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 polyurethane composite material comprising: a polyurethane formed by reaction of a reaction mixture of: one or more monomeric or oligomeric poly- or di-isocyanates; andat least one plant-based polyol; andabout 40 to about 85 weight percent of an inorganic filler, wherein the inorganic filler comprises coal ash.

2. The polyurethane composite material of claim 1, wherein the material comprises about 65 to about 75 weight percent of the inorganic filler.

3. The polyurethane composite material of claim 1, wherein the material comprises about 60 to about 85 weight percent of the inorganic filler.

4. The polyurethane composite material of claim 1, wherein the material comprises fly ash.

5. The polyurethane composite material of claim 1, wherein the coal ash comprises a mixture of bottom ash and fly ash.

6. The polyurethane composite material of claim 1, wherein the material additionally comprises one or more selected from the group consisting of chain extenders, cross linkers, and combinations thereof.

7. The polyurethane composite material of claim 1, wherein the material additionally comprises a chain extender.

8. The polyurethane composite material of claim 7, wherein the chain extender is one or more selected from the group consisting of ethylene glycol, glycerin, 1,4-butane diol, trimethylolpropane, glycerol, sorbitol, and combinations thereof.

9. The polyurethane composite material of claim 7, wherein the chain extender is a diamine chain extender.

10. The polyurethane composite material of claim 7, wherein the material comprises glycol extenders.

11. The polyurethane composite material of claim 1, wherein the material in the form of a shaped article.

12. The polyurethane composite material of claim 11, wherein the shaped article is selected from the group consisting of roofing material, siding material, carpet backing, synthetic lumber, building panels, scaffolding, cast molded products, decking material, fencing material, marine lumber, doors, door parts, moldings sills, stone, masonry, brick products, post signs, guard rails, retaining walls, park benches, tables slats, and railroad ties.

13. A solid surface article comprising a portion, wherein the portion comprises polyurethane composite material of claim 1.

14. A method of forming a polyurethane composite material, the method comprising: providing at least one plant based polyol;providing at least one poly or di-isocyanate;providing about 45 to about 85 weight percent of an inorganic filler; andextruding the at least one plant-based polyol, the at least one poly or di-isocyanate, and the inorganic filler, to produce a composite material.

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

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

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

18. The method of claim 14, further comprising placing the extruded mixture in a mold.

19. The method of claim 18, further comprising shaping the extruded mixture in the mold.

20. The method of claim 19, wherein the mold is formed by one or more belts of a forming device.

21. The method of claim 14, further comprising mixing the at least one plant-based polyol with a solvent

22. The method of claim 21, wherein the solvent comprises about to 2 to about 10 wt % of one or more solvents selected from the group consisting of pentane, hexane, carbon tetrachloride, trichloroethylene, methylene chloride, chloroform, methyl chloroform, perchloroethylene, and ethyl acetate.