Composite structural components, methods for making the same, and methods of mitigating detrimental effects by contaminants in recycled polymers

Abstract

The present disclosure is directed to composite components of a structure, comprising: 1) a polymeric resin having a surface in a planar or three-dimensional shape, comprising a recycled polymer present in the polymeric resin at 1 to 100 percent by weight; and 2) a surfacing agent comprising a microporous sheet adhered to the polymeric resin. The microporous sheet comprises a polyolefin polymeric matrix; particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet. The structure comprises a vehicle, building, bridge, transportation infrastructure, oil rig, oil platform, water tower, power line tower, support structure, wind turbine blade, wall, or shipping container. Also provided are methods of making a molded composite component for a structure, methods of recycling a polymer, and methods of mitigating detrimental effects on a surface of a molded composite vehicle component caused by contaminants present in a recycled polymer.

Description

COMPOSITE STRUCTURAL COMPONENTS, METHODS FOR MAKING THE SAME, AND METHODS OF MITIGATING DETRIMENTAL EFFECTS BY CONTAMINANTS IN RECYCLED POLYMERSFIELD OF THE DISCLOSURE

[0001] The present disclosure relates to composite components of a structure, in particular, vehicle components, methods for making them, methods of mitigating detrimental effects on a surface of a molded composite vehicle component caused by contaminants present in a recycled polymer, and methods of recycling polymers.BACKGROUND

[0002] Composite materials can provide desired mechanical properties to vehicular and other industrial structural components at lower weights than metals or other materials, and their use has become widespread in numerous industries. Moreover, there is continued interest in recycling various plastics for use in such composites. However, because recycled plastics often contain contaminants, the surface of the composite material may be discolored or exhibit other aesthetic surface defects, particularly on injection molded pieces, and require additional treatment before the material can be painted and used.SUMMARY OF THE DISCLOSURE

[0003] The present disclosure is directed to composite components of a structure, comprising:1 ) a polymeric resin having a surface in a planar or three-dimensional shape, comprising recycled content present in the polymeric resin in an amount of 1 to 100 percent by weight, based on the total weight of the polymeric resin; and2) a surfacing agent comprising a microporous sheet adhered to the polymeric resin, the microporous sheet comprising a polyolefin polymeric matrix; finely divided particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet; wherein the structure comprises a vehicle, building, bridge, transportation infrastructure, oil rig, oil platform, water tower, power line tower, support structure, wind turbine blade, wall, or shipping container.

[0004] The present disclosure is further directed to methods of making a molded composite component for a structure and methods of recycling a polymer, each comprising:1 ) lining at least a portion of an open mold interior with a microporous sheet;2) closing the mold;3) adding a polymeric resin to the mold on the microporous sheet; wherein the mold is closed prior to adding the polymeric resin to the mold in an injection molding process, and the mold is closed after adding the polymeric resin to the mold in a compression molding process; and4) hardening the polymeric resin to form a molded composite component; wherein the microporous sheet comprises a polyolefin polymeric matrix; finely divided particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet; and wherein the polymeric resin comprises recycled content (e. g., polymer to be recycled), present in the polymeric resin in an amount of 1 to 100 percent by weight, based on the total weight of the polymeric resin; and wherein the structure comprises a vehicle, building, bridge, transportation infrastructure, oil rig, oil platform, water tower, power line tower, support structure, wind turbine blade, wall, or shipping container.

[0005] Also provided are methods of mitigating detrimental effects on a surface of a molded composite vehicle component caused by contaminants present in recycled content, comprising:1 ) lining at least a portion of an open mold interior with a microporous sheet;2) closing the mold;3) adding a polymeric resin to the mold on the microporous sheet; wherein the mold is closed prior to adding the polymeric resin to the mold in an injection molding process, and the mold is closed after adding the polymeric resin to the mold in a compression molding process; and4) hardening the polymeric resin to form a molded composite vehicle component;5) removing the molded composite vehicle component from the mold; and6) applying a decorative design and / or coating layer to the microporous sheet, the coating layer comprising a conductive coating layer, a primer layer, an adhesion layer, a basecoat layer, a clear coat layer, and / or a monocoat layer, wherein thecoating layer is applied to the microporous sheet either prior to lining the mold interior with the microporous sheet or after removing the molded composite vehicle component from the mold; wherein the microporous sheet comprises a polyolefin polymeric matrix; finely divided particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet; and wherein the polymeric resin comprises the recycled content, present in the polymeric resin in an amount of 1 to 100 percent by weight, based on the total weight of the polymeric resin.

[0006] The present disclosure is further directed to composite components of a structure, comprising:1 ) an extruded polymeric resin having a surface in a planar or three-dimensional shape, comprising recycled content, present in the polymeric resin in an amount of 1 to 100 percent by weight, based on the total weight of the polymeric resin; and2) a surfacing agent comprising a microporous sheet adhered to the extruded polymeric resin, the microporous sheet comprising a polyolefin polymeric matrix; finely divided particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet; wherein the structure comprises a vehicle, building, bridge, transportation infrastructure, oil rig, oil platform, water tower, power line tower, support structure, wind turbine blade, wall, or shipping container.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. 1 is a photograph of a thermoformed surfacing agent formed from a microporous sheet 10, used to prepare a composite component 100 of a structure in accordance with the present disclosure. In this example, the thermoformed surfacing agent formed from the microporous sheet 10 has four corners, each of which has a protrusion formed during the thermoforming process.

[0008] FIG. 2a illustrates a schematic bottom view drawing of the composite component 100 formed from the microporous sheet 10 shown in the photograph of FIG. 1 and from the polymeric resin 20, identifying a comparatively “flat” region 12 at the center of the composite component 100, and the peak 16 of a protrusion formed during thermoforming and molding. FIG. 2b illustrates a schematic cross-sectional view of the composite component 100 (along the line delineated in FIG 2a as “a-a”),identifying the peak 16 of a protrusion formed during molding, the middle region 14, which is located 1 ” downwards from the peak of the protrusion 16, and the comparatively flatter region 12.

[0009] FIG. 3 is a graph of the Compressive Strain (%) of three separate surfacing agents formed from microporous sheets 10 having the same composition but three different thicknesses, and measured at three different regions 12, 14 and 16 on each sheet after thermoforming, as used in the Examples below. The compressive strain of a material can be calculated as the ratio between tmand to, wherein tmis the thickness of the material after thermoforming, and to is the thickness of the material prior to thermoforming; compressive strain is expressed as a percent.

[0010] FIG. 4 is a flow chart demonstrating the major steps in the methods of making a molded composite component for a structure and methods of recycling a polymer of the present disclosure.DETAILED DESCRIPTION

[0011] Other than in any operating examples, or where otherwise indicated, all numbers expressing, for example, quantities of ingredients used in the specification and claims are to be understood as being modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties to be obtained by the disclosed components. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0012] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard variation found in their respective testing measurements.

[0013] Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of “1 to 10” is intended to include all sub-ranges between (and including) the recited minimumvalue of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.

[0014] In this application, the use of the singular includes the plural and plural encompasses singular, unless specifically stated otherwise. Further, in this application, the use of “a” or “an” means “at least one” unless specifically stated otherwise. For example, “an” additive, “a” silica, and the like refer to one or more of these items. Also, as used herein, the term “polymer” is meant to refer to prepolymers, oligomers, and both homopolymers and copolymers. The term “resin” is used interchangeably with “polymer.”

[0015] The present disclosure is directed to composite components 100 of a structure. The structure may comprise a vehicle, building, bridge, transportation infrastructure, oil rig, oil platform, water tower, power line tower, support structure, wind turbine blade, wall, shipping container, or similar structure. For example, the component 100 may comprise a quarter panel, bumper, fender, hood, door panel, roof, or other component of a vehicle. The component 100 may comprise roofing, siding, window framing, or other component of a building.

[0016] The composite component 100 comprises 1 ) a polymeric resin 20 having a surface in a planar or three-dimensional shape, comprising recycled content. The recycled content may comprise a recycled polymer that may in turn comprise, for example, low-density polyethylene (such as 910 to 930 kg / m3), medium-density polyethylene (such as 925 to 940 kg / m3, with some overlap with other polyethylenes), high-density polyethylene (usually 930 to 970 kg / m3, again with some overlap with other polyethylenes), polycarbonate, polystyrene, polypropylene, polyethylene terephthalate, thermoplastic polyolefin, polyvinyl chloride, polyamide, poly (methyl methacrylate), thermoplastic elastomer, styrene-butadiene polymer, polybutadiene and / or thermoplastic polyurethane. Density as discussed herein may be determined in accordance with ISO 1 183-1 :2025. The recycled content may additionally comprise inorganic materials such as glass, metals, inorganic particles and / or fibers including glass fibers, silica, metal oxides such as pigments, metals, carbon particles or fibers, and the like. Sources of such recycled content may include post-industrial and / or postconsumer products such as electronic articles, fiber optic cables and other equipment, containers (food, beverage, household products, and the like) and other packaging, labels, spent automotive parts (tires, bumpers, trim, paint, surfacing agents, etc.),spent building materials (rigid or flexible plastic sheeting, foams, glazes, roofing, tarps, PVC pipes, etc.), and similar non-hazardous waste materials that are recyclable.

[0017] The recycled content is typically present in the polymeric resin 20 in an amount of 1 to 100 percent by weight, such as 1 to 75 percent by weight, or 1 to 50 percent by weight, or 1 to 35 percent by weight, or 1 to 25 percent by weight, or 5 to 100 percent by weight, or 5 to 75 percent by weight, or 5 to 50 percent by weight, or 5 to 35 percent by weight, or 5 to 25 percent by weight, based on the total weight of the polymeric resin. In particular non-limiting examples, the polymeric resin may comprise 10 percent by weight recycled polypropylene, or 30 percent by weight recycled polypropylene, or 30 percent by weight of a mixture of two or more recycled polymers, based on the total weight of the polymeric resin.

