# US 9,752,015 B2 · Filled polymeric composites including short length fibers > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,752,015 B2 - Document ID: US9752015B2 - Status: Granted - Kind: B2 - Application number: 14/889,094 - Filed: 2014-08-05 - Published: 2016-09-29 - Granted: 2017-09-05 - Earliest claimed: 2014-08-05 - Assignees: Boral IP Holdings (Australia) PTY Limited - Applicants: Amitabha Kumar; Guy Crocco; Russell L. Hill; Li Ai; Jacob Myers - Inventors: Amitabha Kumar; Guy Crocco; Russell L. Hill; Li Ai; Jacob Myers - Web page: https://patentgrep.com/patent/US9752015B2 ## CPC - C08K 11/005: {Waste materials, e.g. treated or untreated sewage sludge} - C08K 3/00: Use of inorganic substances as compounding ingredients - C08K 3/013: Fillers, pigments or reinforcing additives - C08K 7/02: Fibres or whiskers - C08K 7/04: inorganic - C08K 7/14: Glass - C08K 9/06: with silicon-containing compounds - C08K 11/00: Use of ingredients of unknown constitution, e.g. undefined reaction products - C08L 101/00: Compositions of unspecified macromolecular compounds - C08K 2201/003: Additives being defined by their diameter - C08K 2201/004: Additives being defined by their length - 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) ## Abstract Polymeric composites and methods for preparing the composites are described herein. The polymeric composites can comprise a polymer, an inorganic filler, and a plurality of short length fibers. The polymer in the composites can include homopolymers and copolymers and can also include plastics, resins, elastomers, thermoplastics, thermosets, and hot melts. The inorganic filler can be fly ash. The short length fibers can have an average length of 650 μm or less. Methods for making the polymeric composites are also described. ## Claims ### Claim 1 A composite comprising: (a) a polymer; (b) from 25% to 90% by weight of an inorganic filler comprising fly ash; and (c) a plurality of short length fibers having an average length of 650 μm or less. ### Claim 2 (depends on 1) The composite of claim 1, wherein the short length fibers have an average aspect ratio of length to diameter of 5:1 to 250:1. ### Claim 3 A composite comprising: (a) a polymer; (b) from 25% to 90% by weight of an inorganic filler; and (c) a plurality of short length fibers having an average aspect ratio of length to diameter of 8:1 to 250:1, wherein the short length fibers are selected from the group consisting of mineral wool, cellulose, wood fiber, saw dust, wood shavings, cotton, lint, and combinations thereof. ### Claim 4 (depends on 1) The composite of claim 1, wherein the short length fibers are selected from the group consisting of mineral wool, cellulose, wood fiber, saw dust, wood shavings, cotton, lint, and combinations thereof. ### Claim 5 (depends on 3) The composite of claim 3, wherein the short length fibers have an average length of from 50 μm to 650 μm. ### Claim 6 (depends on 1) The composite of claim 1, wherein the short length fibers have an average length of from 100 μm to 250 μm. ### Claim 7 (depends on 1) The composite of claim 1, wherein the short length fibers have an average diameter of from 1 to 20 μm. ### Claim 8 (depends on 1) The composite of claim 1, wherein the short length fibers are present in an amount from 0.5% to 15% by weight, based on the total weight of the composite. ### Claim 9 (depends on 1) The composite of claim 1, wherein the inorganic filler is present in an amount from 50% to 80% by weight, based on the total weight of the composite. ### Claim 10 (depends on 1) The composite of claim 1, further comprising a plurality of glass fibers having a minimum length of 1 mm. ### Claim 11 (depends on 10) The composite of claim 10, wherein the glass fiber is present in an amount from 0.5% to 10% by weight, based on the total weight of the composite. ### Claim 12 (depends on 1) The composite of claim 1, wherein the polymer is selected from the group consisting of polyolefins, ethylene copolymers, polystyrenes, polyvinyl chlorides, polyvinylidene chlorides, polyvinyl acetates, polyacrylonitriles, polyamides, polyisobutylenes, polyacetals, chlorinated and fluorinated polymers, fluoroelastomers, fluorosilicones, polycarbonates, epoxies, phenolics, polyesters, acrylic polymers, acrylate polymers, polyurethanes, alkyds, silicones, styrene-butadiene copolymers, acrylonitrile-butadiene-styrene copolymers, nitrile rubbers, diallyl phthalates, melamines, polybutadienes, aramids, cellulosics, cellulose acetobutyrates, ionomers, parylenes, polyaryl ethers, polyaryl sulfones, polyarylene sulfides, polyethersulfones, polyallomers, polyimides, polyamideimides, polymethylpentenes, polyphenylene oxides, polyphenylene sulfides, polysulfones, polyetherketones, polyetherimides, polyaryleneketones, polychloroprenes, and blends thereof. ### Claim 13 (depends on 1) The composite of claim 1, wherein the polymer is 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. ### Claim 14 (depends on 1) The composite of claim 1, wherein the composite has a density of 20 lb/ft3 to 60 lb/ft3. ### Claim 15 (depends on 1) A building material comprising the composite of claim 1. ### Claim 16 A method of preparing a polyurethane composite, comprising: (a) mixing (1) 25% to 90% by weight of an inorganic filler based on the total weight of the composite; (2) at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates, and combinations thereof; (3) at least one polyol; (4) a plurality of short length fibers having a length of 650 μm or less; and (5) a catalyst; and (b) allowing the at least one isocyanate and the at least one polyol to react in the presence of the inorganic filler, and the plurality of short length fibers to form the polyurethane composite. ### Claim 17 (depends on 16) The method of claim 16, wherein the short length fibers are selected from the group consisting of mineral wool, cellulose, wood fiber, saw dust, wood shavings, cotton, lint, and combinations thereof. ### Claim 18 (depends on 3) The composite of claim 3, wherein the inorganic filler comprises fly ash. ### Claim 19 A composite comprising: (a) a polymer; (b) from 25% to 90% by weight of an inorganic filler; (c) a plurality of short length fibers having an average length of 650 μm or less; and (d) a plurality of glass fibers having a minimum length of 1 mm. ### Claim 20 (depends on 19) The composite of claim 19, wherein the glass fibers are present in an amount from 0.5% to 10% by weight, based on the total weight of the composite. ### Claim 21 A composite comprising: (a) a polymer; (b) from 25% to 90% by weight of an inorganic filler; (c) a plurality of short length fibers having an average length of 650 μm or less; and (d) a plurality of glass fibers, wherein the glass fibers are present in an amount from 0.5% to 10% by weight, based on the total weight of the composite. ### Claim 22 A composite comprising: (a) a polymer; (b) from 25% to 90% by weight of an inorganic filler; (c) a plurality of short length fibers having an average length of 650 μm or less; wherein the short length fibers are selected from the group consisting of mineral wool, cellulose, wood fiber, saw dust, wood shavings, cotton, lint, and combinations thereof. ### Claim 23 A method of preparing a polyurethane composite, comprising: (a) mixing (1) 25% to 90% by weight of an inorganic filler based on the total weight of the composite; (2) at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates, and combinations thereof; (3) at least one polyol; and (4) a plurality of short length fibers having a length of 650 μm or less, wherein the short length fibers are selected from the group consisting of mineral wool, cellulose, wood fiber, saw dust, wood shavings, cotton, lint, and combinations thereof; and (b) allowing the at least one isocyanate and the at least one polyol to react in the presence of the inorganic filler, and the plurality of short length fibers to form the polyurethane composite.