The present disclosure relates generally to polyurethane matrix composite materials, for example, suitable for making an exterior cladding product for houses and other buildings. The present disclosure relates more particularly to a polymer matrix composite material including a polyurethane matrix and an inorganic filler in a range from 45% to 85% by weight of the composite material. The inorganic filler includes a first substance from the group consisting of calcium carbonate, sand, talc, kaolin clay, dolomite, feldspar and mica and any mixture thereof, and fly ash, and/or an iron oxide in a range from 0.5% to 7% by weight of the inorganic filler.

A method of producing a wall section is described. The method includes vacuum forming a carbon fiber sheet to a pyramidal mold core to create a first layer having a plurality of pyramidal shapes. A conductive frame is disposed on the carbon fiber sheet. A first set of solar panel post slots are trimmed from the first layer. Vents are cut in the carbon fiber sheet to expose frame connectors. The carbon fiber sheet is clamped to the conductive frame and wrapped around the conductive frame and over the first layer to create a second layer. A second set of solar panel post slots are trimmed from the second layer so as to overlap the first solar panel post slots. The second layer is trimmed to expose locking post slot areas. The method also includes affixing locking posts to the peaks of the plurality of pyramidal shapes.

A method of recycling tires comprising the comprising the steps of: placing tires and/or pieces of tires within a casing or mold, applying a binder (e.g. adhesives and/or pining with screws, nails, nuts and bolts, pins, wire and steel or nylon bands etc) to the tires and/or pieces of tires so that the tires are bound together; applying a reinforcing means to the tires and/or pieces of tires (e.g. fitting the reinforcing means around, in between and/or through the tires etc); and melting or pouring an encapsulating means over the top of the tires and reinforcing means to encapsulate them inside the casing or mold and the encapsulating means; and causing or allowing the encapsulating means to set such that a recycled product is formed.

A flexible mat forming system may include an elongate, rotatable drum having a plurality of transverse rows of mold cavities about an outer periphery thereof, an elongate hopper positioned adjacent the drum, the hopper shaped to receive a hardenable paste and deposit the hardenable paste along a facing row of the plurality of transverse rows of mold cavities, a spool assembly for feeding a sheet of mesh material between the hopper and the facing row, and a retaining plate extending partially about the outer periphery of the drum and positioned on a downstream side of the elongate hopper, the retaining plate spaced sufficiently close to the outer periphery to retain the mesh material against the outer periphery of the drum and the hardenable paste within the mold cavities adjacent the retaining plate.

A portable structure or hunting blind includes a floor railing or frame system for supporting side walls and a roof. The side walls and roof are formed of polyurethane foam. The side walls and roof can be manufactured by applying uncured polyurethane foam over a sheeting material, which is supported by a removable set of forms. The polyurethane foam is then allowed to cure, and once cured the forms are removed. A door and windows and floor decking can then be installed to finish out the hunting blind. The exterior of the polyurethane foam walls and roof can be coated with an elastomer coating for UV protection.

The present invention relates to a novel device to manufacture polyurethane foam boards used in structurally insulated panel known as insulated building material press. The press enables the application of pressure across a large area while foaming and curing polyurethane under pressure, curing glue or otherwise bonding materials into a finished product or to form multiple panels in a single press at the same time. The building material press can be used to manufacture multiple structurally insulated panels simultaneously. The press is mobile and can be transported by means of a vehicle to a remote location.

The present invention relates to a process of fabricating a multi-layer composite structure by 3D printing, said composite structure comprises at least one cured mortar layer formed by curing of a mortar composition, and at least one polyurethane layer formed by polymerization of a first polyurethane forming composition, wherein said mortar composition and said first polyurethane forming composition are dispensed individually and simultaneously via adjacent printing nozzles. The mortar composition is optionally modified by a second polyurethane forming composition.

A wood-grained polymer substrate includes a plurality of layers of different colors. The substrate is formed into elongated boards and used in the production of various end products similar to natural wood. Methods for producing the wood-grained polymer substrate are also provided.

A method of manufacturing building panels includes assembling a frame of a building panel. The frame defines at least one cavity and at least one injection aperture in fluid communication with the at least one cavity. The method also includes positioning the frame on one of a base and a shelf of a multi-panel consolidation device having a plurality of shelves, with the shelves being in an expanded configuration, and at least substantially enclosing the at least one cavity. The method also includes forcing the shelves of the multi-panel consolidation device into a collapsed configuration, and injecting an expandable polymer through the at least one injection aperture into the at least one cavity. The method further includes forcing the shelves into an expanded configuration after a predetermined period of time selected to permit the expandable polymer to form a foam bonded to the frame.

This invention aims to provide a novel material to be used for the production of components used in the construction industry such as construction blocks, wall panels, floor and roof tiles, lintels and any other product that could use this novel material. The novel material is a paper concrete made with 50% to 90% of recycled paper in the base mixture. This invention also aims to provide a novel process for making a construction block with the base mixture of paper concrete. The process for making the lightweight building blocks with this paper concrete has three main steps with two stages each. The base mixture for the paper concrete is essentially interlinked with the process for making this construction block. The two first steps of the process are crucial to achieve the base mixture and the following step is crucial to achieve a construction block. Thereafter, there are possibilities for producing these blocks with different colors by adding pigment to the paper pulp at stage 1 and adding artistic molds to the molds on the block making machine in stage 6.