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 polymer matrix contains a polyurethane network formed by the reaction of a poly- or di-isocyanate and one or more saturated polyether or polyester polyols, and an optional polyisocyanurate network formed by the reaction of optionally added water and isocyanate. 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. The addition of water can also serve to provide a blowing agent to the reaction mixture, resulting in a foamed structure, if such is desired.

1 . A polymer composite material comprising:
 a polyurethane formed by reaction of a mixture comprising:
 a poly- or di-isocyanate; 
 a first polyol comprising a polyether polyol, the first polyol having a first molecular weight in the range of 400 to 481, the first polyol being more rigid relative to the second polyol; and 
 a second polyol comprising a polyether polyol or a polyester polyol, the second polyol having a second molecular weight which is greater than the first molecular weight and falling in the range of 500 to 3000 and being more flexible relative to the first polyol, wherein the second polyol is about 5 wt % to about 20 wt % of the total weight of the first and second polyols; and 
 wherein the polyurethane is less rigid than a second polyurethane that would be formed by the reaction of the first polyol and the poly- or di-isocyanate in the absence of the second polyol; and 
   an inorganic particulate material comprising one or more of fly ash, bottom ash, particulate glass and granite tailings dispersed in the polymer matrix, the inorganic particulate material being about 60 wt % to about 72 wt % of the total weight of the composite material.   
     
     
         2 . The polymer composite material of  claim 1 , wherein the material is foamed. 
     
     
         3 . The polymer composite material of  claim 1 , further comprising one or more inorganic fibers. 
     
     
         4 . The polymer composite material of  claim 1 , further comprising axially oriented fiber rovings disposed on, in, or beneath a surface of the composite. 
     
     
         5 . The polymer composite material of  claim 1 , wherein the inorganic particulate material is one or more of a fly ash, bottom ash, or particulate glass. 
     
     
         6 . The polymer composite material of  claim 1 , wherein the inorganic particulate material has a particle size distribution ranging from about 0.0625 in. to below about 325 mesh. 
     
     
         7 . The polymer composite material of  claim 1 , wherein the inorganic particulate material contains less than about 0.5 wt % water. 
     
     
         8 . The polymer composite material of  claim 1 , wherein the composite material is self-skinning. 
     
     
         9 . The polymer composite material of  claim 1 , having a density ranging from about 20 lb/ft 3  to about 60 lb/ft 3 . 
     
     
         10 . The polymer composite material of  claim 1 , wherein the polymer matrix composite material additionally comprises a polyisocyanurate formed by reaction of the monomeric or oligomeric poly- or di-isocyanate with water. 
     
     
         11 . The polymer composite material of  claim 1 , wherein the poly- or di-isocyanates comprises a methylene diphenyl diisocyanate (MDI). 
     
     
         12 . The polymer composite material of  claim 11 , wherein the MDI provides about 5% to about 10% excess NCO groups. 
     
     
         13 . The polymer composite material of  claim 1 , wherein the ratio of isocyanates to polyols, based on equivalent weights, is from about 0.5:1 to about 1.5:1. 
     
     
         14 . The polymer composite material of  claim 1 , wherein the second polyol is about 15 wt % of the total weight of the first and second polyols. 
     
     
         15 . The polymer composite material of  claim 1 , wherein the first polyol is present in an amount of about 6 to about 18 wt % and the second polyol is present in an amount of about 10 wt % or less, based on the total weight of the composite material. 
     
     
         16 . The polymer composite material of  claim 1 , wherein the inorganic particulate material is one or more of a fly ash and bottom ash. 
     
     
         17 . The polymer composite material of  claim 1 , having a flexural strength of at least 1319 psi. 
     
     
         18 . The polymer composite material of  claim 1 , wherein the composite material comprises extruded composite material. 
     
     
         19 . The polymer composite material of  claim 1 , wherein the composite material comprises extruded polyurethane and inorganic particulate material. 
     
     
         20 . A polymer composite material, comprising:
 a polyurethane formed by reaction of a mixture comprising:
 a poly- or di-isocyanate; 
 a first polyol comprising a polyether polyol, the first polyol having a first molecular weight; 
 a second polyol comprising a polyether polyol or a polyester polyol, the second polyol having a second molecular weight greater than the first molecular weight, wherein the second molecular weigh is in the range of 500 to 3000, wherein the second polyol is about 5 wt % to about 20 wt % of the total weight of the first and second polyols; and 
 wherein the polyurethane is less rigid than a second polyurethane that would be formed by the reaction of the first polyol and the one or more monomeric or oligomeric poly- or di-isocyanates in the absence of the second polyol; and 
 an inorganic particulate material, the inorganic particulate material being about 60 to about 74 wt % of the total weight of the composite material.