Composite coated substrates and moldable composite materials
View Patent ↗A moldable composite material contains flakes of composite material, i.e., flakes of polymeric matrix materials having fibers embedded therein. An improved substrate is provided by providing a substrate and applying a coating onto the substrate, the coating containing the flakes of composite material. A first construction member can be secured to a second construction member by applying the coating onto an attachment region of the first construction member, and applying a fastener onto the first construction member in the coated attachment region to secure the first construction member to the second construction member.
1. A moldable composite material comprising:
first flakes of a first composite material; and
second flakes of a second composite material, the first composite material being different from the second composite material,
wherein the first flakes comprise first fibers in a first polymer matrix and the second flakes comprise second fibers in a second polymer matrix, and wherein the first polymer matrix comprises a thermoplastic material and the second polymer matrix comprises a thermosetting material;
the moldable composite material comprising a filler mixed with the first flakes and the second flakes, the filler comprising substrate pieces being different from the first flakes and the first polymer matrix and different from the second flakes and the second polymer matrix, and
the moldable composite material further comprising an adhesive to provide adherence of the first flakes, the second flakes and the filler in the moldable composite material.
2. The moldable composite material of claim 1 , wherein the first fibers are different from the second fibers.
3. The moldable composite material of claim 1 , wherein at least one of the first composite material and the second composite material is a laminate of at least two composite layers.
4. The moldable composite material of claim 3 , wherein the laminate comprises oriented, continuous fibers.
5. The moldable composite material of claim 3 , wherein the laminate comprises chopped fibers.
6. The moldable composite material of claim 3 , wherein the laminate comprises a combination of chopped fibers and continuous fibers.
7. The moldable composite material of claim 3 , wherein the laminate includes two composite layers with one of the layers including fibers oriented substantially orthogonally to fibers in the other layer.
8. The moldable composite material of claim 3 , wherein the substrate pieces include at least one of wood flakes, sawdust, plastic, plywood, pressboard, particle board, oriented strand board and metal.
9. The moldable composite material of claim 3 , wherein at least one of the first composite material and the second composite material is a recycled or scrap composite material.
10. The moldable composite material of claim 3 , wherein at least one of the first fibers and the second fibers comprise glass fibers.