CN1926282A - 填充型聚合物复合物和合成建筑材料组合物 - Google Patents

填充型聚合物复合物和合成建筑材料组合物 Download PDF

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CN1926282A
CN1926282A CNA2005800030186A CN200580003018A CN1926282A CN 1926282 A CN1926282 A CN 1926282A CN A2005800030186 A CNA2005800030186 A CN A2005800030186A CN 200580003018 A CN200580003018 A CN 200580003018A CN 1926282 A CN1926282 A CN 1926282A
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Abstract

本发明涉及具有聚合物网络基质和颗粒状分散相或纤维状材料的复合物组合物。聚合物基质含有由聚异氰酸酯或二异氰酸酯与一种或一种以上饱和聚醚或聚酯多元醇反应所形成的聚氨基甲酸酯网络，和由视情况所添加的水和异氰酸酯反应所形成的可选聚异氰脲酸酯网络。所述基质填充有颗粒相，其可选自一种或一种以上的各种组份，例如飞灰粒子、轴向纤维、织物、短切无序纤维、矿物纤维、研磨废料玻璃、花岗岩粉尘或其他固体废料。如果需要，加入水也可用于为反应混合物提供发泡剂，导致起泡结构。

Description

填充型聚合物复合物和合成建筑材料组合物
技术领域
本发明涉及具有聚合物网络基质和颗粒状分散相和/或纤维状材料的复合物组合物，其具有极好的机械特性，以使其适用于承重应用，例如在建筑材料中。所述复合物对于风化具有稳定性，可经模塑和着色而达到所需功能和美学特征，并且对环境有益，因为其可利用所回收的颗粒状或纤维状材料作为分散相。
背景技术
含有有机或无机填充材料的聚合复合物材料因其极好的机械特性、风化稳定性和环境有益性而已为多种用途所需要。
由于所述材料起泡，因此其可具有相对低的密度，或当不起泡时具有高密度，但是由于在整个过程中使用的增强粒子和纤维，因此其极为坚固。它们的聚合物内容物也赋予其良好的韧性(意即，抗脆裂性)和当其暴露于环境中时良好的风化降解抗性。所述特性的组合使得某些聚合复合物材料极为适用于建筑材料中，例如屋面材料、装潢或建筑制品、户外制品、绝缘面板及类似物。
此外，所使用的填充材料不需要是原始材料，并且可理想地为作为工业过程的废料或副产物而形成的回收纤维或颗粒。聚合复合物使得所述材料可有利地再使用，而不存在处理问题。
填充型复合物聚合材料已描述于美国专利第5,302,634号、第5,369,147号、第5,548,315号和第5,604,260号中，其各自的内容均以引用的方式并入本文。然而，所述专利中揭示的材料均使用聚酯聚氨基甲酸酯树脂，其作为不饱和聚酯多元醇、饱和多元醇、聚异氰酸酯或二异氰酸酯与反应性单体(例如苯乙烯)的反应产物而形成。不同反应物的数目和由此引起的工艺化学的复杂性通过增加材料投入的成本和通过增加其他工艺设备的资金成本而增加了制备所述材料的成本。
填充型封闭单元泡沫材料揭示于美国专利第4,661,533号(Stobby)中，但其提供比结构建筑制品所需密度低得多的密度。此外，Stobby并未揭示或提议“自身结皮”的复合物材料，意即形成覆盖和保护下层材料的材料表面上的连续皮，其为多孔且经明显刮擦。
发明内容
然而，已发现在不需要上文引用专利中所需的所有组份下，可获得具有良好机械特性的经高度填充、起泡或未起泡的复合物聚合材料。此导致成本大幅减少，因为材料成本减少，且因为工艺化学复杂性降低，导致工艺设备的资金投资减少。
