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Kafe 바로가기국가/구분 | United States(US) Patent 등록 |
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국제특허분류(IPC7판) |
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출원번호 | US-0855368 (2010-08-12) |
등록번호 | US-9481759 (2016-11-01) |
발명자 / 주소 |
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출원인 / 주소 |
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대리인 / 주소 |
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인용정보 | 피인용 횟수 : 2 인용 특허 : 353 |
Composite materials and methods for their preparation are described herein. The composite materials include a polyurethane made from the reaction of at least one isocyanate and at least one polyol, and coal ash (e.g., fly ash). The composite materials are highly reactive systems such as through the
Composite materials and methods for their preparation are described herein. The composite materials include a polyurethane made from the reaction of at least one isocyanate and at least one polyol, and coal ash (e.g., fly ash). The composite materials are highly reactive systems such as through the use of highly reactive polyols, highly reactive isocyanates, or both. The coal ash is present in amounts from about 40% to about 90% by weight of the composite material. Also described is a method of preparing a composite material, including mixing at least one isocyanate, at least one polyol, coal ash, and a catalyst.
1. A method of preparing a composite material, comprising: mixing (1) at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates and mixtures thereof,(2) at least one polyol wherein the at least one polyol includes 70% or more of one or more first polyols, wherein e
1. A method of preparing a composite material, comprising: mixing (1) at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates and mixtures thereof,(2) at least one polyol wherein the at least one polyol includes 70% or more of one or more first polyols, wherein each first polyol comprises a polyester or polyether polyol comprising 75% or more primary hydroxyl groups based on the total number of hydroxyl groups in the polyester or polyether polyol, wherein at least one of the one or more first polyols comprises an aromatic polyol,(3) coal ash, and(4) a catalystto produce a mixture; andallowing the at least one isocyanate and the at least one polyol in the mixture to react in the presence of the coal ash and catalyst to form the composite material, wherein the mixture exhibits a cream time of at least 15 seconds and a wet tack free time of 125 seconds or less, as measured by ASTM 7487-08,wherein the amount of coal ash added in the mixing step comprises from about 40% to about 90% by weight of the composite material. 2. The method of claim 1, wherein the aromatic polyol comprises an aromatic polyester polyol. 3. The method of claim 1, wherein the mixture exhibits a wet tack free time of 90 seconds or less, as measured by ASTM 7487-08. 4. The method of claim 1, wherein the composite material has a density of 20 lb/ft3 to 60 lb/ft3. 5. The method of claim 1, wherein the at least one isocyanate, the at least one polyol, the coal ash, and the catalyst are mixed in an extruder. 6. The method of claim 1, wherein the mixture is allowed to react in a continuous forming system. 7. The method of claim 1, wherein the at least one polyol includes from 70% to 85% of or more of one or more first polyols. 8. The method of claim 1, wherein the at least one polyol includes 75% or more of one or more first polyols. 9. The method of claim 8, wherein the at least one polyol includes greater than 90% of or more of one or more first polyols. 10. The method of claim 1, wherein one or more of the first polyols have a primary hydroxyl number, defined as the hydroxyl number multiplied by the percentage of primary hydroxyl groups based on the total number of hydroxyl groups in the polyol, of greater than 250 mg KOH/g. 11. The method of claim 1, wherein the one or more first polyols each have a primary hydroxyl number, defined as the hydroxyl number multiplied by the percentage of primary hydroxyl groups based on the total number of hydroxyl groups in the polyol, of greater than 250 mg KOH/g. 12. The method of claim 1, wherein one or more of the first polyols has a primary hydroxyl number of greater than 280 mg KOH/g. 13. The method of claim 12, wherein one or more of the first polyols has a hydroxyl number of greater than 300 mg KOH/g. 14. The method of claim 13, wherein one or more of the first polyols has a hydroxyl number of greater than 350 mg KOH/g. 15. The method of claim 1, wherein each first polyol when replacing the polyols used in the standard polyurethane formulation of the Brookfield Viscosity Test produces a Brookfield viscosity of over 50,000 mPa·s in less than 225 seconds. 16. The method of claim 15, wherein each first polyol when replacing the polyols used in the standard polyurethane formulation of the Brookfield Viscosity Test produces a Brookfield viscosity of over 50,000 mPa·s in less than 200 seconds. 17. The method of claim 16, wherein each first polyol when replacing the polyols used in the standard polyurethane formulation of the Brookfield Viscosity Test produces a Brookfield viscosity of over 50,000 mPa·s in less than 175 seconds. 18. The method of claim 1, wherein the at least one isocyanate, the at least one polyol, at least one catalyst, the coal ash, and any other components used to form the polyurethane when mixed together and used as the polyurethane in the Brookfield Viscosity Test produces a Brookfield viscosity of over 50,000 mPa·s in less than 225 seconds. 19. The method of claim 1, wherein the at least one isocyanate, at least one polyol, at least one catalyst, and any other non-filler additives when mixed together in the amounts used in the polyurethane without fly ash and any other fillers produce a surface temperature rise in a cup test of at least 120° F. 20. The method of claim 1, wherein the composite material is foamed. 21. The method of claim 1, wherein the coal ash is fly ash. 22. The method of claim 1, wherein the coal ash comprises from about 60% to about 85% by weight of the mixture. 23. The method of claim 1, further comprising mixing a crosslinker with the at least one isocyanate, the at least one polyol, the coal ash, and the catalyst. 24. The method of claim 23, wherein the crosslinker includes glycerin. 25. The method of claim 1, further comprising mixing fibers with the at least one isocyanate, the at least one polyol, the coal ash, and the catalyst. 26. The method of claim 1, wherein the at least one polyol further includes one or more second polyols, wherein each second polyol comprises 50% or less primary hydroxyl groups based on the total number of hydroxyl groups in the second polyol. 27. The method of claim 26, wherein one or more of the second polyols have a primary hydroxyl number, defined as the hydroxyl number multiplied by the percentage of primary hydroxyl groups based on the total number of hydroxyl groups in the polyol, of less than 200 mg KOH/g. 28. The method of claim 27, wherein one or more of the second polyols have a primary hydroxyl number, defined as the hydroxyl number multiplied by the percentage of primary hydroxyl groups based on the total number of hydroxyl groups in the polyol, of less than 150 mg KOH/g. 29. The method of claim 1, further comprising mixing a silicone surfactant with the at least one isocyanate, the at least one polyol, the coal ash, and the catalyst. 30. The method of claim 1, wherein the catalyst comprises an amine-containing catalyst. 31. The method of claim 1, wherein the composite material comprises a building material. 32. The method of claim 31, wherein the building material is selected from the group consisting of siding material, carpet backing, building panels, and roofing material.
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