Patent ID: 7199168

Claim:
A process for the production of a cellular composite consisting of: (A) preparing a mixture consisting of (1) a polyisocyanate and (2) water, wherein said water is present in an amount such that there is an excess of from 2 to 5 times the stoichiometric quantity required based on the NCO group content of said polyisocyanate; (B) adding the mixture formed in (A) to (3) an inorganic component consisting of inorganic hollow microspheres under low shear mixing, in which the amount of mixture formed in (A) is from 20 to 38.5% by weight and the amount of hollow microspheres is from 61.5 to 80% by weight, with the sum of the %'s by weight totaling 100% by weight of the cellular composite; (C) completely filling a mold with the mixture formed in (B); and (D) heating the filled mold at a temperature of from 100 to 280° C.; thereby reacting the polyisocyanate and water to form a polyurea which binds the hollow microspheres, thus forming a cellular composite.