Thermoplastic composite building material and method of making same

Abstract

Polymer composite building materials are provided which contain about 30-80 weight percent resin, 20-70 weight percent fillers and additives, in which the fillers contain at least one bulk filler for reducing the amount of resin needed to make the building material, and at least one aesthetically functional filler for providing the building material with an aesthetic appearance. The bulk filler and the aesthetically functional filler are non toxic, resistant to bacterial attack, and have a Mohs hardness of less than about 5.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present application is a Divisional of U.S. patent application Ser. No. 10 / 281,795 filed Oct. 28, 2002. The present application is also related to U.S. patent application Ser. No. 09 / 988,985, filed Nov. 19, 2001, and is also related to U.S. patent application Ser. No. 10 / 281,796, filed Oct. 28, 2002, which are all hereby incorporated by reference herein.FIELD OF THE INVENTION [0002] The present invention relates to a consolidated form of the commingled continuous filaments of glass fibers and polymeric fibers as reinforcement. BACKGROUND OF THE INVENTION [0003] Most fence and rail materials are either traditional lumber or thermoplastics. Typical plastics in these applications are PVC (polyvinyl chloride) and polyethylene. PVC typically does not have the strength and rigidity of wood and lumber and therefore, the rail for the fence and railing needs the steel or aluminum reinforcement channel inside the rail. These metal reinforceme...

AI Technical Summary

Benefits of technology

[0020] The present invention serves to correct the shortcomings noted above. The deck panel produced in accordance with the present invention has superior resistance to color fading, possesses superior cold impact strength, has a well-defined wood grain surface, and is lightweight.

[0021] One of the objectives of the present invention is the production of a high strength plastic alternative to the traditional wrought iron or aluminum ornamental rail and fence. Metal fences and rails are constantly under the threat of corrosion attack, and need periodic painting. To date, there have not been any non-composite products with the necessary performance properties and aesthetic appearance comparable to these metal products. In that sense, there have not been any thermoplastic composite products in the market. The present invention discloses thermoplastic composite products that resemble wrought iron, and aluminum wrought iron alternative, but are maintenance-free, kink-free, light and perform equally as well.

[0022] An additional objective is to make the dark color thermoplastic post and rail fence (e.g., split post and rails) possible. The fiberglass reinforcement stabilizes the uneven contraction and expansion, in spite of different heat buildup on the surface.

[0023] A further objective of the present invention is providing non-metallic heavy duty rail and fence systems for use in industrial and commercial applications. The metallic railing in an industrial atmosphere is often exposed to chemical gases or acids and is prone to corrosion attack. The integrity of the industrial railing is critical for the safety of those in the workplace. The thermoplastic railing system that is strengthened by reinforcing tapes or rods of fiberglass / thermoplastic polymer composite provides superior strength and rigidity to its metal counterparts.

Problems solved by technology

Companies with only one or two colors enjoy only a limited market share.

The use of industrial pigments to obtain dark colors represents a significant component of the raw material cost.

While many companies have started to engrave or emboss the plastic composite products to duplicate a wood grain, such techniques are expensive and time consuming.

Images