Extra strength polymer composite construction material and process for making the same

摘要

A composite material that can be economically produced without the emission of VOCs that is extremely strong and is bonded at the molecular level. An embodiment of the present invention can be a composite of two or more layers with a first layer made from an aliphatic polymer like a polyurea and a resin like an isocyanate resin. A third layer of strengthened urethane foam can optionally be used. The composite material can be made up of layers of material with a first layer of a polyurea polymer and the second layer of an isocyanate resin chemically bonded to the first layer. The first layer can have a glossy outer surface if desired. The second layer can also optionally contain carbon fibers, nano-tubes or basalt fibers for extra strength if desired. The material can be produced in sheets of from 8 to 12 feet wide and from 40 to 60 feet long. Carbon fibers, carbon nano-tubes and Basalt fibers can be added for strength and rigidity. The optional urethane foam layer can contain carbon fibers, carbon nano-tubes or basalt or other fibers for strengthening.