Filled polyurethane or polyisocyanurate foam and method of making same

Abstract

Polyurethane or polyisocyanate form stock and methods of manufacturing are described herein. The foam stock can include (a) a polyurethane or polyisocyanate 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; and (b) a filler present in an amount from greater than 50% to 90% by weight, based on the total weight of the foam stock. The density of the foam stock can be from 10 lb/ft 3 to 35 lb/ ft 3 . The flexural strength of the foam stock can be at least 100 psi. The resulting foam stock can be used to produce polyurethane or polyisocyanate foam to be used in composite panels.

What is claimed is: 
     
         1 - 57 . (canceled) 
     
     
         58 . A method of making a polyurethane or polyisocyanurate foam, the method comprising:
 mixing one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof; one or more polyols; and a filler to produce a mixture, wherein the filler is present in an amount from greater than 50% to 90% by weight, based on the total weight of the mixture;   applying the mixture to a mold at a viscosity of 20,000 cPs to 100,000 cPs at the temperature of the mixture; and   allowing the mixture to react and expand to form the polyurethane or polyisocyanurate foam;   wherein the foam does not reach a hardness of 20 shore D in less than 5 minutes.   
     
     
         59 . The method of  claim 58 , wherein the foam has a flexural strength of from 100 psi to 700 psi. 
     
     
         60 . The method of  claim 58 , wherein filler includes a particulate filler, a plurality of fibers, or a combination thereof. 
     
     
         61 . The method of  claim 58 , wherein the filler comprises glass fibers, polyalkylene fibers, polyester fibers, polyamide fibers, phenol-formaldehyde fibers, polyvinyl chloride fibers, polyacrylic fibers, acrylic polyester fibers, polyurethane fibers, polyacrylonitrile fibers, rayon fibers, cellulose fibers, carbon fibers, metal and metal-coated fibers, mineral fibers, or combinations thereof. 
     
     
         62 . The method of  claim 58 , wherein the foam has a density of 10 lb/ft 3  to 35 lb/ft 3 . 
     
     
         63 . The method of  claim 58 , wherein the mixture further comprises a catalyst. 
     
     
         64 . The method of  claim 58 , wherein the mixture applied to the mold has a tack free time of from 90 seconds to 7 minutes. 
     
     
         65 . The method of  claim 58 , wherein the mixture applied to the mold has a cream time of from 20 seconds to 120 seconds. 
     
     
         66 . The method of  claim 58 , wherein the foam has a thickness from 0.1 inch to 6 inches. 
     
     
         67 . A method of making a polyurethane or polyisocyanurate foam, the method comprising:
 mixing one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof; one or more polyols; and a filler to produce a mixture, wherein the filler is present in an amount from greater than 50% to 90% by weight, based on the total weight of the mixture;   applying the mixture to a mold; and   allowing the mixture to react and expand to form the polyurethane or polyisocyanurate foam,   wherein the mixture applied to the mold has a tack free time of from 90 seconds to 7 minutes and   wherein the resulting polyurethane or polyisocyanurate foam has a density of 10 lb/ft 3  or greater.   
     
     
         68 . The method of  claim 67 , wherein the foam has a flexural strength of from 100 psi to 700 psi. 
     
     
         69 . The method of  claim 67 , wherein the foam has a compressive strength from 100 psi to 300 psi. 
     
     
         70 . The method of  claim 67 , wherein the filler comprises an inorganic particulate filler and a plurality of fibers. 
     
     
         71 . The method of  claim 70 , wherein the plurality of fibers comprises glass fibers, polyalkylene fibers, polyester fibers, polyamide fibers, phenol-formaldehyde fibers, polyvinyl chloride fibers, polyacrylic fibers, acrylic polyester fibers, polyurethane fibers, polyacrylonitrile fibers, rayon fibers, cellulose fibers, carbon fibers, metal and metal-coated fibers, mineral fibers, or combinations thereof. 
     
     
         72 . The method of  claim 67 , wherein the mixture has a viscosity of 20,000 cPs to 100,000 cPs when applied to the mold. 
     
     
         73 . The method of  claim 67 , wherein the mixture applied to the mold has a cream time of from 80 seconds to 120 seconds. 
     
     
         74 . The method of  claim 67 , wherein the foam does not reach a hardness of 20 shore D in less than 5 minutes. 
     
     
         75 . A method of making a polyurethane or polyisocyanurate foam, the method comprising:
 mixing one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof; one or more polyols; and a filler to produce a mixture, wherein the filler is present in an amount from greater than 50% to 90% by weight, based on the total weight of the mixture;   applying the mixture to a mold; and   allowing the mixture to react and expand to form the polyurethane or polyisocyanurate foam,   wherein the mixture applied to the mold has a cream time of from 80 seconds to 120 seconds.   
     
     
         76 . The method of  claim 75 , wherein the foam has a flexural strength of from 100 psi to 700 psi.