Composite materials

Abstract

A composite board having a top surface, a core, and a bottom surface includes a polymeric material and a plurality of particles contacting the polymeric material to form a mixture. The weight percentage of the particles is greater than the weight percentage of the matrix material in the composite board. The volume of the plurality of particles range from 25% by volume to 88% by volume of the composite board. The composite board has a density in the range from 0.38 g/cm 3 to 2.2 g/cm 3 . The top surface, the core, and the bottom surface are substantially comprised of the mixture.

1 . A composite board having a top surface, a core, and a bottom surface comprising:
 a polymeric material; and   a plurality of particles contacting the polymeric material to form a mixture, the weight percentage of the particles being greater than the weight percentage of the matrix material in the composite board and the volume of the plurality of particles range from 25% by volume to 88% by volume of the composite board, the composite board having a density in the range from 0.38 g/cm 3  to 2.2 g/cm 3 ,   wherein the top surface, the core, and the bottom surface are substantially comprised of the mixture.   
   
   
       2 . The composite board of  claim 1 , wherein the composite board has a density in the range a density in the range of 0.38 g/cm 3  to less than 1.0 g/cm 3 . 
   
   
       3 . The composite board of  claim 1 , wherein the particles comprise a range from 15% by weight to 48% by weight of the composite board. 
   
   
       4 . The composite board of  claim 1 , wherein the particles are distributed substantially randomly within the polymeric material of the mixture. 
   
   
       5 . The composite board of  claim 1 , wherein the plurality of particles comprises a first portion having a first weight and being substantially spheroidal shaped. 
   
   
       6 . The composite board of  claim 5 , wherein the plurality of particles comprises a second portion having a second weight and being a shape other than spheroidal. 
   
   
       7 . The composite board of  claim 6 , wherein the second weight exceeds that of the first weight. 
   
   
       8 . The composite board of  claim 5 , wherein the particles comprise microspheres having a diameter ranging from 15 microns to 120 microns. 
   
   
       9 . The composite board of  claim 8 , wherein the microspheres comprise cenospheres. 
   
   
       10 . The composite board of  claim 1 , wherein the plurality of particles includes a fiber. 
   
   
       11 . The composite board of  claim 10 , wherein the fiber includes a glass fiber. 
   
   
       12 . The composite board of  claim 11 , wherein the glass fiber includes a chopped glass fiber. 
   
   
       13 . The composite board of  claim 11 , wherein the composite board is shaped in a substantially rectangular cross-section to form an exterior wall product. 
   
   
       14 . A composite board comprising:
 a thermoset polymeric material comprising a core having an interior and a surface, the thermoset polymeric material comprising a range of 12% by weight to 75% by weight of the composite board; and   a plurality of particles contacting the thermoset polymeric material to form a mixture, the particles ranging from 25% by volume to 88% by volume of the composite board, the composite board having a density in the range from 0.38 g/cm 3  to 1.0 g/cm 3 ;   wherein the interior and the surface are substantially comprised of the mixture.   
   
   
       15 . The composite board of  claim 14 , further comprises a reinforcing fiber, a substantial portion of the reinforcing fiber being encapsulated by the mixture and at least a substantial portion of the reinforcing fiber being disposed in the interior of the core. 
   
   
       16 . The composite board of  claim 15 , wherein the reinforcing fiber includes a glass fiber infused with a portion of the thermoset polymeric material. 
   
   
       17 . The composite board of  claim 15 , wherein at least a portion of the reinforcing fiber is selected from the group consisting of a carbon fiber, a carbon fiber mat, an aramid fiber, a woven fiber, a non-woven fiber, a cloth fiber, an open-pore fiber, a closed pore fiber, and a wire braid, wherein the thermoset polymer comprises reactive resin materials when uncured, the fibers being infused with a portion of the reactive resin materials. 
   
   
       18 . The composite board of  claim 15 , wherein the particles include at least a portion of particles ranging in diameter from 27 microns to 37 microns. 
   
   
       19 . The composite board of  claim 15 , wherein the thermoset polymeric material includes a polyurethane. 
   
   
       20 . The composite board of  claim 14 , wherein the thermoset polymeric material includes a polyurethane. 
   
   
       21 . An uncured composite material having a core, a top surface, and a bottom surface, the uncured composite comprising:
 an uncured composite composition including a reactive resin matrix material; and   a plurality of particles contacting the reactive resin matrix material to form a first mixture, the plurality of particles ranging in weight from 15% by weight to 48% by weight and range in volume from 40% by volume to 85% by volume of the uncured composite material;   wherein the core, the top surface, and the bottom surface are comprised of the first mixture.   
   
   
       22 . The composite material of  claim 21 , wherein a portion of the particles comprise microspheres having a volume percentage in the uncured composite greater than the volume percentage of the reactive resin matrix material in the uncured composite. 
   
   
       23 . The composite material of  claim 21 , wherein the particles include an entrapped air component, the particles and the entrapped air component range from 40% by volume to 85% by volume of the uncured composite material. 
   
   
       24 . The composite material of  claim 21 , wherein the particles comprise a portion of particles having a shape other than spheroidal. 
   
   
       25 . The composite material of  claim 21 , wherein the matrix material is selected from a group consisting of a powdered resin, plastic pellets, and a curable resin. 
   
   
       26 . The composite material of  claim 25 , further comprising a second mixture including the first mixture and a fiber wherein the second mixture comprises a fluid composite. 
   
   
       27 . The composite material of  claim 21 , wherein the reactive resin matrix material includes reactants capable of forming polyurethanes. 
   
   
       28 . A method for making a shapeable curable composite composition for use in a continuous manufacturing process, the method comprising:
 blending a curable matrix material;   starting curing of the curable matrix material;   mixing a fiber into contact with the matrix material during curing of the matrix material to form a first mixture;   mixing a plurality of particles into contact with the first mixture during curing of the matrix material to form a second mixture, the particles comprising a portion of microspheres and a portion of particles having a shape other than spheroidal;   controlling a ratio of weight of the microspheres to a weight of the particles having a shape other than spheroidal in order to maintain the second mixture in a flowable condition in the continuous manufacturing process; and   compacting the second mixture prior to curing completely the matrix material in order to form a shapeable curable composite composition.   
   
   
       29 . The method of  claim 28 , wherein the continuous manufacturing process is a sheeting process. 
   
   
       30 . A composite board, comprising:
 a shape formed from a shapeable curable composite composition made by the method of  claim 28 , the method further comprising substantially completing the curing of the matrix material.   
   
   
       31 . The composite board of  claim 30 , wherein the shape is substantially rectangular in cross-section. 
   
   
       32 . The method of  claim 28 , wherein the microspheres include cenospheres, wherein the weight of the portion of microspheres exceeds the weight of the portion of the particles having a shape other than substantially spheroidal.