[0018] The polymeric resin 20 may further comprise sheet molding compounds, bulk molding compounds, pelletized thermoplastic polymers, thermoplastic molding compounds, thermosetting molding compounds, polymer matrix composites, or combinations thereof. For example, the polymeric resin 20 may further comprise a polyurethane, polyamine, acrylonitrile-butadiene-styrene, low-density polyethylene, medium-density polyethylene, high-density polyethylene, polycarbonate, polyamide, high impact polystyrene, polypropylene, polyetherketone, an epoxy resin, a phenolic resin, a melamine resin, a urea resin, polyaryl ether ketone, polyoxymethylene, polystyrene, polyester, polyimide, polyacetal, polyphenylene oxide, polyphenylene sulfide, polyethersulfone, cyclic polyolefin, a copolymer of a norbornene-based monomer and an olefin-based monomer, vinyl-based polymer, cellulose resin, a maleimide resin, a halogenated resin, silicone, an inorganic resin, an organic / inorganic hybrid resin, fiber-reinforced thermoplastic polymers such as glass fiber-reinforced or carbon fiber-reinforced thermoplastic polymers, or combinations thereof. Any of the thermoplastic polymers listed above may be pelletized, for faster melting and convenient introduction into a mold.

[0019] Fiber-reinforced thermoplastic polymers may include fibrous reinforcing materials (such as short glass fibers) and non-fibrous fillers (such as graphite, kaolin, talc, silica, mica, or wollastonite). Other non-limiting examples of reinforcing fillers include chopped fibers, continuous fibers, filaments, tows, bundles, and combinations thereof. Additionally, the reinforcing fibers can be unidirectionally oriented (i.e., aligned in one direction), multi-directional oriented (i.e., aligned in different directions relative to each other such as 45 degrees, 90 degrees, etc.), or randomly oriented, and thereinforcing fibers can form various structures, including but not limited to a sheet, ply, weave, fabric, non-woven, woven, knitted, stitched, wound, and braided structure, as well as swirl mat, veil, felt mat, and chopped mat structures. Woven structures may comprise a plurality of woven tows, in which each tow is composed of a plurality of filaments, including thousands of filaments.

[0020] Non-limiting examples of a filler include glass, glass fibers, glass fabric fibers, glass veils, carbon fibers, carbon fiber fabric, carbon fiber veils, graphite, aramid, polyamide, high-modulus polyethylene (PE), polyester, poly-p-phenylene- benzoxazole (PBO), boron, quartz, basalt, ceramic, organic synthetic materials (such as KEVLAR), ceramic, metals (including copper), thermoplastic polymer resin(s), thermoplastic polymer fibers, thermoplastic polymer veils, natural cellulosic fibers such as flax, hemp, jute, cotton, and combinations thereof. Glass fibers may include Electrical or E-glass fibers, A-glass fibers, C-glass fibers, E-CR-glass fibers, D-glass fibers, R-glass fibers, S-glass fibers, or combinations thereof. Carbon fibers may include carbon fibers formed from a polyacrylonitrile (PAN) polymer, a polyethylene, pitch-based carbon fibers, and combinations thereof. When making high-strength composite materials, the reinforcing fibers can have a tensile strength of greater than 3500 MPa. Such organic fillers, inorganic fillers, and reinforcing materials may likewise be present in the recycled content, combined with the recycled polymers mentioned above. This is particularly likely when the recycled content is sourced from a polymeric composite material.

[0021] In certain examples, a fibrous reinforcing material is distributed throughout the polymeric resin 20, comprising fibers having a length of at least 0.5 mm, or at least 3 mm, and at most 12 mm, or at most 6 mm, or at most 3 mm. For example, the fibers may be shorter, having a length of 0.5 to 12 mm, or 0.5 to 6 mm, or 0.5 to 3 mm, or the fibers may be longer, having a length of 3 to 6 mm or 3 to 12 mm.

[0022] Depending on the composition of the fibers, they typically have a width of at least 5 microns or at least 6 microns, and at most 20 microns, or at most 10 microns, or at most 7 microns. For example, the fibers may have a width of 5 to 20 microns, or 5 to 10 microns, or 5 to 7 microns, or 6 to 20 microns, or 6 to 10 microns, or 6 to 7 microns.

[0023] The composite component 100 further comprises 2) a surfacing agent comprising a microporous sheet 10 adhered to the polymeric resin 20. A material is “porous” (including “microporous”) when it contains spaces, holes, or pores throughwhich liquid or gas may pass. As a microporous sheet, the present surfacing agent is distinct from surfacing agents comprising curable thermoset or thermoplastic films, which are not porous and may release volatile organic compounds (VOCs) when cured. In addition, the microporous sheet 10 may become “interlocked” with the composite material during molding, often due to penetration of the polymeric resin into the pores of the microporous sheet. As used herein, “microporous material” or “microporous membrane” or “microporous sheet” means a material having a network of interconnecting pores, wherein, on a treatment-free, coating-free, printing ink-free, impregnant-free, and pre-bonding basis, the pores typically have a volume average diameter ranging from 0.001 to 1 .0 micrometer, and may constitute at least 5 percent by volume of the microporous material as discussed herein below. In other words, the volume average diameter above is reported for virgin microporous material that has not been coated, impregnated, or otherwise treated.

[0024] The volume average diameter of the pores of the microporous material can be determined by mercury porosimetry using an Autopore III porosimeter (Micromeretics, Inc.) in accordance with the accompanying operating manual. The volume average pore radius for a single scan is automatically determined by the porosimeter. In operating the porosimeter, a scan is made in the high pressure range (from 138 kilopascals absolute to 227 megapascals absolute). If approximately 2 percent or less of the total intruded volume occurs at the low end (from 138 to 250 kilopascals absolute) of the high pressure range, the volume average pore diameter is taken as twice the volume average pore radius determined by the porosimeter. Otherwise, an additional scan is made in the low pressure range (from 7 to 165 kilopascals absolute) and the volume average pore diameter is calculated according to the equation: d = 2 [ viri / wi + varg / wg] I [v wi + V2 / W2] wherein d is the volume average pore diameter, vi is the total volume of mercury intruded in the high pressure range, V2 is the total volume of mercury intruded in the low pressure range, H is the volume average pore radius determined from the high pressure scan, r2is the volume average pore radius determined from the low pressure scan, wi is the weight of the sample subjected to the high pressure scan, and w2is the weight of the sample subjected to the low pressure scan. The volume averagediameter of the pores can be in the range of from 0.001 to 0.70 micrometers, e.g., from 0.30 to 0.70 micrometers.

[0025] In the course of determining the volume average pore diameter of the above procedure, the maximum pore radius detected is sometimes noted. This is taken from the low pressure range scan, if run; otherwise it is taken from the high pressure range scan. The maximum pore diameter is twice the maximum pore radius. Inasmuch as some production or treatment steps, e.g., coating processes, printing processes, impregnation processes and / or bonding processes, can result in the filling of at least some of the pores of the microporous material, and since some of these processes irreversibly compress the microporous material, the parameters in respect of porosity, volume average diameter of the pores, and maximum pore diameter are determined for the microporous material prior to the application of one or more of such production or treatment steps.

[0026] The microporous sheet 10 comprises a polyolefin polymeric matrix; finely divided particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet. With respect to filler particles, by “finely divided” is meant that the particulate filler used in the microporous sheet has a volume average particle size D50 of from 5 to 100 microns, or 5 to 75 microns, or 5 to 50 microns, as determined by the use of a laser diffraction particle size instrument, such as LS230 available from Beckman Coulton, capable of measuring particle diameters as small as 0.04 micron. Usually at least 90 percent by weight of the filler used in preparing the microporous sheet has gross particle sizes in the range of from 5 to 40 microns.

[0027] The polyolefin matrix may comprise ultrahigh molecular weight (UHMW) polyethylene. Non-limiting examples of ultrahigh molecular weight (UHMW) polyethylene can include essentially linear UHMW polyethylene (PE). Inasmuch as UHMW polyolefins are not thermoset polymers having an infinite molecular weight, they are technically classified as thermoplastic materials.

[0028] While there is no particular restriction on the upper limit of the intrinsic viscosity of the UHMW polyethylene, in one non-limiting example, the intrinsic viscosity can range from at least 6 deciliters / gram, or at least 7 deciliters / gram, or at least 18 deciliters / gram, to at most 50 deciliters / gram, or at most 45 deciliters / gram, or at most 18 deciliters / gram, or at most 16 deciliters / gram. Thus, the intrinsic viscosity of the UHMW may be, for example, 6 to 50 deciliters / gram, or 6 to 45 deciliters / gram, or 6 to18 deciliters / gram, or 6 to 16 deciliters / gram, or 7 to 50 deciliters / gram, or 7 to 45 deciliters / gram, or 7 to 18 deciliters / gram, or 7 to 16 deciliters / gram, or 18 to 50 deciliters / gram, or 18 to 45 deciliters / gram.

[0029] For purposes of the present disclosure, intrinsic viscosity may be determined by extrapolating to zero concentration the reduced viscosities or the inherent viscosities of several dilute solutions of the LIHMW polyolefin where the solvent is freshly distilled decahydronaphthalene to which 0.2 percent by weight, 3,5-di-tert- butyl-4-hydroxyhydrocinnamic acid, neopentanetetrayl ester [CAS Registry No. 6683- 19-8] has been added. The reduced viscosities or the inherent viscosities of the UHMW polyolefin are ascertained from relative viscosities obtained at 135°C using an Ubbelohde No. 1 viscometer in accordance with the general procedures of ASTM D 4020-18, except that several dilute solutions of differing concentration are employed.

