Materials, Methods and Compositions for a Composite Building Material

Abstract

A solid composite material is suitable for construction and industrial uses. The solid composite material consists of at least an effective amount of assorted agricultural remnants bound in an effective volume of cured resin.

1 . A solid composite material suitable for construction and industrial uses, the material comprising an effective amount of assorted agricultural remnants bound in an effective volume of cured resin. 
   
   
       2 . The composite material of  claim 1 , wherein the agricultural remnants comprise rice hulls. 
   
   
       3 . The composite material of  claim 1 , wherein the agricultural remnants comprise pecan shell fines. 
   
   
       4 . The composite material of  claim 1 , wherein the agricultural remnants comprise cotton seed husk fines. 
   
   
       5 . The composite material of  claim 1 , wherein the agricultural remnants comprise peanut shell fines. 
   
   
       6 . The composite material of  claim 1 , wherein the resin comprises a polyester resin. 
   
   
       7 . The composite material of  claim 1 , wherein the agricultural remnants comprise cotton seed husk fines, rice hulls, and pecan shell fines and the resin comprises a polyester resin. 
   
   
       8 . The composite material of  claim 7 , wherein peanut shell fines replace the cotton seed husk fines. 
   
   
       9 . A method for making an object from a composite material, the method comprising the steps of:
 preparing a dry mix containing effective amounts of
 cottonseed husks fines 
 pecan shells fines 
 rice Hulls 
 garamite 
 Non-Chloride Accelerator (NCA) 
 calcium carbonate and 
 antimony trioxide (ATH); 
 LT 
   blending the dry mix into an effective amount of a liquid resin;   adding an effective amount of a catalyst that catalyzes at approximately room temperature to form a fluid composite mixture;   pouring the fluid composite mixture in to a mold;   curing the fluid composite mixture at approximately room temperature to form a solid cured composite material; and   removing the cured composite material from the mold.   
   
   
       10 . The method of  claim 9 , wherein peanut shell fines replace the cotton seed husk fines in the dry mix. 
   
   
       11 . The method of  claim 9 , comprising effective amounts of one or more of the components selected from the following: plastic; recycled plastic; peanuts shells; soy beans; cotton husks; fiber glass matting; E-glass; Q-cells; minerals, and pigments and combinations thereof. 
   
   
       12 . The method of  claim 9 , wherein the plastic or recycled plastic comprises one or more plastic selected from the following: Polyetheretherketone (PEEK), poly(ethylene terephthalate) (PETE or PET), and Polytetrafluoroethylene (PTFE or Teflon®) and combinations thereof. 
   
   
       13 . The method of  claim 9 , wherein the minerals comprises one or more mineral selected from the following: talc, cobalt, titanium dioxide, graphite, hydrocal clay, and wollastonite and combinations thereof. 
   
   
       14 . The method of  claim 9 , wherein the catalyst comprises MEKP. 
   
   
       15 . The method of  claim 9 , wherein the dry mix further comprises an effective amount of wheat.