在一实施例中，本发明涉及具有聚合物网络基质和颗粒状分散相或纤维状材料的复合物组合物。聚合物基质含有由聚异氰酸酯或二异氰酸酯与一种或一种以上饱和聚醚或聚酯多元醇反应所形成的聚氨基甲酸酯网络，和由视情况所添加的水和异氰酸酯反应所形成的可选的聚异氰脲酸酯网络。所述基质填充有颗粒相，其可选自一种或一种以上的各种组份，例如飞灰粒子、轴向纤维、织物、短切无序纤维、矿物纤维、研磨废料玻璃、花岗岩粉尘或其他固体废料。如果需要，加入水也可用于为反应混合物提供发泡剂，导致起泡结构。
由于某些原因，本发明的复合物材料有利于用作结构建筑材料，且尤其用作合成木材。首先，甚至当起泡时，其仍具有所需密度以提供结构稳定性和强度。其次，材料组合物可易于调整来修改其特性，例如通过加入定向纤维以增加弯曲刚性，或通过加入颜料或染料以隐藏刮擦作用。这甚至在材料已经挤压成形之后仍可进行。再次，所述材料自身结皮，形成覆盖和保护下层更多孔材料的坚硬、稍微多孔层。此坚硬、连续、高度粘附表皮提供极好的抗水性和抗刮擦性。此外，随着表皮的形成，可在其上压印装饰性图案(例如，模拟木材纹理)，从而增加由此复合物制成的产品的商业可接受性。
在一更为特定的实施例中，本发明涉及一种聚合物基质复合物材料，其包含：
(1)由以下各物反应所形成的聚氨基甲酸酯：
(a)一种或一种以上单体或寡聚体聚异氰酸酯或二异氰酸酯；
(b)具有第一分子量的第一聚醚多元醇；和
(c)具有低于第一分子量的第二分子量的可选第二聚醚多元醇；和
(2)视情况由单体或寡聚体聚异氰酸酯或二异氰酸酯与水或其他发泡剂反应所形成的聚异氰脲酸酯；
(3)颗粒状无机填充物。
如上所述，本发明的聚合物基质复合物材料可具有各种不同用途。然而，其尤其适用于结构应用，并且尤其用作合成木材。因此，本发明的另一特定实施例涉及一种合成木材，其包含上文所述的聚合物基质复合物材料，且具有相对多孔材料和安置于并粘附于多孔材料的相对无孔韧化层。
已发现，用于制造聚合物基质复合物材料和由此所形成的合成木材的过程对于所得材料的外观和特性具有重要影响，且因此对其商业可接受性具有重要影响。因此，本发明的另一特定实施例涉及一种通过以下步骤生产聚合物基质复合物的方法：
(1)将具有第一分子量的第一聚醚多元醇和具有高于第一分子量的第二分子量的第二聚醚多元醇与催化剂、可选水和可选表面活性剂混合；
(2)视情况将增强纤维材料引入混合物中；
(3)将无机填充物引入混合物中；
(4)将聚异氰酸酯或二异氰酸酯引入混合物中；和
(5)除了控制失控放热以外，在无强迫冷却下使放热反应继续进行。
本发明的材料和其制备过程对环境是有益的。如上文所述，其提供一种将颗粒废料再利用于较高价值用途中的机制。此外，其制造过程视情况在聚异氰脲酸酯形成中使用水，其释放出二氧化碳作为发泡剂。因此，这个过程避免了使用对环境有害的发泡剂，例如卤代烃。
具体实施方式
如上文所述，本发明的一个实施例涉及一种复合物组合物，其含有聚合基质相和分散无机颗粒相，且其可含有其他材料，例如增强纤维、颜料和染料、及类似物。材料的所需特性之一为其自身结皮性质。
聚合相理想为含有至少一种聚氨基甲酸酯，通常认为是2部分或热固性聚氨基甲酸酯。聚氨基甲酸酯是由聚异氰酸酯或二异氰酸酯(下文为“异氰酸酯”)，尤其是芳香族二异氰酸酯，更尤其是亚甲基二苯基二异氰酸酯(MDI)与一种或一种以上聚醚多元醇反应而形成，其在下文更详细描述。
用于本发明的MDI可为MDI单体、MDI寡聚物或其混合物。可基于所需总体特性来选择所用的特定MDI，例如起泡量、与无机颗粒的结合强度、反应混合物中无机颗粒的湿度、所得复合物材料的强度和刚性(弹性模数)。尽管可使用甲苯二异氰酸酯，但是MDI通常为优选的，这是由于其较低的挥发性和较低的毒性。影响本发明中所用特定MDI或MDI混合物的其他因素为粘度(从便于操作的角度而言，低粘度较为理想)、成本、挥发性、反应性和2，4异构体含量。对于某些应用而言，颜色可能是重要因素，但通常不影响用于制备合成木材的MDI的选择。
