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US 2011/0086931 A1Published application
Polyurethanes derived from highly reactive reactants and coal ash
AssigneeBoral Material Technologies Inc.
InventorsRonald M. Herrington, Kengqing Jian, Russell L. Hill
Life of this patent
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Abstract
Composite materials and methods for their preparation are described herein. The composite materials include a polyurethane made from the reaction of at least one isocyanate and at least one polyol, and coal ash (e.g., fly ash). The composite materials are highly reactive systems such as through the use of highly reactive polyols, highly reactive isocyanates, or both. The coal ash is present in amounts from about 40% to about 90% by weight of the composite material. Also described is a method of preparing a composite material, including mixing at least one isocyanate, at least one polyol, coal ash, and a catalyst.
Claims33
A composite material comprising:
- a polyurethane formed by the reaction of at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates and mixtures thereof, and at least one polyol wherein the at least one polyol includes 50% or more of one or more highly reactive polyols, the one or more highly reactive polyols each comprising 75% or more primary hydroxyl groups based on the total number of hydroxyl groups in the polyol;
- and
- from about 40% to about 90% by weight coal ash.
A composite material comprising:
- a polyurethane formed by the reaction of at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates and mixtures thereof, and at least one polyol wherein the at least one polyol includes 50% or more of one or more highly reactive polyols, the one or more highly reactive polyols each having a primary hydroxyl number, defined as the hydroxyl number multiplied by the percentage of primary hydroxyl groups based on the total number of hydroxyl groups in the polyol, of greater than 250;
- and
- from about 40% to about 90% by weight coal ash.
A composite material comprising:
- a polyurethane formed by the reaction of at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates and mixtures thereof, and at least one polyol wherein the at least one polyol includes 50% or more of one or more highly reactive polyols, each highly reactive polyol when replacing the polyols used in the standard polyurethane formulation of the Brookfield Viscosity Test produces a Brookfield viscosity of over 50,000 mPa·s in less than 225 seconds;
- and
- from about 40% to about 90% by weight coal ash.
A composite material comprising:
- a polyurethane formed by the reaction of at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates and mixtures thereof, at least one polyol, and at least one catalyst, in the presence of from about 40% to about 90% by weight coal ash, wherein the at least one isocyanate, the at least one polyol, the at least one catalyst, the coal ash, and any other components used to form the polyurethane when mixed together and used as the polyurethane in a Brookfield Viscosity Test produces a Brookfield viscosity of over 50,000 mPa·s in less than 225 seconds.
A composite material comprising:
- a polyurethane formed by the reaction of at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates and mixtures thereof, and at least one polyol and at least one catalyst, wherein the at least one isocyanate, at least one polyol, the at least one catalyst, and any other non-filler additives when mixed together in the amounts used in the polyurethane without fly ash and any other fillers produce a surface temperature rise in a cup test of at least 120° F.;
- and
- from about 40% to about 90% by weight coal ash.
A composite material comprising:
- a polyurethane formed by the reaction of at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates and mixtures thereof, and at least one polyol, wherein the at least one isocyanate includes 50% or more of one or more highly reactive isocyanates, each highly reactive isocyanate when replacing the isocyanate used in the standard polyurethane formulation of the Brookfield Viscosity Test produces a Brookfield viscosity of over 50,000 mPa·s in less than 400 seconds;
- and
- from about 40% to about 90% by weight coal ash.
A method of preparing a composite material, comprising:
- mixing (1) at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates and mixtures thereof, (2) at least one polyol wherein the at least one polyol includes 50% or more of one or more highly reactive polyols, the one or more highly reactive polyols each comprising 75% or more primary hydroxyl groups based on the total number of hydroxyl groups in the polyol, (3) coal ash, and (4) a catalyst;
- and
- allowing the at least one isocyanate and the at least one polyol to react in the presence of the coal ash and catalyst to form the composite material,
- wherein the amount of coal ash added in the mixing step comprises from about 40% to about 90% by weight of the composite material.
1 more element
Dependencies are inferred from the claim text.