Filled polymeric composites including short length fibers

• US 9,752,015 B2
• Filed: 08/05/2014
• Issued: 09/05/2017
• Est. Priority Date: 08/05/2014
• Status: Active Grant

• Current Assignee: EM Resources LLC
• Original Assignee: Boral Ip Holdings (Australia) Pty Limited (Seven Group Holdings Limited)
• Inventors: Kumar, Amitabha, Crocco, Guy, Hill, Russell L., Ai, Li, Myers, Jacob
• Primary Examiner(s): HARLAN, ROBERT D
• Application Number:
  US14/889,094
• Publication Number:
  US 20160280890A1
• Time in Patent Office: 1,127 Days
• CPC Class Codes: C08K 11/00 Use of ingredients of unknown constitution, e.g. undefined reaction products
• CPC Class Codes: C08K 11/005 Waste materials, e.g. treated or untreated sewage sludge
• CPC Class Codes: C08K 2201/003 Additives being defined by their diameter
• CPC Class Codes: C08K 2201/004 Additives being defined by their length
• 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 7/02 Fibres or whiskers
• CPC Class Codes: C08K 7/04 inorganic
• CPC Class Codes: C08K 7/14 Glass
• CPC Class Codes: C08K 9/06 with silicon-containing compounds
• CPC Class Codes: C08L 101/00 Compositions of unspecified macromolecular compounds

Abstract

Polymeric composites and methods for preparing the composites are described herein. The polymeric composites can comprise a polymer, an inorganic filler, and a plurality of short length fibers. The polymer in the composites can include homopolymers and copolymers and can also include plastics, resins, elastomers, thermoplastics, thermosets, and hot melts. The inorganic filler can be fly ash. The short length fibers can have an average length of 650 μm or less. Methods for making the polymeric composites are also described.

Claims

1. A composite comprising:

(a) a polymer;

(b) from 25% to 90% by weight of an inorganic filler comprising fly ash; and

(c) a plurality of short length fibers having an average length of 650 μ

m or less.

2. The composite of claim 1, wherein the short length fibers have an average aspect ratio of length to diameter of 5:

1 to 250;

1.

4. The composite of claim 1, wherein the short length fibers are selected from the group consisting of mineral wool, cellulose, wood fiber, saw dust, wood shavings, cotton, lint, and combinations thereof.

6. The composite of claim 1, wherein the short length fibers have an average length of from 100 μ

m to 250 μ

m.

7. The composite of claim 1, wherein the short length fibers have an average diameter of from 1 to 20 μ

m.

8. The composite of claim 1, wherein the short length fibers are present in an amount from 0.5% to 15% by weight, based on the total weight of the composite.

9. The composite of claim 1, wherein the inorganic filler is present in an amount from 50% to 80% by weight, based on the total weight of the composite.

10. The composite of claim 1, further comprising a plurality of glass fibers having a minimum length of 1 mm.

11. The composite of claim 10, wherein the glass fiber is present in an amount from 0.5% to 10% by weight, based on the total weight of the composite.

12. The composite of claim 1, wherein the polymer is selected from the group consisting of polyolefins, ethylene copolymers, polystyrenes, polyvinyl chlorides, polyvinylidene chlorides, polyvinyl acetates, polyacrylonitriles, polyamides, polyisobutylenes, polyacetals, chlorinated and fluorinated polymers, fluoroelastomers, fluorosilicones, polycarbonates, epoxies, phenolics, polyesters, acrylic polymers, acrylate polymers, polyurethanes, alkyds, silicones, styrene-butadiene copolymers, acrylonitrile-butadiene-styrene copolymers, nitrile rubbers, diallyl phthalates, melamines, polybutadienes, aramids, cellulosics, cellulose acetobutyrates, ionomers, parylenes, polyaryl ethers, polyaryl sulfones, polyarylene sulfides, polyethersulfones, polyallomers, polyimides, polyamideimides, polymethylpentenes, polyphenylene oxides, polyphenylene sulfides, polysulfones, polyetherketones, polyetherimides, polyaryleneketones, polychloroprenes, and blends thereof.

13. The composite of claim 1, wherein the polymer is a polyurethane formed by the reaction of at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates and mixtures thereof, and at least one polyol.

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

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

3. A composite comprising:

(a) a polymer;

(b) from 25% to 90% by weight of an inorganic filler; and

(c) a plurality of short length fibers having an average aspect ratio of length to diameter of 8;

1 to 250;

1, wherein the short length fibers are selected from the group consisting of mineral wool, cellulose, wood fiber, saw dust, wood shavings, cotton, lint, and combinations thereof.

5. The composite of claim 3, wherein the short length fibers have an average length of from 50 μ

m to 650 μ

m.

18. The composite of claim 3, wherein the inorganic filler comprises fly ash.

16. A method of preparing a polyurethane composite, comprising:

(a) mixing

(1) 25% to 90% by weight of an inorganic filler based on the total weight of the composite;

(2) at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates, and combinations thereof;

(3) at least one polyol;

(4) a plurality of short length fibers having a length of 650 μ

m or less; and

(5) a catalyst; and

(b) allowing the at least one isocyanate and the at least one polyol to react in the presence of the inorganic filler, and the plurality of short length fibers to form the polyurethane composite.

17. The method of claim 16, wherein the short length fibers are selected from the group consisting of mineral wool, cellulose, wood fiber, saw dust, wood shavings, cotton, lint, and combinations thereof.

19. A composite comprising:

(a) a polymer;

(b) from 25% to 90% by weight of an inorganic filler;

(c) a plurality of short length fibers having an average length of 650 μ

m or less; and

(d) a plurality of glass fibers having a minimum length of 1 mm.

20. The composite of claim 19, wherein the glass fibers are present in an amount from 0.5% to 10% by weight, based on the total weight of the composite.

21. A composite comprising:

(a) a polymer;

(b) from 25% to 90% by weight of an inorganic filler;

(c) a plurality of short length fibers having an average length of 650 μ

m or less; and

(d) a plurality of glass fibers, wherein the glass fibers are present in an amount from 0.5% to 10% by weight, based on the total weight of the composite.

22. A composite comprising:

(a) a polymer;

(b) from 25% to 90% by weight of an inorganic filler;

(c) a plurality of short length fibers having an average length of 650 μ

m or less;

wherein the short length fibers are selected from the group consisting of mineral wool, cellulose, wood fiber, saw dust, wood shavings, cotton, lint, and combinations thereof.

23. A method of preparing a polyurethane composite, comprising:

(a) mixing

(1) 25% to 90% by weight of an inorganic filler based on the total weight of the composite;

(2) at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates, and combinations thereof;

(3) at least one polyol; and

(4) a plurality of short length fibers having a length of 650 μ

m or less, wherein the short length fibers are selected from the group consisting of mineral wool, cellulose, wood fiber, saw dust, wood shavings, cotton, lint, and combinations thereof; and

(b) allowing the at least one isocyanate and the at least one polyol to react in the presence of the inorganic filler, and the plurality of short length fibers to form the polyurethane composite.