# US 2014/0155504 A1 · Extrusion of polyurethane composite materials > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0155504 A1 - Document ID: US20140155504A1 - Status: Published application - Kind: A1 - Application number: 14/180,805 - Filed: 2014-02-14 - Published: 2014-06-05 - Earliest claimed: 2006-03-24 - Assignees: Century-Board USA, LLC - Applicants: Century-Board USA, LLC - Inventors: Wade H. Brown - Web page: https://patentgrep.com/patent/US20140155504A1 ## CPC - B29C 48/07: Flat, e.g. panels - B29C 48/402: {the screws having intermeshing parts} - B29C 48/54: with additional forward-feeding elements - B29C 48/55: having reverse-feeding elements - B29C 48/56: having grooves or cavities other than the thread or the channel - B29C 48/57: provided with kneading disc-like elements, e.g. with oval-shaped elements - B29C 48/575: provided with elements of a generally circular cross-section for shearing the melt, i.e. shear-ring elements - B29C 48/67: having incorporated mixing devices not provided for in groups B29C48/52 - B29C48/66 - B29C 48/834: {Cooling} - C04B 26/16: Polyurethanes - C08G 18/0895: {Manufacture of polymers by continuous processes (C08G18/0838 takes precedence)} - C08G 18/36: Hydroxylated esters of higher fatty acids - C08G 18/4045: {Mixtures of compounds of group C08G18/58 with other macromolecular compounds} - C08G 18/4804: {Two or more polyethers of different physical or chemical nature} - C08G 18/7657: {containing two or more aromatic rings} - C08G 18/7671: {containing only one alkylene bisphenyl group} - C08J 5/10: characterised by the additives used in the polymer mixture - C08J 9/125: {Water, e.g. hydrated salts} - C08K 3/013: Fillers, pigments or reinforcing additives - C08K 3/04: Carbon - C08K 7/10: Silicon-containing compounds - C08K 7/14: Glass - C08L 75/04: Polyurethanes - C08L 75/08: from polyethers - B29C 45/0001: {characterised by the choice of material} - B29C 48/022: {characterised by the choice of material} - B29C 48/285: Feeding the extrusion material to the extruder - B29C 48/2886: {of fillers or of fibrous materials, e.g. short-fibre reinforcements} - B29C 48/29: in liquid form - B29C 48/297: {at several locations, e.g. using several hoppers or using a separate additive feeding} - B29C 48/395: using screws surrounded by a cooperating barrel, e.g. single screw extruders - B29C 48/405: Intermeshing co-rotating screws - B29C 48/63: having sections without mixing elements or threads, i.e. having cylinder shaped sections - B29K 2049/00: Use of polyacetylene or cyanic ester resins, i.e. polymers having one or more carbon-to-carbon triple bonds or derivatives thereof, as moulding material - B29K 2075/00: Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material - B29K 2105/0005: {containing compounding ingredients (releasing, lubricating or separating agents B29C33/56, fibers B29K2105/08, B29K2105/12; fillers B29K2105/16, recycled material B29K2105/26)} - B29K 2105/0014: {Catalysts} - B29K 2105/0032: {Pigments, colouring agents or opacifiyng agents} - B29K 2105/0044: {Stabilisers, e.g. against oxydation, light or heat} - B29K 2105/005: {Heat sensitisers or absorbers} - B29K 2105/06: containing reinforcements, fillers or inserts - B29K 2105/12: of short lengths, e.g. chopped filaments, staple fibres or bristles - B29K 2105/16: Fillers - B29K 2709/00: Use of inorganic materials not provided for in groups {B29K2703/00 - B29K2707/00}, for preformed parts, e.g. for inserts - C08G 2101/00: Manufacture of cellular products - C08G 2110/0083: prepared using water as the sole blowing agent - C08J 2201/03: Extrusion of the foamable blend - C08J 2375/04: Polyurethanes - C08K 3/00: Use of inorganic substances as compounding ingredients - Y02W 30/91: Use of waste materials as fillers for mortars or concrete - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) - C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09) - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT ## Abstract Methods of extruding polyurethane composite materials are described. One method includes introducing at least one polyol and inorganic filler to a first conveying section of the extruder, transferring the at least one polyol and inorganic filler to a first mixing section of an extruder, mixing the at least one polyol and the inorganic filler in the first mixing section, transferring the mixed at least one polyol and inorganic filler to a second conveying section of the extruder, introducing a di- or poly-isocyanate to the second conveying section, transferring the mixed at least one polyol and inorganic filler and the di- or poly-isocyanate to a second mixing section, mixing the mixed at least one polyol and inorganic filler with the di- or poly-isocyanate in the second mixing section of the extruder to provide a composite mixture, and transferring the composite mixture to an output end of the extruder. Other related methods are also described. ## Claims ### Claim 1 A method of forming a polymeric composite material in an extruder, the method comprising: introducing at least one polyol and inorganic filler to a first conveying section of the extruder; transferring the at least one polyol and inorganic filler to a first mixing section of an extruder; mixing the at least one polyol and the inorganic filler