Abstract: Insulation panels and methods of use and manufacturing are described herein. The insulation panel may comprise a polymer composite comprising a first polymer and a first filler, wherein the first filler is present in an amount of 40% to 80% by weight, based on the total weight of polymer composite, wherein the polymer composite has a closed cell structure, and wherein the polymer composite has a density of 2 pcf to 30 pcf; and a facer covering at least a portion of the polymer composite, the facer comprising a second polymer and a second filler; wherein the insulation panel has an insulation R-value per inch of at least 2.5.

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 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.

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: Insulation panels and methods of use and manufacturing are described herein. The insulation panel may comprise a polymer composite comprising a first polymer and a first filler, wherein the first filler is present in an amount of 40% to 80% by weight, based on the total weight of polymer composite, wherein the polymer composite has a closed cell structure, and wherein the polymer composite has a density of 2 pcf to 30 pcf; and a facer covering at least a portion of the polymer composite, the facer comprising a second polymer and a second filler; wherein the insulation panel has an insulation R-value per inch of at least 2.5.

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: 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: 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 composite materials, including composite building materials, comprising a polyurethane composite core in physical communication with a cementitious layer. Also disclosed are methods for producing the composite materials.

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 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.