Composite materials and methods for their preparation are described herein. The composite materials include a polyurethane made from the reaction of an isocyanate and a mixture of polyols, and coal ash (e.g., fly ash). The mixture of polyols comprises at least two polyols including a high hydroxyl number polyol having a hydroxyl number greater than 250 and comprising from about 1% to about 25% by weight of the total polyol content used to form the polyurethane, and a low hydroxyl number polyol having a hydroxyl number of 250 or lower. The coal ash is present in amounts from about 40% to about 90% by weight of the composite material. Also described is a method of preparing a composite material, including mixing an isocyanate, a mixture of at least two polyols, coal ash (e.g., fly ash), and a catalyst.

Filled polyurethane composites and methods of making same

An inorganic hardening composition contains 100 parts by weight of an alkaline earth metal oxide, and 5 to 80 parts by weight of an organic carbonic acid compound.

Inorganic hardening composition

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

Composite materials and methods for their preparation are described herein. The composite materials include a polyurethane made from the reaction of at least one isocyanate and at least one polyol, and coal ash (e.g., fly ash). The composite materials are highly reactive systems such as through the use of highly reactive polyols, highly reactive isocyanates, or both. The coal ash is present in amounts from about 40% to about 90% by weight of the composite material. Also described is a method of preparing a composite material, including mixing at least one isocyanate, at least one polyol, coal ash, and a catalyst.

Polyurethanes derived from highly reactive reactants and coal ash

Polyurethane composites and methods of preparation are described herein. The methods of making the polyurethane composite can include mixing (1) at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates, and mixtures thereof, (2) at least one polyol, (3) an inorganic filler (4) a catalyst, and (5) 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.

The use of evaporative coolants to manufacture filled polyurethane composites

The present invention relates to a process for the manufacture of foamed or non-foamed compositions, in which one or more organic or inorganic compounds containing at least two isocyanate groups is or are reacted in the presence of an alkaline aqueous solution, an alkaline aqueous suspension or an alkaline aqueous slurry of an alkali metal hydroxide and/or alkaline earth metal hydroxide, and of one or more catalysts and, optionally, inert fillers and/or, optionally, one or more volatile substances as blowing agents. According to the invention, a mixture of the compound or compounds containing the isocyanate groups and the alkali metal hydroxide or oxide and/or alkaline earth metal hydroxide or oxide is added to a mixture of water and catalyst. The oxide employed is preferably calcium oxide.

Process for the manufacture of foamed or non-foamed compositions

The process comprises the reaction of one or several organic or inorganic compounds having at least two isocyanates groups, in the presence of an alkaline aqueous solution, of an alkaline aqueous suspension or an alkaline aqueous poste of alkaline or alkalino-earth hydroxyl, one or several catalysts and if necessary, inert charges and/ or one or several volatile substances as a driving agent. In the process, is added to a mixture of water and catalyst, a mixture of the compound(s) having isocyanates groups and of hydroxyl or alkaline and/or alkalino earth oxide. As an oxide, it is prefered to add the calcium oxide.

Franz G. Reuter

Papers

Process for the manufacture of foamed or non-foamed compositions

Process for preparing foaming or non foaming masses