Boral IP Holdings (Australia) Pty Limited

Westlake Royal Building Products Inc.

Guy Crocco

Russell Hill

Brian Shaw

Russ Majors

Kenneth Bruns

Brian Below

Bob Rathbone

Amitabha Kumar

Hamed Lakrout

Li Ai

Ying Zhang

Li Al

Joel Charlton

Daniel Gomez

Jacob Myers

Polyurethane foams and methods of manufacturing are described herein. The foam can include (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; and (b) a filler. The amount of filler in the foam can be from 50 to 90% by weight, based on the total weight of the foam. The filler can include a plurality of fibers and/or a particulate filler. The polyurethane foams described herein are made without adding a surfactant to the reaction mixture. The density of the polyurethane foam can be at least 5 lb/ft.

Surfactant-free filled polyurethane foam and method of making same

Polyurethane or polyisocyanurate foam stock and methods of manufacturing are described herein. The foam stock can include (a) a polyurethane or polyisocyanurate 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/ftto 35 lb/ft. The flexural strength of the foam stock can be at least 100 psi. The resulting foam stock can be used to produce polyurethane or polyisocyanurate foam to be used in composite panels.

Filled polyurethane or polyisocyanurate foam and method of making same

Composite materials and methods for their preparation are described herein. The composite materials can comprise a polyurethane and an absorptive filler. The polyurethane can be formed from the reaction of at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates, and combinations thereof, and one or more isocyanate-reactive monomers. The one or more isocyanate-reactive monomers can comprise at least one polyol and a first isocyanate-reactive monomer which includes one or more isocyanate-reactive functional groups and a moiety configured to associate with the absorptive filler.

Composites formed from an absorptive filler and a polyurethane

Polyurethane composites and methods of preparation are described herein. The methods of making the polyurethane composite can include mixing () at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, () at least one polyol, () an inorganic filler, and () an evaporative coolant in an extruder to form a mixture. The method also include extruding the mixture into a mold cavity, generating heat in the mold cavity from the reaction of the at least one isocyanate and the at least one polyol, and allowing the evaporative coolant to migrate to an interface between the mixture and the interior mold surface. The temperature of the mixture causes evaporation of the evaporative coolant at the interface thereby removing heat at the interface. Suitable evaporative coolants for use in the methods of making the polyurethane composites include hydrofluorocarbons and hydrochlorofluorocarbons.

Use of evaporative coolants to manufacture filled polyurethane composites

Composite materials and methods for their preparation are described herein. The composite materials can comprise (a) a polyurethane and (b) from 35% to 90% by weight, based on the total weight of the composite, of a particulate filler dispersed in the polyurethane. The polyurethane can be 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. The one or more polyols that form the polyurethane comprise a high hydroxyl number polyol having a hydroxyl number of at least 250 mg KOH/g. In some cases, the one or more polyols that form the polyurethane can have a weight average equivalent weight of from 200 to 1100 amu. In some cases, the one or more polyols that form the polyurethane can include less than 5% by weight, based on the total weight of the one or more polyols that form the polyurethane, of one or more flexible polyols having a hydroxyl number of less than 150 mg KOH/g and a functionality of less than 3.

Highly filled polyurethane composites

Methods are disclosed of forming a joint between a relatively hardened strip of material, such as a molded and cured conveyor belt strip, and an adjacent material that is in the process of curing. The curing material shrinks during the curing process, pulling away from the edge of the relatively hardened strip. The method includes moving the relatively hardened strip of material toward the curing, adjacent material strip to compensate for the shrinkage. An apparatus, for example, grips the relatively hardened strip of material and maintains a constant pressure at the interface between the relatively hardened strip of material and the curing material strip while the latter cures and shrinks.

Elastomeric thermo-mechanical compensator

Polymeric composites and methods for preparing the composites are described herein. The polymeric composites can comprise a polymer, an inorganic filler, and a plurality of short length fibers. The polymer in the composites can include homopolymers and copolymers and can also include plastics, resins, elastomers, thermoplastics, thermosets, and hot melts. The inorganic filler can be fly ash. The short length fibers can have an average length of 650 &#x3bc;m or less. Methods for making the polymeric composites are also described.

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New Braunfels, TX, United States of America

Guy Crocco