http://www.centuryboardusa.com/
We return herein to a subject, and it's potentials, we've touched on in a few earlier reports, as in, for just one example:
West Virginia Coal Association | Bayer Is Converting Coal Power Plant CO2 Into Plastics | Research & Development; which centered on the article: "Bayer Material Science CO2-to-Plastics Pilot Plant; In February 2011, Bayer MaterialScience started a new pilot plant (in the) North Rhine-Westphalia state of Germany for producing plastics from carbon dioxide (CO2). It will be used to develop polyurethanes from the waste gas released during power generation".
In that report, we also included links to other past reports demonstrating how "power generation" "waste gas" "carbon dioxide" could be utilized and consumed in the synthesis of "polyurethanes"; and, we will have more to offer on those potentials in additional reports to follow.
However, in another prior report:
West Virginia Coal Association | Carbon Dioxide + Coal Fly Ash = Synthetic Lumber | Research & Development; we not only further confirmed the potentials for consuming Carbon Dioxide in the synthesis of Polyurethane base reactants, with the inclusion of information concerning:
"United States Patent 5,371,183 - Preparation of Urethane from Polyamine and Carbon Dioxide; 1994; Assignee: Monsanto Company; Abstract: The present invention provides a process for preparing urethanes and carbonates from an amine or an alcohol, carbon dioxide and a hydrocarbyl halide";
but, we also demonstrated how such CO2-based polyurethane could be used to help consume, and productively utilize, another Coal-use byproduct, Fly Ash, via documentation of:
"US Patent Application 20080029925 - Filled Polymer Composite and Synthetic Building Material; 2008; Inventor: Wade Brown, FL; Abstract: The invention relates to composite compositions having a matrix of polymer networks and dispersed phases of particulate or fibrous materials. The matrix is filled with a particulate phase, which can be selected from one or more of a variety of components, such as fly ash particles ... . Claims: A method of continuously forming a molded material comprising: forming a composite mixture in an extruder, wherein the composite mixture comprises: (polyurethane reaction components, and) about 45 to about 85 weight percent of inorganic particulate material ...; and a catalyst; extruding the mixture through a die; and molding the mixture into a shaped article. (And) wherein the shaped article is a building material (such as) lumber (or) roofing (or) siding".
The above patent application has proven successful; and, as it happens, the named inventor, Wade Brown, is not only a prolific composite materials scientist focused on the environmentally-beneficial use of recyclable materials, especially Coal Ash, he is employed by a corporation founded in the building materials industry, as revealed by the two United States Patents we enclose in this dispatch, one or the other of which we believe to have issued from the above "US Patent Application 20080029925".
We regret that uncertainty. We've already made note a few times of our personal insufficiencies, which prevent us from doing a better job of direct follow-up for you, and of assuring some precision in our reportage, but don't wish to dwell on them. That said, following are the disclosures of the two patents, demonstrating, again, how and why we could and should start to view the solid residua arising from our indispensable use of Coal in the generation of genuinely economical electric power as a valuable mineral resource:
"United States Patent: 7993552 - Filled Polymer Composite and Synthetic Building Material Compositions
Filled polymer composite and synthetic building material compositions - Century-Board USA LLC
Date: August 9, 2011
Inventor: Wade Brown, FL
Assignee: Century Board, LLC, Fort Myers
(As excerpted from the initial link in this dispatch, to the Century-Board corporate web site:
"Doing well by doing good. That is a business touchstone for the 21st Century. At Century-Board, it is more than a slogan - it's the guiding principle by which we work with our partners and licensees to create profitable business models for the manufacture of environmentally sustainable products and materials. Century-Board is a U.S.-based developer and licensor of processes to manufacture . This green process uses mostly waste or recycled materials. Up to 75% waste can be used in these products. The green content is nearly 85% when plant-based resins are used.
The Century-Board process of making building products using coal ash is commercial in the U.S., and there are several large firms that have licensed this process in major industrial countries. Two new plants are planned to come on-line in 2008-09. Clients in Brazil, Canada, Turkey and Canada and several U.S. States are in various stages of testing, finalizing products and preparing for production.
