Interfacial blending agent for natural fiber composites
First Claim
1. A composite article comprising:
- a first zone, said first zone being comprised of a first polymer; and
a second zone, said second zone being comprised ofa second polymer,a natural cellulose-containing fiber,a porosity agent to control the porosity of said second zone, said second zone having an outer surface, said outer surface being porous to hold and retain wood stain or paint, said porosity agent being present in an amount of from 0.01 to 5% by weight inclusive and selected from the group consisting of a paraffin and a hydrocarbon wax blend; and
an interfacial agent to aid in forming a homogeneous distribution of the natural cellulose-containing fiber in the second polymer, said interfacial agent being functionalized to the extent wherein at least one part of the interfacial agent can form a chemical or a physical bond to at least a portion of a cellulose component of the natural cellulose-containing fiber while at least one other portion of the interfacial agent aids in the compatibilization with the second polymer, said interfacial agent being present in an amount of from 0.01 to 2% by weight inclusive; and
said first and second zones being integral and being coextruded together,said second zone having a porosity of between 5-40% inclusive.
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Accused Products
Abstract
The invention describes a process for the preparation of a natural fiber and thermoplastic composite and the resulting products therefrom. The process includes the steps of mixing the natural fiber and the thermoplastic in a blender with a porosity aid and an interfacial agent to form a mixture; adding the mixture to a heated extruder; compressing the mixture with an extruder screw having a plurality of flight sections, at least one of the flight sections serving as a compression flight section which compresses the mixture by having its flights spaced closer together than other adjacent flight sections, and at least one other vent flight section which allows gaseous reaction products to be removed from the extruder through a vent in the extruder by having its flights spaced farther apart than the compression section, the vent flight section being positioned after the compression flight section; extruding the mixture through an extrusion die as a composite; and shaping the composite in a vacuum calibration device to a desired profile. The process further includes the step of co-extruding a second thermoplastic onto the natural fiber/thermoplastic composite for some applications (e.g., windows, doors and siding).
111 Citations
49 Claims
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1. A composite article comprising:
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a first zone, said first zone being comprised of a first polymer; and a second zone, said second zone being comprised of a second polymer, a natural cellulose-containing fiber, a porosity agent to control the porosity of said second zone, said second zone having an outer surface, said outer surface being porous to hold and retain wood stain or paint, said porosity agent being present in an amount of from 0.01 to 5% by weight inclusive and selected from the group consisting of a paraffin and a hydrocarbon wax blend; and an interfacial agent to aid in forming a homogeneous distribution of the natural cellulose-containing fiber in the second polymer, said interfacial agent being functionalized to the extent wherein at least one part of the interfacial agent can form a chemical or a physical bond to at least a portion of a cellulose component of the natural cellulose-containing fiber while at least one other portion of the interfacial agent aids in the compatibilization with the second polymer, said interfacial agent being present in an amount of from 0.01 to 2% by weight inclusive; and said first and second zones being integral and being coextruded together, said second zone having a porosity of between 5-40% inclusive. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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18. A composite article comprising:
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a first zone, said first zone being comprised of a polyvinyl chloride polymer; and a second zone, said second zone being comprised of a polyvinyl chloride polymer, a natural cellulose-containing fiber, a porosity agent to control the porosity of said second zone, said second zone having an outer surface, said outer surface being porous to hold and retain wood stain or paint, said porosity agent being present in an amount of from 0.01 to 5% by weight inclusive and selected from the group consisting of a paraffin and a hydrocarbon wax blend; and an interfacial agent to form a homogeneous melt of the natural cellulose-containing fiber and the second polymer, said interfacial agent being functionalized to the extent wherein at least one part of the interfacial agent can form a chemical or a physical bond to at least a portion of a cellulose component of the natural cellulose-containing fiber while at least one other portion of the interfacial agent aids in the compatibilization with the second polymer, said interfacial agent being present in an amount of from 0.01 to 2% by weight inclusive; and said first and second zones being integral and being coextruded together, said second zone having a porosity of between 5-40% inclusive. - View Dependent Claims (19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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31. A composite article comprising:
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a first zone, said first zone being comprised of a first polymer; and a second zone, said second zone being comprised of a second polymer, a natural cellulose-containing fiber, a porosity agent to control the porosity of said second zone, said second zone having an outer surface, said outer surface being porous to hold and retain wood stain or paint; and an interfacial agent to aid in forming a homogeneous distribution of the natural cellulose-containing fiber in the second polymer, said interfacial agent having at least one portion which is hydrophilic and at least one other portion wich is hydrophobic; said porosity agent and interfacial agent interacting and combined in a ratio to obtain fusion of said second polymer and natural cellulose-containing fiber, and a porosity of between 5-40% inclusive in said second zone; and said first and second zones being integral and being coextruded together. - View Dependent Claims (32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49)
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Specification