Composite extrusion with non-aligned fiber orientation

• US 10,550,257 B2
• Filed: 02/22/2017
• Issued: 02/04/2020
• Est. Priority Date: 02/23/2016
• Status: Active Grant

• Current Assignee: Andersen Corporation
• Original Assignee: Andersen Corporation
• Inventors: Peterson, Trevor Dean, Ehrlichmann, Jessica Kathryn, Gronlund, Patrick Jerome
• Primary Examiner(s): Thompson, Camie S
• Application Number:
  US15/439,586
• Publication Number:
  US 20170240737A1
• Time in Patent Office: 1,077 Days
• Field of Search: 4282974, 428323, 428332
• CPC Class Codes: B29C 48/11 comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 48/16 Articles comprising two or more components, e.g. co-extruded layers
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 48/2886 of fibrous, filamentary or filling materials, e.g. thin fibrous reinforcements or fillers
• CPC Class Codes: B29K 2105/06 containing reinforcements, fillers or inserts
• CPC Class Codes: B29K 2105/12 of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B29K 2203/00 Use of starch or derivatives as reinforcement
• CPC Class Codes: B29K 2311/10 Natural fibres, e.g. wool or cotton
• CPC Class Codes: B29K 2711/10 Natural fibres, e.g. wool or cotton
• CPC Class Codes: C08K 3/34 Silicon-containing compounds
• CPC Class Codes: C08K 7/02 Fibres or whiskers
• CPC Class Codes: C08K 7/20 Glass
• CPC Class Codes: C08L 27/06 Homopolymers or copolymers of vinyl chloride
• CPC Class Codes: C08L 97/02 Lignocellulosic material, e.g. wood, straw or bagasse manufacture of articles made from lignocellulosic material by dry processes B27N

Abstract

Embodiments herein include compositions, extruded articles, and methods of making the same. In an embodiment, an extruded article is included. The extruded article can include an extruded segment comprising a first composition. The first composition can include a polymer resin, particles and fibers. The fibers can be disposed within the first composition exhibiting a substantially non-aligned directional orientation. In an embodiment, an extruded article is included having a first portion comprising a first composition having a first fiber orientation and a second portion comprising a second composition having a second fiber orientation. The first composition can include a polymer resin and fibers. The second composition can include a polymer resin, particles and fibers. The fibers of the second composition can be oriented more randomly than the fibers of the first composition. Other embodiments are also included herein.

Claims

1. An extruded article comprising:

an extruded segment comprising a first composition, the first composition comprising;

a polymer resin;

at least 1% by weight particles; and

at least 15% by weight fibers, wherein the fibers exhibit an average offset angle relative to the extrusion direction of greater than 20 degrees;

the extruded article comprising a fenestration component.

2. The extruded article of claim 1, the fibers exhibiting an average offset angle relative to the extrusion direction of between 30 and 80 degrees.

3. The extruded article of claim 1, the first composition comprising at least 5% by weight particles.

4. The extruded article of claim 1, the particles comprising glass spheres.

5. The extruded article of claim 1, wherein at least 50 wt. % of the particles are selected from the group of organic particles having an average largest dimension of greater than 100 microns and an aspect ratio of 4:

1 or less and inorganic particles having an average largest dimension of greater than 10 microns and an aspect ratio of 4;

1 or less.

6. The extruded article of claim 1, the particles comprising wood particles.

7. The extruded article of claim 6, the wood particles having an average largest dimension of 180 microns to 600 microns.

8. The extruded article of claim 1, the particles having an aspect ratio of about 10:

1 to about 1;

1.

9. The extruded article of claim 1, the fibers having an aspect ratio of about 800:

1 to about 15;

1.

10. The extruded article of claim 1, the first composition comprising at least 20% fibers.

11. The extruded article of claim 1, the polymer resin comprising polyvinyl chloride.

12. An extruded article comprising:

a first portion comprising a first composition having a first fiber orientation; and

a second portion comprising a second composition having a second fiber orientation;

the first composition comprising;

a polymer resin; and

fibers;

the second composition comprising;

a polymer resin;

particles; and

fibers, wherein the fibers are oriented more randomly than the fibers of the first composition and the fibers exhibit an average offset angle relative to the extrusion direction of greater than 20 degrees.

13. The extruded article of claim 12, where the fibers of the second composition exhibit an average offset angle relative to the extrusion direction that is at least 15 degrees different than the average offset angle relative to the extrusion direction for the fibers of the first composition.

14. The extruded article of claim 12, where the fibers of the second composition exhibit an average offset angle relative to the extrusion direction of greater than 30 degrees.

15. The extruded article of claim 12, wherein the second portion comprises at least one feature selected from the group consisting of an interior wall, an external wall, a corner, an appendage, a single wall area, and a joint between walls.

16. The extruded article of claim 12, wherein the first portion comprises at least one feature selected from the group consisting of an interior wall, an external wall, a corner, an appendage, a single wall area, and a joint between walls.

17. The extruded article of claim 12, wherein the first and second portions comprise layers, wherein the first layer is disposed on the second layer.

18. An extruded article comprising:

an extruded segment comprising a first composition, the first composition comprising;

a polymer resin;

at least 1% by weight particles; and

at least 15% by weight fibers, wherein the fibers exhibit an average offset angle relative to the extrusion direction of greater than 20 degrees;

the particles comprising wood particles.

19. The extruded article of claim 18, the wood particles having an average largest dimension of 180 microns to 600 microns.

20. An extruded article comprising:

an extruded segment comprising a first composition, the first composition comprising;

a polymer resin;

at least 1% by weight particles; and

at least 15% by weight fibers, wherein the fibers exhibit an average offset angle relative to the extrusion direction of greater than 20 degrees;

the particles having an aspect ratio of about 10;

1 to about 1;

1.

21. An extruded article comprising:

an extruded segment comprising a first composition, the first composition comprising;

a polymer resin;

at least 1% by weight particles; and

at least 15% by weight fibers, wherein the fibers exhibit an average offset angle relative to the extrusion direction of greater than 20 degrees;

the fibers having an aspect ratio of about 800;

1 to about 15;

1.

22. An extruded article comprising:

an extruded segment comprising a first composition, the first composition comprising;

a polymer resin;

at least 1% by weight particles; and

at least 15% by weight fibers, wherein the fibers exhibit an average offset angle relative to the extrusion direction of greater than 20 degrees;

the polymer resin comprising polyvinyl chloride.