WO2011019997A1 - Filled polyurethane composites and methods of making same - Google Patents
Filled polyurethane composites and methods of making same Download PDFInfo
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- WO2011019997A1 WO2011019997A1 PCT/US2010/045444 US2010045444W WO2011019997A1 WO 2011019997 A1 WO2011019997 A1 WO 2011019997A1 US 2010045444 W US2010045444 W US 2010045444W WO 2011019997 A1 WO2011019997 A1 WO 2011019997A1
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/30—Low-molecular-weight compounds
- C08G18/36—Hydroxylated esters of higher fatty acids
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
- C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- C04B26/16—Polyurethanes
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
- C08G18/00—Polymeric products of isocyanates or isothiocyanates
- C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
- C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
- C08G18/30—Low-molecular-weight compounds
- C08G18/32—Polyhydroxy compounds; Polyamines; Hydroxyamines
- C08G18/3203—Polyhydroxy compounds
- C08G18/3206—Polyhydroxy compounds aliphatic
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K11/00—Use of ingredients of unknown constitution, e.g. undefined reaction products
- C08K11/005—Waste materials, e.g. treated or untreated sewage sludge
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/02—Elements
- C08K3/04—Carbon
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L75/00—Compositions of polyureas or polyurethanes; Compositions of derivatives of such polymers
- C08L75/04—Polyurethanes
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Definitions
- Polymeric composite materials that contain organic or inorganic filler materials have become desirable for a variety of uses because of their excellent mechanical properties and weathering stability. Foamed versions of these materials can be relatively low density yet the filler materials can provide a composite material that is extremely strong.
- the polymer provided in the composite material can help provide good toughness (i.e., resistance to brittle fracture) and resistance to degradation from weathering to the composite when it is exposed to the environment.
- polymeric composite materials including organic or inorganic fillers can be used in a variety of applications.
- the composite materials include a polyurethane formed by the reaction of an isocyanate and a polyol, and coal ash.
- the coal ash can be, for example, fly ash.
- the isocyanates used in these composites are selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof.
- the polyols used in these composites consist essentially of one or more plant-based polyols, the one or more plant-based polyols including castor oil.
- the fly ash may be 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 which includes mixing an isocyanate selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof; a polyol wherein the polyol consists essentially of one or more plant-based polyols, the one or more plant-based polyols including castor oil, coal ash, and a catalyst.
- the coal ash can be, for example, fly ash.
- the isocyanate and polyol react in the presence of the catalyst and coal ash to form the composite material.
- the amount of fly ash added in the mixing step is from about 40% to about 90% by weight of the composite material.
- the composite materials include a polyurethane formed by the reaction of an isocyanate, selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and a polyol, consisting essentially of one or more plant-based polyols, the plant-based polyol including castor oil (i.e., the one or more plant-based polyols is castor oil or a mixture of castor oil and one or more other plant-based polyols); and coal ash (e.g., fly ash) present in amounts from about 40% to about 90% by weight of the composite material.
- an isocyanate selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof
- a polyol consisting essentially of one or more plant-based polyols, the plant-based polyol including castor oil (i.e., the one or more plant-based polyols is castor oil or a mixture of castor oil and one or more other plant-based polyo
- the composite materials described herein as well as their polyurethane component can be formulated with a high total environmental content.
- total environmental content refers to the sum of the total renewable content and the total recyclable content used to form a composite material or its polyurethane component and is expressed as a weight percent.
- renewable content refers to matter that is provided by natural processes or sources.
- renewable content examples include alcohol and oils from plants, such as castor oil and soybean oil. Isocyanates derived from natural oil, such as castor oil pre-polymers and soybean oil pre-polymers, are also examples of renewable content.
- recyclable content includes content that is derived from materials that would otherwise have been discarded. Examples of recyclable content include a recyclable polyol (e.g., one derived from recyclable polyester), glycerin sourced from a biodiesel plant, and a coal ash. Renewable content and recyclable content are used in the composites described herein to produce composite materials and polyurethane components with a high total environmental content.
- the total environmental content of the polyurethane component (based only on the polyols and isocyanates) of the composite materials described herein can be greater than 35%. Further, the total environmental content of the polyurethane components described herein can be greater than 40% or greater than 45%. Examples of the total environmental content of the polyurethane components include
- the total environmental content of the polyurethane components can be about 36%, about 37%, about 38%, about 39%, about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, or about 50%.
