Filled polymer composite and synthetic building material compositions
AssigneeCentury-Board USA, LLC
InventorWade Brown
Life of this patent
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Abstract
The invention relates to composite compositions having a matrix of polymer networks and dispersed phases of particulate or fibrous materials. The matrix is filled with a particulate phase, which can be selected from one or more of a variety of components, such as fly ash particles, axially oriented fibers, fabrics, chopped random fibers, mineral fibers, ground waste glass, granite dust, or other solid waste materials. A system for providing shape and/or surface features to a moldable material includes, in an exemplary embodiment, at least two first opposed flat endless belts spaced apart a first distance, with each having an inner surface and an outer surface.
Claims41
A method of continuously forming a molded material comprising:
- forming a composite mixture in an extruder, wherein the composite mixture comprises:
- a monomeric or oligomeric poly or di-isocyanate;
- a polyol;
- an inorganic particulate material;
- and
- a catalyst;
- extruding the mixture through a die;
- molding the mixture in a forming system comprising:
- at least two first opposed flat endless belts spaced apart a first distance, each having an inner surface and an outer surface;
- at least two second opposed flat endless belts disposed substantially orthogonal to the first two opposed endless belts and spaced apart a second distance;
- and
- a mold cavity defined at least in part by the inner surfaces of the at least two first and second opposed flat endless belts;
- 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.
A method of continuously forming a molded material comprising:
- forming a composite mixture in an extruder, wherein the composite mixture comprises:
- a monomeric or oligomeric poly or di-isocyanate;
- a first polyol having a first molecular weight;
- a second polyol having a second molecular weight lower than the first molecular weight;
- inorganic particulate material;
- and
- a catalyst;
- extruding the mixture through a die;
- molding the mixture in a forming system comprising:
- at least two first opposed flat endless belts spaced apart a first distance, each having an inner surface and an outer surface;
- at least two second opposed flat endless belts disposed substantially orthogonal to the first two opposed endless belts and spaced apart a second distance;
- and
- a mold cavity defined at least in part by the inner surfaces of the at least two first and second opposed flat endless belts;
- 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.
A method of continuously forming a molded material comprising:
- mixing a polyol with one or more of a catalyst, surfactant, and a foaming agent to form a first mixture;
- mixing the first mixture with a inorganic particulate phase to form a second mixture;
- mixing the second mixture with reinforcing fiber to form a third mixture;
- mixing the third mixture with a poly or di-isocyanate to form a composite mixture;
- molding the composite mixture in a forming system comprising:
- at least two first opposed flat endless belts spaced apart a first distance, each having an inner surface and an outer surface;
- at least two second opposed flat endless belts disposed substantially orthogonal to the first two opposed endless belts and spaced apart a second distance;
- and
- a mold cavity defined at least in part by the inner surfaces of the at least two first and second opposed flat endless belts;
- and
- removing the molded material from the mold cavity after sufficient time has passed for the composite mixture to cure or harden into the molded material.
Dependencies are inferred from the claim text.