Polymeric composite material

Abstract

The present disclosure relates to a polymeric composite material comprising a functionalised polymer and a reinforcement, wherein the functionalised polymer is at least partially cross-linked with the reinforcement. The disclosure also relates to processes for preparing the polymeric composite material and a cross-linkable composition for preparing the polymeric composite material. The disclosure also relates to articles comprising the polymeric composite material.

Description

POLYMERIC COMPOSITE MATERIALTECHNICAL FIELD

[0001] The present disclosure relates to a polymeric composite material comprising a functionalised polymer and a reinforcement, wherein the functionalised polymer is at least partially cross-linked with the reinforcement. The disclosure also relates to processes for preparing the polymeric composite material and a cross-linkable composition for preparing the polymeric composite material. The disclosure also relates to articles comprising the polymeric composite material.BACKGROUND ART

[0002] Polymers are a versatile group of materials. Various physical properties, including flexibility, rigidity and heat resistance, may be controlled by varying the chemical composition of the polymer material, e.g., by varying molecular weight, cross-linking of the polymer and additives. Additionally, polymer materials are often water resistant, durable and can be formed into diverse shapes. As a result, polymers have been utilised in a wide range of building products, such as pipes, water-proof membranes, fittings, window frames, flooring and other building components.

[0003] A common form of polymer found in the building industry is cross-linked polyethylene (PEX). Examples include water pipes, which are often made of a polymer material containing mostly (e.g. >97%) PEX, and cable jacketing or sheathing.

[0004] PEX may be prepared by the peroxide method (also known as the Engel method). In this method, a polymer precursor blend containing a peroxide is fed into an extruder and melted. When heated at high temperatures during the melt stage, free radicals form that initiate crosslinking of the polymer. The material prepared by this method is known as PEX -A and is typically a soft material with a high flexibility. A known problem with the PEX-A is the resulting product often contains residual chemicals from the manufacturing process, which may leach out over the life of the product.

[0005] PEX may also be formed in a two-step process in which extrusion and cross-linking of the polymer is performed separately. For example, a polymer precursor melt blend is extrudedand formed into a desired shaped, e.g. with injection molding. Once in the desired shape, the material is subjected to cross-linking conditions.

[0006] The most common two-step process for forming PEX is the silane method (also known as the Sioplas process). This method utilises a polyethylene functionalised with silicon containing functional groups, e.g. grafted trialkoxysilyl groups such as (MeOjaSi- groups. After extrusion of the melted blend, cross-linking is achieved by exposing the polymer material to water in the presence of a catalyst, e.g. an organotin catalyst. The material prepared by this process is known as PEX-B. When using the silane method, it is critical that the polymer precursor is not exposed to moisture during the extrusion step. Otherwise, excessive, uncontrolled cross-linking may occur during extrusion, leading to blockage of the extruder. This is undesirable because the extruder is typically a costly piece of machinery, which would need to be stripped down to remove the blockage and then reassembled. In high volume manufacturing processes, any extruder down time is highly undesirable from an economic perspective.

[0007] Another two-step process for forming PEX is the irradiation method. A polymer precursor blend is prepared and formed into the desired shape. Cross-linking is then initiated by irradiating the material with a suitable radiation source, typically an electron radiation beam. The material prepared by this process is known as PEX-C. The irradiation method is less common than the peroxide and silane methods owing to high manufacturing costs and safety considerations (e.g. due to use of radioactive substances in a production environment) and potential low durability of the product.

[0008] An emerging application for polymer materials is in roofing, cladding, and siding products, such as in the form of modules. Impact resistance is of particular interest in the roofing industry due to the increasing prevalence of hailstorms and the resultant significant financial implication in the repair or replacement required following such. The economic damage is such that the cost to repair or replace roofing following storms is becoming unviable, leaving building owners or homeowners in a vulnerable position, with buildings then exposed to further weather damage (e.g. water ingress). The dimensional stability of such roofing, cladding, and siding modules is also of particular interest to avoid issues with thermal expansion.

[0009] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form partof the prior art base or were common general knowledge in the field relevant to the present invention as it existed before the priority date.SUMMARY OF THE INVENTION

[0010] The ability to provide a material, for example in the form of a roofing, cladding, or siding module, capable of providing for a greater impact resistance, for example to hail events, and / or thermal stability and / or other improved properties provides for a significant economic advantage across the wider economy.

[0011] It is an object of the present invention to go some way to meeting this need; and / or avoiding one or more of the above disadvantages associated with the prior art; and / or to at least provide the public with a useful choice.

[0012] Other objects of the invention may become apparent from the following description which is given by way of example only.

[0013] In a first aspect, the invention provides a polymeric composite material formed from a cross-linkable composition comprising a) a functionalised polymer and b) a reinforcement capable of cross-linking with the functionalised polymer; wherein in the polymeric composite material the functionalised polymer is at least partially cross -linked with the reinforcement.

[0014] In a second aspect, the invention provides a polymeric composite material comprising a functionalised polymer at least partially cross-linked with a reinforcement.

[0015] In a third aspect, the invention provides a polymeric composite material comprising a reaction product of a) a functionalised polymer and b) a reinforcement capable of cross-linking with the functionalised polymer, wherein in the reaction product the functionalised polymer is at least partially cross-linked with the reinforcement.

[0016] In a fourth aspect, the invention provides a cross-linkable composition for forming a polymeric composite material comprising a) a functionalised polymer and b) a reinforcement capable of cross-linking with the functionalised polymer.