- the term about is intended to capture the range of experimental error (e.g., ⁇ 1%) associated with making the specified measurement. Unless otherwise noted, all percentages and parts are by weight.
- the total environmental content of the composite materials described herein can be greater than 75%. Further, the total environmental content of the composite materials described herein can be greater than 80% or greater than 85%. Examples of the total environmental content of the composite materials include total environmental content greater than 76%, greater than 77%, greater than 78%, greater than 79%, greater than 81%, greater than 82%, greater than 83%, and greater than 84%.
- the total environmental content of the composite materials can be about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, or about 90%.
- the one or more plant-based polyols useful with the composite materials described herein may be single monomers, oligomers, or mixtures thereof.
- the use of plant-based polyols increases the environmental content of the composite material.
- the one or more plant-based polyols includes castor oil. Castor oil is a well-known, commercially available material, and is described, for example, in Encyclopedia of Chemical Technology, Volume 5, John Wiley & Sons (1979).
- Suitable castor oils include those sold by Vertellus Specialities, Inc., e.g., DB® Oil, and Eagle Specialty Products, e.g., T31® Oil.
- the one or more plant-based polyols useful with the composite materials described herein include polyols containing ester groups that are derived from plant- based fats and oils. Accordingly, the one or more plant-based polyols can contain structural elements of fatty acids and fatty alcohols. Starting materials for the plant- based polyols of the polyurethane component include fats and/or oils of plant-based origin with preferably unsaturated fatty acid residues.
- the one or more plant-based polyols useful with the composite materials described herein include, for example, castor oil; coconut oil; corn oil; cottonseed oil; lesquerella oil; linseed oil; olive oil; palm oil; palm kernel oil; peanut oil; sunflower oil; tall oil; and mixtures thereof. In some embodiments, the one or more plant-based polyols can be derived from soybean oil as the plant-based oil.
- the one or more plant-based polyols can include highly reactive polyols that include a large number of primary hydroxyl groups (e.g. 75% or more or 80% or more) as determined using fluorine NMR spectroscopy as described in ASTM D4273 [34]. Suitable highly reactive plant-based polyols can produce a Brookfield viscosity rise to a Brookfield viscosity of over 50,000 cP in less than 225 seconds, or less than 200 seconds when used in a standard Brookfield Viscosity Test procedure.
- highly reactive polyols that include a large number of primary hydroxyl groups (e.g. 75% or more or 80% or more) as determined using fluorine NMR spectroscopy as described in ASTM D4273 [34]. Suitable highly reactive plant-based polyols can produce a Brookfield viscosity rise to a Brookfield viscosity of over 50,000 cP in less than 225 seconds, or less than 200 seconds when used in a standard Brookfield Viscosity
- the polyol is provided in an amount of 100 parts by weight and mixed with DC- 197 surfactant (1.0 parts by weight), DABCO R-8020 catalyst (2.0 parts by weight), fly ash (460.0 parts by weight) and water (0.5 parts by weight) in a 600 mL glass jar at 1000 RPM for 30 seconds using any lab-duty electric stirrer equipped with a Jiffy Mixer brand, Model LM, mixing blade.
- DC- 197 surfactant 1.0 parts by weight
- DABCO R-8020 catalyst 2.0 parts by weight
- fly ash 460.0 parts by weight
- water 0.5 parts by weight
- MONDUR MR Light (a polymeric MDI, having a NCO weight of 31.5%, viscosity of 200 mPa»s @ 25°C, equivalent weight of 133, and a functionality of 2.8) is then added at an isocyanate index of 110 and the components mixed for an additional 30 seconds.
- the glass jar is then removed from the stirrer and placed on a Brookfield viscometer. The viscosity rise is measured using a for 20 minutes or until 50,000 cP is reached.
- Brookfield Viscosity Test is described, for example, in Polyurethane Handbook: Chemistry, Raw Materials, Processing Application, Properties, 2 nd Edition, Ed: Gunter Oertel; Hanser/Gardner Publications, Inc., Cincinnati, OH; Rigid Plastic Foams, T.H. Ferrigno (1963); and Reaction Polymers: P olyur ethanes, Epoxies, Unsaturated Polyesters, Phenolics, Special Monomers and Additives : Chemistry, Technology, Applications, Wilson F. Gum et al. (1992), which are all herein incorporated by reference.