[0030] The nominal molecular weight of UHMW polyethylene is empirically related to the intrinsic viscosity of the polymer in accordance with the following equation:M=5.37x104[n]1 37wherein M is the nominal molecular weight and [q] is the intrinsic viscosity of the UHMW polyethylene expressed in deciliters / gram. Similarly, the nominal molecular weight of UHMW polypropylene is empirically related to the intrinsic viscosity of the polymer according to the following equation:M=8.88x104[q]1 25wherein M is the nominal molecular weight and [q] is the intrinsic viscosity of the UHMW polypropylene expressed in deciliters / gram.

[0031] Often, the polyolefin matrix further comprises high density polyethylene (HDPE), which usually has a density of at least 900 kg / m3, such as 930 to 940 kg / m3. In certain examples, other thermoplastic organic polymers also may be present in the polyolefin matrix, provided that their presence does not materially affect the properties of the microporous sheet in an adverse manner. The amount of the other thermoplastic polymer which may be present depends upon the nature of such polymer. Non-limiting examples of thermoplastic organic polymers that optionally may be present in the matrix include low density polyethylene, poly(tetrafluoroethylene), polypropylene, copolymers of ethylene and propylene, copolymers of ethylene and butylene, copolymers of ethylene and (meth)acrylic (i. e., acrylic and / or methacrylic) acid, polyetherketone, polyvinylidene fluoride (PVDF), polysulfone, and / or polyethersulfone. Note that the phrase “and / or” when used in a list is meant to encompass alternativeexamples including each individual component in the list as well as any combination of components. For example, the list “A, B, and / or C” is meant to encompass seven separate examples that include A, or B, or C, or A + B, or A +C, or B + C, or A + B + C.

[0032] The polyolefin may be present in the microporous sheet 10 in an amount of at least 10 percent by weight, or at least 20 percent by weight, and at most 90 percent by weight, or at most 50 percent by weight, based on the total weight of the polyolefin matrix and particulate filler, described below. For example, the polyolefin may be present in the microporous sheet in an amount of 10 to 90 percent by weight, or 10 to 50 percent by weight, or 20 to 90 percent by weight, or 20 to 50 percent by weight, based on the total weight of the polyolefin matrix and the particulate filler. Often the polyolefin matrix comprises a mixture of high density polyethylene (HDPE) and ultrahigh molecular weight polyethylene (LIHMWPE). When this mixture is used, the polyolefin matrix is typically present in the microporous sheet in an amount of 20 to 50 percent by weight, based on the total weight of the polyolefin matrix and the particulate filler.

[0033] The microporous sheet 10 further comprises finely divided, particulate filler often comprising silica, distributed throughout the polyolefin matrix. The filler is often substantially water-insoluble. By “substantially insoluble” is meant that less than 3 percent by weight, or less than 1 percent by weight of the filler particles, based on the total weight of the filler particles, dissolves into the liquid phase at 25°C when dispersed therein. This can facilitate retention of the filler in the microporous material.

[0034] The filler can include any of a number of additional fillers known in the art. The filler is usually finely divided and substantially water insoluble to permit uniform distribution throughout the polyolefin matrix during manufacture of the microporous sheet. Generally, the filler comprises silica, such as precipitated silica, talc, carbon black, charcoal, graphite, titanium oxide, iron oxide, copper oxide, zinc oxide, antimony oxide, zirconia, magnesia, alumina, molybdenum disulfide, zinc sulfide, barium sulfate, strontium sulfate, calcium carbonate, and / or magnesium carbonate. Often the filler comprises silica, and may further comprise an antioxidant and / or a peroxide scavenger. Anti-oxidants such as those sold by BASF under the names IRGANOX® and IRGAFOS®, and those sold by Solvay under the name CYANOX®, are suitable for use.

[0035] The filler may be in the form of ultimate particles, aggregates of ultimate particles, or a combination of both.

[0036] The filler typically has a high surface area, which may be influenced by particle size and / or porosity, allowing the filler to carry much of the processing plasticizer used to form the microporous sheet. The surface area of the filler particles can range from at least 20 square meters per gram, or at least 25 square meters per gram, to at most 900 square meters per gram, or at most 850 square meters per gram; e. g., from 20 to 900 square meters per gram, or from 20 to 850 square meters per gram, or from 25 to 900 square meters per gram, or from 25 to 850 square meters per gram, as determined by the Brunauer, Emmett, Teller (BET) method according to ASTM C 819-77 using nitrogen as the adsorbate but modified by outgassing the system and the sample for one hour at 130°C. Prior to nitrogen sorption, filler samples are dried by heating to 160°C in flowing nitrogen (PS) for 1 hour.

[0037] In a particular example, the inorganic filler comprises precipitated silica, silica gel, or fumed silica. The silica may demonstrate a BET of 125 to 700 m2 / g, determined as noted above.

[0038] Silica gel is generally produced commercially by acidifying an aqueous solution of a soluble metal silicate, e.g., sodium silicate at low pH with acid. The acid employed is generally a strong mineral acid, such as sulfuric acid or hydrochloric acid, although carbon dioxide can be used. Inasmuch as there is essentially no difference in density between the gel phase and the surrounding liquid phase while the viscosity is low, the gel phase does not settle out, that is to say, it does not precipitate. Consequently, silica gel may be described as a non-precipitated, coherent, rigid, three- dimensional network of contiguous particles of colloidal amorphous silica. The state of subdivision ranges from large, solid masses to submicroscopic particles, and the degree of hydration from almost anhydrous silica to soft gelatinous masses containing on the order of 100 parts of water per part of silica by weight.

[0039] Precipitated silica generally is produced commercially by combining an aqueous solution of a soluble metal silicate, ordinarily alkali metal silicate such as sodium silicate, and an acid so that colloidal particles of silica will grow in a weakly alkaline solution and be coagulated by the alkali metal ions of the resulting soluble alkali metal salt. Various acids may be used, including but not limited to mineral acids. Non-limiting examples of acids that can be used include hydrochloric acid and sulfuric acid, but carbon dioxide can also be used to produce precipitated silica. In the absenceof a coagulant, silica is not precipitated from solution at any pH. In a non-limiting example, the coagulant used to effect precipitation of silica may be the soluble alkali metal salt produced during formation of the colloidal silica particles, or it may be an added electrolyte, such as a soluble inorganic or organic salt, or it may be a combination of both.

[0040] Precipitated silica can be described as precipitated aggregates of ultimate particles of colloidal amorphous silica that have not at any point existed as macroscopic gel during the preparation. The sizes of the aggregates and the degree of hydration may vary widely. Precipitated silica powders differ from silica gels that have been pulverized in that the precipitated silica powders generally have a more open structure, that is, a higher specific pore volume. However, the specific surface area of precipitated silica, as measured by the Brunauer, Emmet, Teller (BET) method using nitrogen as the adsorbate, is often lower than that of silica gel.

[0041] Many different precipitated silicas can be employed as the filler used to prepare the microporous sheet 10. Precipitated silicas are well-known commercial materials, and processes for producing them are described in detail in many United States patents, including United States Patent Numbers 2,940,830 and 4,681 ,750. The average ultimate particle size (irrespective of whether or not the ultimate particles are agglomerated) of precipitated silicas used is generally less than 0.1 micrometer, e.g., less than 0.05 micrometer or less than 0.03 micrometer, as determined by transmission electron microscopy. Non-limiting examples of suitable precipitated silicas include those sold under the HI-SIL tradename by PPG (Pittsburgh, PA).

[0042] The microporous sheet 10 typically comprises 10 to 90 weight percent, or 25 to 90 weight percent, or 30 to 90 weight percent, or 40 to 90 weight percent, or 50 to 90 weight percent, or 60 to 90 weight percent, or 10 to 85 weight percent, or 25 to 85 weight percent, or 30 to 85 weight percent, or 40 to 85 weight percent, or 50 to 85 weight percent, or 60 to 85 weight percent, or 10 to 70 weight percent, or 25 to 70 weight percent, or 30 to 70 weight percent, or 40 to 70 weight percent, or 50 to 70 weight percent, or 60 to 70 weight percent of the inorganic filler, based on the total weight of the microporous sheet.

[0043] The microporous sheet 10 may further comprise a network of interconnecting pores communicating throughout the polyolefin matrix.

[0044] On a treatment-free, coating free, or impregnant-free basis, such pores can make up at least 5 percent by volume, or at least 15 percent by volume, or at least 20percent by volume, or at least 25 percent by volume, or at least 35 percent by volume, or at least 45 percent by volume, and at most 95 percent by volume, or at most 75 percent by volume. Thus, the pores can make up 5 to 95 percent by volume, or 15 to 95 percent by volume, or 20 to 95 percent by volume, or 25 to 95 percent by volume, or 35 to 95 percent by volume, or 45 to 95 percent by volume, or 5 to 70 percent by volume, or 15 to 70 percent by volume, or 20 to 70 percent by volume, or 25 to 70 percent by volume, or 35 to 70 percent by volume, or 45 to 70 percent by volume of the microporous sheet. Often, the pores comprise at least 35 percent by volume, or even at least 45 percent by volume of the microporous sheet.

[0045] The microporous sheet 10 typically has a thickness of 4 to 25 mils (101 .6 to 635 microns), or 5 to 25 mils (127 to 635 microns), or 6 to 25 mils (152 to 635 microns), or 4 to 18 mils (101.6 to 457 microns), or 5 to 18 mils (127 to 457 microns), or 6 to 18 mils (152 to 457 microns), or 4 to 14 mils (101 .6 to 356 microns), or 5 to 14 mils (127 to 356 microns), or 6 to 14 mils (152 to 356 microns).

[0046] In certain examples, the composite component 100 further comprises one or more coating layers comprising a conductive coating layer, a primer layer, an adhesion layer, a basecoat layer, a clear coat layer, and / or a monocoat layer. Such coatings are known in the art, and appropriate coating compositions may be used depending on the intended use of the composite component.