[0017] In a fifth aspect, the invention provides a process for preparing a polymeric composite material, the process comprising:i. providing in a container a cross-linkable composition comprising a) a functionalised polymer and b) a reinforcement capable of cross-linking with the functionalised polymer,ii. mixing the cross-linkable composition in the container at a temperature and a pressure and for a time sufficient to melt the functionalised polymer and cause the functionalised polymer to at least partially cross-link with the reinforcement, thereby providing a melt of the polymeric composite material,iii. expelling the melt from the container,iv. cooling the expelled melt.

[0018] In a sixth aspect, the invention provides a process for preparing a polymeric composite material, the process comprising:i. charging an extruder with a cross-linkable composition comprising a) a functionalised polymer and b) a reinforcement capable of cross-linking with the functionalised polymer,ii. mixing the cross-linkable composition at a temperature and a pressure and for a time sufficient to melt the functionalised polymer and cause the functionalised polymer to at least partially cross-link with the reinforcement, thereby providing a melt of the polymeric composite material,iii. extruding the melt,iv. cooling the extruded melt.

[0019] In a seventh aspect, the invention provides a process for preparing a polymeric composite material, the process comprising:i. charging an extruder with cross-linkable composition comprising a) a functionalised polymer and b) a reinforcement capable of cross-linking with the functionalised polymer,11. mixing the cross-linkable composition in the presence of water at a temperature and a pressure and for a time sufficient to melt the functionalised polymer and cause thefunctionalised polymer to at least partially cross-link with the reinforcement, thereby providing a melt of the polymeric composite material,iii. extruding the melt,iv. cooling the extruded melt.

[0020] In an eighth aspect, the invention provides a polymeric composite material obtained by a process of the fifth, sixth or seventh aspect.

[0021] In a ninth aspect, the invention provides an article comprising the polymeric composite material of the first, second, third or eighth aspect.

[0022] The following embodiments refer to any one or more of the above aspects.

[0023] The following embodiments and preferences may relate alone or in any combination of any two or more to any of the above aspects.

[0024] In some embodiments, the process comprises:i. charging an extruder with cross-linkable composition comprising a) a functionalised polymer and b) a reinforcement capable of cross -linking with the functionalised polymer,ii. mixing the cross-linkable composition in the presence of water at a temperature and a pressure and for a time sufficient to melt the functionalised polymer and cause the functionalised polymer to at least partially cross-link with the reinforcement, thereby providing a melt of the polymeric composite material,iii. extruding the melt,iv. cooling the extruded melt,wherein the cross-linkable composition comprises the functionalised polymer in an amount of about 30% or less by weight and the reinforcement in an amount of about 30% or less by weight.

[0025] In some embodiments, the polymeric composite material is an extruded polymeric composite material, an injection molded polymeric composite material or a compression molded polymeric composite material. In some embodiments, the polymeric composite material is an extruded polymeric composite material.

[0026] The functionalised polymer comprises a functional group capable of cross-linking with the reinforcement. In some embodiments, the functionalised polymer comprises a reactive silicon based functional group. In some embodiments, the reactive silicon based functional group is a group of the formula -Si(OR1)3, wherein each R1is independently H or a suitable organic group. In some embodiments, the reactive silicon based functional group is a group of the formula -Si(OR1)3, wherein each R1is independently a suitable organic group. In some embodiments, each R1is independent selected from a H, alkyl, alkenyl, cycloalkyl. In some embodiments, each R1is independently selected from a Ci-ealkyl, C2-ealkenyl or C3-6cycloalkyl. In some embodiments, each R1is independently selected from a Ci-ealkyl. In some embodiments, each R1is independently selected from methyl, ethyl or propyl, preferably methyl or ethyl, preferably methyl. In some embodiments, the reactive silicon based functional group is an alkoxysilyl group, preferably a trialkoxysilyl group.

[0027] In some embodiments, the functionalised polymer is a functionalised polyolefin. In some embodiments, the functionalised polymer is a functionalised polyethylene, e.g. a low-density polyethylene (LDPE), medium-density polyethylene (MDPE), high density polyethylene (HDPE), a polyolefin elastomer (POE) or combination of any two or more thereof. In some embodiments, the functionalised polymer is a functionalised polyolefin comprising a reactive silicon based functional group. In some embodiments, the functionalised polymer is a functionalised polyolefin comprising a reactive silicon based functional group is a group of the formula -Si(OR1)3, wherein each R1is independently H or a suitable organic group. In some embodiments, the functionalised polymer is a functionalised polyolefin comprising a reactive silicon based functional group is a group of the formula -Si(OR1)3, wherein each R1is independently a suitable organic group. In some embodiments, each R1is independent selected from a H, alkyl, alkenyl, cycloalkyl. In some embodiments, each R1is independently selected from a Ci-ealkyl, C2-ealkenyl or C3-6cycloalkyl. In some embodiments, each R1is independently selected from a Ci-ealkyl. In some embodiments, each R1is independently selected from methyl, ethyl or propyl, preferably methyl or ethyl, preferably methyl. In some embodiments, thefunctionalised polymer is a functionalised polyethylene comprising an alkoxysilyl group, preferably a trialkoxysilyl group.

