Filled polymer composite and synthetic building material compositions

  • US 7,993,552 B2
  • Filed: 04/20/2006
  • Issued: 08/09/2011
  • Est. Priority Date: 01/23/2004
  • Status: Active Grant
First Claim
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1. A method of continuously forming a highly filled molded composite material comprising:

  • mixing in a multi-zone extruder the ingredients of the material by adding the ingredients of the highly filled composite material to the various zones of the multi-zone extruder without adding heat to the mixture, wherein the composite mixture comprises;

    a monomeric or oligomeric poly or di-isocyanate having a viscosity in the range of about 25 cp to about 200 cP at 25°

    C.;

    a first polyol having a viscosity in the range of about 480 cP to about 840 cP at 25°

    C.;

    a second polyol having a viscosity in the range of about 480 cP to about 840 cP at 25°

    C.;

    a foaming agent;

    an inorganic particulate material comprising about 60 wt % to about 85 wt % of the composite mixture, wherein the particulate material provides filler material which adds strength and reinforcement to the molded material and is added to the mixture prior to forming; and

    a catalyst;

    extruding or spraying the highly filled mixture by expulsion of the mixture through a die onto or into a forming system, the forming system comprising;

    at least a first and a second opposed mold belt spaced apart a distance, each having an inner surface and an outer surface;

    at least a first and a second opposed endless belt spaced apart a distance, each having an inner surface and an outer surface, wherein the inner surface of the first belt is contactable with the outer surface of the first mold belt to move with and support the first mold belt during molding, and wherein the inner surface of the second belt is contactable with the outer surface of the second mold belt to travel with and support the second mold belt during molding; and

    a mold cavity defined at least in part by the inner surfaces of the at least a first and a second opposed mold belt;

    supporting the first and second opposed endless belts with a pair of platens, each platen contacting and supporting the outer surface of the endless belts along substantially the entire length of the mold cavity;

    transferring the mixture along the mold cavity by longitudinal movement of the opposed mold belts;

    exerting substantially equal and continuous pressure on the mixture through the opposed mold belts to mold the mixture; and

    removing the molded material from the mold cavity after sufficient time has passed for the mixture to cure or harden into the molded material, wherein the molded material comprises a density of at least about 30 lb/ft3.

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