Composite panel with solid polyurethane binder, and process for manufacture

Abstract

The embodiments of the invention are directed to a composite material comprising a fiber reinforcing material, a binder resin and polyurethane foam particles. Other embodiments are related to a process for manufacturing a composite material comprising a fiber reinforcing material, a binder resin and polyurethane foam particles, the method comprising depositing the binder resin and polyurethane foam particles the fiber reinforcing material to form a composite precursor and treating the composite precursor to form the composite material.

1 . A composite material comprising:
 a surface layer comprising a solid reinforcing material and solid polyurethane particles;   a core layer comprising the solid reinforcing material and a binder resin;   wherein the solid polyurethane particles and the binder resin have different compositions;   wherein the surface layer and the core layer are located such that the surface layer and the core layer are separate layers having different compositions; and   wherein the solid reinforcing material comprises wood.   
     
     
         2 . The composite material of  claim 1 , wherein the weight percent of the solid polyurethane particles in a matrix is 5 to 95 weight percent of the matrix. 
     
     
         3 . The composite material of  claim 1 , wherein the weight percent of the solid polyurethane particles in a matrix is 30 to 60 weight percent of the matrix. 
     
     
         4 . The composite material of  claim 1 , wherein the wood is in a form selected from the group consisting of sheets, plies, wafers, strands, chips, particles, dust and combinations thereof. 
     
     
         5 . The composite material of  claim 1 , wherein the solid reinforcing material further comprises fibers. 
     
     
         6 . The composite material of  claim 5 , wherein the fibers are selected from the group consisting of carbon fibers, glass fibers, aramid fibers, cellulose fibers and combinations thereof. 
     
     
         7 . The composite material of  claim 1 , wherein a matrix is in a form of a continuous phase or a discontinuous phase. 
     
     
         8 . The composite material of  claim 1 , wherein the binder is selected from the group consisting of polymeric MDI, phenol formaldehyde, urea formaldehyde, melamine formaldehyde and combinations thereof. 
     
     
         9 . The composite material of  claim 1 , wherein the solid reinforcing material is oriented in a plane of the composite material. 
     
     
         10 . The composite material of  claim 1 , wherein the composite material is an oriented strand board. 
     
     
         11 . The composite material of  claim 1 , wherein the core layer contains no solid polyurethane particles. 
     
     
         12 . The composite material of  claim 1 , wherein the core layer contains no solid polyurethane particles. 
     
     
         13 . The composite material of  claim 1 , wherein at least 50 weight percent of the composite material comprises wood. 
     
     
         14 . A composite material, wherein the composite material is an oriented strand board, comprising:
 a surface layer comprising a solid reinforcing material and solid polyurethane particles;   a core layer comprising the solid reinforcing material and a binder resin;   wherein the solid polyurethane particles and the binder resin have different compositions;   wherein the surface layer and the core layer are located such that the surface layer and the core layer are separate layers having different compositions;   wherein the solid reinforcing material comprises wood,   wherein the wood is in a form selected from the group consisting of sheets, plies, wafers, strands, chips, particles, dust and combinations thereof, and   wherein the solid polyurethane particles comprise particles of ground rigid polyurethane foam.