Fiber polymer composite
The claimed material relates to a fiber and polymer composite having enhanced modulus, viscoelastic and rheological properties.
1. A thermoplastic method of forming a composite comprising a discontinuous phase dispersed in a polymer phase, the method comprising:
(i) providing a fiber, free of a particulate, having an exterior coating comprising an interfacial modifier,
(ii) combining the coated fiber with a polymer to form a blend, and
(iii) extruding the blend to form a composite comprising a discontinuous phase dispersed in a polymer phase wherein;
(a) the discontinuous phase comprises the coated fiber, the coated fiber having a length greater than about 1 mm, a diameter greater than about 2 microns and an aspect ratio greater than about 100, and
(b) the polymer phase comprises the polymer selected from a vinyl polymer, a condensation polymer, or a fluorocarbon polymer; wherein the discontinuous phase comprises greater than about 40 vol. % of the composite and the composite has a flexural modulus as measured by ASTM D790 of greater than 8 GPa; and
wherein the composite comprises:
about 10 to 70 wt. % of the polymer phase; and
about 0.01 to 3 wt. % of the interfacial modifier, the wt. % based on the composite.
2. The method of claim 1 wherein the fiber comprises a synthetic fiber.
3. The method of claim 1 wherein the fiber comprises a glass fiber.
4. The method of claim 1 wherein the fiber comprises a wood fiber.
5. The method of claim 3 wherein the fiber comprises a glass fiber and a wood fiber.
6. The method of claim 1 wherein there is greater than 50 vol. % of the coated fiber based on the composite.
7. The method of claim 1 wherein there is greater than 60 vol. % of the coated fiber based on the composite.
8. The method of claim 1 wherein the composite is injection molded to form a product.