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 method of making a treated low density filler for use in lightweight molded components, the method comprising the steps of:
combining about 85% by weight of a dispersing agent with about 15% by weight of a silane carrier composition to form an additive package;
combining about 20% to about 97% by weight of the additive package with about 3% to about 80% by weight of a thermoplastic resin or a reactive resin to form a diluted mixture;
applying heat to the diluted mixture to form a solvated polymer mixture; and
combining about 0.5% to about 20% by weight of the solvated polymer mixture with about 80% to about 99.5% by weight of an untreated low density filler to form a treated low density filler.
2. A method of making a composite formulation for use in lightweight molded parts, the method comprising the steps of:
preparing an additive package, wherein the additive package comprises about 85% by weight of a dispersing agent and about 15% by weight of a silane carrier composition;
combining about 20% to about 97% by weight of the additive package with about 3% to about 80% by weight of a thermoplastic resin or a reactive resin to form a diluted mixture; and
heating the diluted mixture to form a solvated polymer mixture.
3. The method of claim 2 , wherein the method further comprises the steps of:
combining about 0.5% to about 20% by weight of the solvated polymer mixture with about 80% to about 99.5% by weight of an untreated low density filler to form a treated low density filler;
preparing a polymer paste; and
combining the polymer paste with the treated low density filler.
4. The method of claim 2 , wherein the method further comprises the steps of:
combining the solvated polymer mixture with a polymer paste to form a solvated polymer paste; and
combining the solvated polymer paste with an untreated low density filler.