- the highly reactive plant-based polyol can 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, of greater than 250.
- Exemplary highly reactive plant- based polyols include Pel-Soy 744 and Pel-Soy P-750, soybean oil based polyols commercially available from Pelron Corporation; Agrol Diamond, a soybean oil based polyol commercially available from BioBased Technologies; Ecopol 122, Ecopol 131 and Ecopol 132, soybean oil polyols formed using polyethylene terephthalate and commercially available from Ecopur Industries; Honey Bee HB- 530, a soybean oil-based polyol commerically available from MCPU Polymer Engineering; Renewpol, a castor oil-based polyol commercially available from
- the highly reactive plant-based polyols can be formed by the reaction of a soybean oil and a polyester to produce a plant-based polyester polyol.
- An example of such a soybean oil-based polyester polyol is Ecopol 131, which is a highly reactive aromatic polyester polyol comprising 80% primary hydroxyl groups.
- the castor oil component when combined with a highly reactive polyol such as Ecopol 131 also provides benefits such as increased resiliency, toughness and handleability.
- the castor oil and highly reactive polyol can be combined in various percentages, e.g., 15-40% of the castor oil and and 60-85% of the highly reactive polyol.
- the castor oil also provides a polyurethane foam product that is harder to break and thus that can be used for more demanding applications.
- Polyols or combinations of polyols useful with the composite materials described herein have an average functionality of about 1.5 to about 8.0.
- Useful polyols additionally have an average functionality of about 1.6 to about 6.0, about 1.8 to about 4.0, about 2.5 to about 3.5, or about 2.6 to about 3.1.
- the average hydroxy 1 number values for polyols useful with the composite materials described herein include hydroxyl numbers from about 100 to about 600, about 150 to about 550, about 200 to about 500, about 250 to about 440, about 300 to about 415, and about 340 to about 400.
- Isocyanates useful with the composite materials described herein include one or more monomeric or oligomeric poly- or di-isocyanates.
- the monomeric or oligomeric poly- or di-isocyanate include aromatic diisocyanates and polyisocyanates.
- the isocyanates can also be blocked isocyanates.
- An example of a useful monomeric or oligomeric poly- or di-isocyanates include aromatic diisocyanates and polyisocyanates.
- the isocyanates can also be blocked isocyanates.
- MDI methylene diphenyl diisocyanate
- Useful MDIs include MDI monomers, MDI oligomers, and mixtures thereof.
- useful isocyanates include those having NCO (i.e., the reactive group of an isocyanate) contents ranging from about 25% to about 35% by weight.
- NCO i.e., the reactive group of an isocyanate
- useful isocyanates are found, for example, in Poly ur ethane Handbook: Chemistry, Raw Materials, Processing Application, Properties, 2 nd Edition, Ed: Gunter Oertel; Hanser/Gardner Publications, Inc., Cincinnati, OH, which is herein incorporated by reference.
- aromatic polyisocyanates include 2,4- or 2,6-toluene diisocyanate, including mixtures thereof; /?-phenylene diisocyanate; tetramethylene and hexamethylene diisocyanates; 4,4- dicyclohexylmethane diisocyanate; isophorone diisocyanate; 4,4-phenylmethane diisocyanate; polymethylene polyphenylisocyanate; and mixtures thereof.
- triisocyanates may be used, for example, 4,4,4-triphenylmethane triisocyanate; 1,2,4- benzene triisocyanate; polymethylene polyphenyl polyisocyanate; methylene polyphenyl polyisocyanate; and mixtures thereof.
- Suitable blocked isocyanates are formed by the treatment of the isocyanates described herein with a blocking agent (e.g., diethyl malonate, 3,5-dimethylpyrazole, methylethylketoxime, and
- Isocyanates are commercially available, for example, from Bayer Corporation (Pittsburgh, PA) under the trademarks MONDUR and DESMODUR.
- suitable isocyanates include Mondur MR Light (Bayer
- the average functionality of isocyanates or combinations of isocyanates useful with the composites described herein is between about 1.5 to about 5. Further, examples of useful isocyanates include isocyanates with an average functionality of about 2 to about 4.5, about 2.2 to about 4, about 2.4 to about 3.7, about 2.6 to about 3.4, and about 2.8 to about 3.2.
- an isocyanate is reacted with a polyol, wherein the polyol consists essentially of one or more plant- based polyols (the one or more polyols including castor oil).