[0028] In some embodiments, the polymeric composite material or the cross -linkable composition comprises the functionalised polymer in an amount of about 30% or less by weight, for example about 20% or less, 15% or less, 10% or less, 9% or less, 8% or less, 7% or less, 6% or less, or 5% or less by weight. In some embodiments, the polymeric composite material or the cross-linkable composition comprises the functionalised polymer in an amount of about 0.1 to 30% by weight, for example about 0.5 to 30%, 1 to 30%, 0.1 to 20%, 0.5 to 20%, 1 to 20%, 0.1 to 15%, 0.5 to 15%, 1 to 15%, 0.1 to 10%, 0.5 to 10%, 1 to 10%, 0.1 to 9%, 0.5 to 9%, 1 to 9%, 0.1 to 8%, 0.5 to 8%, 1 to 8%, 0.1 to 7%, 0.5 to 7%, 1 to 7%, 0.1 to 6%, 0.5 to 6%, 1 to 6%, 0.1 to 5%, 0.5 to 5%, 1 to 5%, 2 to 10%, 2 to 9%, 2 to 8%, 2 to 7%, 2 to 6%, 2 to 5%, or 2 to 4% by weight. In some embodiments, the polymeric composite material or the cross-linkable composition comprises the functionalised polymer in an amount of about 0.1 to 10% by weight, for example about 1 to 10%, 1 to 9%, 1 to 8%, 1 to 7%, 1 to 6%, 1 to 5%, or 1 to 4% by weight, preferably about 2 to 6%, 2 to 5% or 2 to 4% by weight, more preferably 2 to 5%. In some embodiments the polymeric composite material or the cross -linkable composition comprises the functionalised polymer in an amount of about 2, 3, 4, or 5% by weight, preferably about 2, 3, or 4%.

[0029] In some embodiments, the functionalised polymer is a cross -linkable PE and / or a cross-linkable PP. In some embodiments, the cross-linkable PP is a silane grafted propylene copolymer. In some embodiments, the functionalised polymer is a cross -linkable PE. In some embodiments, the cross-linkable PE is a silane grafted ethylene copolymer. In some embodiments, the cross-linkable PE is a cross-linkable HDPE. In some embodiments, the crosslinkable PE is a cross-linkable MDPE.

[0030] In some embodiments, the functionalised polymer has a density of from about 0.90 to 0.96, preferably about 0.93 g / cc (as measured by ASTM method 792). In some embodiments, the functionalised polymer has a density of from about 0.93 to 0.96 g / cc (as measured by ASTM method 792). In some embodiments, the functionalised polymer has a density of about 0.9 g / cc (as measured by ASTM method 792). In some embodiments, the functionalised polymer has a melt flow rate of from about 20 to 50, preferably about 20 to 40, more preferably about 20 g / 10 min (as measured with a load of 2.16 kg and at a temperature of 190°C in accordance withASTM method DI 238). In some embodiments, the functionalised polymer has a melt flow rate of from about 20 to 40, preferably about 20 g / 10 min (as measured with a load of 2.16 kg and at a temperature of 190°C in accordance with ASTM method DI 238).

[0031] The reinforcement comprises a functional group capable of cross -linking with the functionalised polymer. In some embodiments, the functional group may be introduced to the reinforcement via chemical modification. In some embodiments, the functional group may be exposed by mechanical manipulation, e.g. grinding or otherwise breaking up the reinforcement, to expose a reactive surface. In some embodiments, the reinforcement may comprise a sizing or a tie-layer comprising the functional group or the reinforcement itself may provide the functional group.

[0032] In some embodiments, the reinforcement comprises a reactive silicon based functional group, an epoxy group, a methacylate group, a peroxide group or a combination of any two or more thereof. In some embodiments, the reinforcement comprises a reactive silicon based functional group. In some embodiments, the reactive silicon based functional group is a silicon hydroxide group. In some embodiments, the reactive silicon based functional group is a group of the formula -Si(OR2)3, wherein each R2is independently H or a suitable organic group. In some embodiments, the reactive silicon based functional group is a group of the formula -Si(OR2)3, wherein each R2is independently a suitable organic group. In some embodiments, each R2is independently selected from a H, alkyl, alkenyl, cycloalkyl. In some embodiments, each R2is independently selected from a Ci-ealkyl, C2-ealkenyl or C3-6cycloalkyl. In some embodiments, each R2is independently selected from a Ci-ealkyl. In some embodiments, each R2is independently selected from methyl, ethyl or propyl. In some embodiments, the reactive silicon based functional group is an alkoxysilyl group, preferably a trialkoxysilyl group.

[0033] In some embodiments, the reinforcement comprises materials having a three-dimensional shape. In some embodiments, the reinforcement retains its three dimensional shape in the polymeric composite material. In some embodiments, the reinforcement is not meltable during the extrusion process.

[0034] In some embodiments, the reinforcement comprises glass, a polyester, an aramid or a combination of any two or more thereof. In some embodiments, the reinforcement comprises fibres, rods, needles, beads, flakes, particles, blocks or a combination of any two or more thereof; preferably the reinforcement comprises fibres. In some embodiments, the reinforcement is amaterial having an elongated shaped, e.g. fibres, rods, needles, or a combination of any two or more thereof. In some embodiments, the reinforcement comprises woven fibres and / or non-woven fibres. In some embodiments, the reinforcement comprises glass fibres. In some embodiments, the reinforcement comprises ground glass. In some embodiments, the reinforcement comprises sized glass, preferably sized glass fibres. In some embodiments, the reinforcement comprises glass, preferably glass fibres, comprising a reactive silicon based functional group.

[0035] In some embodiments, the polymeric composite material or cross -linkable composition comprises the reinforcement in an amount of about 30% or less by weight, for example about 20% or less, 15% or less, 10% or less, 9% or less, 8% or less, 7% or less, 6% or less, or 5% or less by weight. In some embodiments, the polymeric composite material or crosslinkable composition comprises the reinforcement in an amount of about 25% or less or 20% or less by weight. In some embodiments, the polymeric composite material or cross-linkable composition comprises the reinforcement in an amount of about 1 to 30% by weight, for example about 1 to 25%, 1 to 20%, 1 to 15%, 1 to 10%, 5 to 30%, 5 to 25%, 5 to 20%, 5 to 15%, 10 to 30%, 10 to 25%, 10 to 20%, 10 to 15%, 15 to 30%, 15 to 25%, 15 to 20%, 20 to 30%, or 20 to 25% by weight. In some embodiments, the polymeric composite material or cross-linkable composition comprises the reinforcement in an amount of about 10 to 30% by weight, for example about 11 to 29% by weight, 12 to 28% by weight, 13 to 27% by weight, or 14 to 26% by weight, preferably about 15 to 25% by weight. In some embodiments, the polymeric composite material or cross-linkable composition comprises the reinforcement in an amount of about 20% by weight.