光稳定性也并非是选择用于本发明复合物中的MDI的特定考虑因素。实际上，本发明的复合物允许使用因其有限的光稳定性而通常认为并不适于户外使用的异氰酸酯混合物。当用于本发明的复合物中时，这些材料令人吃惊地展现出极好的光稳定性，其具有极少的甚至无黄化或灰化。由于通常认为适于户外使用的异氰酸酯混合物(通常为脂肪族异氰酸酯)比本发明所用的那些显著昂贵，因此本发明使用MDI混合物的能力代表显著的成本优势。
适用于本发明的MDI组合物包括那些在25℃下具有介于约25至约200cp之间的粘度，和介于约30％至约35％之间的NCO含量的组合物。通常使用异氰酸酯，其对多元醇的1当量OH基团提供至少1当量NCO基团，其理想具有约5％至约10％过量的NCO基团。合适异氰酸酯包括BayerMRS-4、Bayer MR Light、Dow PAPI 27、Bayer MR5、Bayer MRS-2和Rubinate9415。
如上文所述，用于本发明的异氰酸酯与一种或一种以上多元醇反应。一般来说，以当量计(对于多元醇而言为OH基团，且对于异氰酸酯而言为NCO基团)，异氰酸酯与多元醇的比率通常在约0.5∶1至约1.5∶1的范围内，更尤其在约0.8∶1至约1.1∶1的范围内。在所述范围内的比率为无机颗粒提供良好的起泡和结合，且产生低吸水量、纤维结合、热扭曲抗性和抗蠕变性的特性。然而，所需比率的精确选择将受系统中水量的影响，包括本身作为发泡剂加入的水和作为“杂质”与其他组份一起引入的水。
所使用的多元醇可以是单一单体、寡聚物或掺合物。可使用多元醇的混合物来影响或控制所得聚合物网络的特性。例如，两种多元醇的混合物，一种为低分子量的弹性(相对于第二)多元醇且另一种为较高分子量、更具刚性的(相对于第一)多元醇。仔细控制刚性多元醇的量以避免使得复合物太脆(已发现挠性多元醇与刚性多元醇的比率在约5wt％与约20wt％之间通常较为合适，更尤其为15wt％左右)。通常需要使用液体形式的多元醇，且通常为可获得的最低粘度的液体形式，因为这些可更易于与无机颗粒材料混合。可使用所谓的“EO”末端多元醇；然而，当暴露于水时，在需要避免聚合物材料“结霜”时，通常避免使用。
一般来说，理想多元醇包括聚醚多元醇，例如MULTRANOL(Bayer)，包括MULTRANOL 3400或MULTRANOL 4035、乙二醇、二乙二醇、三乙二醇、二丙二醇、甘油、2-丁炔-1，4-二醇、新戊基二醇、1，2-丙二醇、季戊四醇、甘露醇、1，6-己二醇、1，3-丁二醇、氢化双酚A、聚四亚甲基二醇醚、聚硫醚和其他二官能基聚醚和多官能基聚醚和聚酯聚醚，和其混合物。多元醇无需可混溶，但在聚合复合物中不应引起相容性问题。
如上文所述，本发明的复合物理想为可通过将多元醇混合在一起(如果使用多种多元醇)，且随后将其与例如催化剂、表面活性剂和发泡剂的各种添加剂混合，然后加入无机颗粒相，随后加入任何增强纤维且最终加入异氰酸酯来制备。
通常加入一种或一种以上催化剂来控制聚合物基质的固化时间(加入异氰酸酯之后)，且所述催化剂可从已知用于起始异氰酸酯与多元醇之间反应的催化剂中选择，例如含胺催化剂(例如DABCO和四甲基丁二胺)、含锡催化剂、含汞催化剂和含铋催化剂。为增加固化的均一性和快速性，可能需要加入多种催化剂，包括通过凝胶作用提供总体固化的催化剂，和另一种提供快速表面固化以形成表皮并消除粘着性的催化剂。例如，视所需固化时间长度而定，可加入大于0wt％且低于约0.10wt％(以总反应混合物计)或更少的量的1份含锡催化剂和10份含胺催化剂的液体混合物。过多催化剂可导致过度固化，其可引起固化材料在加工设备上累积，或材料太硬而不可适当定形，或焦化；在严重的情形下，这可导致产品滞销或着火。固化时间通常基于约5秒钟至约2小时之间。