- the ratio of isocyanate groups to the total isocyanate reactive groups, such as hydroxyl groups, water and amine groups is in the range of about 0.5:1 to about 1.5:1, which when multiplied by 100 produces an isocyanate index between 50 and 150.
- the isocyanate index can be from about 80 to about 120, from about 90 to about 120, from about 100 to about 115, or from about 105 to about 110.
- an isocyanate may be selected to provide a reduced isocyanate index, which can be reduced without compromising the chemical or mechanical properties of the composite material.
- the composite materials described herein include a polyurethane formed by the reaction of an isocyanate and a polyol in the presence of coal ash.
- the coal ash can be fly ash, bottom ash, or combinations thereof.
- the coal ash used is fly ash.
- Fly ash is produced from the combustion of pulverized coal in electrical power generating plants.
- the fly ash useful with the composite materials described herein can be Class C fly ash, Class F fly ash, or a mixture thereof. Fly ash produced by coal-fueled power plants are suitable for incorporation in composites described herein.
- Coal ash is present in the composites described herein in amounts from about 40% to about 90% by weight. Further, coal ash can be present in amounts from about 60% to about 85%. Examples of the amount of coal ash present in the composites described herein include about 40%, about 41%, about 42%, about 43%, about 44%, about 45%, about 46%, about 47%, about 48%, about 49%, about 50%, about 51%, about 52%, about 53%, about 54%, about 55%, about 56%, about 57%, about 58%, about 59%, about 60%, about 61%, about 62%, about 63%, about 64%, about 65%, about 66%, about 67%, about 68%, about 69%, about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%
- One or more additional fillers can be used in the composite materials described herein.
- fillers useful with the composite materials include other types of ash such as those produced by firing fuels including industrial gases, petroleum coke, petroleum products, municipal solid waste, paper sludge, wood, sawdust, refuse derived fuels, switchgrass or other biomass material.
- the one of more additional fillers can also include ground/recycled glass (e.g., window or bottle glass); milled glass; glass spheres; glass flakes; activated carbon; calcium carbonate;
- ATH aluminum trihydrate
- silica silica
- sand ground sand
- silica fume slate dust
- crusher fines red mud
- amorphous carbon e.g., carbon black
- clays e.g., kaolin
- mica talc
- wollastonite alumina
- feldspar bentonite
- quartz garnet
- saponite beidellite
- granite calcium oxide; calcium hydroxide
- antimony trioxide barium sulfate
- magnesium oxide titanium dioxide
- zinc carbonate zinc oxide
- nepheline syenite perlite
- diatomite diatomite; pyrophillite; flue gas desulfurization (FGD) material; soda ash; trona; inorganic fibers; soy meal; pulverized foam; and mixtures thereof.
- FGD flue gas desulfurization
- inorganic fibers or organic fibers can be included in the polymer composite, e.g., to provide increased strength, stiffness or toughness.
- Fibers suitable for use with the composite materials described herein can be provided in the form of individual fibers, fabrics, ravings, or tows. These can be added prior to polymerization and can be chopped before or during the mixing process to provide desired fiber lengths. Alternately, the fibers can be added after polymerization, for example, after the composite material exits the mixing apparatus.
- the fibers can be up to about 2 in. in length.
- the fibers can be provided in a random orientation or can be axially oriented.
- the fibers can be coated with a sizing to modify performance to make the fibers reactive.
- Exemplary fibers include glass, polyvinyl alcohol (PVA), carbon, basalt, wollastonite, and natural (e.g., bamboo or coconut) fibers.
- PVA polyvinyl alcohol
- carbon carbon
- basalt e.g., carbon
- wollastonite e.g., bamboo or coconut
- natural fibers e.g., bamboo or coconut
- the inclusion of fillers in the composite materials as described herein can modify and/or improve the chemical and mechanical properties of the composite materials. For example, the optimization of various properties of the composite materials allows their use in building materials and other structural applications. High filler loading levels can be used in composite materials without a substantial reduction of (and potentially an improvement in) the intrinsic structural, physical, and mechanical properties of a composite.
- filled composites as building materials has advantages over composite materials made using lower filler levels or no filler.
- the use of higher filler loading levels in building materials may allow the building materials to be produced at a substantially decreased cost.
- the use of large filler loadings also provides environmental advantages.
- the incorporation of recyclable or renewable material, e.g., fly ash, as filler provides a composite material with a higher percentage of environmentally friendly materials, i.e., a higher total environmental content.
