COMPOSITE EXTRUSION WITH NON-ALIGNED FIBER ORIENTATION

• US 20200131355A1
• Filed: 12/30/2019
• Published: 04/30/2020
• 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
• Granted Patent: US 11,267,963 B2
• Time in Patent Office: Days
• 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 building component 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 that is not aligned with a direction of extrusion of the extruded segment.

2. The extruded building component of claim 1, the polymer resin selected from the group consisting of PLA, PVC, and PET.

3. The extruded building component of claim 1, the fibers exhibiting an average offset angle relative to the direction of extrusion of greater than 20 degrees.

4. The extruded building component of claim 1, the particles comprising a biomaterial.

5. The extruded building component of claim 1, the particles comprising at least one of wood particles, hemp, kenaf, bamboo, rice hulls, and nutshells.

6. The extruded building component of claim 1, the particles selected from the group consisting of wood particles and glass spheres.

7. The extruded building component of claim 1, wherein at least 50 wt. % of the particles are organic particles having an average largest dimension of greater than 100 microns and an aspect ratio of 4:

1 or less.

8. The extruded building component of claim 1, wherein at least 50 wt. % of the particles are inorganic particles having an average largest dimension of greater than 10 microns and an aspect ratio of 4:

1 or less.

9. The extruded building component of claim 1, the particles having an average largest dimension of greater than 180 microns.

10. The extruded building component of claim 1, the particles having an aspect ratio of about 4:

1 to about 1;

1.

11. The extruded building component of claim 1, the fibers comprising glass fibers.

12. The extruded building component of claim 11, the glass fibers having an average length after extrusion of about 0.2 mm to about 10 mm and an average diameter of about 2 microns to about 50 microns.

13. The extruded building component of claim 1, the fibers comprising carbon fibers.

14. The extruded building component of claim 1, the fibers having an aspect ratio of about 400:

1 to about 15;

1.

15. The extruded building component of claim 1, the extruded building component comprising a fenestration component.

16. The extruded building component of claim 1, further comprising a second extruded segment comprising a second composition, the second composition comprising:

a polymer resin; and

particles.

17. 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

at least one of fibers and particles;

the second composition comprising;

a polymer resin;

particles; and

fibers;

wherein the first fiber orientation is different than the second fiber orientation.

18. The extruded article of claim 17, wherein the fibers of the second composition exhibit an average offset angle relative to a direction of extrusion of the second portion that is at least 5 degrees different than an average offset angle relative to a direction of extrusion for the fibers of the first composition.

19. The extruded article of claim 17, wherein the fibers of the second composition exhibit an average offset angle relative to a direction of extrusion of the second portion that is greater than 20 degrees.

20. The extruded article of claim 17, wherein the second portion includes a single wall segment.

21. The extruded article of claim 17, wherein the second portion includes a joint between wall segments.

22. The extruded article of claim 17, 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.

23. The extruded article of claim 17, 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.

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

25. The extruded article of claim 17, further comprising a third portion comprising a third composition different than the first and second compositions.

26. The extruded article of claim 25, the third composition lacking fibers.

27. The extruded article of claim 25, the third portion comprising a third layer contacting at least one of the first and second layers.

28. The extruded article of claim 25, the third portion comprising a capstock layer and covering at least one of the first and second layers.

29. An extruded article comprising:

a first portion comprising a first composition; and

a second portion comprising a second composition different than the first composition;

the first composition comprising;

a polymer resin;

the second 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 that is not aligned with a direction of extrusion of the extruded segment.

30. An extruded article comprising:

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

a polymer resin selected from the group consisting of PLA, PVC, and PET;

at least 1% by weight particles; and

at least 15% by weight fibers, wherein the fibers exhibit an average offset angle that is not aligned with a direction of extrusion of the extruded segment.

31. An extruded article comprising:

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

a polymer resin;

at least 1% by weight particles, wherein at least 50 wt. % of the particles are organic particles having an average largest dimension of greater than 100 microns and an aspect ratio of 4;

1 or less; and

at least 15% by weight fibers, wherein the fibers exhibit an average offset angle that is not aligned with a direction of extrusion of the extruded segment.