[0036] In some embodiments, the functionalised polymer is a functionalised polyethylene comprising a reactive silicon based functional group, such as a group of the formula -Si(OR1)3, preferably wherein each R1is independently selected from a Ci-ealkyl, and the reinforcement comprises glass, preferably glass fibres. In some embodiments, the functionalised polymer is a functionalised polyethylene comprising a reactive silicon based functional group, such as a group of the formula -Si(OR1)3, preferably wherein each R1is independently selected from a Ci-ealkyl, and the reinforcement comprises glass, preferably glass fibres, comprising a reactive silicon based functional group, such as a group of the formula -Si(OR1)3, preferably wherein each R1is independently selected from a Ci-ealkyl. In some embodiments, the functionalised polymer is a functionalised polyethylene comprising a reactive silicon based functional group, and thereinforcement comprises glass, preferably glass fibres, comprising a reactive silicon based functional group and, in the polymeric composite material, the functionalised polymer is at least partially cross-linked with the reinforcement through a Si-O-Si bond.

[0037] In some embodiments, the weight ratio of the functionalised polymer to the reinforcement is from about 30:1 to 1:30. In some embodiments, the weight ratio of the functionalised polymer to the reinforcement is from about 20: 1 to 1 :30, about 15:1 to 1 :30, about 10:1 to 1:30, about 5:1 to 1:30, about 1:1 to 1:30, about 1:1 to 1:25, about 1:1 to 1:20, about 1:1 to 1 : 15 or about 1 : 1 to 1 : 10. In some embodiments, the weight ratio of the functionalised polymer to the reinforcement is from about 1 :2 to 1:10, about 1 :3 to 1 :9, about 1 :4 to 1 :9 or about 1:4 to 1:8.

[0038] In some embodiments, the cross-linkable composition comprises water. In some embodiments, the cross-linkable composition comprises sufficient water to facilitate a reaction between the functionalised polymer and the reinforcement. In some embodiments, the water is provided in the form of steam. In some embodiments, the water is provided in the form of one or more additive that comprises water. In some embodiments, the one or more additive that comprises water is a filler, a flame retardant, or a combination thereof. In some embodiments, the one or more additive that comprises water is calcium carbonate, magnesium hydroxide, or a combination thereof. In some embodiments, the water is provided in the form of one or more additive that decomposes to provide water during processing, for example during a mixing step of a process of the invention (i.e. step (ii)). In some embodiments, the one or more additive that decomposes to provide water is magnesium hydroxide.

[0039] In some embodiments, the polymeric composite material or the cross-linkable composition further comprises one or more additional polymer(s). In some embodiments, the one or more additional polymer(s) is a thermoplastic polymer.

[0040] In some embodiments, the one or more additional polymer(s) is a polystyrene (GPPS), polyethylene terephthalate (PET), polyester methacrylate (PEM), high impact polystyrene (HIPS), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polyurethanes (PU), polyethylene (PE) including homopolymer, copolymer, block copolymer and terpolymer forms, polylactic acid (PLA), nylon (PA), acrylics (PMMA), high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), cross linked polyethylene (PEX), thermoplastic elastomer (TPE)(including an elastomeric LLDPE, elastomeric MDPE, elastomeric HDPE, or any combination of any two or more thereof), polyolefin elastomer (POE), thermoplastic polyolefin (TPO), thermoplastic rubber (TPR), polypropylene (PP), including homopolymer and copolymer forms, polybutylene terephthalate (PBT), styrene-acrylonitrile resin (SAN), ethylene tetrafluoroethylene (ETFE), vinyl, methacrylate copolymers, foamed polymer, polycarbonates, or a combination of any two or more thereof. In some embodiments, the one or more additional polymer(s) is a polystyrene (GPPS), polyethylene terephthalate (PET), polyester methacrylate (PEM), high impact polystyrene (HIPS), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polyurethanes (PU), polyethylene (PE) including homopolymer, copolymer, block copolymer and terpolymer forms, polylactic acid (PLA), nylon (PA), acrylics (PMMA), high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), cross linked polyethylene (PEX), thermoplastic elastomer (TPE), thermoplastic polyolefin (TPO), thermoplastic rubber (TPR), polypropylene (PP), including homopolymer and copolymer forms, polybutylene terephthalate (PBT), styrene-acrylonitrile resin (SAN), ethylene tetrafluoroethylene (ETFE), vinyl, methacrylate copolymers, foamed polymer, polycarbonates, or a combination of any two or more thereof. In some embodiments, the one or more additional polymer(s) is a polyolefin. In some embodiments, the one or more additional polymer(s) is a POE. In some embodiments, the one or more additional polymer(s) is a polyethylene, e.g. a low-density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium-density polyethylene (MDPE), high density polyethylene (HDPE), TPE (such as an elastomeric LLDPE, elastomeric MDPE, elastomeric HDPE, or any combination of any two or more thereof), POE, or combination of any two or more thereof. In some embodiments, the one or more additional polymer(s) is a polyethylene, e.g. a low-density polyethylene (LDPE), medium-density polyethylene (MDPE), high density polyethylene (HDPE) or combination of any two or more thereof.

[0041] In some embodiments, the one or more additional polymer(s) is selected from a LLDPE, a LDPE, a MDPE, a HDPE, a TPE (such as an elastomeric LLDPE, elastomeric MDPE, elastomeric HDPE, or any combination of any two or more thereof), POE or a combination of any two or more thereof.

