Polymer composite comprising an interfacially modified fiber and particle

Patent metadata

Field	Value
Publication number	US-2016002468-A1
Application number	US-201414771175-A
Country	US
Kind code	A1
Filing date	Mar 13, 2014
Priority date	Mar 14, 2013
Publication date	Jan 7, 2016
Grant date	—

Abstract

Embodiments herein relate to a composite material including about 10 to 80 wt. % of a polymer phase, the polymer phase comprising a thermoplastic polymer with a density of less than about 1.9 g-m-2; and about 20 to 90 wt. % of a dispersed mixed particulate phase, the dispersed mixed particulate phase comprising a mixed particulate and about 0.005 to 8 wt. % of a coating of at least one interfacial modifier. The mixed particulate including a portion of a reinforcing fiber and a portion of a particle. The composite material having a Young's modulus of greater than 700 MPa. In various embodiments, structural building components made from the composite are included as well as additive manufacturing components made from the composite.

First claim

1 . A composite material comprising:
about 10 to 80 wt. % of a polymer phase, the polymer phase comprising a thermoplastic polymer with a density of less than about 1.9 g-m −2 ; and about 20 to 90 wt. % of a dispersed mixed particulate phase, the dispersed mixed particulate phase comprising a mixed particulate and about 0.005 to 8 wt. % of a coating of at least one interfacial modifier; the mixed particulate comprising a portion of a reinforcing fiber and a portion of a particle; wherein the composite material has a Young's modulus of greater than 700 MPa.

2 . The composite material of claim 1 wherein the particle has a circularity of about 13.6 to 40.

3 . The composite material of claim 1 wherein the density of the composite material is less than about 1.0 g-m −2 .

4 . The composite material of claim 1 having a Young's modulus that is greater than an otherwise identical composite material lacking the interfacial modifier.

5 . The composite material of claim 1 , the particle comprising a spherical particle.

6 . The composite material of claim 1 wherein the dispersed mixed particulate phase comprises 0.2 to 6 wt. % of the interfacial modifier.

7 . The composite material of claim 1 wherein the reinforcing fibers have an aspect ratio of 1:1.5 or greater.

8 . The composite material of claim 1 wherein the composite material is a structural composite.

9 . The composite material of claim 1 wherein the polymer phase is a continuous phase in the composite material.

10 . The composite material of claim 1 wherein the mixed particulate comprises about 20 to 80 wt. % of the fiber and about 80 to 20 wt. % of the particle.

11 . The composite material of claim 1 wherein the polymer comprises polyvinyl chloride, and the mixed particulate comprising about 80 to 20 wt. % of a cellulosic fiber and about 20 to 80 wt. % of a hollow glass sphere.

12 . The composite material of claim 11 wherein the fiber comprises the cellulosic fiber with an aspect ratio ranging from of 1:1.5 to 1:15.0.

13 . The composite material of claim of 1 wherein the composite material has a density of about 0.8 to 1.3 g-m −2 .

14 . The composite material of claim 1 wherein the particle has a density less than about 7.0 g-m −2 .

15 . The composite material of claim 1 wherein the particle has a density about 0.3 to 9 g-m −2 .

16 . The composite material of claim 1 wherein the thermoplastic polymer has a density about 0.9 to 1.9 g-m −2 .

17 . The composite material of claim 1 wherein the fiber comprises a wood fiber.

18 . The composite material of claim 1 wherein the fiber comprises a glass fiber

19 . The composite material of claim 17 wherein the wood fiber has a fiber diameter of about 2.0 to 40 microns and a fiber length of about 3000 microns.

20 . The composite material of claim 1 wherein the reinforcing fiber comprises a wood fiber with open cell characteristics.

21 . The composite material of claim 1 wherein the reinforcing fiber has a density about 1.3 to 1.5 g-m −2 .

22 . The composite material of claim 1 , wherein the polymer comprises polyvinyl chloride.

23 . The composite material of claim 1 wherein the particle is a hollow glass sphere.

24 . The composite material of claim 23 wherein the density of the hollow glass sphere is less than 0.7 g-m −2 .

25 . The composite material of claim 23 wherein the hollow glass spheres in the composite comprise about 100 wt. % to 15 wt. % of intact spheres and about 0 wt. % to 85 wt. % of broken spheres.

26 . The composite material of claim 1 wherein the water absorption of the composite is less than about 8%.

27 . The composite material of claim 1 wherein the impact strength of the composite is greater than about 10 joules/cm.

28 . The composite material of claim 1 forming an extruded pellet.

29 . The composite material of claim 1 forming an extruded structural member.

30 . The composite material of claim 1 forming an extruded panel.

31 . The composite material of claim 30 , the panel forming a reinforcing component.

32 . The composite material of claim 31 , the reinforcing component comprising a surface feature.

33 . The composite material of claim 31 , the reinforcing component comprising an internal component.

34 . The composite material of claim 1 forming a container.

35 . The composite material of claim 1 forming an enclosure.

36 . The composite material of claim 1 forming a living module.

37 . The composite material of claim 36 , wherein the living module additionally comprises fenestration openings.

38 . The composite material of claim 1 forming a structural decking member.

39 . The composite material of claim 1 forming a structural fencing member.

40 . The composite material of claim 30 forming at least two extruded panels and joinery features.

41 . The composite material of claim 40 further comprising reinforcing components.

42 . The composite material of claim 40 comprising a fenestration opening.

43 . The composite material of claim 40 comprising structural member framing and decorative panels.

44 . A composite material adapted for use in an additive manufacturing system comprising:
about 10 to 80 wt. % of a polymer phase, the polymer phase comprising a thermoplastic or thermosetting polymer with a density of less than about 1.9 g-m −2 ; and about 20 to 90 wt. % of a dispersed mixed particulate phase, the dispersed mixed particulate phase comprising a mixed particulate and about 0.005 to 8 wt. % of a coating of at least one interfacial modifier; the mixed particulate comprising a portion of a reinforcing fiber and a portion of a particle; wherein the filament has a Young's modulus of greater than 700 MPa.

45 . A method of making a composite material comprising;
(a) combining about 10 to 80 wt. % of a polymer phase with about 20 to 90 wt. % of a dispersed mixed particulate phase to form a mixture; (i) the polymer phase comprising a thermoplastic polymer with a density of less than about 1.9 g-m −2 ; (ii) the dispersed mixed particulate phase comprising a mixed particulate and about 0.005 to 8 wt. % of a coating of at least one interfacial modifier; the mixed particulate comprising a portion of a reinforcing fiber and a portion of a particle; and (b) extruding the mixture to form a composite material.

46 . A method of making a structural member comprising:
extruding a composite material to form the structural member, the composite material comprising about 10 to 80 wt. % of a polymer phase, the polymer phase comprising a thermoplastic polymer with a density of less than about 1.9 g-m −2 ; and about 20 to 90 wt. % of a dispersed mixed particulate phase, the dispersed mixed particulate phase comprising a mixed particulate and about 0.005 to 8 wt. % of a coating of at least one interfacial modifier; the mixed particulate comprising a portion of a reinforcing fiber and a portion of a particle; wherein the composite material has a Young's modulus of greater than 700 M

Assignees

• Tundra Composites Llc

Inventors

• Heikkila Kurt E
• Kroll John S

Classifications

• C08J5/10 Primary

  characterised by the additives used in the polymer mixture · CPC title

• B29C64/165

  using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber · CPC title

• B29C67/00

  Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 · CPC title

• B29K2027/06

  PVC, i.e. polyvinylchloride · CPC title

• C08J5/06

  using pretreated fibrous materials · CPC title