- the use of the environmentally friendly materials in these composites decreases the need of landfills and other waste facilities to store such material.
- Another environmental benefit of using recyclable or renewable materials as filler in these composites includes reducing the production of virgin fillers that may involve energy-intensive methods for their creation and may produce waste or by-product materials.
- One or more catalysts are added to facilitate curing and can be used to control the curing time of the polymer matrix.
- useful catalysts include amine- containing catalysts (such as DABCO and tetramethylbutanediamine) and tin-, mercury-, and bismuth-containing catalysts.
- 0.01 wt% to 2 wt% catalyst or catalyst system e.g., 0.025 wt% to 1 wt%, 0.05 wt% to 0.5 wt %, or 0.1 wt% to about 0.25 wt%) can be used.
- Additional components useful with the composite materials described herein include foaming agents, blowing agents, surfactants, chain-extenders, crosslinkers, coupling agents, UV stabilizers, fire retardants, antimicrobials, anti-oxidants, and pigments. Though the use of such components is well known to those of skill in the art, some of these additional additives are further described herein.
- Foaming agents and blowing agents may be added to the composite materials described herein to produce a foamed version of the composite materials.
- blowing agents include organic blowing agents, such as halogenated hydrocarbons, acetone, hexanes, and other materials that have a boiling point below the reaction temperature.
- Chemical foaming agents include azodicarbonamides (e.g., Celogen manufactured by Lion Copolymer Geismar); and other materials that react at the reaction temperature to form gases such as carbon dioxide.
- Water is an exemplary foaming agent that reacts with isocyanate to yield carbon dioxide.
- the presence of water as an added component or in the filler also can result in the formation of polyurea bonds through the reaction of the water and isocyanate.
- foaming or blowing agents above what is needed to complete the foaming reaction can add strength and stiffness to the composite material, improve the water resistance of the composite material, and increase the thickness and durability of the outer skin of the composite material.
- excessive blowing agent may produce a vigorously foaming reaction product.
- a forming device that contains the pressure or restrains the materials from expanding beyond the design limits may be used, such as a stationary or continuous mold.
- Surfactants can be used as wetting agents and to assist in mixing and dispersing the inorganic particulate material in a composite. Surfactants can also stabilize and control the size of bubbles formed during the foaming event and the resultant cell structure. Surfactants can be used, for example, in amounts below about 0.5 wt % based on the total weight of the mixture. Examples of surfactants useful with the polyurethanes described herein include anionic, non-ionic and cationic surfactants. For example, silicone surfactants such as DC- 197 and DC- 193 (Air Products; Allentown, PA) can be used.
- Chain-extenders are difunctional molecules, such as diols or diamines, that can polymerize to lengthen the urethane polymer chains.
- chain-extenders include ethylene glycol, 1 ,4-butanediol; ethylene diamine; 4,4'- methylenebis (2-chloroaniline) (MBOCA); diethyltoluene diamine (DETDA); and aromatic diamines such as Unilink 4200 (commercially available from UOP).
- Crosslinkers are tri- or greater functional molecules that can integrate into a polymer chain through two functionalities and provide one or more further functionalities (i.e., linkage sites) to crosslink to additional polymer chains.
- crosslinkers include glycerin, diethanolamine, trimethylolpropane, and sorbitol.
- a crosslinker or chain-extender may be used to replace at least a portion of the at least one polyol in the composite material.
- the polyurethane can be formed by the reaction of an isocyanate, a polyol, and a crosslinker.
- Coupling agents and other surface treatments such as viscosity reducers, flow control agents, or dispersing agents can be added directly to the filler or fiber, or incorporated prior to, during, and/or after the mixing and reaction of the composite material.
- Coupling agents can allow higher filler loadings of an inorganic filler such as fly ash and may be used in small quantities.
- the composite material may comprise about 0.01 wt % to about 0.5 wt % of a coupling agent.
- Examples of coupling agents useful with the composite materials described herein include Ken- React LICA 38 and KEN-React KR 55 (Kenrich Petrochemicals; Bayonne, NJ).
- dispersing agents useful with the composite materials described herein include JEFFSPERSE X3202, JEFFSPERSE X3202RF, and JEFFSPERSE X3204 (Huntsman Polyurethanes; Geismar, LA).
