Enhancement of reinforcing fibers, their applications, and methods of making same
The invention relates to composite reinforcing fibers infused or compounded with pulp fibers and/or nano-fibers. The composite reinforcing fibers are composed of polymer, e.g., polymer resin. The pulp fibers and/or nano-fibers impart improved tensile strength to the composite reinforcing fibers, as well as a resulting product formed by the fibers. The composite reinforcing fibers may be used in a variety of cementitious applications, wherein traditional reinforcing fibers are typically used.
1. A method of preparing a composite reinforcing fiber, comprising:
obtaining a water soluble first resin;
obtaining a fiber component, comprising:
a blend, comprising:
pulp fiber; and
nano-fiber composed of a material selected from the group consisting of carbon, aramid, polyacrylonitrile and mixtures thereof;
compounding the first resin and the fiber component to form a compounded second resin;
obtaining a third resin comprising synthetic polymer; and
extruding to blend and melt together the third resin and the second resin to form the composite reinforcing fiber.
2. A method of preparing a composite reinforcing fiber, comprising:
obtaining a water soluble first resin;
obtaining a fiber component selected from the group consisting of pulp fiber, nano-fiber and mixtures thereof;
compounding the fiber component with the first resin to form a compounded second resin;
extruding the second resin to form a master batch;
obtaining a third resin comprising synthetic polymer; and
extruding to blend and melt together the third resin and the master batch to form the composite reinforcing fiber.
3. A method of preparing a composite reinforcing fiber, comprising:
obtaining a synthetic polymer resin;
obtaining a water soluble resin;
obtaining a fiber component selected from the group consisting of pulp fiber, nano-fiber and mixtures thereof;
compounding the fiber component with the water soluble resin;
extruding the compounded fiber component with the water soluble resin and creating a master batch in pellet form;
compounding the synthetic polymer resin with the master batch in pellet form;
forming a resin/fiber blend;
melting the resin/fiber blend; and
extruding the resin/fiber blend to form the composite reinforcing fiber.
4. The method of claim 1 , wherein the water soluble first resin is selected from the group consisting of polyethylene, polypropylene and mixtures thereof.
5. The method of claim 1 , wherein the melt is conducted in an extruder barrel and screw.