[0047] The microporous sheets 10 described above may be prepared by a method comprising:(1 ) mixing a filler comprising silica, a polyolefin polymer, a processing plasticizer, a lubricant, optionally a free radical scavenger, and optionally an antioxidant until a substantially uniform mixture is obtained;(2) introducing the mixture to a heated barrel of a screw extruder, to which is attached a sheeting die to form a sheet;(3) forwarding the sheet to a pair of heated calender rolls acting cooperatively to form a continuous sheet of lesser thickness than the sheet exiting from the die;(4) stretching the sheet in at least one stretching direction to form a stretched sheet; and(5) extracting the processing plasticizer from the stretched sheet.

[0048] In exemplary processes, the components of the polyolefin matrix (typically in solid form such as powder or pellets), filler, processing plasticizer, and minor amounts of lubricant, antioxidant, and free radical scavenger are mixed until a substantiallyuniform mixture is obtained. The weight ratio of filler to polymer employed in forming the mixture is essentially the same as that of the microporous sheet to be produced. The mixture, together with additional processing plasticizer as needed, is introduced to the heated barrel of a screw extruder. Attached to the extruder is a die, such as a sheeting die, to form the desired end shape.

[0049] In exemplary manufacturing processes, when the material is formed into a sheet or film, a continuous sheet or film formed by a die is forwarded to a pair of heated calender rolls acting cooperatively to form a continuous sheet of lesser thickness than the continuous sheet exiting from the die. The final thickness may depend on the desired end-use application.

[0050] Optionally, the sheet may be stretched in at least one stretching direction. Stretching may take place before extraction, after extraction, or both. Stretched microporous material may be produced by stretching the intermediate product in at least one stretching direction, often above the elastic limit. Usually, the stretch ratio is at least 1.2. In many cases, the stretch ratio is at least 1.5. Often it is at least 2. Frequently, the stretch ratio is in the range of from 1 .2 to 15. Often, the stretch ratio is in the range of from 1 .5 to 10. Usually, the stretch ratio is in the range of from 2 to 6.

[0051] The temperatures at which stretching is accomplished may vary widely. Stretching may be accomplished at ambient room temperature, but usually elevated temperatures are employed. Ambient temperature typically ranges from 60 to 90 °F (15.6 to 32.2 °C), such as a typical room temperature, 72°F (22.2°C). The intermediate product may be heated by any of a wide variety of techniques prior to, during, and / or after stretching. Examples of these techniques include radiative heating, such as that provided by electrically heated or gas fired infrared heaters; convective heating, such as that provided by recirculating hot air; and conductive heating, such as that provided by contact with heated rolls. The temperatures which are measured for temperature control purposes may vary according to the apparatus used and personal preference. For example, temperature-measuring devices may be placed to ascertain the temperatures of the surfaces of infrared heaters, the interiors of infrared heaters, the air temperatures of points between the infrared heaters and the intermediate product, the temperatures of circulating hot air at points within the apparatus, the temperature of hot air entering or leaving the apparatus, the temperatures of the surfaces of rolls used in the stretching process, the temperature of heat transfer fluid entering or leaving such rolls, or film surface temperatures. In general, the temperature or temperaturesare controlled such that the intermediate product is stretched about evenly so that the variations, if any, in film thickness of the stretched microporous material are within acceptable limits and so that the amount of stretched microporous material outside of those limits is acceptably low. It will be apparent that the temperatures used for control purposes may or may not be close to those of the intermediate product itself since they depend upon the nature of the apparatus used, the locations of the temperaturemeasuring devices, and the identities of the substances or objects whose temperatures are being measured.

[0052] In view of the locations of the heating devices and the line speeds usually employed during stretching, gradients of varying temperatures may or may not be present through the thickness of the intermediate product. Also, because of such line speeds, it is impracticable to measure these temperature gradients. The presence of gradients of varying temperatures, when they occur, makes it unreasonable to refer to a singular film temperature. Accordingly, film surface temperatures, which can be measured, are best used for characterizing the thermal condition of the intermediate product.

[0053] The film surface temperatures at which stretching is accomplished may vary widely, but in general they are such that the intermediate product is stretched about evenly, as explained above. In most cases, the film surface temperatures during stretching are in the range of from 20°C to 220°C. Often, such temperatures are in the range of from 50°C to 200°C, such as from 75°C to 180°C.

[0054] Stretching may be accomplished in a single step or a plurality of steps as desired. For example, when the intermediate product is to be stretched in a single direction (uniaxial stretching), the stretching may be accomplished by a single stretching step or a sequence of stretching steps until the desired final stretch ratio is attained. Similarly, when the intermediate product is to be stretched in two directions (biaxial stretching), the stretching can be conducted by a single biaxial stretching step or a sequence of biaxial stretching steps until the desired final stretch ratios are attained. Biaxial stretching may also be accomplished by a sequence of one of more uniaxial stretching steps in one direction and one or more uniaxial stretching steps in another direction. Biaxial stretching steps where the intermediate product is stretched simultaneously in two directions and uniaxial stretching steps may be conducted in sequence in any order. Stretching in more than two directions is within contemplation. It may be seen that the various permutations of steps are quite numerous. Other steps,such as cooling, heating, sintering, annealing, reeling, unreeling, and the like, may optionally be included in the overall process as desired.

[0055] Various types of stretching apparatus are well known and may be used to accomplish stretching of the intermediate product. Uniaxial stretching is usually accomplished by stretching between two rollers, wherein the second or downstream roller rotates at a greater peripheral speed than the first or upstream roller. Uniaxial stretching can also be accomplished on a standard tentering machine. Biaxial stretching may be accomplished by simultaneously stretching in two different directions on a tentering machine. More commonly, however, biaxial stretching is accomplished by first uniaxially stretching between two differentially rotating rollers as described above, followed by either uniaxially stretching in a different direction using a tenter machine or by biaxially stretching using a tenter machine. The most common type of biaxial stretching is where the two stretching directions are approximately at right angles to each other. In most cases where the continuous sheet is being stretched, one stretching direction is at least approximately parallel to the long axis of the sheet (machine direction) and the other stretching direction is at least approximately perpendicular to the machine direction and is in the plane of the sheet (transverse direction).

[0056] Stretching the sheets prior to extraction of the processing plasticizer allows for thinner films with larger pore sizes than in microporous materials conventionally processed. It is also believed that stretching of the sheets prior to extraction of the processing plasticizer minimizes thermal shrinkage after processing.

[0057] The product passes to a first extraction zone where the processing plasticizer is substantially removed by extraction with an organic liquid, which is a good solvent for the processing plasticizer, a poor solvent for the organic polymer, and more volatile than the processing plasticizer. Usually, but not necessarily, both the processing plasticizer and the organic extraction liquid are substantially immiscible with water. The product then passes to a second extraction zone where the residual organic extraction liquid is substantially removed by steam and / or water. The product is then passed through a forced air dryer for substantial removal of residual water and remaining residual organic extraction liquid. From the dryer, the microporous material may be passed to a take-up roll, when it is in the form of a sheet.

[0058] The processing plasticizer usually comprises processing oil, such as paraffinic oil, naphthenic oil, or aromatic oil. Suitable processing oils include thosemeeting the requirements of ASTM D 2226-82, Types 103 and 104. Those oils which have a pour point of less than 22°G, or less than 10°C, according to ASTM D 97-66 (reapproved 1978) are used most often. Examples of suitable oils include SHELLFLEX 412 and SHELLFLEX 371 oil (Shell Oil Co. (Houston, TX)), which are solvent refined and hydrotreated oils derived from naphthenic crude. It is expected that other materials, including the phthalate ester plasticizers such as dibutyl phthalate, bis(2- ethylhexyl) phthalate, diisodecyl phthalate, dicyclohexyl phthalate, butyl benzyl phthalate, and ditridecyl phthalate will function satisfactorily as processing plasticizers.

[0059] There are many organic extraction liquids that can be used in the process of manufacturing the microporous sheet. Examples of suitable organic extraction liquids include, but are not limited to, 1 ,1 ,2-trichloroethy lene ; perchloroethylene; 1 ,2- dichloroethane; 1 ,1 ,1 -trichloroethane; 1 ,1 ,2-trichloroethane; methylene chloride; chloroform; 1 ,1 ,2-trichloro-1 ,2,2-trifluoroethane; isopropyl alcohol; diethyl ether; acetone; hexane; heptane and toluene. One or more azeotropes of halogenated hydrocarbons selected from trans-1 ,2-dichloroethylene, 1 ,1 ,1 ,2,2,3, 4,5, 5,5- decafluoropentane, and / or 1 ,1 ,1 ,3,3-pentafluorobutane also can be employed. Such materials are available commercially as VERTREL MCA (a binary azeotrope of 1 ,1 ,1 ,2,2,3,4,5,5,5-dihydrodecafluoropentane and trans-1 ,2-dichloroethylene: 62% / 38%) and VERTREL CCA (a ternary azeotrope of 1 ,1 ,1 ,2, 2, 3, 4, 5,5,5- dihydrodecafluorpentane, 1 ,1 ,1 ,3,3-pentafluorbutane, and trans-1 ,2-dichloroethylene: 33% / 28% / 39%); VERTREL SDG (80-83% trans-1 ,2-dichloroethylene, 17-20% hydrofluorocarbon mixture), all available from MicroCare Corporation (New Britain, CT).

[0060] In the above-described process, extrusion and calendering are facilitated when the filler carries much of the processing plasticizer. The capacity of the filler particles to absorb and hold the processing plasticizer is a function of the surface area of the filler. Therefore, the filler typically has a high surface area as discussed above. The residual processing plasticizer content is usually less than 15 percent by weight of the resulting microporous material and this may be reduced even further to levels, such as less than 5 percent by weight, by additional extractions using the same or a different organic extraction liquid.

