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 polymer matrix contains a polyurethane network formed by the reaction of a poly- or di-isocyanate and one or more saturated polyether or polyester polyols, and an optional polyisocyanurate network formed by the reaction of optionally added water and isocyanate. 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. The addition of water can also serve to provide a blowing agent to the reaction mixture, resulting in a foamed structure, if such is desired.

1 . A method of producing a polymer matrix composite, comprising:
 (1) mixing a first poly ether polyol having a first molecular weight and a second poly ether polyol having a second molecular weight higher than the first molecular weight with one or more catalysts, water, and optional surfactant;   (2) optionally introducing reinforcing fibrous materials into the mixture;   (3) introducing inorganic filler into the mixture;   (4) introducing poly- or di-isocyanate into the mixture; and   (5) allowing the exothermic reaction to proceed without forced cooling except to control runaway exotherm, thereby forming a polymer matrix composite.   
     
     
         2 . The method of  claim 1 , further comprising extruding the mixture or the polymer matrix composite through a die. 
     
     
         3 . The method of  claim 2 , wherein at least a portion of the mixing or reaction, or both occurs in an extruder. 
     
     
         4 . The method of  claim 1 , further comprising molding the polymer matrix composite into a desired shape. 
     
     
         5 . The method of  claim 2 , further comprising forming the polymer matrix composite into a synthetic lumber. 
     
     
         6 . The method of  claim 5 , wherein the forming comprises shaping the polymer matrix composite into a size and shape suitable for synthetic lumber. 
     
     
         7 . The method of  claim 6 , wherein the forming further comprises embossing or impressing at least one surface of the polymer matrix composite with a pattern. 
     
     
         8 . The method of  claim 1 , wherein the one or more catalysts comprise a skin-forming catalyst. 
     
     
         9 . The method of  claim 8 , wherein the skin-forming catalyst comprises an organic tin compound. 
     
     
         10 . The method of  claim 1 , wherein the one or more catalysts comprise a gelation catalyst. 
     
     
         11 . The method of  claim 10 , wherein the gelation catalyst comprises an amine. 
     
     
         12 . The method of  claim 1 , further comprising introducing axially oriented fiber rovings into the polymer matrix composite. 
     
     
         13 . The method of  claim 12 , wherein the fiber rovings are introduced on, in, or beneath the surface of the composite.