视情况可将表面活性剂加入多元醇混合物中充当湿润剂，并辅助混合无机颗粒材料。表面活性剂也稳定在起泡期间形成的气泡(如果需要起泡制品)，并钝化无机颗粒的表面，以使得聚合基质覆盖并结合至较大表面区域。以混合物的总重量计，可使用低于约0.5wt％的表面活性剂，理想为约0.3wt％。过量表面活性剂可导致过量水吸收，这可导致复合物材料的冷冻/解冻损害。已发现，硅酮表面活性剂适用于本发明。实例包括DC-197和DC-193(基于硅酮，Air Products)，和其他非极性与极性(阴离子与阳离子)制品。
如果需要起泡制品，则也可向多元醇混合物中加入起泡剂。尽管这些起泡剂可包括有机发泡剂，例如卤代烃、己烷和其他当由多元醇-异氰酸酯反应而加热时蒸发的物质，已发现水更为廉价，且与异氰酸酯反应产生惰性、安全的CO2，且无需从过程中洗涤。同等重要的是，CO2提供起泡制品中所需类型的聚氨基甲酸酯单元(意即，大部分开放，但某些封闭的单元)，且尤其在高填充物含量时，其与大部分无机颗粒填充物的使用高度相容，并且与增强纤维的使用相容。其他起泡剂将不产生与水所能得到的相同的泡沫结构。
如果不向组合物中加入水，由于与其他组份一起作为“杂质”引入的少量水(以反应混合物的总重量计，0.2wt％左右)的存在，仍可发生某些起泡现象。另一方面，由加入过多水(直接或通过引入“潮湿”反应物或无机颗粒材料)所引起的过度起泡可通过加入例如UOP“T”粉末的吸收剂而得以控制。
系统中所存在水的量将对所得复合物材料的密度具有重要影响。以所加入多元醇的重量计，对于介于约20lb/ft3至约90lb/ft3之间的复合物密度而言，此量通常介于约0.10wt％至约0.40wt％之间。
在引入异氰酸酯之前，也可向多元醇混合物中引入增强纤维。这些增强纤维可包括纤维本身，例如短切玻璃纤维，或织物或织物的部分，例如粗纱或线性丝束，或其组合。特别的，增强纤维一般介于约0.125in至约1in之间，更特定介于约0.25in至约0.5in之间。增强纤维给予材料增加的强度(弯曲、拉伸和压缩)，增加其刚性，且提供增加的韧性(冲击强度或对脆裂的抗性)。织物、粗纱或丝束增加弯曲刚性和抗蠕变性。本发明的特定聚氨基甲酸酯网络的包涵物，连同可选表面活性剂，和所用无机颗粒尺寸使得本发明的复合物尤其且令人吃惊地充分适用于起泡材料中的增强纤维包涵物，通常预期其可破裂或扭曲泡沫泡，并降低复合物系统的强度。
除在聚合作用之前将增强纤维包括于多元醇混合物中以外，在聚合物离开挤出机时且在任何模塑之前，也可在挤出之后向复合物中引入定向轴向纤维。理想的是，可用多元醇(一般为较高分子量、刚性多元醇)与异氰酸酯的混合物将纤维(例如玻璃带)湿润，但不用催化剂或用慢速固化催化剂，或用其他刚性或热固性树脂(例如环氧化物)。这使得可在新添加的材料可固化之前将湿润纤维并入复合物中，且使得此硬化由大量材料中的已固化聚合物的放热来驱动。
无论是在聚合作用和挤出的之前或之后添加，本发明的复合物材料都含有与分散增强纤维强结合的聚合基质相，以增加所得材料的强度和刚性。这使得所述材料即使在相对低密度(例如，约20至约60lb/ft3)下也可用作结构合成木材。
颜料或染料可加入到多元醇混合物中，或可以在过程中的其他点加入。颜料为可选，但可有助于使复合物材料在商业上更可接受，更独特，且有助于隐藏在材料表面可能形成的任何刮擦。颜料的典型实例包括氧化铁，以反应混合物的总重量计，加入量一般介于约2wt％至约7wt％之间。
无机颗粒相为本发明的重要特征，且一般以介于总组合物的约45wt％至约85wt％之间的量存在。增加无机颗粒的比例可导致混合难度的增加，使得更需要包括表面活性剂。无机颗粒材料应具有小于约0.5wt％的水(以颗粒材料的重量计)以避免过度或失控起泡。
通常需要使用具有广泛粒径分布的颗粒材料，因为这可提供较佳的颗粒封装，导致密度增加且每单位重量复合物的树脂含量减少。由于无机颗粒一般为某些形式的废料或刮擦材料，因此其也导致原材料成本降低。已发现，具有介于约0.0625in至低于325目之间的尺寸分布的粒子尤其适用。