in the first mixing section; transferring the mixed at least one polyol and inorganic filler to a second conveying section of the extruder; introducing a di- or poly-isocyanate to the second conveying section, wherein the ratio of the di- or poly-isocyanate to the at least one polyol is about 0.5:1 to about 1.5:1; transferring the mixed at least one polyol and inorganic filler and the di- or poly-isocyanate to a second mixing section; mixing the mixed at least one polyol and inorganic filler with the di- or poly-isocyanate in the second mixing section of the extruder to provide a composite mixture; and transferring the composite mixture to an output end of the extruder. ### Claim 2 (depends on 1) The method of claim 1, wherein the extruder is a twin screw extruder. ### Claim 3 (depends on 1) The method of claim 1, wherein the composite mixture comprises about 40 to about 85 weight percent of the inorganic filler. ### Claim 4 (depends on 1) The method of claim 1, wherein the composite mixture comprises about 60 to about 85 weight percent of the inorganic filler. ### Claim 5 (depends on 1) The method of claim 1, wherein the inorganic filler is fly ash. ### Claim 6 (depends on 1) The method of claim 1, wherein the first conveying section comprises one or more transfer screws. ### Claim 7 (depends on 1) The method of claim 1, wherein the first mixing section comprises a slotted screw. ### Claim 8 (depends on 1) The method of claim 1, wherein the first mixing section comprises a lobal screw. ### Claim 9 (depends on 1) The method of claim 1, wherein the first mixing section comprises a lobal screw and a slotted screw. ### Claim 10 (depends on 1) The method of claim 1, wherein the second conveying section comprises a transfer screw. ### Claim 11 (depends on 1) The method of claim 1, wherein the second mixing section comprises a reverse screw. ### Claim 12 (depends on 11) The method of claim 11, wherein the reverse screw comprises a reverse slotted screw. ### Claim 13 (depends on 1) The method of claim 1, further comprising adding one or more components of the composite mixture in the first conveying section of the extruder, the one or more components being selected from the group consisting of a catalyst, a surfactant, and a blowing agent. ### Claim 14 (depends on 13) The method of claim 13, further comprising blending the one or more components with the at least one polyol prior to introduction to the first conveying section. ### Claim 15 (depends on 1) The method of claim 1, further comprising mixing the mixed at least one polyol and inorganic filler and the di- or poly-isocyanate in a third mixing section subsequent to the second conveying section and prior to the second mixing section. ### Claim 16 (depends on 15) The method of claim 15, wherein the third mixing section comprises a reverse screw. ### Claim 17 (depends on 15) The method of claim 15, further comprising introducing fibrous material in a third conveying section, the third conveying section being located between the second mixing section and the third mixing section. ### Claim 18 (depends on 1) The method of claim 1, further comprising introducing fibrous material in the second conveying section. ### Claim 19 (depends on 18) The method of claim 18, further comprising mixing the fibrous material with the mixed at least one polyol and inorganic filler and the di- or poly-isocyanate in the second mixing section. ### Claim 20 A method of forming a polymeric composite material in an extruder, the method comprising: introducing at least one polyol, inorganic filler, and one or more additional components to a first conveying section of the extruder, wherein the inorganic filler comprises about 60-85 weight percent of the polymeric composite material, wherein the one or more additional components is selected from the group consisting of a catalyst, a surfactant, and a blowing agent, wherein the extruder is a twin screw extruder, and wherein the first conveying section comprises one or more transfer screws; transferring the at least one polyol, the inorganic filler, and the one or more additional components to a first mixing section of an extruder, wherein the first mixing section comprises a lobal screw; mixing the at least one polyol, the inorganic filler, and the one or more additional components in the first mixing section; transferring the at least one polyol, the inorganic filler, and the one or more additional components to a second conveying section of the extruder, wherein the second conveying section comprises a transfer screw; introducing a di- or poly-isocyanate and a fibrous material to the second conveying section, wherein the ratio of the di- or poly-isocyanate to the at least one polyol is about 0.5:1 to about 1.5:1; transferring the at least one polyol, the inorganic filler, the one or more additional components, the di- or poly-isocyanate, and the fibrous material to a second mixing section, wherein the second mixing section comprises a reverse screw; mixing the mixed at least one polyol, the inorganic filler, the one or more additional components, the di- or poly-isocyanate, and the fibrous material in the second mixing section of the extruder to provide a composite mixture; and transferring the composite mixture to an output end of the extruder.