[0061] According to the present disclosure, the microporous sheet 10 may be adaptable to the needs of the user. For example, the microporous sheet 10 might be adapted to increase adhesion to the composite and / or any subsequent layer, such asa coating layer, applied to the sheet. The microporous sheet 10 might be adapted to have a selectively strippable surface, such that a subsequent coating layer can be easily removed / peeled off if needed; for example, during surface repair. The sheet 10 can be formulated to have functional groups; for example, silica particles used as the inorganic filler may be surface functionalized before or after incorporation into the polyolefin polymeric matrix. The sheet 10 can be formulated to include reinforcing material or may be adapted to increase UV resistance of the molded article, such as by incorporation of a UV absorber into the microporous sheet 10.

[0062] Molded articles such as vehicle components can be made using molding methods known in the art, such as high pressure transfer molding, casting, blow molding, compression molding, such as compression resin transfer molding or melt molding, extrusion molding, transfer molding, extrusion molding, injection molding, for example gas assisted injection molding and injection over-molding, structural foam molding, laminating and / or reaction injection molding, matrix molding, rotational molding, spin casting, transfer molding, thermoforming, such as twin sheet thermoforming and vacuum forming, hydroforming, FRP (fiberglass reinforced plastic) molding, such as hand lay-up molding, resin transfer molding, vacuum bag molding, bladder molding, spray up molding, reaction injection molding, pultrusion, and the like, as well as combinations and variations thereof.

[0063] Molded articles can be made using molding methods comprising additional components known in the art such as but not limited to external or internal mold release agents.

[0064] The composite components 100 of the present disclosure may alternatively be prepared from extruded polymeric resins 20, the polymeric resins as described herein for molded components. The surfacing agent formed from the microporous sheet 10 may be coated or uncoated, and applied to the extruded polymeric resin 20 to form the composite component 100. Examples of finished products include gutters, window framing, and the like.

[0065] In accordance with the present disclosure, methods of recycling a polymer and methods of making a molded composite component for a structure are provided, each comprising:1 ) lining at least a portion of a mold interior with a microporous sheet 10;2) closing the mold;3) adding a polymeric resin 20 to the mold on the microporous sheet 10 (step 300, FIG. 4); and4) hardening the polymeric resin 20 to form a molded composite component 100. Hardening of the polymeric resin 20 (step 400, FIG. 4) may include curing of thermosetting polymers in the polymeric resin or cooling / solidifying of thermoplastic polymers as known in the art. The mold is closed prior to adding the polymeric resin to the mold in an injection molding or similar process, and the mold is closed after adding the polymeric resin to the mold in a compression molding or similar process.

[0066] The microporous sheet 10 may comprise any of those described above, and the polymeric resin 20 comprises recycled content, including a recycled polymer (i. e., polymer to be recycled, which may be a composite with other materials as noted above), present in the polymeric resin in an amount of 5 to 100 percent by weight, based on the total weight of the polymeric resin. The structure may comprise a vehicle, building, bridge, transportation infrastructure, oil rig, oil platform, water tower, power line tower, support structure, wind turbine blade, wall, or shipping container.

[0067] “Recycled polymers” and “polymers to be recycled” are terms intended to be interchangeable and may include recycled content from industrial products or postconsumer products such as any of those listed above.

[0068] The method may further comprise applying a decorative design (step 500, FIG. 4) such as a logo and / or a coating layer to the microporous sheet 10 after removal of the molded composite component 100 from the mold, the coating layer comprising a conductive coating layer, a primer layer, an adhesion layer, a basecoat layer, a clear coat layer, and / or a monocoat layer as described above. Alternatively, the coating layer may applied to the microporous sheet 10 prior to lining the mold interior with the microporous sheet 10. In this instance, the microporous sheet 10 is placed in the mold such that the coating layer is situated between the microporous sheet 10 and the mold. In either case, the microporous sheet 10 may be surface treated via corona discharge, ultraviolet radiation, plasma etching, or gamma radiation, prior to applying the coating layer.

[0069] The present disclosure further provides methods of mitigating detrimental effects on a surface of a molded composite vehicle component, caused by contaminants present in recycled content. Such detrimental effects may be aesthetic and / or structural, such as discoloration, poor adhesion of subsequently appliedcoatings, films, or decorative designs, contaminant migration to the surface, surface defects (e. g., inclusion or roughness), and the like. The methods comprise:1 ) lining at least a portion of an open mold interior with a microporous sheet 10;2) closing the mold;3) adding a polymeric resin 20 to the mold on the microporous sheet; wherein the mold is closed prior to adding the polymeric resin 20 to the mold in an injection molding or similar process, and the mold is closed after adding the polymeric resin 20 to the mold in a compression molding or similar process; and4) hardening the polymeric resin 20 to form a molded composite vehicle component;5) removing the molded composite vehicle component from the mold; and6) applying a decorative design and / or a coating layer to the microporous sheet, the coating layer comprising a conductive coating layer, a primer layer, an adhesion layer, a basecoat layer, a clear coat layer, and / or a monocoat layer, wherein the coating layer is applied to the microporous sheet either prior to lining the mold interior with the microporous sheet or after removing the molded composite vehicle component from the mold; wherein the microporous sheet comprises a polyolefin polymeric matrix; finely divided particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet; and wherein the polymeric resin comprises the recycled content, present in the polymeric resin in an amount of 1 to 100 percent by weight, based on the total weight of the polymeric resin. FIG. 4 again demonstrates the major steps of this method.

[0070] The decorative design and / or coating layer may be applied to the microporous sheet 10 after removal of the molded composite vehicle component from the mold. The coating layer may alternatively be applied to the microporous sheet 10 prior to lining the mold interior with the microporous sheet. In this instance, the microporous sheet 10 is placed in the mold such that the coating layer is situated between the microporous sheet and the mold. Again, in either case, the microporous sheet 10 may be surface treated via corona discharge, ultraviolet radiation, plasma etching, or gamma radiation, prior to applying the coating layer.

[0071] In any of the processes described above, the microporous sheet 10, which is initially planar, may be preformed or thermoformed to estimate the contours of the mold and conform to the mold prior to lining the mold with the microporous sheet (step200, FIG. 4). The sheet may additionally be cut using, for example, a plastic stamping technique prior to preforming or thermoforming.

