Non-Porous Thermoformable Polyurethane Solid

Abstract

The subject disclosure presents systems and methods for manufacturing a non-porous thermoformable polyurethane solid by combining an uncured polyurethane resin with Aluminum Trihydrate (ATH), a plurality of particulates, molecular sieves, and color particulates. This combination is mixed in a vacuum for a time period sufficient to initiate an exothermic reaction within the mixture. After the time period, the exothermically reacting mixture is allowed to cure to form the polyurethane solid. The curing may occur in a mold, i.e. by pouring or injecting the mixture into the mold. Alternatively, the mixture may be sprayed on to a surface and allowed to cure.

What is claimed is: 
     
         1 . A thermoformable, non-porous, polyurethane material, comprising:
 a plurality of isocyanates;   a plurality of polyols;   alumina trihydrate (ATH);   a plurality of particulates; and   a plurality of molecular sieves;   wherein the plurality of isocyanates, the plurality of polyols, the ATH, the plurality of particulates, and the plurality of molecular sieves are mixed in a vacuum mixer to form a mixture,   wherein a duration of mixing and a vacuum level of the vacuum mixer are sufficient to induce an exothermic polymerization reaction, and   wherein the mixture is formed into a composite material after said duration of mixing.