Boral IP Holdings (australia) Pty Limited

Westlake Royal Building Products Inc.

Li Ai

Russell Hill

Amitabha Kumar

Guy Crocco

Hamed Lakrout

Russ Majors

Brian Shaw

Cassandra Hill

Zhaozhou Zhang

Mark Joseph Hollett

Robert F Rathbone

Ying Zhang

Matthew Yatco Meneses

Sarah Fortenberry

Jacob Myers

Redmond Richard Lloyd

Louise Margaret Keyte

Composite panels and methods of preparation are described herein. In some embodiments, the composite panel can include a first fiber reinforcement, a polyurethane composite having a first surface and a second surface opposite the first surface, wherein the first surface is in contact with the first fiber reinforcement; and a cementitious material adjacent the first fiber reinforce-opposite the polyurethane composite. The polyurethane composite can be formed from (i) one or more isocyanates selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, (ii) one or more polyols, and (iii) a particulate filler. The fiber reinforcement can be formed from a woven or non-woven material, such as glass fibers. The composite panel can further include a material, such as a second fiber reinforcement and a cementitious layer, in contact with the second surface of the polyurethane composite. Articles comprising the composite panels are also disclosed.

Highly-filled polyurethane composites with fiber reinforcement

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 composites comprising non-silane treated glass fibers and methods of manufacturing are described herein. The polyurethane composites 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; (b) a filler; and (c) non-silane treated glass fibers. In some instances, none of the glass fibers in the polyurethane composites are silane treated. The polyurethane composites comprising the non-silane treated glass fibers can have a flexural strength that is greater than the flexural strength of an identical composition wherein the non-silane treated glass fibers are replaced with silane-treated glass fibers. Articles comprising the polyurethane composites are also disclosed herein.

Highly-filled polyurethane composites with non-silane treated glass fibers

Polyurethane composites and methods of preparation are described herein. The polyurethane composites 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) an inorganic filler, (c) an inorganic fiber, and (d) an organic fiber. Suitable organic fibers can include polyester fibers. The weight ratio of the inorganic fiber to the organic fiber can be from 1:1 to 20:1. Articles comprising the polyurethane composites described herein are also disclosed.

Filled polyurethane composites with organic and inorganic fibers

Polyurethane composites and methods of preparation are described herein. The polyurethane composites 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) a particulate filler having a bulk density of 1 g/cmor greater, (c) optionally a fiber material, and (d) a lightweight filler having a bulk density from 0.01 g/cmto less than 1 g/cm. In some examples, the lightweight filler can be selected from expanded perlite, expanded clay, foamed glass, and combinations thereof. Articles such as building materials comprising the polyurethane composites are also disclosed.

Filled polyurethane composites with lightweight fillers

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 for producing building materials comprising a reinforced substrate are described herein. The method can include providing a substrate having a first surface and an opposed second surface, applying a fabric material to the first surface of the substrate, applying a hydrophobic polymeric woven mesh to the fabric material, applying a coating to the hydrophobic polymeric woven mesh thereby allowing the coating to penetrate the hydrophobic polymeric woven mesh and fabric material, removing the hydrophobic polymeric woven mesh, and curing the coating thereby bonding the fabric material to the first surface of the substrate. The substrate can include a polymeric material. In some embodiments, the substrate can include a polyurethane foam. The substrate can further include a filler. The hydrophobic polymeric woven mesh used in the building materials can be derived from alkylene monomers.

Method of producing reinforced substrate

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.

Filled polymeric composites including short length fibers

Inorganic polymer compositions and methods for their preparation are described herein. The compositions include the reaction product of a reactive powder, an activator, and optionally a retardant. The reactive powder includes fly ash, calcium sulfoaluminate cement, and less than 10% by weight portland cement. In some examples, the composition is substantially free from alkanolamines. In some examples, the ratio of water to reactive powder is from 0.06:1 to less than 0.2:1. Also described herein are building materials including the compositions.

Calcium sulfoaluminate cement-containing inorganic polymer compositions and methods of making same

Inorganic polymer compositions and methods for their preparation are described herein. The compositions include the reaction product of a reactive powder, an activator, and optionally a retardant in the presence of water and an aerating agent. The reactive powder includes 85% or greater fly ash. The aerating agent can be a blowing agent, a foaming agent, or a mixture of these. Also described herein are building materials including the compositions.

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San Antonio, TX, United States of America

Li Ai