[0042] In some embodiments, the LLDPE has a density of from about 0.900 to 0.930, preferably about 0.92 g / cc, more preferably about 0.924 g / cc (as measured by ASTM method D792). In some embodiments, the LLDPE has a melt flow index of about 10 to 50, preferablyabout 20 g / 10 min (as measured with a load of 2.16 kg and at a temperature of 190°C in accordance with ASTM method DI 238).

[0043] In some embodiments, the elastomeric LLDPE has a density of from about 0.910 to 0.930, preferably about 0.92 g / cc, more preferably about 0.920 g / cc (as measured by ASTM method D792). In some embodiments, the elastomeric LLDPE has a melt flow index of about 10 to 50, preferably about 19 g / 10 min (as measured with a load of 2.16 kg and at a temperature of 190°C in accordance with ASTM method DI 238).

[0044] In some embodiments, the elastomeric POE has a density of from about 0.850 to 0.900, preferably about 0.87 g / cc, more preferably about 0.870 g / cc (as measured by ASTM method DI 505). In some embodiments, the elastomeric POE has a melt flow index of about 5 to 15, preferably about 5 g / 10 min (as measured with a load of 2.16 kg and at a temperature of 190°C in accordance with ASTM method DI 238). In some of such embodiments, the POE is an PE copolymer, for example a random PE copolymer.

[0045] In some embodiments, the one or more additional polymer(s) comprises or is a recycled material.

[0046] In some embodiments, the one or more additional polymer(s) does not cross-link with the functionalised polymer during the extrusion process. In some embodiments, the one or more additional polymer(s) does not cross-link with the reinforcement during the extrusion process. In some embodiments, the one or more additional polymer(s) does not cross-link with the functionalised polymer or the reinforcement during the extrusion process.

[0047] In some embodiments, the polymeric composite material or the cross-linkable composition further comprises one or more additive(s) selected from a flame retardant, a filler, a colourant, a UV stabilizer, a thermal stabiliser, a compatibilizer, a foaming agent, a free radical scavenger, a lubricant or a slip agent, a biocide, an additional material, a surface leaching agent or inhibitor, and a combination of any two or more thereof.

[0048] In some embodiments, the flame retardant is an inorganic metal compound, preferably magnesium hydroxide or aluminium trihydroxide (ATH), a halogenated material, or any combination of two or more thereof.

[0049] In some embodiments, the filler is talc, calcium carbonate, mica, silica, kaolin, calcium sulphate, magnesium hydroxide, stabilizers, dolomite or a combination of any two or more thereof.

[0050] In some embodiments, the colourant is an organic pigment, an inorganic pigment or a combination thereof. In some embodiments, the inorganic pigment is carbon black, a metal oxide such as titanium dioxide, a metal carbonate, or a combination of any two or more thereof. In some embodiments, the colourant is carbon black, titanium dioxide or a combination thereof.

[0051] In some embodiments, the UV stabilizer is a hindered amine light stabilizer (HALS).

[0052] In some embodiments, the thermal stabilizer is a phenolic or a phosphite.

[0053] In some embodiments, the lubricant or slip agent is an euricamide, a fatty acid amide slip additive, a fatty acid ester additive, a short-chain fluoro-polymer, zinc stearate or a combination of any two or more thereof.

[0054] In some embodiment, the biocide is silver, preferably silver nanoparticles.

[0055] In some embodiments, the additional material is provided as an additional filler or additional reinforcement. In some embodiments, the additional material comprises materials having a three-dimensional shape. In some embodiments, the additional material retains its three dimensional shape in the polymeric composite material. In some embodiments, the additional material is not meltable during the extrusion process.

[0056] In some embodiments, the additional material comprises fibres, rods, needles, beads, flakes, particles, blocks or a combination of any two or more thereof; preferably the additional material comprises fibres. In some embodiments, the additional material is a material having an elongated shaped, e.g. fibres, rods, needles, or a combination of any two or more thereof. In some embodiments, the additional material comprises woven fibres and / or non-woven fibres.

[0057] In some embodiments, the additional material comprises a natural material, a synthetic material, a non-conductive material or a combination of any two or more thereof. In some embodiments, the additional material comprises glass fibres, glass beads, glass flakes, natural fibres such as flax, cellulose, wood fibres, wood flour, cotton, sawdust, and inorganic or polymerfibres, scrim, knits, weaves, non-woven fibres, aramids, ceramics or a combination of any two or more thereof.

[0058] In some embodiments, the polymeric composite material or the cross-linkable composition is substantially free of any organic peroxide, preferably substantially free of any peroxide. In some embodiments, the polymeric composite material or the cross-linkable composition is substantially free of a cross-linking catalyst, e.g. a tin catalyst. In some embodiments, the cross-linking catalyst is an inorganic catalyst, an organic catalyst, or a peroxide catalyst. In some embodiments, the inorganic catalyst is an inorganic metal catalyst. In some embodiments, the inorganic metal catalyst is an organometal metal catalyst. In some embodiments, the organic catalyst is an anhydride catalyst. In some embodiment, the anhydride catalyst is maleic anhydride, succinic anhydride, or a combination thereof. In some embodiments, the anhydride catalyst is maleic anhydride. In some embodiments, the peroxide catalyst is an organic peroxide.

[0059] In some embodiments, the polymeric composite material comprises a polyolefin and a reinforcement comprising glass, preferably glass fibres; wherein the polyolefin comprises a silane group cross-linked to the glass by a Si-O-Si bond.

[0060] In some embodiments, the polymeric composite material has one or more tensile properties, when measured by Tensile ASTM D638, selected from:a) a Youngs modulus (MD) of at least about 800 MPa;b) a Youngs modulus (TD) of at least about 200 MPa;c) a tensile strength (MD) of at least about 10 MPa; andd) a tensile strength (TD) of at least about 5 MPa.