[0072] The present disclosure is further drawn to the following aspects:1 . A composite component of a structure, comprising:1 ) a polymeric resin comprising recycled content, present in the polymeric resin in an amount of 1 to 100 percent by weight, based on the total weight of the polymeric resin; and2) a surfacing agent comprising a microporous sheet adhered to the polymeric resin, the microporous sheet comprising a polyolefin polymeric matrix; finely divided particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet; wherein the structure comprises a vehicle, building, bridge, transportation infrastructure, oil rig, oil platform, water tower, power line tower, support structure, wind turbine blade, wall, or shipping container.2. The composite component of aspect 1 , wherein the recycled content is present in the polymeric resin in an amount of 1 to 75 percent by weight, based on the total weight of the polymeric resin.3. The composite component of any preceding aspect, wherein the recycled content is present in the polymeric resin in an amount of 1 to 50 percent by weight, based on the total weight of the polymeric resin.4. The composite component of any preceding aspect, wherein the recycled content is present in the polymeric resin in an amount of 1 to 35 percent by weight, based on the total weight of the polymeric resin.5. The composite component of any preceding aspect, wherein the recycled content is present in the polymeric resin in an amount of 1 to 25 percent by weight, based on the total weight of the polymeric resin.6. The composite component of any preceding aspect, wherein the recycled content is present in the polymeric resin in an amount of 5 to 100 percent by weight, based on the total weight of the polymeric resin.7. The composite component of any preceding aspect, wherein the recycled content is present in the polymeric resin in an amount of 5 to 75 percent by weight, based on the total weight of the polymeric resin.8. The composite component of any preceding aspect, wherein the recycled content is present in the polymeric resin in an amount of 5 to 50 percent by weight, based on the total weight of the polymeric resin.9. The composite component of any preceding aspect, wherein the recycled content is present in the polymeric resin in an amount of 5 to 35 percent by weight, based on the total weight of the polymeric resin.10. The composite component of any preceding aspect, wherein the recycled content is present in the polymeric resin in an amount of 5 to 25 percent by weight, based on the total weight of the polymeric resin.11 . The composite component of any preceding aspect, wherein the polymeric resin further comprises sheet molding compounds, bulk molding compounds, pelletized thermoplastic polymers, thermoplastic molding compounds, thermosetting molding compounds, polymer matrix composites, or combinations thereof.12. The composite component of any preceding aspect, wherein the polymeric resin further comprises a polyurethane, polyamine, acrylonitrile-butadiene- styrene, low-density polyethylene, medium-density polyethylene, high-density polyethylene, polycarbonate, polyamide, high impact polystyrene, polypropylene, polyetherketone, an epoxy resin, a phenolic resin, a melamine resin, a urea resin, polyaryl ether ketone, polyoxymethylene, polystyrene, polyester, polyimide, polyacetal, polyphenylene oxide, polyphenylene sulfide, polyethersulfone, cyclic polyolefin, a copolymer of a norbornene-based monomer and an olefin-based monomer, vinyl-based polymer, cellulose resin, a maleimide resin, a halogenated resin, silicone, an inorganic resin, an organic / inorganic hybrid resin, fiber-reinforced thermoplastic polymers or combinations thereof.13. The composite component of any preceding aspect, wherein the recycled content comprises low-density polyethylene, medium-density polyethylene, high-density polyethylene, polycarbonate, polystyrene, polypropylene, polyethylene terephthalate, thermoplastic polyolefin, polyvinyl chloride, polyamide, poly (methyl methacrylate), thermoplastic elastomer, styrene-butadiene polymer, polybutadiene and / or thermoplastic polyurethane.14. The composite component of any preceding aspect, wherein the microporous sheet comprises 10 to 90 weight percent of the inorganic filler, based on the total weight of the microporous sheet.15. The composite component of any preceding aspect, wherein the microporous sheet comprises 25 to 90 weight percent of the inorganic filler, based on the total weight of the microporous sheet.16. The composite component of any preceding aspect, wherein the microporous sheet comprises 30 to 90 weight percent of the inorganic filler, based on the total weight of the microporous sheet.17. The composite component of any preceding aspect, wherein the microporous sheet comprises 40 to 90 weight percent of the inorganic filler, based on the total weight of the microporous sheet.18. The composite component of any preceding aspect, wherein the microporous sheet comprises 50 to 90 weight percent of the inorganic filler, based on the total weight of the microporous sheet.19. The composite component of any preceding aspect, wherein the microporous sheet comprises 60 to 90 weight percent of the inorganic filler, based on the total weight of the microporous sheet.20. The composite component of any preceding aspect, wherein the microporous sheet comprises 10 to 85 weight percent of the inorganic filler, based on the total weight of the microporous sheet.21 . The composite component of any preceding aspect, wherein the microporous sheet comprises 25 to 85 weight percent of the inorganic filler, based on the total weight of the microporous sheet.22. The composite component of any preceding aspect, wherein the microporous sheet comprises 30 to 85 weight percent of the inorganic filler, based on the total weight of the microporous sheet.23. The composite component of any preceding aspect, wherein the microporous sheet comprises 40 to 85 weight percent of the inorganic filler, based on the total weight of the microporous sheet.24. The composite component of any preceding aspect, wherein the microporous sheet comprises 50 to 85 weight percent of the inorganic filler, based on the total weight of the microporous sheet.25. The composite component of any preceding aspect, wherein the microporous sheet comprises 60 to 85 weight percent of the inorganic filler, based on the total weight of the microporous sheet.26. The composite component of any preceding aspect, wherein the microporous sheet comprises 10 to 70 weight percent of the inorganic filler, based on the total weight of the microporous sheet.27. The composite component of any preceding aspect, wherein the microporous sheet comprises 25 to 70 weight percent of the inorganic filler, based on the total weight of the microporous sheet.28. The composite component of any preceding aspect, wherein the microporous sheet comprises 30 to 70 weight percent of the inorganic filler, based on the total weight of the microporous sheet.29. The composite component of any preceding aspect, wherein the microporous sheet comprises 40 to 70 weight percent of the inorganic filler, based on the total weight of the microporous sheet.30. The composite component of any preceding aspect, wherein the microporous sheet comprises 50 to 70 weight percent of the inorganic filler, based on the total weight of the microporous sheet.31 . The composite component of any preceding aspect, wherein the microporous sheet comprises 60 to 70 weight percent of the inorganic filler, based on the total weight of the microporous sheet.32. The composite component of any preceding aspect, wherein the microporous sheet has a thickness of 4 to 25 mils (101 .6 to 635 microns).33. The composite component of any preceding aspect, wherein the microporous sheet has a thickness of 5 to 25 mils (127 to 635 microns).34. The composite component of any preceding aspect, wherein the microporous sheet has a thickness of 6 to 25 mils (152 to 635 microns).35. The composite component of any preceding aspect, wherein the microporous sheet has a thickness of 4 to 18 mils (101 .6 to 457 microns).36. The composite component of any preceding aspect, wherein the microporous sheet has a thickness of 5 to 18 mils (127 to 457 microns).37. The composite component of any preceding aspect, wherein the microporous sheet has a thickness of 6 to 18 mils (152 to 457 microns).38. The composite component of any preceding aspect, wherein the microporous sheet has a thickness of 4 to 14 mils (101 .6 to 356 microns).39. The composite component of any preceding aspect, wherein the microporous sheet has a thickness of 5 to 14 mils (127 to 356 microns).40. The composite component of any preceding aspect, wherein the microporous sheet has a thickness of 6 to 14 mils (152 to 356 microns).41 . The composite component of any preceding aspect, further comprising a decorative design and / or one or more coating layers comprising a conductive coating layer, a primer layer, an adhesion layer, a basecoat layer, a clear coat layer, and / or a monocoat layer applied to the surfacing agent.42. The composite component of any preceding aspect, wherein the structure comprises a vehicle.43. Use of the composite component of any of aspects 1 to 37 in a vehicle.44. A method of making a molded composite component for a structure, comprising:1 ) lining at least a portion of a mold interior with a microporous sheet;2) closing the mold;3) adding a polymeric resin to the mold on the microporous sheet; wherein the mold is closed prior to adding the polymeric resin to the mold in an injection molding process, and the mold is closed after adding the polymeric resin to the mold in a compression molding process; and4) hardening the polymeric resin to form a molded composite component; wherein the microporous sheet comprises a polyolefin polymeric matrix; finely divided particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet; and wherein the polymeric resin comprises recycled content, present in the polymeric resin in an amount of 1 to 100 percent by weight, based on the total weight of the polymeric resin; andwherein the structure comprises a vehicle, building, bridge, transportation infrastructure, oil rig, oil platform, water tower, power line tower, support structure, wind turbine blade, wall, or shipping container.45. The method of aspect 44, wherein the recycled content is present in the polymeric resin in an amount of 5 to 75 percent by weight, based on the total weight of the polymeric resin.46. The method of aspect 44 or 45, wherein the recycled content is present in the polymeric resin in an amount of 5 to 50 percent by weight, based on the total weight of the polymeric resin.47. The method of any of aspects 44 to 46, wherein the recycled content is present in the polymeric resin in an amount of 5 to 35 percent by weight, based on the total weight of the polymeric resin.48. The method of any of aspects 44 to 47, wherein the recycled content is present in the polymeric resin in an amount of 5 to 25 percent by weight, based on the total weight of the polymeric resin.49. The method of any of aspects 44 to 48, wherein the structure comprises a vehicle.50. The method of any of aspects 44 to 49, further comprising applying a decorative design and / or a coating layer to the microporous sheet after removal of the molded composite component from the mold, the coating layer comprising a conductive coating layer, a primer layer, an adhesion layer, a basecoat layer, a clear coat layer, and / or a monocoat layer.51 . The method of aspect 50, further comprising surface treating the microporous sheet via corona discharge, ultraviolet radiation, plasma etching, or gamma radiation, prior to applying the coating layer.52. A method of mitigating detrimental effects on a surface of a molded composite vehicle component, caused by contaminants present in recycled content, comprising:1 ) lining at least a portion of an open mold interior with a microporous sheet;2) closing the mold;3) adding a polymeric resin to the mold on the microporous sheet; wherein the mold is closed prior to adding the polymeric resin to the mold in an injection molding process, and the mold is closed after adding the polymeric resin to the mold in a compression molding process;4) hardening the polymeric resin to form a molded composite vehicle component;5) removing the molded composite vehicle component from the mold; and6) applying a decorative design and / or a coating layer to the microporous sheet, the coating layer comprising a conductive coating layer, a primer layer, an adhesion layer, a basecoat layer, a clear coat layer, and / or a monocoat layer, wherein the coating layer is applied to the microporous sheet either prior to lining the mold interior with the microporous sheet or after removing the molded composite vehicle component from the mold; wherein the microporous sheet comprises a polyolefin polymeric matrix; finely divided particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet; and wherein the polymeric resin comprises the recycled content, present in the polymeric resin in an amount of 1 to 100 percent by weight, based on the total weight of the polymeric resin.53. The method of aspect 52, wherein the recycled content is present in the polymeric resin in an amount of 1 to 75 percent by weight, based on the total weight of the polymeric resin.54. The method of aspect 52 or 53, wherein the recycled content is present in the polymeric resin in an amount of 1 to 50 percent by weight, based on the total weight of the polymeric resin.55. The method of any of aspects 52 to 54, wherein the recycled content is present in the polymeric resin in an amount of 1 to 35 percent by weight, based on the total weight of the polymeric resin.56. The method of any of aspects 52 to 55, wherein the recycled content is present in the polymeric resin in an amount of 1 to 25 percent by weight, based on the total weight of the polymeric resin.57. The method of any of aspects 52 to 56, wherein the recycled content is present in the polymeric resin in an amount of 5 to 100 percent by weight, based on the total weight of the polymeric resin.58. The method of any of aspects 52 to 57, wherein the recycled content is present in the polymeric resin in an amount of 5 to 75 percent by weight, based on the total weight of the polymeric resin.59. The method of any of aspects 52 to 58, wherein the recycled content is present in the polymeric resin in an amount of 5 to 50 percent by weight, based on the total weight of the polymeric resin.60. The method of any of aspects 52 to 59, wherein the recycled content is present in the polymeric resin in an amount of 5 to 35 percent by weight, based on the total weight of the polymeric resin.61 . The method of any of aspects 52 to 60, wherein the recycled content is present in the polymeric resin in an amount of 5 to 25 percent by weight, based on the total weight of the polymeric resin.62. The method of any of aspects 52 to 61 , further comprising surface treating the microporous sheet via corona discharge, ultraviolet radiation, plasma etching, or gamma radiation prior to applying the coating layer.63. A method of recycling a polymer, comprising:1 ) lining at least a portion of an open mold interior with a microporous sheet;2) closing the mold;3) adding a polymeric resin to the mold on the microporous sheet; wherein the mold is closed prior to adding the polymeric resin to the mold in an injection molding process, and the mold is closed after adding the polymeric resin to the mold in a compression molding process; and4) hardening the polymeric resin to form a molded composite component; wherein the microporous sheet comprises a polyolefin polymeric matrix; finely divided particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet; and wherein the polymeric resin comprises a polymer to be recycled, present in the polymeric resin in an amount of 1 to 100 percent by weight, based on the total weight of the polymeric resin; and wherein the molded composite component comprises a component of a structure comprising a vehicle, building, bridge, transportation infrastructure, oil rig, oil platform, water tower, power line tower, support structure, wind turbine blade, wall, or shipping container.64. The method of aspect 63, wherein the polymer to be recycled is present in the polymeric resin in an amount of 1 to 75 percent by weight, based on the total weight of the polymeric resin.65. The method of aspect 63 or 64, wherein the polymer to be recycled is present in the polymeric resin in an amount of 1 to 50 percent by weight, based on the total weight of the polymeric resin.66. The method of any of aspects 63 to 65, wherein the polymer to be polymer is present in the polymeric resin in an amount of 1 to 35 percent by weight, based on the total weight of the polymeric resin.67. The method of any of aspects 63 to 66, wherein the polymer to be recycled is present in the polymeric resin in an amount of 1 to 25 percent by weight, based on the total weight of the polymeric resin.68. The method of any of aspects 63 to 67, wherein the polymer to be recycled is present in the polymeric resin in an amount of 5 to 100 percent by weight, based on the total weight of the polymeric resin.69. The method of any of aspects 63 to 68, wherein the polymer to be recycled is present in the polymeric resin in an amount of 5 to 75 percent by weight, based on the total weight of the polymeric resin.70. The method of any of aspects 63 to 69, wherein the polymer to be recycled is present in the polymeric resin in an amount of 5 to 50 percent by weight, based on the total weight of the polymeric resin.71 . The method of any of aspects 63 to 70, wherein the polymer to be recycled is present in the polymeric resin in an amount of 5 to 35 percent by weight, based on the total weight of the polymeric resin.72. The method of any of aspects 63 to 71 , wherein the polymer to be recycled is present in the polymeric resin in an amount of 5 to 25 percent by weight, based on the total weight of the polymeric resin.73. The method of any of aspects 63 to 72, wherein the structure comprises a vehicle.74. The method of any of aspects 63 to 73, further comprising applying a decorative design and / or a coating layer to the microporous sheet after removal of the molded composite component from the mold, the coating layer comprising a conductive coating layer, a primer layer, an adhesion layer, a basecoat layer, a clear coat layer, and / or a monocoat layer.75. The method of aspect 74, further comprising surface treating the microporous sheet via corona discharge, ultraviolet radiation, plasma etching, or gamma radiation, prior to applying the coating layer.76. The method of any of aspects 63 to 75, wherein the polymer to be recycled comprises low-density polyethylene, medium-density polyethylene, high- density polyethylene, polycarbonate, polystyrene, polypropylene, polyethylene terephthalate, thermoplastic polyolefin, polyvinyl chloride, polyamide, poly (methyl methacrylate), thermoplastic elastomer, styrene-butadiene polymer, polybutadiene and / or thermoplastic polyurethane.77. The method of any of aspects 44 to 76, wherein the microporous sheet is preformed or thermoformed to conform to the mold prior to lining the mold with the microporous sheet.78. A composite component of a structure, comprising:1 ) an extruded polymeric resin comprising recycled content, present in the polymeric resin in an amount of 1 to 100 percent by weight, based on the total weight of the polymeric resin; and2) a surfacing agent comprising a microporous sheet adhered to the extruded polymeric resin, the microporous sheet comprising a polyolefin polymeric matrix; finely divided particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet; wherein the structure comprises a vehicle, building, bridge, transportation infrastructure, oil rig, oil platform, water tower, power line tower, support structure, wind turbine blade, wall, or shipping container.79. The composite component of any of aspects 1 to 37, wherein the polymeric resin has a surface in a planar or three-dimensional shape, and / or the composite component is in a planar or three-dimensional shape, and / or a surface of the polymeric resin is in a planar or three-dimensional shape, and / or a surface of the composite component is in a planar or three-dimensional shape.80. The composite component or the method of any of preceding aspects, wherein the polymeric resin is a thermoplastic polymeric resin or a thermoset polymeric resin.81 . The composite component or the method of any of preceding aspects, wherein the recycled content comprises thermoplastic polymers.82. The composite component or the method of any of preceding aspects, wherein the microporous sheet is a thermoplastic microporous sheet or a thermoset microporous sheet, particularly a thermoplastic microporous sheet.

