Silica and silicate blended fiber polymer composite

Patent metadata

Field	Value
Publication number	US-11479665-B2
Application number	US-201916547888-A
Country	US
Kind code	B2
Filing date	Aug 22, 2019
Priority date	Aug 22, 2019
Publication date	Oct 25, 2022
Grant date	Oct 25, 2022

Abstract

The claimed material relates to a mixed silica and silicate fiber and polymer composite having enhanced modulus, viscoelastic and rheological properties.

First claim

We claim:

1. A thermoplastic composite comprising about 90 to 10 vol. % of a discontinuous fiber phase dispersed in about 10 to 90 vol. % of a continuous polymer phase:
(a) the discontinuous phase comprising a mixed fiber comprising up to 95 wt. %, the mixed fiber comprising about 8 to 50 wt. % of a CaSiO 3 fiber, and about 45 to 87 wt. % of a silica fiber having a length greater than about 1 mm, a diameter greater than about 0.8 microns and an aspect ratio greater than about 100, the CaSiO 3 fiber having a length greater than about 10 microns, a diameter greater than about 3 microns and an aspect ratio greater than about 12:1, the 10 mixed fibers having about 0.1 to 5 wt. % of an exterior coating comprising an organometallic interfacial modifier, the wt. % based on the discontinuous phase; and
(b) the continuous polymer phase comprising a vinyl chloride polymer;

wherein the composite has a notched IZOD impact resistance of about 0.4 to 3.0 ft-lb-in·1 (ASTM D256), a COTE of about less than 2×10·5 in·in −1 ° F. (ASTM 696), a tensile modulus 15 (ASTM D638) of greater than 700,000 psi at 72° F., a flexural modulus (ASTM D790) of greater than 700,000 psi at 72° F., a flexural strength (ASTM D790) of greater than 2,500 psi at 72° F., a tensile strength (ASTM D638) of greater than 2,000 psi at 72° F.

2. The composite of claim 1 wherein the CaSiO 3 fiber comprises a wollastonite fiber.

3. The composite of claim 1 comprising about 15 to 50 vol. % of the silica fiber comprising a discontinuous glass fiber phase and about 50 to 85 vol. % continuous polymer phase.

4. The composite of claim 1 wherein the polymer comprises a polyvinylchloride homopolymer.

5. The composite of claim 1 wherein the polymer K value is about 35-80 (ISO 1628-2).

6. The composite of claim 1 comprising about 0.1 to 3 wt.-% of an interfacial modifier.

7. The composite of claim 1 wherein the organometallic interfacial modifier comprises a titanate compound.

8. The composite of claim 1 wherein the exterior coating comprises a continuous layer having a thickness of about 100 to 1500 A.

9. The composite of claim 1 wherein the organometallic interfacial modifier is free of any reactive coupling agent.

10. The composite of claim 1 wherein the wherein the composite is free of any epoxy or silane reactive coupling agent.

11. The composite of claim 1 wherein the silicate fiber comprises wollastonite fiber with a fiber having a length about 50-250 microns, a diameter about 5-20 microns and an aspect ratio greater than about 15, the fiber having about 0.1 to 5 wt. % of an exterior coating comprising an organotitanate interfacial modifier.

12. The composite of claim 1 wherein the silica fiber comprises glass having a length about 20 0.1 to 20 mm, a diameter about 5 to 20 microns and an aspect ratio greater than about 100.

13. A pellet comprising a cylindrical object with a diameter of about 1 to 20 mm and a length of about 1 to 50 mm comprising the composition of claim 1 .

14. A master batch pellet comprising a cylindrical object with a about 1 to 20 mm and a length of about 1 to 50 mm comprising an increased amount of the discontinuous fiber phase such that the masterbatch pellet can be combined with a vinyl chloride polymer at a ratio of about 10 to 2 parts by weight of polymer per part by weight of pellet to form the composition of claim 1 .

15. A masterbatch pellet comprising a cylindrical object with a about 1 to 20 mm and a length of about 1 to 50 mm comprising an increased amount of the discontinuous fiber phase such that the masterbatch pellet can be combined with a vinyl chloride polymer at a ratio of about 5 to 2 parts by weight of polymer per part by weight of pellet to form the composition of claim 1 .

16. A thermoplastic composite comprising about 50 to 25 vol. % of a discontinuous fiber phase dispersed in about 50 to 75 vol. % of a continuous polymer phase:
(a) the discontinuous phase comprising a mixed fiber comprising up to 95 wt. % of a 10 wood or glass fiber and about 5 to 60 wt. % of a wollastonite fiber, about 40 to 95 wt. % of the wood or glass fiber having a length greater than about 1 mm, a diameter greater than about 0.8 microns and an aspect ratio greater than about 100, the wollastonite fiber having a length about 10-125 microns, a diameter about 5-30 microns and an aspect ratio greater than about 15, the mixed fibers having about 0.1 to 5 wt. % of an exterior coating comprising an organometallic interfacial modifier, the wt. % based on the discontinuous phase; and
(b) the continuous polymer phase comprising a vinyl polymer;
wherein the composite has a notched IZOD impact resistance of about 0.5 to 3.0 ft-lb-in·1 (ASTM D256), a COTE of about 2×I0·6 to 2×10·5 in·in −1 ° F. (ASTM 696), a tensile modulus (ASTM D638) of greater than 0.7 to 2.75 Mpsi at 72° F., a flexural modulus (ASTM D790) of 20 greater than 0.7 to 2.7 Mpsi at 72° F., a flexural strength (ASTM D790) of 2.5 to 20 kpsi at 72° F., a tensile strength (ASTM D638) of 2 to 20 kpsi at 72° F.

17. The composite of claim 16 wherein the vinyl polymer comprises a vinyl chloride homopolymer.

18. The composite of claim 16 wherein the exterior coating comprises a continuous layer having a thickness of about 100 to 1500 Å.

19. A shaped article comprising the composite of claim 16 that can be extruded and reextruded.

20. The shaped article of claim 19 wherein the article is a linear extrudate.

21. The article of claim 20 wherein the article is a fenestration unit, siding member, decking member, railing member, trim member.

Assignees

• Tundra Composites Llc

Inventors

• Bartel Adam
• Bohnen Scott
• Heikkila Kurt

Classifications

• C08J3/12

  Powdering or granulating · CPC title

• C08J5/043

  with glass fibres · CPC title

• C08K2201/004

  Additives being defined by their length · CPC title

• C08J2327/06

  Homopolymers or copolymers of vinyl chloride · CPC title

• C08L2310/00

  Masterbatches · CPC title