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: 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 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: 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 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: 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: 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.