Binary filler-containing extrudate composition and building products formed from same
A composition includes about 60 to about 90 wt. % polyvinyl chloride (PVC) resin, about 10 to about 40 wt. % filler material, where the filler material includes about 25 to about 75 wt. % wood flour and about 25 to about 75 wt. % wollastonite, about 1 to about 2 wt. % heat stabilizer, and about 0.1 to about 3 wt. % lubricant.
1 . A composition comprising:
about 60 to about 90 wt. % polyvinyl chloride (PVC) resin;
about 10 to about 40 wt. % filler material;
wherein the filler material comprises:
about 25 to about 75 wt. % wood flour and
about 25 to about 75 wt. % wollastonite,
about 1 to about 2 wt. % heat stabilizer; and
about 0.1 to about 3 wt. % lubricant, wherein the wood flour comprises acicular particles having an average length of 50 micrometers to 1000 micrometers and an aspect ratio of 5:1 to 15:1; wherein the wollastonite comprises acicular particles having an average length of 20 micrometers to 100 micrometers and an aspect ratio of 10:1 to 20:1; and a weight ratio of the wood flour to the wollastonite is 1:3 to 3:1.
2 . The composition of claim 1 , wherein the polyvinyl chloride (PVC) resin comprises recycled polyvinyl chloride (PVC).
3 . The composition of claim 1 , wherein the polyvinyl chloride (PVC) resin comprises recycled polyvinyl chloride (PVC) and virgin polyvinyl chloride (PVC).
4 . The composition of claim 1 , wherein the heat stabilizer is selected from the group consisting of organotin stabilizers, calcium-zinc stabilizers, barium-zinc stabilizers, and combinations thereof.
5 . The composition of claim 1 , wherein the lubricant is selected from the group consisting of stearic acid, calcium stearate, and polyethylene wax.
6 . A composition comprising:
60 to 90 wt. % polyvinyl chloride (PVC) resin;
2.5 to 30 wt. % wood flour; and
2.5 to 30 wt. % wollastonite, wherein the wood flour comprises acicular particles having an average length of 50 micrometers to 1000 micrometers and an aspect ratio of 5:1 to 15:1; the wollastonite comprises acicular particles having an average length of 20 micrometers to 100 micrometers and an aspect ratio of 10:1 to 20:1; and a weight ratio of the wood flour to the wollastonite is 1:3 to 3:1.
7 . The composition of claim 6 , further comprising:
1 to 2 wt. % heat stabilizer and
0.1 to 3 wt. % lubricant.
8 . The composition of claim 6 , comprising:
5 to 20 wt. % wood flour and
5 to 20 wt. % wollastonite.
9 . The composition of claim 7 , wherein the heat stabilizer is selected from the group consisting of organotin stabilizers, calcium-zinc stabilizers, barium-zinc stabilizers, and combinations thereof.
10 . The composition of claim 7 , wherein the lubricant is selected from the group consisting of stearic acid, calcium stearate, and polyethylene wax.
11 . An article comprising:
a body comprising polyvinyl chloride (PVC) resin; and
first and second filler materials dispersed throughout the body, wherein the first filler material comprises particles of wood flour, and wherein the second filler material comprises particles of wollastonite, wherein the body comprises 60 to 90 wt % polyvinyl chloride (PVC) resin, 5-30 wt. % wood flour particles and 5 to 30 wt % wood flour particles,
wherein the particles of wood flour comprise acicular particles having an average length of 50 micrometers to 1000 micrometers and an aspect ratio of 5:1 to 15:1, and the particles of wollastonite comprise acicular particles having an average length of 20 micrometers to 100 micrometers and an aspect ratio of 10:1 to 20:1; and a weight ratio of the wood flour particles to the wollastonite particles is 1:3 to 3:1.
12 . The article of claim 11 , wherein the particles of wood flour and wollastonite are acicular particles substantially aligned along an extrusion direction of the body.
13 . The article of claim 11 , wherein the body comprises:
60 to 90 wt. % polyvinyl chloride (PVC) resin;
5 to 20 wt. % wood flour particles; and
5 to 20 wt. % wollastonite particles.
14 . A composition comprising:
60 to 90 wt. % polyvinyl chloride (PVC) resin;
2.5 to 30 wt. % wood flour;
2.5 to 30 wt. % wollastonite;
1 to 2 wt. % heat stabilizer; and
0.1 to 3 wt. % lubricant,
wherein the wood flour comprises acicular particles having an average length of 50 micrometers to 1000 micrometers and an aspect ratio of 5:1 to 15:1;
wherein the wollastonite comprises acicular particles having an average length of 20 micrometers to 100 micrometers and an aspect ratio of 10:1 to 20:1;
wherein a weight ratio of the wood flour to the wollastonite is 1:3 to 3:1; and
wherein the composition has a thermogravimetric analysis (TGA)-derived ash content of less than 30 wt. %.