Polymer composite comprising an interfacially modified fiber and particle
Embodiments herein relate to a composite material including about 10 to 80 wt. % of a polymer phase, the polymer phase comprising a thermoplastic polymer with a density of less than about 1.9 g-m−2; and about 20 to 90 wt. % of a dispersed mixed particulate phase, the dispersed mixed particulate phase comprising a mixed particulate and about 0.005 to 8 wt. % of a coating of at least one interfacial modifier. The mixed particulate including a portion of a reinforcing fiber and a portion of a particle. The composite material having a Young's modulus of greater than 700 MPa. In various embodiments, structural building components made from the composite are included as well as additive manufacturing components made from the composite.
1. A method of forming an extruded thermoplastic composite material comprising:
(a) combining:
(i) about 10 to 80 wt. % of a polymer phase comprising a thermoplastic polymer with a density of less than about 1.9 g-m −3 : and
(ii) about 20 to 90 wt. % of a dispersed particulate phase consisting essentially of greater than 50 wt. % of a reinforcing cellulosic fiber and the balance comprising at least 5 vol. % of a mineral particulate or a glass particulate, the dispersed phase comprising about 0.2-3 wt. % of a coating of at least one interfacial modifier to form a mixture; and
(b) extruding the mixture; wherein the composite material has a Young's modulus of greater than 700 Mpa; and
wherein the interfacial modifier coating can form a close association between the particulate and polymer and no covalent bonding between fiber, particulate and polymer is formed.
2. The method of claim 1 wherein the polymer comprises polyvinyl chloride, and the particulate comprises cellulosic fiber and hollow glass sphere.
3. The method of claim 1 wherein the fiber comprises a wood fiber.
4. The method of claim 1 wherein the glass particulate is a hollow glass sphere.
5. A method of forming an extruded thermoplastic composite structural member comprising:
(a) combining:
(i) about 10 to 80 wt. % of a polymer phase comprising a thermoplastic polymer with a density of less than 1.9 g-m −3 : and
(ii) about 20 to 90 wt. % of a dispersed particulate phase consisting essentially of greater than 50 wt. % of a reinforcing cellulosic fiber and the balance comprising at least 5 vol. % of a mineral particulate or a glass particulate, the dispersed phase comprising about 0.2-3 wt. % of a coating of at least one interfacial modifier to form a mixture; and
(b) extruding the mixture to form a structural member; wherein the composite material has a Young's modulus of greater than 700 MPa; and
wherein the interfacial modifier coating can form a close association between the particulate and polymer and no covalent bonding between fiber, particulate and polymer is formed.
6. The method of claim 5 forming a structural decking member.
7. The method of claim 5 forming an extruded panel.
8. The method of claim 5 forming a structural fencing member.
9. The method of claim 5 forming at least two extruded panels and joinery features.
10. The method of claim 5 comprising a fenestration opening.