Rubber filled oriented polymer composition article

Abstract

Including crosslinked rubber particles in an oriented polymer composition induces cavitation in the oriented polymer composition and can increases the scratch and mar resistance as well as fibrillation resistance.

Description

CROSS REFERENCE STATEMENT [0001]This application claims the benefit of U.S. Provisional Application No. 61 / 117,584, filed Nov. 25, 2008 which is incorporated herein by reference.BACKGROUND OF THE INVENTION[0002]1. Field of the Invention[0003]The present invention relates to an oriented polymer composition article comprising crosslinked rubber particles and a process for preparing such an article. A desirable embodiment of the invention relates to an expanded oriented polymer composition article comprising crosslinked rubber particles.[0004]2. Description of Related Art[0005]Oriented polymer composition articles (OPCs) are gaining market share in construction markets previously occupied almost solely by wood materials. For example, a number of different OPC decking materials are now available for use instead of cedar, redwood, treated pine, or other more historically standard decking materials. High strength and low maintenance are but a few of the desirable characteristics of OPCs t...

AI Technical Summary

Benefits of technology

[0013]Even more surprising, when the crosslinked rubber particles are present at a concentration of about 25 wt % or more based on the polymer composition weight the resulting OPC demonstrates an inherently improved scratch and mar resistance and an inherently improved resistance to fibrillation. Die drawing the polymer composition can further induce cavitation to produce an EOPC with these enhanced properties.

Problems solved by technology

Unfortunately, OPCs are susceptible to scratching and marring that is undesirably visible, particularly in dark colored OPCs.

OPCs also tend be undesirably susceptible to fibrillation when cut or exposed to abrasion across fibrils proximate to the OPC's surface.

These drawbacks reduce the appeal of OPCs for applications such as decking where cutting is necessary and where scratching, abrasion and / or marring is likely to occur.

Applying a coating on a polypropylene article adds considerable complexity to OPC processing by requiring an application step after fabricating the article.

Moreover, selection of the coating material and application method requires careful screening and testing to ensure that the coating adheres to polypropylene because if the coating delaminates from the article the scratch and mar resistance is lost.

This process is effective at reducing fibrillation but is generally less effective at reducing the appearance of scratches and mars on an OPC and can actually accentuate the appearance of subsequent scratches and mars.