Wood-Plastic Composites Utilizing Ionomer Capstocks and Methods of Manufacture

• US 20100159213A1
• Filed: 12/21/2009
• Published: 06/24/2010
• Est. Priority Date: 12/19/2008
• Status: Active Grant

• Current Assignee: Fiber Composites, LLC (Fortune Brands Innovations, Inc.)
• Original Assignee: Fiber Composites, LLC (Fortune Brands Innovations, Inc.)
• Inventors: Mancosh, Douglas, Przybylinski, James P.
• Granted Patent: US 9,073,295 B2
• Time in Patent Office: Days
• US Class Current: 428/195.100
• CPC Class Codes: B29B 7/40 with single shaft
• CPC Class Codes: B29B 7/46 with more than one shaft
• CPC Class Codes: B29B 7/603 in measured doses, e.g. proportioning of several materials
• CPC Class Codes: B29B 7/728 Measuring data of the driving system, e.g. torque, speed, power, vibration B29B7/724 takes precedence
• CPC Class Codes: B29B 7/845 Venting, degassing or removing evaporated components in devices with rotary stirrers
• CPC Class Codes: B29B 7/92 Wood chips or wood fibres
• CPC Class Codes: B29C 48/18 the components being layers
• CPC Class Codes: B32B 1/00 Layered products having a non-planar shape
• CPC Class Codes: B32B 21/02 the layer being formed of fibres, chips, or particles , e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 21/10 Next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2262/065 Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
• CPC Class Codes: B32B 2262/067 Wood fibres
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/4026 within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2307/584 Scratch resistance
• CPC Class Codes: B32B 2307/71 Resistive to light or to UV
• CPC Class Codes: B32B 2307/7145 Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/18 : characterised by the use of special additives
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/04 : characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
• CPC Class Codes: C08L 2207/20 : Recycled plastic
• CPC Class Codes: C08L 23/06 : Polyethene
• CPC Class Codes: C08L 23/0876 : Neutralised polymers, i.e. ionomers
• CPC Class Codes: C08L 2666/06 : Homopolymers or copolymers of unsaturated hydrocarbons; Derivatives thereof
• CPC Class Codes: C08L 2666/26 : Natural polymers, natural resins or derivatives thereof according to C08L1/00 - C08L5/00, C08L89/00, C08L93/00, C08L97/00 or C08L99/00
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/269 : including synthetic resin or polymer layer or component
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31913 : Monoolefin polymer
• CPC Class Codes: Y10T 428/31938 : Polymer of monoethylenically unsaturated hydrocarbon
• CPC Class Codes: Y10T 428/31971 : Of carbohydrate
• CPC Class Codes: Y10T 428/31989 : Of wood

Abstract

An extruded composite adapted for use as a building material includes a core having a base polymer and a natural fiber in a substantially homogeneous mixture and an ionomer capstock. To improve adherence of the ionomer to a base polymer, the ionomer can be mixed with a similar or substantially similar base polymer prior to coextrusion with the core. Additionally, various additives may be mixed with the capstock material to improve visual aesthetics of the product and performance of the building material, especially over time.

Claims

1. An extruded composite adapted for use as a building material, the extruded composite comprising:

a core comprising a base polymer and a natural fiber in a substantially homogeneous mixture; and

a capstock comprising an ionomer.

2. The extruded composite of claim 1, wherein the base polymer is selected from the group consisting of polypropylene, polyethylene, HDPE, MDPE, LDPE, LLDPE, and combinations thereof.

3. The extruded composite of claim 1, wherein the natural fiber is selected from the group consisting of wood chips, wood flour, wood flakes, sawdust, flax, jute, hemp, kenaf, rice hulls, abaca, and combinations thereof.

4. The composite of claim 1, wherein the capstock further comprises a capstock polymer, wherein the ionomer and the capstock polymer comprise a substantially homogeneous mixture.

5. The extruded composite of claim 4, wherein the base polymer comprises a first polymer and the capstock polymer comprises the first polymer.

6. The extruded composite of claim 5, wherein the first polymer is HDPE.

7. The extruded composite of claim 4, wherein the capstock further comprises an additive.

8. The extruded composite of claim 7, wherein the additive comprises at least one of a colorant, a UV stabilizer, an antioxidant, a biocide, and a fire retardant.

9. The extruded composite of claim 8, wherein the colorant comprises a variegated colorant.

10. The extruded composite of claim 1, wherein the core comprises about 1% to about 100% base polymer, by weight.

11. The extruded composite of claim 10, wherein the core comprises about 46% base polymer, by weight.

12. The extruded composite of claim 4, wherein the capstock comprises about 1% to about 100% ionomer, by weight.

13. The extruded composite of claim 4, wherein the capstock comprises about 20% to about 80% ionomer, by weight.

14. The extruded composite of claim 4, wherein the capstock comprises about 27.5% ionomer, by weight.

15. The extruded composite of claim 4, wherein the capstock comprises about 0% to about 99% capstock polymer, by weight.

16. The extruded composite of claim 4, wherein the capstock comprises about 20% to about 80% capstock polymer, by weight.

17. The extruded composite of claim 4, wherein the capstock comprises about 72.5% capstock polymer, by weight.

18. The extruded composite of claim 4, wherein the capstock comprises less than about 50% capstock polymer, by weight.

19. The extruded composite of claim 4, wherein the capstock comprises a thickness of about 0.012 inches to about 0.040 inches.

20. The extruded composite of claim 19, wherein the capstock comprises a thickness of about 0.015 inches to about 0.020 inches.

21. The extruded composite of claim 1, wherein the capstock is bonded directly to at least one side of the core via coextrusion.

22. A method of manufacturing an extruded composite adapted for use as a building material, the method comprising the steps of:

providing a base polymer;

providing a natural fiber;

mixing and heating the base polymer and the natural fiber to produce a base mixture comprising a substantially homogeneous melt blend;

providing an ionomer; and

coextruding the ionomer onto at least a portion of the base mixture through a die to form an extruded profile.

23. The method of claim 22, further comprising the steps of:

providing a capstock polymer; and

mixing and heating the ionomer and the capstock polymer to produce a capstock mixture comprising a substantially homogeneous melt blend.

24. The extruded composite of claim 22, wherein the base polymer comprises a first polymer and the capstock polymer comprises the first polymer.

25. The extruded composite of claim 24, wherein the first polymer is selected from the group consisting of polypropylene, polyethylene, HDPE, MDPE, LDPE, LLDPE, and combinations thereof.

26. The extruded composite of claim 24, wherein the first polymer is HDPE.

27. The method of claim 23, further comprising the steps of:

providing an additive; and

mixing and heating the ionomer, the capstock polymer, and the additive to produce a capstock mixture comprising a substantially homogeneous melt blend.

28. The method of claim 27, wherein the additive comprises at least one of a colorant, a UV stabilizer, an antioxidant, a biocide, and a fire retardant.

29. The method of claim 22, further comprising the step of cooling the extruded profile.

30. The method of claim 28, wherein the step of cooling comprises passing the extruded profile through a liquid.

31. The method of claim 29, wherein the liquid comprises at least one of a water and a coolant.