Our proprietary, patented process utilizes dry granular or powdered fillers that can be waste material, such as ... coal ash and waste plastics ... . Typically, liquid polyurethanes and polyesters with specialized additives are used in our process. These are mixed in extruders to yield a mud-like mixture, which is then continuously cast into finished products or poured into molds, and cures without added heat into finished products. Three-dimensional surface finishes like wood grain or slate can be molded in using this process, and colorants can be added to achieve virtually any color."
Note the statement, that: "The green content is nearly 85% when plant-based resins are used."
Among the precedent and supporting arts and technologies cited by Wade Brown and Century-Board in the full Disclosure of our subject, "US Patent 7,993,552", is:
"United States Patent: 6433121 - Method of Making Natural Oil-Based Polyols and Polyurethanes; 2002; Abstract: A method for making natural oil-based polyols directly from vegetable or animal oil. ... The natural oil-based polyols created by this method may be reacted with isocyanates so as to form polyurethanes, which is another embodiment of the present invention. Alternatively, fillers such as silica may be combined with these natural oil-based polyols before they are reacted with isocyanates to form polyurethanes";
which discloses another route - - in addition to the direct processes developed by Bayer Corporation, as cited in our earlier report concerning the "Bayer Material Science CO2-to-Plastics Pilot Plant" - - for the indirect, botanically-mediated recycling of CO2 in the making of polyurethane raw materials. We will have more to offer on such potentials for the permanent, both direct and indirect, chemical "sequestration" of Carbon Dioxide in a number of future reports now in process.)
Abstract: The invention relates to composite compositions having a matrix of polymer networks and dispersed phases of particulate or fibrous materials. The matrix is filled with a particulate phase, which can be selected from one or more of a variety of components, such as fly ash ... . A system for providing shape and/or surface features to a moldable material includes, in an exemplary embodiment, at least two first opposed flat endless belts spaced apart a first distance, with each having an inner surface and an outer surface.
Claims: A method of continuously forming a highly filled molded composite material comprising: mixing in a multi-zone extruder the ingredients of the material by adding the ingredients of the highly filled composite material to the various zones of the multi-zone extruder without adding heat to the mixture, wherein the composite mixture comprises: a ... poly or di-isocyanate (as specified); a first polyol (as specified); a second polyol (as specified); a foaming agent; an inorganic particulate material comprising about 60 wt % to about 85 wt % of the composite mixture, wherein the particulate material provides filler material which adds strength and reinforcement to the molded material and is added to the mixture prior to forming; and a catalyst; extruding or spraying the highly filled mixture by expulsion of the mixture through a die onto or into a forming system (as described) and removing the molded material ... after sufficient time has passed for the mixture to cure or harden into the molded material, wherein the molded material comprises a density of at least about 30 lb/ft3.
The method ... further comprising providing shape, surface features, or both to the molded material (and)further comprising embossing or impressing a pattern on the mixture in the forming system ... wherein the pattern comprises a simulated wood grain.
The method ... wherein the inorganic particulate material is fly ash (or) bottom ash ... .
(Note, significantly, that: "fly ash (or) bottom ash" can comprise "60 ... to about 85" percent, by weight, "of the composite mixture". The simulated wood, forest-sparing building product that results consists, for the most part, of Coal Ash; with a little bit of plastic resin, which can be synthesized, directly or indirectly, in part from Carbon Dioxide, holding it all together.)
The method ... wherein the polyol (and) the isocyanate (and) the catalyst (and) the inorganic particulate material are mixed (as specified and directed).
The method ... wherein the molded material is a building material (and) wherein the building material is lumber (and/or) roofing (and/or) siding.
(There is extended discussion of the design of the molding system itself, which can be continuous, and which can provide a very high through-put and high productivity. A lot of Coal Ash could be utilized.)
A method of continuously forming a molded material comprising: adding the ingredients of a highly filled composite mixture, to a multi-zone extruder without adding heat, wherein the composite mixture comprises: a monomeric or oligomeric poly or di-isocyanate; a first polyol (as specified); a second polyol (as specified); a foaming agent; inorganic particulate material comprising about 60 wt % to about 85 wt % of the composite mixture, the particulate material comprising a reinforcing filler; ... .
(We will note, that, in a separate section of the full Disclosure, a number of Bayer Corporation polyurethane raw materials, polyols and isocyanates, are specified as suitable and appropriate for use in this process and technology. Maybe their compositions based on recycled Carbon Dioxide, as in our above-cited earlier report, would qualify.)
