Composite material including rigid foam with inorganic fillers
AssigneeCertainTeed Corporation
InventorFyodor A. Shutov
Life of this patent
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Abstract
A composite material includes, in an exemplary embodiment a polyurethane foam and a plurality of inorganic particles dispersed therein. The polyurethane foam is formed from a reaction mixture that includes a first polyether polyol having a first molecular weight and a functionality of about 3 or less, a second polyether polyol having a second molecular weight less than the first molecular weight and a functionality of greater than about 3, and at least one isocyanate. The ratio of an amount of the first polyol in the reaction mixture to an amount of the second polyol in the reaction mixture is between about 1:1 to about 5:1.
Claims12
A synthetic lumber article formed from a composite material, said composite material comprising a polyurethane foam and a plurality of inorganic filler particles dispersed therein, said polyurethane foam formed from a reaction mixture comprising:
- a first polyether polyol having a first molecular weight and a functionality of about 3 or less;
- a second polyether polyol having a second molecular weight and a functionality of about 3 or greater, the second molecular weight less than said first molecular weight;
- an aromatic hydrocarbon present in amount of up to about 5 weight percent based on the total weight of said composite material;
- at least one polyisocyanate,
- wherein a weight ratio of an amount of the first polyol in the reaction mixture to an amount of the second polyol in the reaction mixture is between about 1:1 to about 5:1, the plurality of inorganic filler particles is present in an amount of about 50 wt % to about 85 wt % based on the total weight of the composite material, the inorganic filler particles include fly ash and glass fibers, wherein a weight ratio of the fly ash to the glass fibers ranges from 6.87:1 to 7.77:1, and the composite material has a density of 52.1 lb/ft3 or less and has an average flexural stress of at least 2330 psi.
A method of producing a composite material comprising a polyurethane foam and a plurality of inorganic particles dispersed therein, the method comprising:
- mixing a first polyether polyol having a first molecular weight and a functionality of about 3 or less with a second polyether polyol having a second molecular weight and a functionality of greater than 3 to form a polyol mixture wherein a ratio of an amount of the first polyol in the mixture to an amount of the second polyol in the mixture is between about 1:1 to about 5:1, the second molecular weight less than the first molecular weight;
- adding up to about 5 weight percent based on the total weight of the composite material of an aromatic hydrocarbon;
- adding an amount of about 50 wt % to about 85 wt % of the plurality of inorganic filler particles to the mixture, the plurality of inorganic filler particles include fly ash and glass fibers, wherein a weight ratio of the fly ash to the glass fibers ranges from 6.87:1 to 7.77:1;
- adding at least one polyisocyanate to the polyol mixture;
- and
- extruding the mixture into a mold to form a composite material having a density of 52.1 lb/ft3 or less and has an average flexural stress of at least 2330 psi.
Dependencies are inferred from the claim text.