- UV light stabilizers such as UV absorbers
- UV light stabilizers include hindered amine type stabilizers and opaque pigments like carbon black powder.
- Fire retardants can be included to increase the flame or fire resistance of the composite material.
- Antimicrobials can be used to limit the growth of mildew and other organisms on the surface of the composite.
- Antioxidants such as phenolic antioxidants, can also be added. Antioxidants provide increased UV protection, as well as thermal oxidation protection.
- Pigments or dyes can optionally be added to the composite materials described herein.
- An example of a pigment is iron oxide, which can be added in amounts ranging from about 2 wt % to about 7 wt %, based on the total weight of the composite material.
- Examples of compositions illustrating aspects of the composites as described herein are shown in Tables 1-3.
- Exemplary ingredients for a first fly ash filled composite material (Composite 1) are shown in Table 1.
- fly ash filler and glycerin both have recyclable content
- castor oil has renewable content.
- the surfactants, catalysts, water, and glass fibers are not generally considered to have renewable or recyclable content.
- the use of castor oil as the polyol provides a polyurethane component of the composite (based only on the polyols and isocyanates) with a total environmental content of 41.66 wt %, and the total environmental content for Composite 1 is 79.84%.
- Composite 2 includes Ecopol 131, which is understood from the product literature to include 40% soybean oil (renewable content) and 40% recycled polyester (recyclable content).
- the fly ash filler contains recyclable content
- castor oil has renewable content.
- surfactants, catalysts, water, and glass fibers are not considered to contain renewable or recyclable content.
- the use of castor oil as the polyol provides a polyurethane component of the composite with a total environmental content of 38.97 wt %, and the total environmental content for Composite 2 is 79.19%.
- Exemplary ingredients for a third fly ash filled composite material are shown in Table 3.
- fly ash filler and glycerin contain recyclable content
- castor oil contains renewable content.
- the surfactants, catalysts, water, and glass fibers are not considered to contain renewable or recyclable content.
- the use of castor oil as the polyol provides a polyurethane component of the composite with a total environmental content of 37.45 wt %, and the total environmental content for Composite 3 is 78.83%.
- Table 3 Composite 3
- Composites 1-3 used as examples above are all based upon a filler loading of about 70 wt % fly ash. However, filler loading can be increased to about 85 wt % fly ash or greater, which would increase the total environmental content (other component amounts being held constant). While the percentages of castor oil in exemplary Composites 1-3 were at 85%, 20%, and 18%, the percentages of castor oil as a portion of the polyol can be, for example, 10-50%, 15-45%, 15-40%, 20-40%, 25-40%, or 30-40%. For further example, the percentages of castor oil as a portion of the polyol can be 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, or 50%.
- a method of preparing a composite material includes mixing (1) an isocyanate selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof; (2) a polyol, wherein the polyol consists essentially of one or more plant-based polyols (the one or more plant-based polyols including castor oil); (3) coal ash (e.g., fly ash) present in amounts from about 40% to about 90% by weight of the composite material; and (4) a catalyst.
- the isocyanate and polyol are allowed to react in the presence of the coal ash and catalyst to form the composite material.
- the composite material can be produced using a batch, semi-batch, or continuous process. At least a portion of the mixing step, reacting step, or both, can be conducted in a mixing apparatus such as a high speed mixer or an extruder. The method can further include the step of extruding the resulting composite material through a die or nozzle.
- a mixing step of the method used to prepare the composite materials described herein includes: (1) mixing the polyol and fly ash; (2) mixing the isocyanate with the polyol and the fly ash; and (3) mixing the catalyst with the isocyanate, the polyol, and the fly ash.
- a mixing step of the method used to prepare the composite materials described herein includes mixing the liquid ingredients (i.e., the polyol, isocyanate, catalyst, surfactants, and water) and then combining the mixed liquid ingredients with the fly ash and optional fiber.
- the composite material may be placed in a mold for post-extrusion curing and shaping.
- the composite material can be allowed to cure in individual molds or it can be allowed to cure in a continuous forming system such as a belt molding system.
- An ultrasonic device can be used for enhanced mixing and/or wetting of the various components of the composite materials described herein.
- Such enhanced mixing and/or wetting can allow a high concentration of filler (e.g., fly ash) to be mixed with the polyurethane matrix, including about 40 wt %, about 50 wt %, about 60 wt %, about 70 wt %, about 80 wt %, and about 90 wt % of the inorganic filler.
