to 90% by weight fly ash, based on the total weight of the second layer.

4. The composite of claim 1, wherein the reactive powder includes less than 5% by weight of portland cement.

5. The composite of claim 1, wherein greater than 75% of the fly ash in the first layer comprises Class C fly ash.

6. The composite of claim 1, wherein the activator includes citric acid.

7. The composite of claim 1, wherein the activator includes sodium hydroxide.

8. The composite of claim 1, wherein the inorganic polymer is substantially free from retardants.

9. The composite of claim 1, wherein the inorganic polymer further comprises fibers.

10. The composite of claim 1, wherein the inorganic polymer further comprises a photocatalyst.

11. The composite of claim 1, wherein the weight ratio of water to reactive powder is from 0.06:

1 to 0.25;

1.

12. The composite of claim 1, wherein the organic polymer is a polyurethane.

13. The composite of claim 12, wherein the polyurethane is foamed.

14. The composite of claim 1, wherein the first layer is directly adhered to the second layer without the use of an adhesive layer.

15. The composite of claim 1, wherein the composite includes 75% by weight or greater of the second layer and 25% by weight or less of the first layer.

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

17. The building material of claim 16, wherein the building material is a synthetic stone or a panel.

2. An inorganic polymer/organic polymer composite, comprising:

a first layer comprising an inorganic polymer formed by reacting in the presence of water;

a reactive powder comprising fly ash and less than 10% by weight portland cement, based on the total weight of the reactive powder; and

an activator; and

a second layer adhered to the first layer comprising an organic polymer and from 40% to 90% by weight fly ash, based on the total weight of the second layer.

3. The composite of claim 2, wherein the fly ash in the first layer is present in an amount of greater than 85% by weight of the reactive powder.

18. The composite of claim 2, wherein greater than 75% of the fly ash in the inorganic polymer reactive mixture comprises Class C fly ash.

19. The composite of claim 2, wherein the inorganic polymer is substantially free from retardants.