合适的无机颗粒可包括研磨玻璃粒子、飞灰、炉底灰、砂子、花岗岩粉尘和类似物，以及其混合物。飞灰较为理想是因其稠度均一，含有一些碳(其由于包括已知对塑料提供风化保护的精细碳粒子和不透明灰尘粒子阻挡紫外(UV)光的作用而可对制品提供某些所需的风化特性)，且含有一些金属物质，例如金属氧化物，相信其可为聚合反应提供其他催化作用。研磨玻璃(例如窗或瓶玻璃)吸收较少树脂，降低了复合物的成本。也已发现，煤飞灰和炉底灰的1∶1混合物适合用作无机颗粒组合物。一般来说，具有极低体积密度(例如，低于约40lb/ft3)和/或高碳含量(例如，约20wt％或更高)的飞灰较不合适，因为其更难于并入树脂系统中，且可能需要添加具有更少碳的其他无机填充物(例如铸造用砂)。已发现，由燃煤发电厂(包括HoustonLighting和Power发电厂)产生的飞灰，来自Southern California Edison工厂(Navajo或Mohave)的飞灰和炉底灰，来自怀俄明州(Wyoming)的ScottishPower/Jim Bridger发电厂的飞灰和来自Central Hudson发电厂的飞灰适用于本发明。
生产复合物材料的过程可以批量、半批量或连续方式来操作。可使用例如班伯里(Banbury)型混炼机、搅拌槽和类似物的常规混炼机进行混合，或可在例如双螺杆同向挤出机的挤出机中进行混合。当使用挤出机时，尤其在如果使用液体多元醇时，通常不必额外加热。此外，除最小冷却以控制过度或失控放热以外，通常无需强制冷却。
例如，可使用多区域挤出机，其中将多元醇和添加剂引入至第一区，无机颗粒引入至第二区，且短切纤维、异氰酸酯和颜料引入至第五区。可使用双螺杆同向挤出机(例如100mm直径，尽管直径实质上可变化)，其仅具有水冷却(以维持室温)，且不具有挤出机真空(除灰尘以外)。可将液体材料泵入至挤出机中，而可通过合适给料斗/螺杆进料器装置加入固体。在这个例示性装置中所形成的内部压力并不显著。
尽管基本上立即发生凝胶作用，但完全固化可能需要48小时之久，且因此在评估复合物的机械特性之前需要至少等待如此长的时间，以使其组成与特性均稳定。
如上文所解释，本发明的复合物材料有利地用于结构制品中，包括合成木材。合成木材可以批量、半批量或连续形式形成。例如，在连续操作中，将离开挤出机的经聚合(和正在聚合)的材料(在后挤出机纤维、丝束或粗纱的视情况并入之后)供应给形成系统，其对材料提供空间限制，且其可用于使所得合成木材的表面具有模拟木材纹理或其他设计的图案，以使得这种材料更为商业所需。例如，可使用包含2、4或6条由挠性树脂制造的带的传送带系统，所述挠性树脂其中具有木材纹理或经模塑的其他设计。一种这种合适系统描述于同一日期申请的同在申请中的美国专利申请案第系列(律师备审案件目录第_号)中，其全文内容以引用的方式并入本文中。所述带理想地由自身释放橡胶或弹性材料形成，以使其不粘着至聚合物复合物。如果需要涂覆例如蜡、硅酮或氟聚合物的释放剂，则合适带材料包括硅酮橡胶、浸渍油的聚氨基甲酸酯或者合成或天然橡胶。
下文提供以总复合物组合物计的合成木材的代表性合适组成范围(％)：
刚性多元醇             约6至约18wt％
挠性多元醇             0至约10wt％
表面活性剂             约0.2至约0.5wt％
表皮形成催化剂         约0.002至约0.01wt％
凝胶作用催化剂         约0.02至约0.1wt％
水                     0至约0.5wt％
短切玻璃纤维           0至约10wt％
颜料                   0至约6wt％
无机颗粒               约60至约85wt％
异氰酸酯               约6至约20wt％
轴向丝束               0至约6wt％。
可参考以下非限制性实例进一步了解本发明。
实例1
