Reinforced board

Abstract

A composite board comprises feather barb reinforced resin. The resin is typically polyurethane, which may be foamed or unfoamed. One or both surfaces can be reinforced by embedded fiberglass mats. The products are hard, heat and weather resistant, flexible, stronger than plywood, light and screw retentive. The board is be molded from a polyurethane precursors-feather barb slurry with or without blowing agents and with or without one or two polyurethane saturated fiberglass mats embedded in the surface. Alternatively the board can be molded continuously using conveyor belts. The polyurethane is the same throughout in the fiberglass reinforced surface and the feather barb reinforced core, whether foamed or not.

1 . Reinforced board comprising cured resin and feather barbs.  
     
     
         2 . Board of  claim 1  wherein said resin is polyurethane.  
     
     
         3 . Board of  claim 2  wherein said board comprises a fiberglass mat embedded in polyurethane resin on at least one surface.  
     
     
         4 . Board of  claim 2 , wherein said board comprises fiberglass mats embedded in polyurethane resin on both surfaces.  
     
     
         5 . Board of  claim 2  wherein said resin is foamed polyurethane resin.  
     
     
         6 . Board of  claim 5  wherein said board comprises a fiberglass mat embedded in unfoamed polyurethane resin on at least one surface.  
     
     
         7 . Board of  claim 5 , wherein said board comprises fiberglass mats embedded in unfoamed polyurethane resin on both surfaces.  
     
     
         8 . Board of  claim 2  wherein said cured polyurethane resin comprises feather barbs from about 5 to about 80% by volume, said barbs being at least about 80 microns long.  
     
     
         9 . Board of  claim 8  comprising fiberglass mats weighing at least about ½ ounce/square foot and embedded in unfoamed polyurethane resin from about 1/32 to about ¼ inch thick on both surfaces.  
     
     
         10 . Board of  claim 9 , wherein said cured polyurethane comprising said feather barbs is solid and from about ⅛ to about 1 inch thick.  
     
     
         11 . Board of  claim 9 , wherein said cured polyurethane comprising said feather barbs is foamed, and has a density of about 1½ to about 62½ lbs/cubic foot, and has a thickness of from about ¼ to about 6 inches.  
     
     
         12 . Board of  claim 11 , wherein said foamed polyurethane has a density of from about 5 to about 10 lbs/cubic foot.  
     
     
         13 . Method of manufacture of a board comprising the steps of forming a resin components-feather barb slurry and; 
 placing said slurry in a mold and;    closing said mold and;    curing said resin components.    
     
     
         14 . Method of  claim 13 , wherein said resin components are polyurethane precursors.  
     
     
         15 . Method of  claim 14 , comprising the steps of placing a fiberglass mat in a mold and; 
 saturating said fiberglass mat with polyurethane precursors and;    forming a polyurethane precursors-feather barb slurry and;    placing said slurry in said mold on said fiberglass mat and;    closing said mold and;    curing said polyurethane precursors.    
     
     
         16 . Method of  claim 15 , comprising the steps of placing a fiberglass mat in a mold and; 
 saturating said fiberglass mat with polyurethane precursors and;    forming a polyurethane precursors-feather barb-blowing agent slurry and;    placing said slurry in said mold on said fiberglass mat and;    closing said mold and;    curing and foaming said polyurethane precursors.    
     
     
         17 . Method of  claim 15 , comprising the steps of placing a fiberglass mat in a mold and; 
 saturating said fiberglass mat with polyurethane precursors and;    forming a polyurethane precursors-feather barb slurry and;    placing said slurry in said mold on said fiberglass mat and;    placing a second fiberglass mat on said slurry and;    saturating said second fiberglass mat with polyurethane precursors and;    closing said mold and;    curing said polyurethane precursors.    
     
     
         18 . Method of  claim 17 , comprising the steps of placing a fiberglass mat in a mold and; 
 saturating said fiberglass mat with polyurethane precursors and;    forming a polyurethane precursors-feather barb-blowing agent slurry and;    placing said slurry in said mold on said fiberglass mat and;    placing a second fiberglass mat on said slurry and;    saturating said second fiberglass mat with polyurethane precursors and;    closing said mold and;    curing and foaming said polyurethane precursors.    
     
     
         19 . Method of manufacture of a board comprising the steps of placing a first fiberglass mat on a first lower conveyor belt and; 
 spraying polyurethane precursors on said first fiberglass mat to saturate said first fiberglass mat and;    forming a polyurethane precursor-feather barb slurry and;    spraying said slurry on said first fiberglass mat and;    placing a second fiberglass mat on said slurry and;    spraying polyurethane precursors on said second fiberglass mat to saturate said second fiberglass mat and;    contacting said second fiberglass mat with a second upper conveyor belt and;    curing said polyurethane precursors between said conveyor belts.    
     
     
         20 . Method of  claim 19  comprising the steps of placing a first fiberglass mat on a first lower conveyor belt and; 
 spraying polyurethane precursors on said first fiberglass mat to saturate said first fiberglass mat and;    forming a polyurethane precursor-feather barb-blowing agent slurry and;    spraying said slurry on said first fiberglass mat and;    placing a second fiberglass mat on said slurry and;    spraying polyurethane precursors on said second fiberglass mat to saturate said second fiberglass mat and;    contacting said second fiberglass mat with a second upper conveyor belt and;    curing and foaming said polyurethane precursors between said conveyor belts.