Lightweight reinforced composite formulation and method of making the same
A composite formulation for use in lightweight molded components includes an untreated low density filler, such as glass bubbles, a solvated polymer mixture, and polymer paste. In one embodiment the solvated polymer mixture is used to treat the low density filler to form a treated low density filler. The solvated polymer mixture many include a thermoplastic resin or a reactive resin and an additive package. The additive package may include a dispersing agent and a silane carrier composition.
1. A composite formulation for use in lightweight molded components, wherein the composite formulation comprises
a treated low density filler comprising
an untreated low density filler and
a solvated polymer mixture, wherein the solvated polymer mixture comprises a thermoplastic resin or a reactive resin and an additive package, the additive package comprising a dispersing agent;
wherein the solvated polymer mixture is present in an amount of about 0.5% to about 20% by weight based on the weight of the untreated low density filler; and
wherein the solvated polymer mixture is combined with about 80% to about 99.5% by weight of the untreated low density filler to form the treated low density filler.
2. The composite formulation of claim 1 , wherein the additive package further comprises a silane carrier composition.
3. The composite formulation of claim 1 , wherein the composite formulation further comprises a polymer paste.
4. The composite formulation of claim 1 , wherein the solvated polymer mixture comprises about 20% to about 97% by weight of the additive package and about 3% to about 80% by weight of the thermoplastic resin or a reactive resin.
5. The composite formulation of claim 4 , wherein the solvated polymer mixture comprises about 60% by weight of the additive package and about 40% by weight of the thermoplastic resin or reactive resin.
6. A composite formulation for use in lightweight molded components, wherein the composite formulation comprises:
an untreated low density filler;
a solvated polymer mixture, wherein the solvated polymer mixture comprises a thermoplastic resin or a reactive resin and an additive package, the additive package comprising a dispersing agent and a silane carrier composition;
wherein the solvated polymer mixture is present in an amount of about 0.5% to about 20% by weight based on the weight of the untreated low density filler; and
wherein the additive package comprises about 68% to about 96% by weight of the dispersing agent and from about 4% to about 32% by weight of the silane carrier composition.
7. The composite formulation of claim 6 , wherein the additive package comprises about 85% by weight of the dispersing agent and about 15% by weight of the silane carrier composition.
8. The composite formulation of claim 3 , wherein the polymer paste comprises a low density sheet molded compound, a bulk molding compound, a pultrusion compound, or a cast polymer compound.
9. The composite formulation of claim 1 , wherein the dispersing agent is an alkyl amine-based or fluorocarbon-based polymer.
10. The composite formulation of claim 1 , wherein the untreated low density filler comprises hollow spheres.
11. A treated low density filler for use in lightweight molded components, wherein the treated low density filler comprises:
an untreated low density filler;
from about 0.5% to about 20% by weight of a solvated polymer mixture based on the weight of the untreated low density filler, wherein the solvated polymer mixture comprises a thermoplastic resin or a reactive resin and an additive package, the additive package including a dispersing agent and optionally, a silane carrier composition; and
wherein the solvated polymer mixture is combined with about 80% to about 99.5% by weight of the untreated low density filler to form the treated low density filler.
12. The treated low density filler of claim 11 , wherein the solvated polymer mixture comprises about 20% to about 97% by weight of the additive package and about 3% to about 80% by weight of the thermoplastic resin or a reactive resin.
13. The treated low density filler of claim 12 , wherein the solvated polymer mixture comprises about 60% by weight of the additive package and about 40% by weight of the thermoplastic resin or reactive resin.
14. A treated low density filler for use in lightweight molded components, wherein the treated low density filler comprises:
an untreated low density filler;
from about 0.5% to about 20% by weight of a solvated polymer mixture based on the weight of the untreated low density filler, wherein the solvated polymer mixture comprises a thermoplastic resin or a reactive resin and an additive package, the additive package including a dispersing agent and a silane carrier composition;
wherein the solvated polymer mixture is combined with about 80% to about 99.5% by weight of the untreated low density filler to form the treated low density filler; and
wherein the additive package comprises about 68% to about 96% by weight of the dispersing agent and from about 4% to about 32% by weight of the silane carrier composition.
15. The treated low density filler of claim 14 , wherein the additive package comprises about 85% by weight of the dispersing agent and about 15% by weight of the silane carrier composition.
16. The treated low density filler of claim 11 , wherein the untreated low density filler comprises hollow spheres.
17. The treated low density filler of claim 11 , wherein the dispersing agent is an alkyl amine-based or a fluorocarbon-based polymer.