POLYURETHANE COMPOSITE MATERIALS

Abstract

Polymeric composite materials, particularly highly filled polyurethane composite materials are described herein. Such highly filled polyurethane composite materials may be formed by reaction and extrusion of one or more polyols, one or more di- or poly-isocyanates, and from about 45 to about 85 weight percent of inorganic filler such as fly ash. Certain polyols, including plant-based polyols can be used. Certain composite materials also contain chain extenders and/or crosslinkers. The polyurethane composite material may also contain fibers such as chopped or axial fibers which further provide good mechanical properties to the composite material. Shaped articles containing the polyurethane composite material have been found to have good mechanical properties, such that the shaped articles are suitable for building applications.

Description

Claims

1. A method of forming a polyurethane composite material, the method comprising: providing at least one polyol;providing at least one poly or di-isocyanate;providing about 45 to about 85 weight percent of an inorganic filler;providing excess blowing agent; andextruding the at least one polyol, the at least one poly or di-isocyanate, the inorganic filler, and the excess blowing agent into an extruded, foaming mixture; andcontaining the extruded mixture in a mold.

2. The method of claim 1, wherein the excess blowing agent comprises water.

3. The method of claim 1, wherein the at least one polyol comprises a plant-based polyol.

4. The method of claim 1, wherein the at least one polyol comprises a first polyol having a first hydroxyl number and a second polyol having a second hydroxyl number less than the first hydroxyl number.

5. The method of claim 4, wherein the first and second polyols are selected from the group consisting of a polyester polyol or a polyether polyol.

6. The method of claim 4, wherein the weight ratio of the first polyol to the second polyol is about 4 to about 80.

7. The method of claim 4, wherein the weight ratio of the first polyol to the second polyol is about 4 to about 10.

8. The method of claim 4, wherein the weight ratio of the first polyol to the second polyol is about 5 to about 8.

9. The method of claim 1, wherein the extruded material comprises about 65 to about 75 weight percent of the inorganic filler.

10. The method of claim 1, wherein the extruded material comprises about 60 to about 85 weight percent of the inorganic filler.

11. The method of claim 1, wherein the inorganic filler comprises fly ash.

12. The method of claim 1, further comprising extruding a catalyst with the composite material.

13. The method of claim 12, wherein the catalyst is blended with the at least one polyol prior to mixing in the extruder.

14. A method of coating a solid surface article, the method comprising: depositing a polyurethane composite material on a solid surface article, the polyurethane composite material comprising: a reaction product of at least one polyol and at least one di- or poly-isocyanate, andabout 45 to about 85 weight percent of an inorganic filler;shaping the polyurethane composite material on the solid surface article in a mold; andcuring the polyurethane composite material on the solid surface article.

15. The method of claim 14, wherein the solid surface article is a tile.

16. The method of claim 14, wherein the inorganic filler comprises fly ash.

17. The method of claim 14, wherein the polyurethane composite material comprises about 65 to about 75 weight percent of the inorganic filler.

18. The method of claim 14, wherein the polyurethane composite material comprises about 60 to about 85 weight percent of the inorganic filler.

19. The method of claim 14, wherein the at least one polyol comprises a first polyol having a first hydroxyl number and a second polyol having a second hydroxyl number less than the first hydroxyl number.

20. The method of claim 14, wherein the first and second polyols are selected from the group consisting of a polyester polyol or a polyether polyol.