通过将9.5wt％刚性多元醇(MULTRANOL 4035，Bayer)、0.3wt％橡胶多元醇(ARCOL LG-56，Bayer)、0.3wt％表面活性剂/湿润剂(DC-197，AirProducts)、0.005wt％膜形成有机锡催化剂(UL-28/22，Air Products)、0.03wt％胺凝胶作用催化剂(33LV，Air Products)和作为起泡剂的0.05wt％的水引入至100mm直径的双螺杆同向挤出机的驱动端来制备聚合物复合物组合物，期间以水冷却以维持室温。在挤出机约60％长度点处，添加长度为1/4至1/2英寸的4.2wt％短切玻璃纤维(Owens Corning)，以及4.0wt％褐色颜料(Interstar)、74wt％飞灰(ISG)和9.6wt％异氰酸酯(MONDUR MR Light，Bayer)。在室温(75)下，以200rpm操作挤出机1小时。挤出之后，向经挤出材料的表面加入0.4wt％的橡胶多元醇(ARCOL LG-56，Bayer)和异氰酸酯(MONDUR MR Light，Bayer)的树脂混合物，为玻璃丝束提供结合粘着性。加入2wt％左右的量、长度为1/4至1/2英寸的玻璃丝束(OwensCorning)以提供增加的刚性，且刚好加入至由挤出机制造的材料表面以下。
所得复合物材料尤其可用作合成装饰材料。
实例2
在分批反应器中，将16.4wt％刚性多元醇(Bayer 4035)与1.9wt％挠性多元醇(Bayer 3900)、0.2wt％表面活性剂(DC-197)、水、3.2wt％颜料、0.0001wt％UL-28有机锡催化剂和0.1wt％33LV胺催化剂组合，并充分混合1分钟。随后加入31.5wt％Wyoming飞灰，并再混合1分钟。最后加入17.3wt％异氰酸酯(1468A，Hehr)、0.9wt％短切褐色纤维、3.5wt％短切玻璃(直径0.25in.)和另外25.2wt％Wyoming飞灰，并混合30秒钟。所得材料具有36％的树脂含量、90％的刚性与橡胶多元醇比率、64％的固体含量、10％过量的异氰酸酯含量和4.4％的纤维含量，除非另外说明，否则所有这些都是以总组合物的重量计。所得材料适用于形成合成木板。
实例3
在分批反应器中，将16.4重量wt％刚性多元醇(Bayer 4035)与1.9重量wt％挠性多元醇(Bayer 3900)、0.2重量wt％表面活性剂(DC-197)、水、3.2重量wt％颜料、3.5重量wt％短切玻璃(直径0.25in.直径)、0.4重量wt％左右Mohave炉底灰、0.0001重量wt％UL-28有机锡催化剂和0.1重量wt％33LV胺催化剂组合，并充分混合1分钟。随后加入31.5重量wt％Wyoming飞灰，并再混合1分钟。最后加入17.3重量wt％异氰酸酯(1468A，Hehr)、0.9重量wt％短切褐色纤维和另外25.2重量wt％Wyoming飞灰，并混合30秒钟。所得材料具有36％的树脂含量、90％的刚性与橡胶多元醇的比率、64％的固体含量、10％过量的异氰酸酯含量和4.4％的纤维含量，除非另外说明，否则所有这些都以总组合物计。所得材料适用于形成合成木板。
对于实例2和3的每一个实例而言，以下文所示量(以所加入的总多元醇百分比计)加入水；测试所得材料的物理特性，且结果提供于下文中。200lb冲击测试是通过使200lb的人在18英寸宽度的合成木板上跳跃来进行，2×6英寸的合成木板支撑在空中距离地面约1ft的高度，并评估所述板是否断裂。
  实例   H2O(占多元醇的％)   密度(lb/ft3)   断裂强度(psi)   100psi挠度(in)  硬度(硬度计C)   弯曲强度(psi)   弯曲模数(psi)   200lb冲击测试(P/F)
  2   0.10   63   730   0.15   62   3129   118,331   P
  2   0.23   59   650   0.15   57   2786   118,331   P
