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Kafe 바로가기국가/구분 | United States(US) Patent 등록 |
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국제특허분류(IPC7판) |
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출원번호 | US-0893838 (2015-06-05) |
등록번호 | US-10030126 (2018-07-24) |
국제출원번호 | PCT/US2015/034509 (2015-06-05) |
국제공개번호 | WO2016/195717 (2016-12-08) |
발명자 / 주소 |
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출원인 / 주소 |
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대리인 / 주소 |
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인용정보 | 피인용 횟수 : 0 인용 특허 : 366 |
Polyurethane composites and methods of preparation are described herein. The polyurethane composites can comprise (a) a polyurethane formed by the reaction of (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and (ii) one or more
Polyurethane composites and methods of preparation are described herein. The polyurethane composites can comprise (a) a polyurethane formed by the reaction of (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and (ii) one or more polyols, (b) a particulate filler having a bulk density of 1 g/cm3 or greater, (c) optionally a fiber material, and (d) a lightweight filler having a bulk density from 0.01 g/cm3 to less than 1 g/cm3. In some examples, the lightweight filler can be selected from expanded perlite, expanded clay, foamed glass, and combinations thereof. Articles such as building materials comprising the polyurethane composites are also disclosed.
1. A composite comprising: (a) a polyurethane formed by the reaction of (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and(ii) one or more polyols;(b) from 35% to 75% by weight, based on the total weight of the composite, of a
1. A composite comprising: (a) a polyurethane formed by the reaction of (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and(ii) one or more polyols;(b) from 35% to 75% by weight, based on the total weight of the composite, of a particulate filler having a bulk density of 1 g/cm3 or greater; and(c) from 4% to 20% by weight, based on the total weight of the composite, of a lightweight filler having a bulk density of from 0.01 g/cm3 to less than 1 g/cm3, wherein the lightweight filler is chosen from expanded volcanic ash, expanded perlite, pumicite, expanded vermiculite, expanded clay, foamed glass, soybean hulls, rice hulls, seeds, seed husks, chopped straw, expanded polystyrene beads, scoria, and combinations thereof;wherein the composite has a density of from 2 lb/ft3 to 37 lb/ft3; andwherein the composite has flexural strength of 1000 psi or greater as measured by ASTM C1185-08 (2012). 2. The composite of claim 1, wherein the lightweight filler has a bulk density of from 0.05 g/cm3 to 0.6 g/cm3. 3. The composite of claim 1, wherein the lightweight filler includes expanded perlite, expanded clay, foamed glass, or a combination thereof. 4. The composite of claim 1, wherein the lightweight filler has an average particle size diameter of from 0.01 micron to 2 mm. 5. The composite of claim 1, wherein the particulate filler comprises fly ash. 6. The composite of claim 5, wherein the fly ash is present in an amount of from 50% to 75% by weight, based on the total weight of the composite. 7. The composite of claim 1, wherein the weight ratio of the lightweight filler to the particulate filler is from 1:10 to 1:1. 8. A building material comprising the composite of claim 1. 9. The composite of claim 1, where the density is from 10 lb/ft3 to 35 lb/ft3. 10. A method of making a polyurethane composite comprising: (a) mixing (1) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof,(2) one or more polyols,(3) 35% to 75% by weight, based on the total weight of the mixture, of a particulate filler having a bulk density of 1 g/cm3 or greater, and(4) 4% to 20% by weight, based on the total weight of the mixture, of a lightweight filler having a bulk density of from 0.01 g/cm3 to less than 1 g/cm3 to form a mixture, wherein the lightweight filler is chosen from expanded volcanic ash, expanded perlite, pumicite, expanded vermiculite, expanded clay, foamed glass, soybean hulls, rice hulls, seeds, seed husks, chopped straw, expanded polystyrene beads, scoria, and combinations thereof;(b) allowing the one or more isocyanates and the one or more polyols to react in the presence of the particulate filler and the lightweight filler to form the polyurethane composite having (1) a density of from 2 lb/ft3 to 37 lb/ft3, and(2) flexural strength of 1000 psi or greater as measured by ASTM C1185-08 (2012), andwherein the mixture is free of a blowing or foaming agent other than water. 11. The method of claim 10, wherein the mixture further comprises a catalyst. 12. The method of claim 10, wherein the mixture contains less than about 0.5 wt % water. 13. The composite of claim 1, wherein the polyurethane is present in an amount of from 15% to 40%, by weight, based on the total weight of the composite. 14. The composite of claim 13, further comprising from 4% to 8% by weight, based on the total weight of the composite, of a fiber material. 15. The method of claim 10, wherein the mixture is processed at a temperature of from 200° F. to 500° F. 16. The method of claim 10, wherein the mixture does not comprise a catalyst. 17. The composite of claim 1, wherein the composite has a handleability of 9 in-lb/in or greater as measured by ASTM C1185-08 (2012). 18. The method of claim 10, wherein the polyurethane composite has a handleability of 9 in-lb/in or greater as measured by ASTM C1185-08 (2012). 19. The composite of claim 3, wherein the particulate filler includes fly ash. 20. The method of claim 10, wherein the particulate filler includes fly ash, and wherein the lightweight filler includes expanded perlite, expanded clay, foamed glass, or a combination thereof.
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