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 highly filled molded composite material comprising:
 mixing in a multi-zone extruder the ingredients of the material by adding the ingredients of the highly filled composite material to the various zones of the multi-zone extruder without adding heat to the mixture, wherein the composite mixture comprises:   a monomeric or oligomeric poly or di-isocyanate having a viscosity in the range of about 25 cp to about 200 cP at 25° C.;   a first polyol having a viscosity in the range of about 480 cP to about 840 cP at 25° C.;   a second polyol having a viscosity in the range of about 480 cP to about 840 cP at 25° C.;   a foaming agent;   an inorganic particulate material comprising about 60 wt % to about 85 wt % of the composite mixture, wherein the particulate material provides filler material which adds strength and reinforcement to the molded material and is added to the mixture prior to forming; and   a catalyst;   extruding or spraying the highly filled mixture by expulsion of the mixture through a die onto or into a forming system, the forming system comprising:   at least a first and a second opposed mold belt spaced apart a distance, each having an inner surface and an outer surface;   at least a first and a second opposed endless belt spaced apart a distance, each having an inner surface and an outer surface, wherein the inner surface of the first belt is contactable with the outer surface of the first mold belt to move with and support the first mold belt during molding, and wherein the inner surface of the second belt is contactable with the outer surface of the second mold belt to travel with and support the second mold belt during molding; and   a mold cavity defined at least in part by the inner surfaces of the at least a first and a second opposed mold belt;   supporting the first and second opposed endless belts with a pair of platens, each platen contacting and supporting the outer surface of the endless belts along substantially the entire length of the mold cavity;   transferring the mixture along the mold cavity by longitudinal movement of the opposed mold belts;   exerting substantially equal and continuous pressure on the mixture through the opposed mold belts to mold the mixture; and   removing the molded material from the mold cavity after sufficient time has passed for the mixture to cure or harden into the molded material, wherein the molded material comprises a density of at least about 30 lb/ft 3 .   
     
     
         2 . The method of  claim 1 , further comprising providing shape, surface features, or both to the molded material. 
     
     
         3 . The method of  claim 1 , further comprising embossing or impressing a pattern on the mixture in the forming system. 
     
     
         4 . The method of  claim 3 , wherein the pattern comprises a simulated wood grain. 
     
     
         5 . The method of  claim 1 , further comprising introducing fiber rovings on, in, or beneath the surface of the mixture. 
     
     
         6 . The method of  claim 5 , wherein the fiber rovings are axially oriented fiber rovings. 
     
     
         7 . The method of  claim 1 , wherein the inorganic particulate material is fly ash, bottom ash, or particulate glass. 
     
     
         8 . The method of  claim 1 , wherein the inorganic particulate material has a particle size distribution ranging from about 0.0625 in. to below about 0.0017 in. 
     
     
         9 . The method of  claim 1 , wherein the inorganic particulate material contains less than about 0.5 wt % water. 
     
     
         10 . The method of  claim 1 , wherein the polyol is mixed with the catalyst prior to being mixed with the isocyanate. 
     
     
         11 . The method of  claim 1 , wherein the polyol and the catalyst are mixed prior to being introduced to the extruder. 
     
     
         12 . The method of  claim 1 , wherein the polyol, the catalyst, and the inorganic particulate material are mixed prior to being mixed with the isocyanate. 
     
     
         13 . The method of  claim 1 , wherein the molded material is a building material. 
     
     
         14 . The method of  claim 13 , wherein the building material is lumber. 
     
     
         15 . The method of  claim 13 , wherein the building material is roofing. 
     
     
         16 . The method of  claim 13 , wherein the building material is siding. 
     
     
         17 . The method of  claim 1 , wherein the molded material comprises a relatively porous material and a relatively non-porous toughening layer disposed on and adhered to the porous material. 
     
     
         18 . The method of  claim 1 , further comprising allowing an exothermic reaction to proceed without forced cooling except to control a runaway exotherm. 
     
     
         19 . The method of  claim 1 , wherein the outer surface of one of the at least two first or second opposed endless belts is supported by a rigid supporting surface. 
     
     
         20 . The method of  claim 19 , wherein the at least two first opposed endless belts are upper and lower-endless belts. 
     
     
         21 . The method of  claim 19 , wherein the rigid supporting surface comprises a slider bed or platen. 
     
     
         22 . The method of  claim 1 , wherein the first opposed endless belts or the second opposed endless belts, or both, are adjustable such that the mold cavity can be varied. 
     
     
         23 . The method of  claim 1 , wherein the mold cavity is at least partly defined by the inner surfaces of two opposed profiled mold belts disposed inside the at least two first opposed endless belts, and having outer surfaces in contact with the inner surfaces of the at least two second opposed endless belts. 
     
     
         24 . The method of  claim 23 , wherein the profile mold belts form the mixture into a shape having a cross-section at least approximately corresponding to that of the mold cavity. 
     
     
         25 . The method of  claim 23 , wherein the profile mold belts impart a surface pattern to the moldable material. 
     
     
         26 . A method of continuously forming a molded material comprising:
 adding the ingredients of a highly filled composite mixture, to a multi-zone extruder without adding heat, wherein the composite mixture comprises:   a monomeric or oligomeric poly or di-isocyanate;   a first polyol having a first molecular weight having a viscosity in the range of about 480 cP to about 840 cP at 25° C.;   a second polyol having a second molecular weight lower than the first molecular weight having a viscosity in the range of about 480 cP to about 840 cP at 25° C.;   a foaming agent;   inorganic particulate material comprising about 60 wt % to about 85 wt % of the composite mixture, the particulate material comprising a reinforcing filler; and   a catalyst;   adding the particulate material to the mixture prior to forming;   depositing the mixture through an aperture to extrude or spray the material from the container to a forming system, the forming system comprising:   at least two first opposed endless belts spaced apart a first distance, each having an inner surface and an outer surface;   a mold cavity defined at least in part by a gap separating the inner surfaces of the at least two first and second opposed endless belts; and   a drive mechanism for imparting motion to the opposed endless belts;   precisely maintaining the gap in the mold cavity substantially continuously along the length of the mold cavity;   supporting the first and second opposed endless belts with a rigid substantially continuous supporting surface along substantially the entire length of the mold cavity to maintain substantially equal pressure on the moldable material; and   transferring the moldable material along the mold cavity by longitudinal movement of the opposed endless belts;   removing the molded material from the mold cavity after sufficient time has passed for the mixture to cure or harden into the molded material, wherein the molded material comprises a density of at least about 30 lb/ft 3 .   
     
     
         27 . The method of  claim 26 , wherein the first and second polyol are mixed prior to be introduced to the container. 
     
     
         28 . The method of  claim 26 , wherein the first and second polyol are mixed with the catalyst prior to being mixed with the isocyanate. 
     
     
         29 . The method of  claim 26 , wherein at least one of the first or second polyols is mixed with the catalyst prior to being introduced to the container. 
     
     
         30 . The method of  claim 26 , wherein the first polyol, the second polyol, the catalyst, and the inorganic particulate material are mixed prior to being mixed with the isocyanate. 
     
     
         31 . The method of  claim 1 , wherein the composition mixture has a density in the range of about 20 lb/ft 3  to about 90 lb/ft 3 . 
     
     
         32 . The method of  claim 1 , wherein the poly- or di-isocyanate comprises methylene diphenyl diisocyanate.