  2   0.40   47   450   0.15   52   1929   118,331   F
  3   0.10   63   810   0.15   62   3472   118,331   P
实例4
将纤维玻璃粗纱(Ahlstrom，0.755g/ft)或褐色玄武岩粗纱(0.193g/ft)置于2×4英寸合成木材的24英寸模中，并使其稳定以限制其相对于模表面(在模表面中距其约0.125in.)的移动且保持其拉紧。对粗纱进行干燥、涂覆且用合成木材组合物(过筛灰和短切玻璃)预固化，并用49wt％刚性多元醇(MULTRANOL 4035)、0.098wt％表面活性剂(DC-197)、0.20wt％胺催化剂(33LV)和49.59wt％异氰酸酯(Hehr 1468A)的混合物将其润湿。
向模中加入合成木材混合物，所述合成木材混合物是通过组合16.6wt％刚性多元醇(MULTRANOL 4035)、5.5wt％挠性多元醇(MULTRANOL3900)、0.16wt％表面活性剂(DC-197)、0.07wt％水、3.7wt％颜料、0.003wt％有机锡催化剂(UL-28，Air Products)和0.1wt％胺催化剂(33LV)，并混合1分钟，随后加入26.4wt％Wyoming飞灰，混合物1分钟，且最后加入20.4wt％异氰酸酯(MRS4，Bayer)、1.1wt％短切褐色纤维、3.4wt％短切0.25in.玻璃纤维和22.5wt％Wyoming飞灰，并混合30秒钟而形成的。
评估所得板的物理特性，并在下文中阐述。也制备不同密度的对照板，且也评价其物理特性。轴向定向粗纱大幅增加弯曲强度，而重量增加很小。随着材料上负载的增加，粗纱倾向于具有更为明显的加固作用。
  粗纱类型   粗纱数目   粗纱涂层   密度(lb/ft3)   弯曲强度(psi)   100psi下的弯曲模数(Ksi)   200psi下的弯曲模数(Ksi)
  玄武岩   10   干燥   41   1191   73   53
  玻璃纤维   10   经预固化树脂   58   4000   188   135
  玻璃纤维   10   干燥   62   5714   339   169
  玄武岩   40   干燥   49   2465   96   101
  玄武岩   40   干燥   31   1650   62   165
  玻璃纤维   10   干燥   32   2717   37   57
  玻璃纤维   10   潮湿   36   3533   77   93
  玻璃纤维   5   潮湿   36   2410   64   71
  玻璃纤维   15   潮湿   38   4594   171   80
  玻璃纤维   20   潮湿   35   4356   84   80
  无   55   1808   147   98
  无   66   4724   121   100
  无   68   ---   169   135
  无   59   2568   70   84
  无   45   1319   82   62
  无   35   1174   56   63
  无   41   746   59   0
发现由本发明生产的合成木材具有良好的阻燃特性，达到25的火焰蔓延指数，且当锯开时仅产生少量尺寸小于10μm的可吸入粒子。其提供极好的压缩强度、固持螺钉和钉子的特性，和密度。本发明的经挤出复合物通常提供远远优于由经模塑复合物所提供的机械特性。

Claims (26)

1.一种聚合物基质复合物材料，其包含：
(1)由反应混合物的反应所形成的聚氨基甲酸酯，所述反应混合物
包含：
(a)一种或一种以上单体或寡聚体聚异氰酸酯或二异氰酸酯；
(b)具有第一分子量的选自由聚醚多元醇和聚酯多元醇所组成群组的第一多元醇；和
