Composite materials comprising aggregate and an elastomeric composition

Abstract

A composite material comprises aggregate and an elastomeric composition. The elastomeric composition comprises the reaction product of an isocyanate component and an isocyanate-reactive component. The isocyanate component comprises a polymeric isocyanate, and optionally, an isocyanate-prepolymer. The isocyanate-reactive component comprises a hydrophobic polyol and a chain extender having at least two hydroxyl groups and a molecular weight of from about 62 to about 220. The chain extender is present in the isocyanate-reactive component in an amount of from about 1 to about 20 parts by weight based on 100 parts by weight of the isocyanate-reactive component. The aggregate may be rock, crumb rubber, and/or glass. The composite material has excellent physical properties and may be formed underwater, used in various locations, and used in various applications, such as for pavement, revetments, etc. Methods of forming and using the composite material and systems for forming the elastomeric composition are also disclosed.

1 - 34 . (canceled) 
     
     
         35 . A system for forming an elastomeric composition which bonds aggregate, said system comprising:
 I) an isocyanate component comprising
 a polymeric isocyanate, and 
 an isocyanate-prepolymer 
 wherein said isocyanate-prepolymer is present in said isocyanate component in an amount of from about 25 to about 75 parts by weight based on 100 parts by weight of said isocyanate component; and 
   II) an isocyanate-reactive component comprising
 a hydrophobic polyol, and 
 a chain extender having at least two hydroxyl groups and a molecular weight of from about 62 to about 220; 
 wherein said chain extender is present in said isocyanate-reactive component in an amount of from about 1 to about 20 parts by weight based on 100 parts by weight of said isocyanate-reactive component. 
   
     
     
         36 . The system as set forth in  claim 35 , wherein said hydrophobic polyol comprises a natural oil polyol. 
     
     
         37 . The system as set forth in  claim 36 , wherein said natural oil polyol is castor oil. 
     
     
         38 . The system as set forth in  claim 35 , wherein said chain extender comprises an alkylene glycol. 
     
     
         39 . The system as set forth in  claim 38 , wherein said alkylene glycol is dipropylene glycol. 
     
     
         40 . The system as set forth in  claim 35 , wherein said isocyanate-prepolymer comprises the reaction product of a diphenylmethane diisocyanate and a polyol, has an NCO content of about 22.9 wt. %, and an average NCO functionality of from about 2 to about 3. 
     
     
         41 . The system as set forth in  claim 35 , wherein said polymeric isocyanate comprises polymeric diphenylmethane diisocyanate, has an NCO content of about 31.5 wt. %, and an average NCO functionality of from about 2 to about 3. 
     
     
         42 . The system as set forth in  claim 35 , wherein said hydrophobic polyol is present in an amount of from about 80 to about 99 parts by weight, alternatively, in an amount of from about 85 to about 95 parts by weight, each based on 100 parts by weight of said isocyanate-reactive component. 
     
     
         43 - 45 . (canceled) 
     
     
         46 . The system as set forth in  claim 35 , wherein said isocyanate-prepolymer is present in an amount of from about 50 to about 75 parts by weight, alternatively, in an amount of from about 55 to about 65 parts by weight, each based on 100 parts by weight of said isocyanate component. 
     
     
         47 . The system as set forth in  claim 35 , wherein said isocyanate-prepolymer and said polymeric isocyanate are present in said isocyanate component in a weight ratio of from about 1:2 to about 2.5:1, alternatively, in a weight ratio of about 1.5:1. 
     
     
         48 . The system as set forth in  claim 35 , wherein said chain extender has a molecular weight of from about 62 to about 150. 
     
     
         49 . The system as set forth in  claim 35 , wherein said chain extender is present in an amount of from about 5 to about 10 parts by weight based on 100 parts by weight of said isocyanate-reactive component. 
     
     
         50 . The system as set forth in  claim 35 , further comprising:
 i) a molecular sieve in an amount of from about 0.01 to about 5.0 parts by weight based on 100 parts by weight of said isocyanate-reactive component;   ii) an antifoaming agent in an amount of from about 0.01 to about 0.10 parts by weight based on 100 parts by weight of said isocyanate-reactive component; or   iii) both i) and ii).   
     
     
         51 . A system for forming an elastomeric composition which bonds aggregate, said system comprising:
 I) an isocyanate component comprising
 a polymeric isocyanate, and 
 an isocyanate-prepolymer 
 wherein said isocyanate-prepolymer is present in said isocyanate component in an amount of from about 50 to about 75 parts by weight based on 100 parts by weight of said isocyanate component; and 
   II) an isocyanate-reactive component comprising
 a hydrophobic polyol comprising a natural oil polyol, and 
 a chain extender comprising an alkylene glycol having at least two hydroxyl groups and a molecular weight of from about 62 to about 150; 
 wherein said chain extender is present in said isocyanate-reactive component in an amount of from about 5 to about 10 parts by weight based on 100 parts by weight of said isocyanate-reactive component. 
   
     
     
         52 . The system as set forth in  claim 51 , wherein:
 i) said natural oil polyol is castor oil;   ii) said alkylene glycol is dipropylene glycol; or   iii) both i) and ii).   
     
     
         53 . The system as set forth in  claim 51 , wherein said isocyanate-prepolymer is present in an amount of from about 55 to about 65 parts by weight based on 100 parts by weight of said isocyanate component. 
     
     
         54 . The system as set forth in  claim 51 , wherein said isocyanate-prepolymer and said polymeric isocyanate are present in said isocyanate component in a weight ratio of from about 1:2 to about 2.5:1, alternatively, in a weight ratio of about 1.5:1. 
     
     
         55 . The system as set forth in  claim 51 , wherein:
 i) said isocyanate-prepolymer comprises the reaction product of a diphenylmethane diisocyanate and a polyol, has an NCO content of about 22.9 wt. %, and an average NCO functionality of from about 2 to about 3;   ii) said polymeric isocyanate comprises polymeric diphenylmethane diisocyanate, has an NCO content of about 31.5 wt. %, and an average NCO functionality of from about 2 to about 3; or   iii) both i) and ii).   
     
     
         56 . The system as set forth in  claim 51 , further comprising:
 i) a molecular sieve in an amount of from about 0.01 to about 5.0 parts by weight based on 100 parts by weight of said isocyanate-reactive component;   ii) an antifoaming agent in an amount of from about 0.01 to about 0.10 parts by weight based on 100 parts by weight of said isocyanate-reactive component; or   iii) both i) and ii).   
     
     
         57 . An elastomeric composition comprising the reaction product of the system as set forth in  claim 51 .