Abstract: 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.

Abstract: Foam composites and methods of preparation thereof are discussed. For example, the foam composite may include a polymeric material and a particulate filler, wherein the compressive strength of the foam composite is equal to or greater than 20 psi, the density is 4 pcf to 40 pcf, and wherein the thermal conductivity is equal to or less than 0.050 W/m K. the particulate filler may include fly ash, e.g., in an amount of about of 45% to about 75% by weight with respect to the total weight of the foam composite. The foam composite may be prepared from a mixture of a polyol, an isocyanate, the particulate filler, and a liquid blowing agent having a boiling point equal to or greater than 25° C. or 30° C.

Abstract: Cutting apparatuses and methods of use thereof are discussed. For example, the cutting apparatus may include a chassis with one or more substrate interfaces and a scribe guide. The cutting apparatuses also may include a plurality of support pistons, a deformable support, a locking mechanism, and/or an anchor extension. The support pistons may be adjustable to generally conform to a substrate, such as a non-planar substrate.

Abstract: 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 reinforcement 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.

Abstract: Disclosed herein are organic-inorganic composite materials. Also disclosed herein are organic-inorganic composite materials including polymer substrates with at least one cementitious layer comprising inorganic fibers and organic fibers. Also disclosed herein are organic-inorganic composite materials including polymer substrates with at least one cementitious layer comprising fibers of varying length and diameter. Also disclosed herein are organic-inorganic composite materials including polymer substrates with at least one cementitious layer comprising a plurality of fibers having an average diameter of 7 microns or greater. Also disclosed herein are methods of making and using the same.

Abstract: The present invention relates to the use of sacrificial agents to counteract the deleterious impact of gypsum contaminants on the effectiveness of certain stucco additives, particularly, water reducing agents and foaming agents, in a stucco slurry used to make gypsum wallboard.

Abstract: Polyurethane composites having improved mechanical strength and linear coefficient of thermal expansion (LCTE) and methods of manufacturing are described herein. The 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 in an amount of from greater than 50% to 90% by weight, based on the total weight of the polyurethane composite, (c) from 0.25% to 10% by weight, based on the total weight of the composite, of glass fibers; and (d) from 0.025% to 5% by weight, based on the total weight of the composite, of polyester fibers. The polyester fibers can have an average aspect ratio of length to diameter of from 5:1 to 600:1. The LCTE (?40° C. to 70° C.) of the polyurethane composite can be 2.2×10-5/° C. or less.

Abstract: Disclosed herein are building products comprising a polyurethane formed by the reaction of at least one isocyanate selected from the group consisting of diisocyanates, polyisocyanates and mixtures thereof and at least one polyol in the presence of fly ash and a non-silicone surfactant, wherein, the fly ash is present in an amount from 40% to 90% by weight based on the total weight of the building product; and wherein, the non-silicone surfactant is present in an amount from 0.5% to 2.2% by weight of polyol used to form the polyurethane. The building products possess desirable surfaces that are substantially free of pinholes, while also possessing a modulus, and other properties, that is comparable to or greater than that of building products substantially free of a non-silicone surfactant. Also disclosed are methods for producing the building products.

Abstract: A panel is configured for attachment to a mounting surface of a building structure. The panel includes a first end surface and a second end surface, spaced from each other along a longitudinal axis; a top edge surface and a bottom edge surface, spaced from each other and offset from the longitudinal axis; and an inner surface and an outer surface, opposed to each other and extending from the first end surface and the second end surface. The inner surface includes a contact portion and a contour portion. The contact portion is disposed on a reference plane. The contour portion is contoured toward the outer surface, away from the reference plane, such that the contour portion defines a channel. The channel extends along at least a portion of a length of the panel, between the first end surface and the second end surface.

Abstract: 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/ft3.

Abstract: Disclosed herein are composite building materials having at least one textured surface. The textured surface includes at least a plurality of particles. The textured surface closely mimics conventional building materials. The building materials can contain an image printed using ink jet printing methods with inks optimized for enhanced color stability.

Abstract: A wall panel for installation on a supporting wall includes a facing surface that includes a plurality of separate and spaced apart design elements. The design elements define a channel therebetween. The panel also includes a backing surface having at least one rib opposite the channel. The rib extends transversely across the backing surface, such as a parallel to one of the upper or lower edges of the panel or at an angle between 0 and 90 relative to one of the upper or lower edges of panel. Fasteners are engagable through the channel and the rib for securing the wall panel to the supporting wall. Upon installation of the wall panel on the supporting wall, one or more air gaps are defined by the rib and the backing surface opposite the design elements. The rib provides additional material opposite the channel to prevent the panel from breaking during installation.

Abstract: The present invention relates to the use of sacrificial agents to counteract the deleterious impact of gypsum contaminants on the effectiveness of certain stucco additives, particularly, water reducing agents and foaming agents, in a stucco slurry used to make gypsum wallboard.

Abstract: The present invention relates to the use of sacrificial agents to counteract the deleterious impact of gypsum contaminants on the effectiveness of certain stucco additives, particularly, water reducing agents and foaming agents, in a stucco slurry used to make gypsum wallboard.

Abstract: Proppants and methods for their preparation are described herein. The proppants can be prepared by a process comprising (a) directing the molten slag material at a temperature above 1300° C. to an atomizing apparatus to output the molten slag material in the form of atomized droplets, (b) projecting the droplets of the molten slag material, wherein a substantial portion of the droplets at least partially solidifies in flight, (c) maintaining the at least partially solidified droplets at a temperature between 700° C. and 1300° C. to provide proppant particles having a crystalline phase; and (d) cooling the proppant particles to below 700° C. Methods for hydraulic fracturing of a well in a subterranean formation having a fracturing stress are also described herein.

Abstract: 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.

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.

Abstract: Filled polyurethane foams having tailored microstructures, as well as methods of making these polyurethane foams, are described herein. By tailoring the microstructure of the polyurethane foam, composite materials having desirable mechanical properties (e.g., elastic modulus, compressive strength, or combination thereof) can be obtained.

Abstract: Disclosed herein are composite building materials having at least one textured surface. The textured surface includes at least a plurality of particles. The textured surface closely mimics conventional building materials. The building materials can contain an image printed using ink jet printing methods with inks optimized for enhanced color stability.