[0073] The following examples are intended to illustrate various aspects of the disclosure, and should not be construed as limiting the disclosure in any way. Components that are mentioned elsewhere in the specification as suitable alternative materials for use, but which are not demonstrated in the working Examples below, are expected to provide results comparable to their demonstrated counterparts. Unless otherwise indicated, all parts are by weight.EXAMPLESExamples 1-5 (Injection molded parts with virgin polypropylene)

[0074] A commercial grade of polypropylene (PP1 105E1 , available from Exxonmobil Corporation) was used as a virgin polymer to injection mold 3D structures. Surfacing agents (i. e., “surfacing films”; “SF”) comprising a mixture of high density polyethylene (HDPE) and ultrahigh molecular weight polyethylene (UHMWPE) and ca. 60 percent by weight precipitated silica filler were prepared as described in paragraphs [0047- 0060] above at various thicknesses (18 mils (0.4572 mm), 14 mils (0.3556 mm) and 10.5 mils (0.2667 mm)). Surfacing agents used in odd-numbered Examples were preformed by thermoforming as follows:

[0075] Thermoforming of surfacing films was done on a lab-scale Formech 450 DT vacuum thermoformer, available from Formech USA. 12” x 12” size surfacing films were cut and mounted on the thermoformer. The film was heated in the range of 155°C to 170°C, depending on the thickness of the surfacing film. Thicker films needed a higher temperature for thermoforming. This range of temperatures was measured immediately before forming. These preformed surfacing films were cut into the size of the 3D-part prior to taking them to the injection molding machine.

[0076] After thermoforming, extra material in the preformed film was cut off and the preformed films were used for injection molding. A photograph of a thermoformedsurfacing film formed from a microporous sheet 10 used in the Examples is shown in FIG. 1 .

[0077] To injection mold a 3D-part, an all-electric injection molding machine (ENGEL e-motion 85, available from Engel Machinery, Inc.) was used. Thermoformed surfacing film was inserted in the slots of the injection molding machine and molten thermoplastic polymer (polypropylene) was injected. The temperature of the barrel zones was kept at 400°F. Injection speed was kept at 5.24 m / s and hold time was 3.5 seconds. Demolding of part was done after cooling it for 3 seconds.• Injection molding with preformed film: Polypropylene pellets were added in the extruder of the injection molding machine and melted. Preformed surfacing film was inserted in the slot of the injection molding machine. Molten polypropylene polymer was injected on top of the surfacing film. After cooling down, the injection molded part with surfacing film on one side of part was demolded.• Injection molding with flat film: Polypropylene pellets were added in the extruder of the injection molding machine and melted. As-received surfacing film (no preforming) was attached with two sides tape outside the slot of the injection molding machine. Molten polypropylene polymer was injected on top of the surfacing film. After cooling down, the injection molded part with surfacing film on one side of part was demolded.Examples 7-18 (Injection molded part with recycled polypropylene)

[0078] A commercial grade of polypropylene (PP1 105E1 , available from Exxonmobil Corporation) was used as a virgin polymer. Recycled polypropylene (PP) was produced by grinding previously injection molded articles formed with virgin PP polymer. Granules of recycled PP was added to virgin PP at two loading levels: 10 wt% and 30 wt%. Examples 7 to 12 were produced with 10 wt% recycled PP and Examples 13-18 were produced using 30 wt% recycled PP. Surfacing films of various thicknesses (18 mils, 14 mils and 10.5 mils) were thermoformed as described above. After thermoforming, extra material in the preformed film was cut off and the preformed surfacing films were used for injection molding.• Injection molding with preformed film: Virgin PP combined with recycled PP were added in the extruder of the injection molding machine and melted together. Preformed surfacing film was inserted in the slot of the injection molding machine. Molten polymer formed in the extruder from the virgin and recycled PP was injectedon top of the surfacing film. After cooling down, the injection molded part with surfacing film on one side of part was demolded.• Injection molding with flat film: Polypropylene pellets were added in the extruder of the injection molding machine and melted. As-received surfacing film (no preforming) was inserted in the slot of the injection molding machine and fixed in place with tape outside the slot of the injection molding machine. Molten polymer was injected on top of the surfacing film. After cooling down, the injection molded part with surfacing film on one side of part was demolded.Examples 19-24 (Injection molded part with recycled content containing polypropylene and surfacing film)

[0079] A commercial grade of polypropylene (PP1 105E1 , available from Exxonmobil Corporation) was used as a virgin polymer. Recycled content was produced by using a plastic shredder (available from Conair). Recycled content was formed from injection molded PP with a surfacing film (comprising a mixture of high density polyethylene (HDPE) and ultrahigh molecular weight polyethylene (LIHMWPE) with ca. 60 percent by weight precipitated silica filler, prepared as described in paragraphs [0047-0060] above). 30 wt% of granules of the recycled content (recycled PP and surfacing film) was added to virgin PP.

