Filled polyurethane composites with size-graded fillers

Abstract

Polyurethane composites and methods of preparing polyurethane composites are described herein. The polyurethane composite can comprise (a) a polyurethane formed by the reaction of (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and (ii) one or more polyols; (b) fly ash comprising 50% or greater by weight, fly ash particles having a particle size of from 0.2 micron to 100 microns; and (c) a coarse filler material comprising 80% or greater by weight, filler particles having a particle size of from greater than 250 microns to 10 mm. The coarse filler material can be present in the composite in an amount of from 1% to 40% by weight, based on the total weight of the composite. The weight ratio of the fly ash to the coarse filler material can be from 9:1 to 200:1.

1 . A composite comprising:
 (a) a polyurethane formed by the reaction of (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and (ii) one or more polyols;   (b) from 20% to 90% by weight, based on the total weight of the composite, of fly ash comprising 50% or greater by weight, fly ash particles having a particle size of from 0.2 micron to 100 microns; and   (c) from 1% to 40% by weight, based on the total weight of the composite, of a coarse filler material comprising 80% or greater by weight, filler particles having a particle size of from greater than 250 microns to 10 mm,   wherein the weight ratio of the fly ash to the coarse filler material is from 9:1 to 200:1.   
     
     
         2 . The composite of  claim 1 , wherein the particle size of the 80% or greater by weight, filler particles is from greater than 500 microns to 1 mm. 
     
     
         3 . The composite of  claim 1 , wherein the particle size of the 80% or greater by weight, filler particles is from 300 microns to 500 microns. 
     
     
         4 . (canceled) 
     
     
         5 . The composite of  claim 1 , wherein the coarse filler material includes silica sand, silica fume, cement, slag, metakaolin, talc, mica, wollastonite, limestone, calcium carbonate, perlite, clay, shale, ceramic, glass, seed hull, organic waste, or combinations thereof. 
     
     
         6 . (canceled) 
     
     
         7 . (canceled) 
     
     
         8 . (canceled) 
     
     
         9 . (canceled) 
     
     
         10 . The composite of  claim 1 , further comprising a fiber material, wherein the fiber material is present in an amount of from 1% to 20% by weight, based on the total weight of the composite. 
     
     
         11 . (canceled) 
     
     
         12 . The composite of  claim 9 , wherein the fiber material includes a plurality of glass fibers. 
     
     
         13 . (canceled) 
     
     
         14 . (canceled) 
     
     
         15 . The composite of  claim 1 , wherein the fly ash is present in an amount of from 50% to 80% by weight, based on the total weight of the composite. 
     
     
         16 . (canceled) 
     
     
         17 . The composite of  claim 1 , wherein the fly ash has a particle size distribution comprising a first mode having a median particle diameter from 0.3 micron to 1 micron, a second mode having a median particle diameter from 10 microns to 25 microns, and a third mode having a median particle diameter from 40 microns to 80 microns. 
     
     
         18 . The composite of  claim 17 , wherein the weight ratio of the fly ash to the coarse filler material is from 9:1 to 150:1. 
     
     
         19 . (canceled) 
     
     
         20 . (canceled) 
     
     
         21 . (canceled) 
     
     
         22 . (canceled) 
     
     
         23 . The composite of  claim 1 , wherein the composite has a density of from 5 lb/ft 3  to 70 lb/ft 3 . 
     
     
         24 . (canceled) 
     
     
         25 . (canceled) 
     
     
         26 . A building material comprising the composite of  claim 1 . 
     
     
         27 . (canceled) 
     
     
         28 . A composite comprising:
 (a) from 15% to 60% by weight, based on the total weight of the composite, of a polyurethane formed by the reaction of (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, and (ii) one or more polyols;   (b) from 20% to 80% by weight, based on the total weight of the composite, of Class C fly ash having a particle size distribution comprising a first mode having a median particle diameter from 0.3 micron to 1 micron, a second mode having a median particle diameter from 10 microns to 25 microns, and a third mode having a median particle diameter from 40 microns to 80 microns;   (c) from 1% to 40% by weight, based on the total weight of the composite, of a coarse filler material comprising 80% or greater by weight, filler particles having a particle size of from 250 microns to 10 mm, and   (d) from 1% to 20% by weight, based on the total weight of the composite, of a glass fiber material,   wherein the weight ratio of the fly ash to the coarse filler material is from 9:1 to 200:1.   
     
     
         29 . The composite of  claim 28 , wherein the particle size of the 80% or greater by weight, filler particles is from 300 microns to 1 mm. 
     
     
         30 . (canceled) 
     
     
         31 . The composite of  claim 28 , wherein the coarse filler material includes silica sand, silica fume, cement, slag, metakaolin, talc, mica, wollastonite, limestone, calcium carbonate, perlite, clay, shale, ceramic, glass, seed hull, organic waste, or combinations thereof. 
     
     
         32 . The composite of  claim 28 , further comprising a fiber material selected from polyacrylonitrile fibers, polyamide fibers, polyester fibers, glass fibers, mineral wool, rayon, cellulose, wood fiber, saw dust, wood shavings, cotton, lint, polypropylene fibers, polyethylene fibers, polyacrylic fibers, or combinations thereof. 
     
     
         33 . (canceled) 
     
     
         34 . The composite of  claim 28 , wherein the weight ratio of the Class C fly ash to the coarse filler material is from 9:1 to 150:1. 
     
     
         35 . (canceled) 
     
     
         36 . A method of making a polyurethane composite comprising:
 (a) mixing (1) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, (2) one or more polyols, (3) 20% to 90% by weight, based on the total weight of the composite, of fly ash comprising 50% or greater by weight, fly ash particles having a particle size of from 0.2 micron to 100 microns, and (4) 1% to 40% by weight, based on the total weight of the composite, of a coarse filler material comprising 80% or greater by weight, filler particles having a particle size of from 250 microns to 10 mm to form a mixture, wherein the weight ratio of the fly ash to the coarse filler material is from 9:1 to 200:1; and   (b) allowing the one or more isocyanates and the one or more polyols to react in the presence of the fly ash and the coarse filler material to form the polyurethane composite.   
     
     
         37 . The method of  claim 36 , wherein the mixture further comprises a catalyst. 
     
     
         38 . The method of  claim 36 , wherein the mixture further includes 1% to 20% by weight, based on the total weight of the mixture, of a fiber material. 
     
     
         39 . The method of  claim 36 , wherein the coarse filler material includes silica sand, silica fume, cement, slag, metakaolin, talc, mica, wollastonite, limestone, calcium carbonate, perlite, clay, shale, ceramic, glass, seed hull, organic waste, or combinations thereof. 
     
     
         40 . (canceled) 
     
     
         41 . (canceled)