Polyurethane composite materials

  • US 8,138,234 B2
  • Filed: 03/26/2007
  • Issued: 03/20/2012
  • Est. Priority Date: 03/24/2006
  • Status: Active Grant
First Claim
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1. A method of forming a polyurethane composite material, the method comprising:

  • providing at least a first polyol having first hydroxyl number in the range of about 320 mg KOH/g to about 600 mg KOH/g; and

    providing at least a second polyol having a second hydroxyl number which is at least about 20 mg KOH/g and is less than the first hydroxyl number;

    wherein the ratio of first polyol to second polyol is about 3 to about 80;

    wherein the first polyol and the second polyol are plant based polyester polyols; and

    wherein the first polyol and the second polyol, when mixed together, have a viscosity of about 1500 cP or less at 20°

    C.;

    providing at least one poly or di-isocyanate;

    providing an inorganic filler;

    providing a blowing agent consisting essentially of about 0.1 wt % to about 0.4 wt % water based upon the weight of the composite material; and

    mixing the first polyol, the second polyol, and the poly or di-isocyanate, the inorganic filler, and the blowing agent to form a reaction mixture, and extruding the reaction mixture into an extruded, foaming mixture; and

    containing the extruded mixture in a mold; and

    allowing the composite material to cure in the mold;

    wherein substantially no halogenated hydrocarbons are added;

    wherein the composite material comprises about 60 to about 85 weight percent of an the inorganic filler; and

    wherein the composite material has a density in the range of about 30 lb/ft3 to about 80 lb/ft3.

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