- the ultrasonic device produces an ultrasound of a certain frequency that can be varied during the mixing and/or extrusion process.
- the ultrasonic device useful in the preparation of composite materials described herein can be attached to or adjacent to an extruder and/or mixer.
- the ultrasonic device can be attached to a die or nozzle or to the port of an extruder or mixer.
- An ultrasonic device may provide de- aeration of undesired gas bubbles and better mixing for the other components, such as blowing agents, surfactants, and catalysts.
- the composite materials described herein can be foamed.
- the polyol and the isocyanate can be allowed to produce a foamed composite material after mixing the components according to the methods described herein.
- the composite materials described herein can be formed while they are actively foaming or after they have foamed.
- the material can be placed under the pressure of a mold cavity prior to or during the foaming of the composite material.
- the pressure that the foamed part exerts on the belts impacts the resulting mechanical properties. For example, as the pressure of the foaming increases and if the belt system can hold this pressure without the belts separating, then the product may have higher flexural strength than if the belts allowed leaking or pressure drop.
- the composite materials described herein can be formed into shaped articles and used in various applications including building materials.
- building materials include siding material, roof coatings, roof tiles, roofing material, carpet backing, flexible or rigid foams such as automotive foams (e.g., for dashboard, seats or roofing), component coating, and other shaped articles.
- shaped articles made using composite materials described herein include roofing material such as roof tile shingles; siding material; trim boards; carpet backing; synthetic lumber; building panels; scaffolding; cast molded products; decking materials;
- the composite materials described herein further can be used as reinforcement of composite structural members including building materials such as doors; windows; furniture; and cabinets and for well and concrete repair.
- the composite materials described herein also can be used to fill gaps, particularly to increase the strength of solid surface articles and/or structural components.
- the composite materials can be flexible, semi-rigid or rigid foams. In some embodiments, the flexible foam is reversibly deformable (i.e. resilient) and can include open cells.
- a 8" x 1" x 1" piece of a flexible foam can generally wrap around a 1" diameter mandrel at room temperature without rupture or fracture.
- Flexible foams also generally have a density of less than 5 lb/ft 3 (e.g. 1 to 5 lb/ft 3 ).
- the rigid foam is irreversibly deformable and can be highly crosslinked and/or can include closed cells.
- Rigid foams generally have a density of 5 lb/ft 3 or greater (e.g. 5 to 60 lb/ft 3 , 20 to 55 lb/ft 3 , or 30 to 50 lb/ft 3 ).
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Organic Chemistry (AREA)
- Health & Medical Sciences (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Polyurethanes Or Polyureas (AREA)
Abstract
Description
Claims
Priority Applications (2)
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CA2770909A CA2770909A1 (en) | 2009-08-14 | 2010-08-13 | Filled polyurethane composites and methods of making same |
AU2010282395A AU2010282395A1 (en) | 2009-08-14 | 2010-08-13 | Filled polyurethane composites and methods of making same |
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US23396609P | 2009-08-14 | 2009-08-14 | |
US61/233,966 | 2009-08-14 |
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WO2011019997A1 true WO2011019997A1 (en) | 2011-02-17 |
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PCT/US2010/045444 WO2011019997A1 (en) | 2009-08-14 | 2010-08-13 | Filled polyurethane composites and methods of making same |
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US (1) | US20110086933A1 (en) |
AU (1) | AU2010282395A1 (en) |
CA (1) | CA2770909A1 (en) |
WO (1) | WO2011019997A1 (en) |
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US10472281B2 (en) | 2015-11-12 | 2019-11-12 | Boral Ip Holdings (Australia) Pty Limited | Polyurethane composites with fillers |
CN107827435A (en) * | 2017-11-24 | 2018-03-23 | 广东净雨环保科技有限公司 | A kind of big plate of light ceramics and preparation method thereof |
CN110684165A (en) * | 2018-07-04 | 2020-01-14 | 国家能源投资集团有限责任公司 | Polyurethane composition, polyurethane composite material and preparation method thereof |
CN110684165B (en) * | 2018-07-04 | 2021-10-26 | 国家能源投资集团有限责任公司 | Polyurethane composition, polyurethane composite material and preparation method thereof |
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US20110086933A1 (en) | 2011-04-14 |
CA2770909A1 (en) | 2011-02-17 |
AU2010282395A1 (en) | 2012-03-01 |
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