[0061] In some embodiments, the polymeric composite material has one or more tensile properties when measured by Tensile ASTM D638 selected from:a) a Youngs modulus (MD) of at least about 900, 1,000, 1,100, 1,200, 1,300, 1,400, 1,500, 1,600, 1,700, 1,800, 1,900, 2,000, 2,100, 2,200, 2,300, 2,400, 2,500, 2,600, 2,700, 2,800, 2,900 or 3,000 MPa;b) a Youngs modulus (TD) of at least about 300, 400, 500, 600, 700, 800, 900 or 1,100 MPa;c) a tensile strength (MD) of at least about 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27 or 28 MPa; andd) a tensile strength (TD) of at least about 6, 10, 11, 12, 13, 14, 15, 16, 17, 18 or 19 MPa.

[0062] In some embodiments, the polymeric composite material has one or more tensile properties when measured by Tensile ASTM D638 selected from:a) a Youngs modulus (MD) of at least about 900, 1,000, 1,100, 1,200, 1,300, 1,400, 1,500 MPa;b) a Youngs modulus (TD) of at least about 300, 400, 500, 600, 700, 800, 900 or 1,100 MPa;c) a tensile strength (MD) of at least about 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27 or 28 MPa; andd) a tensile strength (TD) of at least about 6, 10, 11, 12, 13, 14, 15, 16, 17, 18 or 19 MPa.

[0063] In some embodiments, the polymeric composite material has two or more tensile properties as defined above. In some embodiments, the polymeric composite material has three or more tensile properties as defined above. In some embodiments, the polymeric composite material has four tensile properties as defined above.

[0064] In some embodiments, the polymeric composite material has one or more flexural properties when measured by Flexural ASTMD790, selected from:a) a Youngs modulus (MD) of at least about 1,100 MPa;b) a Youngs modulus (TD) of at least about 400 MPa;c) a flex stress at 5% (MD) of at least about 20 MPa; andd) a flex stress at 5% (TD) of at least about 11 MPa.

[0065] In some embodiments, the polymeric composite material has one or more flexural properties when measured by Flexural ASTMD790, selected from:a) a Youngs modulus (MD) of at least about 1,200, 1,300 or 1,400 MPa;b) a Youngs modulus (TD) of at least about 450, 500, 550, 600 or 650 MPa;c) a flex stress at 5% (MD) of at least about 25, 30, 35, 40, 45, 50 or 55 MPa; andd) a flex stress at 5% (TD) of at least about 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25 or 26 MPa.

[0066] In some embodiments, the polymeric composite material has two or more flexural properties as defined above. In some embodiments, the polymeric composite material has three or more flexural properties as defined above. In some embodiments, the polymeric composite material has four flexural properties as defined above.

[0067] In some embodiments, the polymeric composite material has a coefficient of thermal expansion (MD) of about 3.81 x 10-5 or less. In some embodiments, the polymeric composite material has a coefficient of thermal expansion (TD) of about 1.18x10-4 or less. In some embodiments, the polymeric composite material has a coefficient of thermal expansion (MD) of about 3.81 x 10-5. In some embodiments, the polymeric composite material has a coefficient of thermal expansion (TD) of about 1.18x10-4.

[0068] In some embodiments, the functionalised polymer is at least partially cross -linked with the reinforcement prior to forming an article having a desired three-dimensional shape from the polymeric composite material.

[0069] In some embodiments, the container in step (i) is a barrel of an extruder or a barrel of an injection molding device.

[0070] In some embodiments, the polymeric composite material is an extruded polymeric composite material and after extrusion the material is not subjected to any step for initiating further cross-linking of the functionalised polymer with the reinforcement. In some embodiments, the polymeric composite material is an injection molded polymeric composite material or a compression molded polymeric composite material and after conveying thematerial into a mold is not subjected to any step for initiating further cross -linking of the functionalised polymer with the reinforcement.

[0071] In some embodiments, step (ii) comprises mixing the cross-linkable composition at a temperature of at least about 80, 100, 120, 140, 160, 180, 200 or 220°C. In some embodiments, step (ii) comprises mixing the cross-linkable composition at a temperature less than about 300, 280, 270, 260, 250 or 240°C. In some embodiments, step (ii) comprises mixing the crosslinkable composition at a temperature of about 80 to 300°C, 200 to 280°C, 210 to 270°C, 220 to 260°C; preferably about 230 to 250°C. In some embodiments, step (ii) comprises mixing the cross-linkable composition at a temperature of about 240°C. In some embodiments, step (ii) comprises mixing the cross-linkable composition at a temperature greater than about 200°C and less than about 250°C.

[0072] In some embodiments, step (ii) comprises mixing the cross-linkable composition at a pressure of at least about 700, 800, 900, 1,000, 1,100, 1,200, 1,300, 1,400, 1,500, 1,600, 1,700, 1,800, 1,900 or 2,000 psi. In some embodiments, step (ii) comprises mixing the cross-linkable composition at a pressure of at least about 1 ,500, 1 ,600, 1 ,700, 1 ,800, 1 ,900 or 2,000 psi. In some embodiments, step (ii) comprises mixing the cross-linkable composition at a pressure less than about 3,000, 2,900, 2,800, 2,700, 2,600, 2,500 or 2,400 psi. In some embodiments, step (ii) comprises mixing the cross-linkable composition at a pressure of about 750 to 3,000, 1,000 to 3, 000, 1,250 to 3,000, 1,500 to 3,000 psi, 1,600 to 2,900 psi, 1,700 to 2,800 psi, 1,800 to 2,600 psi, 1,900 to 2,400 psi, preferably 1,500 to 3,000 psi, 1,600 to 2,900 psi, 1,700 to 2,800 psi, 1,800 to 2,600 psi, 1,900 to 2,400 psi, more preferably about 2,000 to 2,200 psi. In some embodiments, step (ii) comprises mixing the cross-linkable composition at a pressure of about 1,500 to 3,000 psi, 1,600 to 2,900 psi, 1,700 to 2,800 psi, 1,800 to 2,600 psi, 1,900 to 2,400 psi, preferably about 2,000 to 2,200 psi. In some embodiments, step (ii) comprises mixing the cross -linkable composition at a pressure greater than about 1,800 psi and less than about 2,200 psi.

