POLYMER-BASED CONSTRUCTION MATERIALS
Aspects described herein relate to polymer-based building materials that include combining thermoplastic and thermoset polymers to the polymer-based cap. By including thermoset polymers, deficiencies in polymer-based construction materials can be address. The addition of thermoset polymers may facilitate improved scratch, abrasion and slip resistance for polymer-based building materials.
1 . A polymer-based building material, comprising:
a core having a first thickness extending between a first planar surface and a second planar surface; and
a cap, the cap adjacent to at least the first planar surface, the cap including a matrix comprising a thermoplastic polymer and a thermoset polymer,
wherein the thermoset polymer is uniformly distributed throughout the cap.
2 . The building material of claim 1 , wherein the cap includes a first cap portion adjacent the first planar surface of the core; and
a second cap portion adjacent the second planar surface of the core.
3 . The building material of claim 1 , wherein the thermoset polymer is a cross-linked high density polyethylene (HDPE).
4 . The building material of claim 1 , wherein the thermoplastic polymer comprises one or more of recycled high density polyethylene (HDPE), or polypropylene (PP).
5 . The building material of claim 1 , wherein the thermoplastic polymer is a virgin polymer.
6 . The building material of claim 1 , wherein the cap does not comprise cellulose.
7 . The building material of claim 2 , wherein the core includes a first core portion perpendicularly connecting the first planar surface to the second planar surface.
8 . The building material of claim 7 , wherein the first cap portion includes a subsection that is adjacent to at least a portion of the first core portion.
9 . The building material of claim 8 , wherein the first cap portion has a first thickness and the second cap portion has a second thickness.
10 . The building material of claim 2 , wherein the first cap portion and the second cap portion are connected by a third cap portion that is perpendicular to the first cap portion and the second cap portion and surrounds at least a portion of the core.
11 . The building material of claim 1 , wherein the thermoset polymer comprises a range of 0.1% and 20% by weight.
12 . A polymer-based building material, comprising:
a core having a first planar surface and a second planar surface; and
a cap adjacent to the first planar surface, the cap including
a polymeric composition having a thermoplastic polymer and a thermoset polymer,
wherein the thermoset polymer in the polymeric composition is in a range of up to 20% by weight.
13 . The building material of claim 12 , wherein the thermoset polymer is a cross-linked high density polyethylene (HDPE).
14 . The building material of claim 12 , wherein the thermoplastic polymer comprises one or more of recycled high density polyethylene (HDPE), polypropylene (PP), or a virgin polymer.
15 . The building material of claim 12 , wherein the thermoplastic polymer comprises at least 80% of a polymer-based mixture by weight.
16 . The building material of claim 12 , wherein the thermoset polymer is 5% by weight.
17 . The building material of claim 12 , wherein the cap does not comprise cellulose.
18 . The building material of claim 12 , wherein the core includes a first core portion perpendicularly connecting the first planar surface to the second planar surface.
19 . The building material of claim 18 , wherein the cap further comprises:
a first cap portion having a subsection that is adjacent to at least a portion of the first core portion; and
a second cap portion, wherein the first cap portion has a first thickness and the second cap portion has a second thickness.
20 . The building material of claim 19 , wherein the first cap portion and the second cap portion are connected by a third cap portion that is perpendicular to the first cap portion and the second cap portion and surrounds at least a portion of the core.