Composite extrusion with non-aligned fiber orientation

Patent metadata

Field	Value
Publication number	US-11267963-B2
Application number	US-201916730110-A
Country	US
Kind code	B2
Filing date	Dec 30, 2019
Priority date	Feb 23, 2016
Publication date	Mar 8, 2022
Grant date	Mar 8, 2022

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 building component 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 that is not aligned with a direction of extrusion of the extruded segment;
the extruded building component comprising a fenestration component.

2. The extruded building component of claim 1 , the polymer resin selected from the group consisting of polylactic acid (PLA), polyvinylchloride (PVC), and polyethylene terephthalate (PET).

3. The extruded building component of claim 1 , the fibers exhibiting an average offset angle relative to the direction of extrusion of greater than 20 degrees.

4. The extruded building component of claim 1 , the particles comprising a biomaterial.

5. The extruded building component of claim 1 , the particles comprising at least one of wood particles, hemp, kenaf, bamboo, rice hulls, and nutshells.

6. The extruded building component of claim 1 , the particles selected from the group consisting of wood particles and glass spheres.

7. The extruded building component of claim 1 , wherein at least 50 wt. % of the particles are organic particles having an average largest dimension of greater than 100 microns and an aspect ratio of 4:1 or less.

8. The extruded building component of claim 1 , wherein at least 50 wt. % of the particles are inorganic particles having an average largest dimension of greater than 10 microns and an aspect ratio of 4:1 or less.

9. The extruded building component of claim 1 , the particles having an average largest dimension of greater than 180 microns.

10. The extruded building component of claim 1 , the particles having an aspect ratio of about 4:1 to about 1:1.

11. The extruded building component of claim 1 , the fibers comprising glass fibers.

12. The extruded building component of claim 11 , the glass fibers having an average length after extrusion of about 0.2 mm to about 10 mm and an average diameter of about 2 microns to about 50 microns.

13. The extruded building component of claim 1 , the fibers comprising carbon fibers.

14. The extruded building component of claim 1 , the fibers having an aspect ratio of about 400:1 to about 15:1.

15. The extruded building component of claim 1 , further comprising a second extruded segment comprising a second composition, the second composition comprising:
a polymer resin; and
particles.

16. 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
at least one of fibers and particles;

the second composition comprising:
a polymer resin;
particles; and
fibers;
wherein the first fiber orientation is different than the second fiber orientation;
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.

17. The extruded article of claim 16 , wherein the fibers of the second composition exhibit an average offset angle relative to a direction of extrusion of the second portion that is at least 5 degrees different than an average offset angle relative to a direction of extrusion for the fibers of the first composition.

18. The extruded article of claim 16 , wherein the fibers of the second composition exhibit an average offset angle relative to a direction of extrusion of the second portion that is greater than 20 degrees.

19. The extruded article of claim 16 , wherein the second portion includes a single wall segment.

20. The extruded article of claim 16 , wherein the second portion includes a joint between wall segments.

21. The extruded article of claim 16 , 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.

22. The extruded article of claim 16 , wherein the first and second portions comprise layers, wherein the first layer is disposed on the second layer.

23. The extruded article of claim 16 , further comprising a third portion comprising a third composition different than the first and second compositions.

24. The extruded article of claim 23 , the third composition lacking fibers.

25. The extruded article of claim 23 , the third portion comprising a third layer contacting at least one of the first and second layers.

26. The extruded article of claim 23 , the third portion comprising a capstock layer and covering at least one of the first and second layers.

27. An extruded article comprising:
a first portion comprising a first composition; and
a second portion comprising a second composition different than the first composition;
the first composition comprising:
a polymer resin;

the second 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 that is not aligned with a direction of extrusion of the extruded segment.

28. An extruded article comprising:
an extruded segment comprising a first composition, the first composition comprising:
a polymer resin selected from the group consisting of polylactic acid (PLA), polyvinylchloride (PVC), and polyethylene terephthalate (PET);
at least 1% by weight particles; and
at least 15% by weight fibers, wherein the fibers exhibit an average offset angle that is not aligned with a direction of extrusion of the extruded segment.

29. An extruded article comprising:
an extruded segment comprising a first composition, the first composition comprising:
a polymer resin;
at least 1% by weight particles, wherein at least 50 wt. % of the particles are organic particles having an average largest dimension of greater than 100 microns and an aspect ratio of 4:1 or less; and
at least 15% by weight fibers, wherein the fibers exhibit an average offset angle that is not aligned with a direction of extrusion of the extruded segment.

Assignees

• Andersen Corp

Inventors

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

Classifications

• B29C48/11 Primary

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

• B29C48/21

  the layers being joined at their surfaces · CPC title

• C08L97/02

  Lignocellulosic material, e.g. wood, straw or bagasse {(manufacture of articles made from lignocellulosic material by dry processes B27N)} · CPC title

• B29K2105/12

  of short lengths, e.g. chopped filaments, staple fibres or bristles · CPC title

• C08L27/06 Primary

  Homopolymers or copolymers of vinyl chloride · CPC title