Composite extrusion with non-aligned fiber orientation

Patent metadata

Field	Value
Publication number	US-10550257-B2
Application number	US-201715439586-A
Country	US
Kind code	B2
Filing date	Feb 22, 2017
Priority date	Feb 23, 2016
Publication date	Feb 4, 2020
Grant date	Feb 4, 2020

Abstract

Embodiments herein include compositions, extruded articles, and methods of making the same. In an embodiment, an extruded article is included. The extruded article can include an extruded segment comprising a first composition. The first composition can include a polymer resin, particles and fibers. The fibers can be disposed within the first composition exhibiting a substantially non-aligned directional orientation. In an embodiment, an extruded article is included having a first portion comprising a first composition having a first fiber orientation and a second portion comprising a second composition having a second fiber orientation. The first composition can include a polymer resin and fibers. The second composition can include a polymer resin, particles and fibers. The fibers of the second composition can be oriented more randomly than the fibers of the first composition. Other embodiments are also included herein.

First claim

The invention claimed is:

1. An extruded article comprising:
an extruded segment comprising a first composition, the first composition comprising:
a polymer resin;
at least 1% by weight particles; and
at least 15% by weight fibers, wherein the fibers exhibit an average offset angle relative to the extrusion direction of greater than 20 degrees;
the extruded article comprising a fenestration component.

2. The extruded article of claim 1 , the fibers exhibiting an average offset angle relative to the extrusion direction of between 30 and 80 degrees.

3. The extruded article of claim 1 , the first composition comprising at least 5% by weight particles.

4. The extruded article of claim 1 , the particles comprising glass spheres.

5. The extruded article of claim 1 , wherein at least 50 wt. % of the particles are selected from the group of organic particles having an average largest dimension of greater than 100 microns and an aspect ratio of 4:1 or less and inorganic particles having an average largest dimension of greater than 10 microns and an aspect ratio of 4:1 or less.

6. The extruded article of claim 1 , the particles comprising wood particles.

7. The extruded article of claim 6 , the wood particles having an average largest dimension of 180 microns to 600 microns.

8. The extruded article of claim 1 , the particles having an aspect ratio of about 10:1 to about 1:1.

9. The extruded article of claim 1 , the fibers having an aspect ratio of about 800:1 to about 15:1.

10. The extruded article of claim 1 , the first composition comprising at least 20% fibers.

11. The extruded article of claim 1 , the polymer resin comprising polyvinyl chloride.

12. An extruded article comprising:
a first portion comprising a first composition having a first fiber orientation; and
a second portion comprising a second composition having a second fiber orientation;
the first composition comprising:
a polymer resin; and
fibers;

the second composition comprising:
a polymer resin;
particles; and
fibers, wherein the fibers are oriented more randomly than the fibers of the first composition and the fibers exhibit an average offset angle relative to the extrusion direction of greater than 20 degrees.

13. The extruded article of claim 12 , where the fibers of the second composition exhibit an average offset angle relative to the extrusion direction that is at least 15 degrees different than the average offset angle relative to the extrusion direction for the fibers of the first composition.

14. The extruded article of claim 12 , where the fibers of the second composition exhibit an average offset angle relative to the extrusion direction of greater than 30 degrees.

15. The extruded article of claim 12 , wherein the second portion comprises at least one feature selected from the group consisting of an interior wall, an external wall, a corner, an appendage, a single wall area, and a joint between walls.

16. The extruded article of claim 12 , wherein the first portion comprises at least one feature selected from the group consisting of an interior wall, an external wall, a corner, an appendage, a single wall area, and a joint between walls.

17. The extruded article of claim 12 , wherein the first and second portions comprise layers, wherein the first layer is disposed on the second layer.

18. An extruded article comprising:
an extruded segment comprising a first composition, the first composition comprising:
a polymer resin;
at least 1% by weight particles; and
at least 15% by weight fibers, wherein the fibers exhibit an average offset angle relative to the extrusion direction of greater than 20 degrees;
the particles comprising wood particles.

19. The extruded article of claim 18 , the wood particles having an average largest dimension of 180 microns to 600 microns.

20. An extruded article comprising:
an extruded segment comprising a first composition, the first composition comprising:
a polymer resin;
at least 1% by weight particles; and
at least 15% by weight fibers, wherein the fibers exhibit an average offset angle relative to the extrusion direction of greater than 20 degrees;
the particles having an aspect ratio of about 10:1 to about 1:1.

21. An extruded article comprising:
an extruded segment comprising a first composition, the first composition comprising:
a polymer resin;
at least 1% by weight particles; and
at least 15% by weight fibers, wherein the fibers exhibit an average offset angle relative to the extrusion direction of greater than 20 degrees;
the fibers having an aspect ratio of about 800:1 to about 15:1.

22. An extruded article comprising:
an extruded segment comprising a first composition, the first composition comprising:
a polymer resin;
at least 1% by weight particles; and
at least 15% by weight fibers, wherein the fibers exhibit an average offset angle relative to the extrusion direction of greater than 20 degrees;
the polymer resin comprising polyvinyl chloride.

Assignees

• Andersen Corp

Inventors

• Peterson Trevor Dean
• Ehrlichmann Jessica Kathryn
• Gronlund Patrick Jerome

Classifications

• B29K2711/10

  Natural fibres, e.g. wool or cotton · CPC title

• B29K2311/10

  Natural fibres, e.g. wool or cotton · CPC title

• B29K2203/00

  Use of starch or derivatives as reinforcement · CPC title

• B29C48/11 Primary

  comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped · CPC title

• B29C48/2886

  of fillers or of fibrous materials, e.g. short-fibre reinforcements · CPC title