Background and Field: The invention relates to composite compositions having matrices of polymer networks and dispersed phases of particulate and/or fibrous materials, which have excellent mechanical properties, rendering them suitable for use in load bearing applications, such as in building materials. The composites are stable to weathering, can be molded and colored to desired functional and aesthetic characteristics, and are environmentally friendly, since they can make use of recycled particulate or fibrous materials as the dispersed phase. The invention relates to methods and systems for imparting desired shape and surface characteristics to a moldable or pliable material as the material cures or hardens. It is particularly applicable to the shaping and embossing of thermosetting resin systems during curing, and can be used to form these resin systems into a variety of products, including synthetic lumber, roofing, and siding.
Polymeric composite materials that contain organic or inorganic filler materials have become desirable for a variety of uses because of their excellent mechanical properties, weathering stability, and environmental friendliness.
These materials can be relatively low density, due to their foaming, or high density when unfoamed, but are extremely strong, due to the reinforcing particles or fibers used throughout. Their polymer content also gives them good toughness (i.e., resistance to brittle fracture), and good resistance to degradation from weathering when they are exposed to the environment. This combination of properties renders some polymeric composite materials very desirable for use in building materials, such as roofing materials, decorative or architectural products, outdoor products, insulation panels, and the like.
In addition, the filler materials used need not be virgin materials, and can desirably be recycled fibers or particulates formed as waste or by-product from industrial processes. Polymeric composites allow these materials to be advantageously reused, rather than present disposal problems.
Summary: It has been found ... that a highly filled, foamed or unfoamed composite polymeric material having good mechanical properties can be obtained (in a way that) results in a substantial decrease in cost, because of decreased materials cost, and because of decreased complexity of the process chemistry, leading to decreased capital investment in process equipment.
In one embodiment, the invention relates to composite compositions having a matrix of polymer networks and dispersed phases of particulate or fibrous materials. The polymer matrix contains a polyurethane network formed (as described). The matrix is filled with a particulate phase, which can be selected from one or more of a variety of components, such as fly ash particles ... . The addition of water can also serve to provide a blowing agent to the reaction mixture, resulting in a foamed structure, if such is desired.
The composite material of the invention is advantageously used as structural building material, and in particular as synthetic lumber... ."
-------------------------------
As we've said before, in an earlier report concerning somewhat similar and related technology:
West Virginia Coal Association | Coal Ash Can Save Millions of Trees | Research & Development; concerning, primarily: "Development and Demonstration of Coal Combustion Byproducts-Filled Composite Materials for Utility Pole Fabrication; Southern Illinois University (for) Combustion Byproducts Recycling Consortium, West Virginia University":
Yo! Save The Trees!
And: Coal Ash can do that!
Wade Brown and Century-Board confirm that fact in another, nearly-identical and immediately subsequent patent issued contiguously with the above "US Patent 7,883,552", as seen in:
"United States Patent: 7993553 - Filled Polymer Composite and Synthetic Building Material Compositions
Filled polymer composite and synthetic building material compositions - Century-Board USA LLC
Date: August 9, 2011
Inventor: Wade Brown, FL
Assignee: Century Board, LLC, Fort Myers
Abstract: The invention relates to composite compositions having a matrix of polymer networks and dispersed phases of particulate or fibrous materials. The matrix is filled with a particulate phase, which can be selected from one or more of a variety of components, such as fly ash particles, axially oriented fibers, fabrics, chopped random fibers, mineral fibers, ground waste glass, granite dust, or other solid waste materials. A system for providing shape and/or surface features to a moldable material includes, in an exemplary embodiment, at least two first opposed flat endless belts spaced apart a first distance, with each having an inner surface and an outer surface.
Claims: A method of continuously forming a molded material comprising: mixing a highly filled composite mixture in a multi-zone extruder essentially at room temperature and without adding heat, wherein the composite mixture comprises: a monomeric or oligomeric poly or di-isocyanate; a first liquid polyol having a first molecular weight and a second polyol (as described and specified); a foaming agent; an inorganic particulate material comprising about 60 wt % to about 85 wt % of the composite mixture; and a catalyst; extruding the highly filled composite mixture through a die; molding the mixture in a forming system comprising: at least a first and a second opposed mold belt (as described); a mold cavity disposed between the inner surfaces of the at least two opposed mold belts; and removing the molded material from the mold cavity after sufficient time has passed for the mixture to cure or harden into the molded material, wherein the molded material comprises a density of at least about 30 (pounds per cubic foot).
