Foam composites and methods of preparation thereof
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.
1. A foam composite comprising:
a polymeric material; and
25% to 75% by weight, with respect to the total weight of the foam composite, of a particulate filler;
wherein a compressive strength of the foam composite is equal to or greater than 20 psi;
wherein a density of the foam composite is 2 pcf to 10 pcf;
wherein a flexural strength of the foam composite is 20 psi to 100 psi; and
wherein a thermal conductivity of the foam composite is equal to or less than 0.050 W/m K.
2. The foam composite of claim 1 , wherein the polymeric material is prepared from an isocyanate, the polymeric material having an isocyanate index equal to or less than 130.
3. The foam composite of claim 1 , wherein the polymeric material comprises polyurethane.
4. The foam composite of claim 1 , wherein at least one of a glass transition temperature or a melting point of the foam composite is less than 200° C., and a thermal degradation temperature of the foam composite is less than 400° C.
5. The foam composite of claim 4 , wherein at least one of the glass transition temperature or the melting point of the foam composite is 50° C. to 200° C., and the thermal degradation temperature of the foam composite is 100° C. to 400° C.
6. The foam composite of claim 1 , wherein the particulate filler comprises fly ash.
7. The foam composite of claim 1 , wherein the foam composite is prepared with a liquid blowing agent comprising water, an organic liquid having a boiling point equal to or greater than 30° C., or a combination thereof, and wherein the foam composite has a closed cell content equal to or greater than 50%.
8. The foam composite of claim 7 , wherein the liquid blowing agent comprises hexafluorobutene.
9. The foam composite of claim 1 , wherein the compressive strength is 20 psi to 200 psi.
10. The foam composite of claim 1 , wherein the density is 4 pcf to 10 pcf, and the thermal conductivity is 0.020 W/m K to 0.050 W/m K.
11. The foam composite of claim 1 , further comprising an additive selected from a flame retardant, a surfactant, a catalyst, or a combination thereof.
12. The foam composite of claim 1 , wherein a moisture permeance per 25 mm thickness is equal to or less than 146 ng/m 2 s Pa.
13. A building material comprising the foam composite of claim 1 , wherein the building material comprises insulation.
14. A foam composite comprising:
polyurethane; and
fly ash in an amount of 45% to 75% by weight with respect to the total weight of the foam composite;
wherein at least one of a glass transition temperature or a melting point of the foam composite is 50° C. to 200° C., and a thermal degradation temperature of the foam composite is less than 400° C.; and
wherein the foam composite has
a closed cell content equal to or greater than 50%;
a compressive strength equal to or greater than 20 psi;
a flexural strength of 20 psi to 100 psi;
a density of 2 pcf to 25 pcf; and
a thermal conductivity equal to or less than 0.050 W/m K.
15. The foam composite of claim 14 , wherein the density of the foam composite is 4 pcf to 10 pcf, and the thermal conductivity of the foam composite is equal to or less than 0.030 W/m K.
16. A foam composite comprising:
a polymeric material; and
a particulate filler in an amount of 25% by weight to about 75% by weight with respect to the total weight of the foam composite;
wherein the foam composite has a density of 2 pcf to 10 pcf; and a thermal conductivity of 0.020 W/m K to 0.040 W/m K; and
wherein a flexural strength of the foam composite is 20 psi to 100 psi.
17. The foam composite of claim 16 , wherein the foam composite further comprises a flame retardant selected from an organohalogen compound, organophosphorus compound, or a combination thereof.
18. The foam composite of claim 16 , wherein the foam composite comprises tris(chloropropyl)phosphate.