Patent ID: 7842349

Claim:
A highly filled multilayer composite structure, prepared by spraying onto a substrate, at least one non-foam polyurethane layer comprising: a) an isocyanate component containing minimally about 5 weight percent of a stable particulate filler dispersed therein, the isocyanate component comprising an aromatic isocyanate, modified aromatic isocyanate, or aromatic isocyanate prepolymer, wherein the aromatic isocyanate comprises a toluene diisocyanate, methylene diphenylene diisocyanate, or polymethylene polyphenylene polyisocyanate, and b) a polyol component containing minimally about 15 weight percent of a particulate filler dispersed therein, wherein the components a) and b) are mixed together and immediately sprayed onto the substrate to form a particulate filler and fiber reinforced layer, wherein fibrous reinforcement is additionally included in the composite structure by introducing chopped fibers into a spray cone which impinges upon the fibrous reinforcement and directs it to the substrate, wherein the total particulate filler content of the layer is minimally 20 weight percent, and wherein the total of particulate filler and fiber reinforcement is greater than 30 weight percent, and optionally repeating the spraying to form a multilayer structure, wherein the isocyanate component is substantially free of water and the polyol component is substantially free of water.