Polymeric substrates with an improved thermal expansion coefficient and a method for producing the same
A substrate and method for providing a thermoplastic composite having a fiberglass mat embedded within a thermoplastic polymer. The characteristics of the fiberglass mat combined with a thermal compression bonding method allow for a substantially improved and desirable thermal expansion coefficient over conventionally filled thermoplastic substrates or other fiberglass reinforced thermoplastics.
1. A substrate comprising: a thermoplastic composite having a fiberglass mat embedded in a thermoplastic resin, wherein the fiberglass mat has a basis weight of 76 to 500 g/m 2 and about 20 to about 3000 fiberglass intersections per cm 2 , and wherein the thermoplastic composite possesses (i) a Thermal Expansion Coefficient of ⅓ or less than that of a substrate derived from a neat embodiment of the thermoplastic resin, or (ii) a Thermal Expansion Coefficient of 50*10 −6 m/(m*° C.) or lower.
2. A substrate according to claim 1 , wherein the thermoplastic composite has a Thermal Expansion Coefficient of 40*10 −6 m/(m*° C.) or lower.
3. A substrate according to claim 1 , wherein the thermoplastic composite meets the specification of flatness in the flooring industry, with gaps measured over a 45 cm span of less than 0.35 cm.
4. A substrate according to claim 1 , further comprising one or more fillers in the thermoplastic composite.
5. A substrate according to claim 4 , wherein the one or more fillers comprise cellulose, calcium carbonate, volcanic ash, expanded volcanic ash, wood flour or rice hulls.
6. A substrate according to claim 4 , wherein the one or more fillers include a mineral filler or an organic filler.
7. A substrate according to claim 1 , wherein the thermoplastic resin comprises a polyolefin and the thermoplastic composite has a thickness of 2 mm to 7 mm and a Thermal Expansion Coefficient of 50*10 −6 m/(m*° C.) or lower.
8. A substrate according to claim 1 , wherein the thermoplastic resin comprises a polypropylene, polyethylene, polyolefin copolymer, polyvinyl chloride, polyethylene terephthalate, polyamide, a polyolefin from a hydropulping process, or combination thereof.
9. A substrate according to claim 1 , wherein the thermoplastic composite has a basis weight between 500 g/m 2 to 10,000 g/m 2 .
10. A substrate according to claim 1 , further comprising at least one additional layer bonded to the thermoplastic composite to form a multilayered article.
11. An article comprising a substrate derived from thermal compression bonding a thermoplastic resin with a fiberglass mat and optionally one or more fillers, wherein the fiberglass mat has a basis weight of 76 to 1250 g/m 2 and about 20 to about 3000 fiberglass intersections per cm 2 , and wherein the thermoplastic composite possesses a Thermal Expansion Coefficient of ⅓ or less than that of a substrate derived from a neat embodiment of the thermoplastic resin, or (ii) a Thermal Expansion Coefficient of 50*10 −6 m/(m*° C.) or lower.
12. A method comprising: (a) scattering a thermoplastic resin with optionally one or more fillers onto a fiberglass mat positioned on a first rotating belt, wherein the fiberglass mat has a weight of at least 76 up to 1250 g/m 2 and about 20 to about 3000 fiberglass intersections per cm 2 (b) thermal compression bonding the thermoplastic resin with optionally one or more fillers and the fiberglass mat between the first rotating belt with a second rotating belt to form a substrate, wherein the substrate possesses (i) a Thermal Expansion Coefficient of ⅓ or less than that of a substrate derived from a neat embodiment of the thermoplastic resin, or (ii) a Thermal Expansion Coefficient of 50*10 −6 m/(m*° C.) or lower.
13. A method according to claim 12 , wherein the substrate possesses a Thermal Expansion Coefficient of 40*10 −6 m/(m*° C.) or lower.
14. A method according to claim 12 , further comprising first scattering an additional layer of a thermoplastic resin with optionally one or more fillers onto the first rotating belt before positioning the fiberglass mat onto the first rotating belt.
15. A method according to claim 14 , wherein the thermoplastic resin has a particle size of 0.05 cm to 0.5 cm.
16. A method according to claim 12 , wherein thermal compression bonding is performed on a continuous double belt press.
17. A method according to claim 12 , wherein the thermoplastic resin comprises a polypropylene, polyethylene, polyolefin copolymer, polyvinyl chloride, polyethylene terephthalate, polyamide, polyolefin from a hydropulping process, or combination thereof.
18. A method according to claim 12 , further comprising treating a surface of the substrate.
19. A method according to claim 18 , wherein treating comprises plasma treatment, corona treatment, silane treatment, use of primer materials or heat treatment.
20. A method according to claim 12 , further comprising bonding at least one additional layer to the substrate to form a multilayered article.