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/n 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: 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: 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: 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: Polyurethane or polyisocyanate form stock and methods of manufacturing are described herein. The foam stock can include (a) a polyurethane or polyisocyanate 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/ft3 to 35 lb/ ft3. The flexural strength of the foam stock can be at least 100 psi. The resulting foam stock can be used to produce polyurethane or polyisocyanate foam to be used in composite panels.

Abstract: Composite panels and methods of use and manufacturing are described herein. The composite panels may comprise a foam composite and one or more layers of a facing material. The foam composite may have a density less than or equal to 20 pcf, and the layer(s) of facing material, e.g., inorganic facing material, may have a thickness of 1/16 inch to 1 inch covering at least the front surface of the foam composite.

Abstract: Net-shape composites and methods of manufacturing are described herein. The method of preparing net-shape composites may include combining a first semi-solid component with a second semi-solid component to form a polymer composition, and forming the polymer composition into the net-shape composite, wherein each of the semi-solid components has a yield stress of at least 50 Pa. The first semi-solid component may include a first portion of a filler, and the second semi-solid component may include a second portion of a filler that is the same or different than the filler of the first semi-solid component.

Abstract: Low combustibility thermal insulation and methods of use and preparation thereof are described herein. The low combustibility thermal insulation may include a foam composite comprising a polymer material and a fire retardant component disposed in and/or adjacent to the polymer material; and a first controlled combustion layer adjacent to a first surface of the foam composite, wherein the foam composite and first controlled combustion layer are configured to control combustion of the insulation such that a total heat generated in a period of 10 minutes by the panel is equal to or less than 8 MJ/m2, as measured according to ISO 5660-1, and wherein a thermal conductivity of the insulation is equal to or less than 0.050 W/m K.

Abstract: Panel systems and related methods of controlling sound transmission are discussed. For example, the panel system may include a sound control component, which may include a foam composite of a polymer and an inorganic filler. The panel system may further include an attachment mechanism, e.g., including at least one fastener, at least one bracket, and/or at least one rail or rail system. The attachment mechanism may be configured to secure the sound control component between a first wall and a second wall, such that the panel system controls sound transmission between the first and second walls.

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: 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: 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/ft3 to 35 lb/ft3. 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.

Abstract: Shapeable composites and methods of use and manufacturing arc described herein. The shapeable composites may include a polymer and a functional filler, e.g., the functional filler present in an amount greater than or equal to 40% by weight, based on the total weight of the shapeable composite. The shapeable composite may be a foam composite having a viscoelasticity, such that the shapeable composite is configured to be reshaped.

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: 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: 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: 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: Composite materials and methods of use and manufacturing are described herein. The composite materials may include a substrate comprising a polymer composite, the substrate having a density of 2 pcf to 15 pcf; and a facer covering at least a portion of the substrate, the facer including a polymer and a filler, wherein the filler is present in an amount greater than or equal to 50% by weight, with respect to the total weight of the facer.