Laminated Composite Products and Methods for Manufacturing the Same
In accordance with one embodiment of the present disclosure a laminated composite product is provided. The product comprises a composite base, the composite base including filler material and a thermoplastic material. The product further comprises a surface layer extruded on at least a portion of the base, the surface layer being non-adhesively joined to the composite base and including about 0.1 weight percent to about 10 weight percent pigment.
1 . A laminated composite product comprising:
a composite base, the composite base comprising filler material and a thermoplastic material; and
a surface layer extruded on at least a portion of the base, the surface layer being non-adhesively joined to the composite base and comprising about 0.1 weight percent to about 15 weight percent pigment.
2 . The laminated composite product of claim 1 , wherein the thermoplastic material comprises polypropylene, polyvinyl chloride, polyethylene, nylon, polyesters, polysulfones, polyphenylene oxide, polyphenylene sulphide, epoxies, cellulosics, or combinations thereof.
3 . The laminated composite product of claim 1 , wherein the thermoplastic material is present in an amount of about 35 weight percent to about 55 weight percent.
4 . The laminated composite product of claim 1 , wherein the filler material comprises cellulosic fiber, glass fiber, glass spheres, graphite fiber, or combinations thereof.
5 . The laminated composite product of claim 1 , wherein the filler material comprises cellulosic fiber.
6 . The laminated composite product of claim 1 , wherein the filler material is present in an about of about 35 weight percent to about 65 weight percent.
7 . The laminated composite product of claim 1 , wherein the pigment is present in an amount of about 1 weight percent to about 10 weight percent.
8 . The laminated composite product of claim 1 , wherein the surface layer further comprises aluminum oxide, talc, calcium carbonate, or combinations thereof.
9 . The laminated composite product of claim 1 , wherein the surface layer further comprises aluminum oxide.
10 . The laminated composite product of claim 1 , wherein the surface layer includes a wood grained pattern.
11 . A method for making a laminated composite product comprising:
extruding a mass comprising filler material and thermoplastic resin to form a composite base;
heating at least a portion of the outer surface of the composite base; and
extruding a layer onto at least a portion of the heated outer surface of the composite base resulting in the layer being non-adhesively joined to the composite base to form a laminated composite product.
12 . The method of claim 11 , further comprising embossing at least a portion of the laminated composite product.
13 . The method of claim 11 , wherein the layer is extruded through a die, the die configured to accommodate the composite base so that the layer is extruded onto the heated outer surface within the die.
14 . The method of claim 13 , wherein the die is heated.
15 . The method of claim 13 , wherein the die defines a cavity having a circumference that is about 0.01 millimeters to about 0.5 millimeters larger than the circumference of the composite base.
16 . The method of claim 11 , wherein the thermoplastic material comprises polypropylene, polyvinyl chloride, polyethylene, nylon, polyesters, polysulfones, polyphenylene oxide, polyphenylene sulphide, epoxies, cellulosics, or combinations thereof.
17 . The method of claim 11 , wherein the filler material comprises cellulosic fiber, glass fiber, glass spheres, graphite fiber, or combinations thereof.
18 . The method of claim 11 , wherein the layer comprises about 0.1 weight percent to about 15 weight percent pigment..
19 . The method of claim 18 , wherein the layer further comprises aluminum oxide, talc, calcium carbonate, or combinations thereof.
20 . The method of claim 11 , wherein the layer is a virgin layer.