Filled polymer composite and synthetic building material compositions

Abstract

The invention relates to composite compositions having a matrix of polymer networks and dispersed phases of particulate or fibrous materials. The matrix is filled with a particulate phase, which can be selected from one or more of a variety of components, such as fly ash particles, axially oriented fibers, fabrics, chopped random fibers, mineral fibers, ground waste glass, granite dust, or other solid waste materials. A system for providing shape and/or surface features to a moldable material includes, in an exemplary embodiment, at least two first opposed flat endless belts spaced apart a first distance, with each having an inner surface and an outer surface.

1 . A method of continuously forming a molded material comprising: 
 forming a composite mixture in an extruder, wherein the composite mixture comprises: 
 a monomeric or oligomeric poly or di-isocyanate;  
 a polyol;  
 about 45 to about 85 weight percent of inorganic particulate material; and  
 a catalyst;  
   extruding the mixture through a die; and    molding the mixture into a shaped article.    
   
   
       2 . The method of  claim 1 , wherein the shaped article is a building material.  
   
   
       3 . The method of  claim 2 , wherein the building material is lumber.  
   
   
       4 . The method of  claim 2 , wherein the building material is roofing.  
   
   
       5 . The method of  claim 2 , wherein the building material is siding.  
   
   
       6 . The method of  claim 1 , wherein the molded material is a foamed material.  
   
   
       7 . The method of  claim 1 , further comprising allowing an exothermic reaction to proceed in the extruded without forced cooling except to control a runaway exotherm.  
   
   
       8 . A polymer matrix composite material, comprising: 
 a polyurethane formed by reaction of a reaction mixture, comprising: 
 one or more monomeric or oligomeric poly- or di-isocyanates;  
 a polyol selected from the group consisting of polyether polyols and polyester polyols,  
   about 45 to about 85 wt % of an inorganic particulate material, based on the total weight of the composite material    wherein the inorganic particulate material contains less than about 0.5 wt % of water.