(c)具有低于第一分子量的第二分子量，选自由聚醚多元醇和聚酯多元醇所组成群组的可选的第二多元醇；和
(2)由单体或寡聚体聚异氰酸酯或二异氰酸酯与已视情况加入反应混合物中的水的反应所形成的可选的聚异氰脲酸酯；
(3)无机颗粒材料。
2.根据权利要求1所述的聚合物基质复合物材料，其特征在于：所述材料经起泡。
3.根据权利要求1所述的聚合物基质复合物材料，其特征在于：进一步包含一种或一种以上遍及聚合物基质的无机纤维。
4.根据权利要求1所述的聚合物基质复合物材料，其特征在于：进一步包含轴向定向纤维粗纱，所述粗纱安置于复合物表面以上、复合物表面中或复合物表面以下。
5.根据权利要求1所述的聚合物基质复合物材料，其特征在于：所述第二聚醚多元醇以介于第一聚醚多元醇的0至20wt％之间的量存在。
6.根据权利要求1所述的聚合物基质复合物材料，其特征在于：以所述组合物的总重量计，所述无机颗粒材料以介于45wt％至80wt％之间的量存在。
7.根据权利要求1所述的聚合物基质复合物材料，其特征在于：所述无机颗粒材料为飞灰、炉底灰或颗粒玻璃。
8.根据权利要求1所述的聚合物基质复合物材料，其特征在于：所述无机颗粒材料具有介于0.0625in.至低于325目之间的粒径分布。
9.根据权利要求1所述的聚合物基质复合物材料，其特征在于：所述无机颗粒材料含有少于0.5wt％的水。
10.一种合成木材，其包含根据权利要求1所述的聚合物基质复合物材料；
其特征在于：所述复合物材料包含相对多孔材料和放置并粘附于所述
多孔材料上的相对无孔韧化层。
11.根据权利要求10所述的合成木材，其特征在于：具有对应于市售木材制品的尺寸和形状的尺寸和形状。
12.根据权利要求11所述的合成木材，其特征在于：所述合成木材包含至少一个已经浮雕或压印图案的表面。
13.根据权利要求13所述的合成木材，其特征在于：所述图案包含模拟木材纹理。
14.一种生产聚合物基质复合物的方法，其包含：
(1)将具有第一分子量的第一聚醚多元醇和具有高于第一分子量的第二分子量的第二聚醚多元醇与一种或一种以上的催化剂、水和可选表面活性剂混合；
(2)视情况将增强纤维材料引入所述混合物中；
(3)将无机填充物引入所述混合物中；
(4)将聚异氰酸酯或二异氰酸酯引入所述混合物中；且
(5)除控制失控放热以外，使放热反应在无强制冷却下进行，从而形成聚合物基质复合物。
15.根据权利要求15所述的方法，其特征在于：进一步包含通过模具挤出所述混合物或所述聚合物基质复合物。
16.根据权利要求16所述的方法，其特征在于：混合或反应的至少一部分，或两者均在挤出机中发生。
17.根据权利要求15所述的方法，其特征在于：进一步包含将所述聚合物基质复合物模塑成所需形状。
18.根据权利要求16所述的方法，其特征在于：进一步包含使所述聚合物基质复合物形成为合成木材。
19.根据权利要求19所述的方法，其特征在于：所述形成包含将所述聚合物基质复合物定形为适用于合成木材的尺寸和形状。
20.根据权利要求20所述的方法，其特征在于：所述形成进一步包含对所述聚合物基质复合物的至少一个表面浮雕或压印图案。
21.根据权利要求15所述的方法，其特征在于：所述一种或一种以上的催化剂包含表皮形成催化剂。
22.根据权利要求22所述的方法，其特征在于：所述表皮形成催化剂包含有机锡化合物。
23.根据权利要求15所述的方法，其特征在于：所述一种或一种以上的催化剂包含凝胶作用催化剂。
24.根据权利要求24所述的方法，其中所述凝胶作用催化剂包含胺。
25.根据权利要求15所述的方法，其特征在于：进一步包含将轴向定向纤维粗纱引入所述聚合物基质复合物中。
26.根据权利要求26所述的方法，其特征在于：所述纤维粗纱是在所述复合物表面以上、复合物表面中或复合物表面以下引入。
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