The method ... further comprising exerting pressure on the mixture with the at least two opposed endless belts (and) further comprising embossing or impressing a pattern on the mixture in the forming system (and) wherein the pattern comprises a simulated wood grain.
The method ... wherein the inorganic particulate material is fly ash (or) bottom ash, or particulate glass.
The method ... wherein the molded material is a building material (and) wherein the building material is lumber (or) roofing (or) siding.
Background and Field: The invention relates to composite compositions having matrices of polymer networks and dispersed phases of particulate and/or fibrous materials, which have excellent mechanical properties, rendering them suitable for use in load bearing applications, such as in building materials. The composites are stable to weathering, can be molded and colored to desired functional and aesthetic characteristics, and are environmentally friendly, since they can make use of recycled particulate or fibrous materials as the dispersed phase. The invention relates to methods and systems for imparting desired shape and surface characteristics to a moldable or pliable material as the material cures or hardens. It is particularly applicable to the shaping and embossing of thermosetting resin systems during curing, and can be used to form these resin systems into a variety of products, including synthetic lumber, roofing, and siding.
Summary: It has been found ... that a highly filled, foamed or unfoamed composite polymeric material having good mechanical properties can be obtained (with) a substantial decrease in cost, because of decreased materials cost, and because of decreased complexity of the process chemistry, leading to decreased capital investment in process equipment.
In one embodiment, the invention relates to composite compositions having a matrix of polymer networks and dispersed phases of particulate or fibrous materials. The polymer matrix contains a polyurethane network formed by the reaction of a poly- or di-isocyanate and one or more saturated polyether or polyester polyols, and an optional polyisocyanurate network formed by the reaction of optionally added water and isocyanate. The matrix is filled with a particulate phase, which can be selected from one or more of a variety of components, such as fly ash particles ...
The synthetic lumber produced by the invention was found to have good fire retardant properties ... and to produce only small quantities of respirable particles ... when sawn. It provides excellent compressive strength, screw and nail holding properties, and density."
------------------------
In other words, we can make a substitute for, basically, lumber, that will hold nails and screws pretty much just like real wood; that can be made to look something like real wood; that will "have excellent mechanical properties (and be) suitable for use in load bearing applications"; and, which is "stable to weathering out", out of a little bit, 15%, of a plastic resin that we just might be able to make, at least in part, out of Carbon Dioxide, and a lot, "85%", of Coal-fired power plant "fly ash (or) bottom ash".
Note, again, that such a concept is borne out by a few of our earlier reports and references, a couple of which we cited above.
In point of fact, inventor Wade Brown and Century-Board, LLC, have continued to refine and develop that concept, as we will see in reports to follow concerning their further advancements in such and related utilization of Coal Ash, and of other "waste" materials; and, in those coming reports, we'll better explain Century-Board LLC's published concepts concerning their reduction to commercial practice.
Such developments, in a way similar to those represented, for only one example, in our report of:
West Virginia Coal Association | May, 2012, CO2 to Gasoline and Jet Fuel | Research & Development; concerning: "United States Patent 8,168,143 - Systems, Methods and Compositions for Production of Synthetic Hydrocarbon Compounds; 2012; Fuelcor, LLC; Abstract: A process and system for producing hydrocarbon compounds or fuels that recycle products of hydrocarbon compound combustion--carbon dioxide or carbon monoxide, or both, and water. The energy for recycling is electricity derived from preferably not fossil based fuels, like from ... renewable energy";
should inspire us all to start disciplining ourselves to stop thinking in negative terms, or to stop allowing ourselves to be influenced and swayed by those who, for reasons we all must now hold suspect, insist on speaking in negative terms, about the "products of hydrocarbon compound", i.e., Coal, "combustion".
Otherwise, we will continue to allow ourselves, and our nation, to be seduced into thinking of them only as noxious wastes; with the taint of that stigma extending back in a way that devalues not only our precious Coal in the common perception, but the people who mine the Coal, as well.
Make no mistake:
Coal is a precious resource, with a multiplicity of direct and indirect values; as are the people who mine it.
And, it's far, far past time we insisted on those facts being acknowledged, even trumpeted; most especially by our supposedly-loyal Coal Country public media.