[0073] In some embodiments, step (ii) comprises mixing the cross -linkable composition at a temperature greater than about 200°C and less than about 250°C and a pressure greater than about 1,800 psi and less than about 2,200 psi.

[0074] In some embodiments, the time of step (ii) is at least about 1, 2, 3, 4 or 5 minutes. In some embodiments, the time of step (ii) is less than about 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 minute. In some embodiments, the time of step (ii) is about 1 to 15 minutes, 2 to 10minutes; preferably about 3 to 7 minutes. In some embodiments, the time of step (ii) is greater than about 2 minutes and less than about 15 minutes.

[0075] In some embodiments, the residence time of the composition in step (ii) is at least about 1, 2, 3, 4 or 5 minutes. In some embodiments, the residence time of the composition in step (ii) is less than about 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 minute. In some embodiments, the residence time of the composition in step (ii) is about 1 to 15 minutes, 2 to 10 minutes; preferably about 3 to 7 minutes. In some embodiments, the residence time of the composition in step (ii) is greater than about 2 minutes and less than about 15 minutes.

[0076] In some embodiments, the extruder comprises a barrel and at least one screw. In some embodiments, the extruder is a twin screw extruder. In some embodiments, the twin-screw extruder is a co-rotating twin screw extruder. In other embodiments, the twin-screw extruder is a counter-rotating twin screw extruder.

[0077] In some embodiments, charging the extruder with the cross-linkable composition comprises adding the functionalised polymer and the reinforcement to extruder together (i.e. adding a cross-linkable composition of the invention). In some embodiments, charging the extruder with the cross-linkable composition comprises adding the functionalised polymer and the reinforcement to the extruder separately (simultaneously or sequentially). In some embodiments, charging the extruder with the cross-linkable composition comprises adding the functionalised polymer and the reinforcement to the extruder separately at different points located along the length of the barrel. In some embodiments, charging the extruder with the cross-linkable composition comprises adding the functionalised polymer and the reinforcement to the extruder simultaneously and separately at different points located along the length of the barrel.

[0078] In some embodiments, providing the cross-linkable composition in the container comprises adding the functionalised polymer and the reinforcement to a barrel of an extruder or an injection moulding device together (i.e. adding a cross -linkable composition of the invention). In some embodiments, providing the cross-linkable composition in the container comprises adding the functionalised polymer and the reinforcement to a barrel of an extruder or an injection molding device separately (simultaneously or sequentially). In some embodiments, providing the cross-linkable composition in a container comprises adding the functionalised polymer and the reinforcement to a barrel of an extruder or an injection molding device at different points locatedalong the length of the barrel. In some embodiments, providing the cross-linkable composition in the container comprises adding the functionalised polymer and the reinforcement to a barrel of an extruder or an injection molding device simultaneously and separately at different points located along the length of the barrel.

[0079] In some embodiments, the process further comprises charging the extruder with water. In some embodiments, the amount of water is sufficient to facilitate a reaction between the functionalised polymer and the reinforcement. In some embodiments, the water is provided in the form of one or more additive that comprises water, for example one or more additive that comprise available water, for example residual moisture. In some embodiments, the water is provided by one or more additive that decomposes to provide water during the mixing. In some embodiments, the extruder is charged with water in the form of steam. In some embodiments, the extruder is charged with one or more additive that comprises water. In some embodiments, the one or more additive that comprises water is a filler, a flame retardant, or a combination thereof. In some embodiments, the one or more additive that comprises water is calcium carbonate, magnesium hydroxide, or a combination thereof. In some embodiments, the extruder is charged with one or more additive that decomposes to provide water during the mixing. In some embodiments, the one or more additive that decompose to provide water is magnesium hydroxide.

[0080] In some embodiments, the process further comprises after step (iii) forming the extruded melt into an article having a desired three-dimensional shape.

[0081] In some embodiments, the process further comprises after step (iii) forming the melt into an article having a desired three-dimensional shape with injection molding or compression molding. In some preferred embodiments, the process further comprises after step (iii) forming the melt into an article having a desired three-dimensional shape with compression molding.

[0082] In some embodiments, the process does not comprise after step (iii) any step for initiating further cross-linking of the functionalised polymer with the reinforcement, or at least no steps actively taken to initiate or carry on cross-linking.

[0083] In some embodiments, the article is a building product. In some embodiments, the building product is a roof, cladding or siding product, e.g. a roof, cladding or siding module. In some embodiments, the building product is a hail-resistant roof, cladding or siding module.

[0084] In some embodiments, the article or building product is a photovoltaic module. In some embodiments, the article or building product is a roof, cladding or siding module comprising an integrated photovoltaic module.

[0085] In some embodiments, the article comprises one or more layers. In some embodiments, the article comprises two or more layers. In some embodiments, the article comprises a first layer comprising the polymeric composite material and a second layer comprising a polymeric material. In some embodiments, the article comprises a first layer comprising the polymeric composite material and a second layer comprising a polymeric composite material.