[0080] Surfacing films of various thicknesses (18 mils, 14 mils and 10.5 mils) were thermoformed as described above. After thermoforming, extra material in the preformed film was cut off and preformed films were used for injection molding.• Injection molding with preformed film: Virgin PP with recycled content were added in the extruder of the injection molding machine and melted. Preformed surfacing film was inserted in the slot of the injection molding machine. Molten polymer formed in the extruder was injected on top of the surfacing film. After cooling down, the injection molded part with surfacing film on one side of part was demolded.• Injection molding with flat film: Polypropylene pellets were added in the extruder of the injection molding machine and melted. As-received surfacing film (no preforming) was inserted in the slot of the injection molding machine and fixed in place with tape outside the slot of the injection molding machine. Molten polymer was injected on top of the surfacing film. After cooling down, the injection molded part with surfacing film on one side of part was demolded.Measurement of compressive strain:

[0081] The thickness of the as-received surfacing film (to) before the thermoforming process was measured using a micrometer. After measuring the thickness, the surfacing film 10 was thermoformed into a specific 3-D shape. Three regions on the thermoformed film 10 as shown in FIG. 1 were selected to measure thickness after thermoforming (tm). First is the comparatively “flat” region 12 at the center of the thermoformed film 10, 0.5” from the center point, which was specified as the flat region 12 (shown in FIGs 1 , 2a and 2b). By “flat” is meant that the region underwent less deformation or distortion during thermoforming than the regions where a protrusion is formed. The second area is the middle region 14, which is located about 1 ” downwards from the peak 16 of the thermoformed protrusion (see FIGs 1 and 2b). The last region is the peak 16 of the thermoformed protrusion (shown in FIGs 1 , 2a and 2b). The thickness (tm) was measured three times and averaged. The compressive strain after thermoforming for each location can be calculated as the ratio between tmand to. Compressive strain for samples of the surfacing film 10 at each film thickness and at each of the three regions is shown in the graph of FIG. 3. Note that the compressive strain of the flat region 12 of the 10.5 mil thick sample was negligible.Performance of injection molded part with preformed and planar surfacing film

[0082] 3D-parts were injection molded with preformed surfacing film and planar surfacing film separately as described above. Planar surfacing film refers to as- received surfacing film as a sheet, i. e., without preforming. A list of different combinations of surfacing film and virgin or recycled polymers are given in the table below. The performance of the injection molded part was evaluated based on the number of tearings in the surfacing film in the four protrusions. If there was no tearing of surfacing film, parts were rated “5”. If there were one or two tearings, they were rated “4”. if there were three or four tearings, they were rated “3”. If there were five or six tearings, they were rated “2”. If there were more than six tearings, they were rated “1 ”. As given in the table below, all injection molded 3D parts were rated “5” when they were molded with preformed surfacing films. Without preformed surfacing films, they were rated “1 ” with thicker surfacing film, such as 14 mils and 18 mils. With thinner surfacing films, 10.5 mils thick, number of tearing reduced but none of them were rated “5”.TABLEAdhesion measurements

[0083] Adhesion of the surfacing film to the injection molded polypropylene was measured according to ASTM D3359 (2017). An X-cut was made to the film using a razor blade at different locations (i. e., flat, middle, and peak). Then pressure sensitive adhesive tape was applied to the cut and removed directly. After removing the tape, the site was inspected to see signs of delamination around the cut area and rated qualitatively. If there was no delamination, it was rated as a 5. The test was repeated3 times and compared between multiple operators. Adhesion for all the Examples 1 - 24, with virgin as well as recycled polymers, was rated “5”, indicating that the surfacing film has good adhesion with recycled PP as well.

[0084] Whereas particular examples of this disclosure have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present disclosure may be made without departing from the disclosure as defined in the appended claims.

Claims

What is claimed is:1 . A composite component of a structure, comprising:1 ) a polymeric resin having a surface in a planar or three-dimensional shape, comprising recycled content, present in the polymeric resin in an amount of 1 to 100 percent by weight, based on the total weight of the polymeric resin; and2) a surfacing agent comprising a microporous sheet adhered to the polymeric resin, the microporous sheet comprising a polyolefin polymeric matrix; finely divided particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet; wherein the structure comprises a vehicle, building, bridge, transportation infrastructure, oil rig, oil platform, water tower, power line tower, support structure, wind turbine blade, wall, or shipping container.

2. The composite component of claim 1 , wherein the polymeric resin further comprises sheet molding compounds, bulk molding compounds, pelletized thermoplastic polymers, thermoplastic molding compounds, thermosetting molding compounds, polymer matrix composites, or combinations thereof.

3. The composite component of claim 1 or 2, wherein the polymeric resin further comprises a polyurethane, polyamine, acrylonitrile-butadiene-styrene, low- density polyethylene, medium-density polyethylene, high-density polyethylene, polycarbonate, polyamide, high impact polystyrene, polypropylene, polyetherketone, an epoxy resin, a phenolic resin, a melamine resin, a urea resin, polyaryl ether ketone, polyoxymethylene, polystyrene, polyester, polyimide, polyacetal, polyphenylene oxide, polyphenylene sulfide, polyethersulfone, cyclic polyolefin, a copolymer of a norbornene-based monomer and an olefin-based monomer, vinyl-based polymer, cellulose resin, a maleimide resin, a halogenated resin, silicone, an inorganic resin, an organic / inorganic hybrid resin, fiber-reinforced thermoplastic polymers or combinations thereof.

4. The composite component of any preceding claim, wherein the recycled content comprises a recycled polymer comprising low-density polyethylene, mediumdensity polyethylene, high-density polyethylene, polycarbonate, polystyrene,polypropylene, polyethylene terephthalate, thermoplastic polyolefin, polyvinyl chloride, polyamide, poly (methyl methacrylate), thermoplastic elastomer, styrene-butadiene polymer, polybutadiene and / or thermoplastic polyurethane; and wherein the recycled content optionally further comprises glass particles, glass fibers, silica, metal oxide particles, metal oxide fibers, metal particles, metal fibers, carbon particles and / or carbon fibers.

5. The composite component of any preceding claim, wherein the microporous sheet comprises 10 to 90 weight percent of the inorganic filler, based on the total weight of the microporous sheet.

6. The composite component of any preceding claim, wherein the microporous sheet has a thickness of 4 to 25 mils (101 .6 to 635 microns).

7. The composite component of any preceding claim, further comprising a decorative design and / or one or more coating layers comprising a conductive coating layer, a primer layer, an adhesion layer, a basecoat layer, a clear coat layer, and / or a monocoat layer applied to the surfacing agent.

8. The composite component of any preceding claim, wherein the structure comprises a vehicle.

9. Use of the composite component of any of claims 1 to 8 in a vehicle.

10. A method of recycling a polymer and making a molded composite component for a structure, comprising:1 ) lining at least a portion of an open mold interior with a microporous sheet;2) closing the mold;3) adding a polymeric resin to the mold on the microporous sheet; wherein the mold is closed prior to adding the polymeric resin to the mold in an injection molding process, or the mold is closed after adding the polymeric resin to the mold in a compression molding process; and4) hardening the polymeric resin to form a molded composite component;wherein the microporous sheet comprises a polyolefin polymeric matrix; finely divided particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet; and wherein the polymeric resin comprises a polymer to be recycled, present in the polymeric resin in an amount of 1 to 100 percent by weight, based on the total weight of the polymeric resin; and wherein the structure comprises a vehicle, building, bridge, transportation infrastructure, oil rig, oil platform, water tower, power line tower, support structure, wind turbine blade, wall, or shipping container.1 1 . The method of claim 10, wherein the structure comprises a vehicle.

12. The method of claim 10 or 1 1 , further comprising applying a coating layer to the microporous sheet either prior to lining the mold interior with the microporous sheet or after removal of the molded composite component from the mold, the coating layer comprising a conductive coating layer, a primer layer, an adhesion layer, a basecoat layer, a clear coat layer, and / or a monocoat layer.

13. The method of claim 12, further comprising surface treating the microporous sheet via corona discharge, ultraviolet radiation, plasma etching, or gamma radiation, prior to applying the coating layer.

14. The method of any of claims 10 to 13, wherein the polymer to be recycled comprises low-density polyethylene, medium-density polyethylene, high-density polyethylene, polycarbonate, polystyrene, polypropylene, polyethylene terephthalate, thermoplastic polyolefin, polyvinyl chloride, polyamide, poly (methyl methacrylate), thermoplastic elastomer, styrene-butadiene polymer, polybutadiene and / or thermoplastic polyurethane; and wherein the recycled polymer is optionally combined with glass particles, glass fibers, silica, metal oxide particles, metal oxide fibers, metal particles, metal fibers, carbon particles and / or carbon fibers.

15. A method of mitigating detrimental effects on a surface of a molded composite vehicle component caused by contaminants present in recycled content, comprising:1 ) lining at least a portion of an open mold interior with a microporous sheet;2) closing the mold;3) adding a polymeric resin to the mold on the microporous sheet; wherein the mold is closed prior to adding the polymeric resin to the mold in an injection molding process, or the mold is closed after adding the polymeric resin to the mold in a compression molding process; and4) hardening the polymeric resin to form a molded composite vehicle component;5) removing the molded composite vehicle component from the mold; and6) applying a decorative design and / or coating layer to the microporous sheet, the coating layer comprising a conductive coating layer, a primer layer, an adhesion layer, a basecoat layer, a clear coat layer, and / or a monocoat layer, wherein the coating layer is applied to the microporous sheet either prior to lining the mold interior with the microporous sheet or after removing the molded composite vehicle component from the mold; wherein the microporous sheet comprises a polyolefin polymeric matrix; finely divided particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet; and wherein the polymeric resin comprises the recycled content, present in the polymeric resin in an amount of 1 to 100 percent by weight, based on the total weight of the polymeric resin.

16. The method of claim 15, further comprising surface treating the microporous sheet via corona discharge, ultraviolet radiation, plasma etching, or gamma radiation, prior to applying the coating layer.

17. The method of any of claims 10 to 16, wherein the microporous sheet is preformed or thermoformed to conform to the mold prior to lining the mold with the microporous sheet.

18. A composite component of a structure, comprising:1 ) an extruded polymeric resin comprising recycled content, present in the polymeric resin in an amount of 1 to 100 percent by weight, based on the total weight of the polymeric resin; and2) a surfacing agent comprising a microporous sheet adhered to the extruded polymeric resin, the microporous sheet comprising a polyolefin polymeric matrix; finely divided particulate, inorganic filler distributed throughout the matrix; and a network of interconnecting pores communicating throughout the microporous sheet; wherein the structure comprises a vehicle, building, bridge, transportation infrastructure, oil rig, oil platform, water tower, power line tower, support structure, wind turbine blade, wall, or shipping container.

Images