[0086] This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

[0087] In addition, where features or aspects of the invention are described in terms of Markush groups, those persons skilled in the art will appreciate that the invention is also thereby described in terms of any individual member or subgroup of members of the Markush group.

[0088] Unless the context indicates otherwise, any percentages indicated are by weight.

[0089] As used herein “(s)” following a noun means the plural and / or singular forms of the noun.

[0090] As used herein the term “and / or” means “and” or “or” or both.

[0091] The term “comprising” as used in this specification means “consisting at least in part of’. When interpreting each statement in this specification that includes the term “comprising”, features other than that or those prefaced by the term may also be present. Related terms such as “comprise” and “comprises” are to be interpreted in the same manner.

[0092] It is intended that reference to a range of numbers disclosed herein (for example, 1 to 10) also incorporates reference to all rational numbers within that range (for example, 1 , 1.1, 2, 3, 3.9, 4, 5, 6, 6.5, 7, 8, 9 and 10) and also any range of rational numbers within that range (forexample, 2 to 8, 1.5 to 5.5 and 3.1 to 4.7) and, therefore, all sub-ranges of all ranges expressly disclosed herein are hereby expressly disclosed. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

[0093] Although the present invention is broadly as defined above, those persons skilled in the art will appreciate that the invention is not limited thereto and that the invention also includes embodiments of which the following description gives examples.DETAILED DESCRIPTION OF THE INVENTION

[0094] The present invention relates to a polymeric composite material comprising a functionalised polymer and reinforcement, a process for preparing the polymeric composite material, and a cross-linkable composition for forming the polymeric composite material. The polymeric composite material is useful in the manufacture of an article, e.g., building products including a roof, siding or cladding module or photovoltaic module.1. Polymeric composite material

[0095] The polymeric composite material may be formed by reacting a functionalised polymer and a suitable reinforcement. The functionalised polymer and reinforcement are selected to be capable of cross-linking under certain conditions, e.g. at a sufficient temperature and a pressure for a sufficient time. The resulting polymeric composite material comprises the functionalised polymer at least partially cross-linked with the reinforcement by one or more covalent bonds. Cross-linking between the functionalised polymer and reinforcement may also comprise one or more non-covalent bonding interactions, for example polymer chain entanglement or entrapment, van der Walls interactions, hydrogen bonding, mechanical interlocking, etc. Without wishing to be bound by theory, it is believed the cross-linked functionalised polymer and reinforcement forms a three-dimensional framework.Advantageously, the polymeric composite material may have improved properties, e.g. tensile strength, flexibility and / or dimensional stability (for example, reduced thermal expansion). Further components, such as one or more additional polymer(s) or additive(s), may be added or the amounts of existing components adjusted to modulate the properties of the polymeric composite material, e.g. flexibility or fire resistance, as desired for various applications. Again,without wishing to be bound by theory, it is believed these further components may fill or at least partially occupy the interstitial spaces within the three-dimensional framework formed by cross-linking between the functionalised polymer and reinforcement.

[0096] The functionalised polymer is a polymer comprising a functional group capable of reacting with the reinforcement to provide cross-linking between the functionalised polymer and reinforcement. As used herein, the term ‘functionalised polymer’ in the context of the crosslinkable composition (i.e. the precursor composition prior to cross-linking) refers to the polymer comprising a functional group capable of cross -linking with the reinforcement. In the context of the polymeric composite material, the term ‘functionalised polymer’ refers to the same polymer except at least partially cross -linked to the reinforcement.

[0097] The phrase “at least partially cross-linked” (and related terms such as at least partially cross-link) as used herein in the context of a functionalised polymer at least partially cross-linked with a reinforcement or the formation thereof refers to a product wherein the functionalised polymer and reinforcement are bound to each other by at least one covalent bond. The at least one covalent bond may be produced by one or more of functional group of the functionalised polymer capable of reacting with one or more functional group of the reinforcement reacting with one or more functional group of the reinforcement capable of reacting with one or more functional group of the functionalised polymer. The phrase “at least partially cross-linked” encompasses any suitable degree of cross-linking with respect to the reactive functional groups of the functionalised polymer. For example, in some embodiments, at least about 5%, 10%, 20%, 30%, 40%, or 50% of reactive functional groups on the functionalised polymer have reacted to cross-link with the reinforcement. In some embodiments, at least about 60%, 70%, 80%, 90%, 95% or 99% of reactive functional groups on the functionalised polymer have reacted to crosslink with the reinforcement. In some embodiments, substantially all reactive functional groups on the functionalised polymer have reacted to cross -link with the reinforcement. In other embodiments, only a portion but not all of the functional groups on the functionalised polymer have reacted to cross-link with the reinforcement.

[0098] The polymer of the functionalised polymer may be derived from any suitable polymer, preferably a polyolefin. For example, in some embodiments the polymer of the functionalised polymer may be derived from a polyethylene (PE) such as a low-density polyethylene (LDPE), a linear low-density polyethylene (LLDPE), medium-density polyethylene (MDPE), high densitypolyethylene (HDPE), a polyolefin elastomer (POE) or combination of any two or more thereof. The polymer acts as a backbone onto which one or more functional group are provided. For example, in some embodiments, the polymer provides a backbone onto which one or more functional group are grafted. The polymer may be selected based on the desired properties of the polymeric composite material. Preferably, the polymer is a HDPE.

[0099] The functional group of the polymer is capable of reacting with a functional group of the reinforcement. Accordingly, the functional group is selected to be compatible with the reinforcement in this regard. In certain preferred embodiments, the functional group is a reactive silicon based functional group, such as a group of the formula -Si(OR1)3, wherein each R1is independently a suitable organic group. In some embodiments, each R1is independently selected from a Cnealkyl, C2-ealkenyl or C3-ecycloalkyl. In some embodiments, eachR1is independently selected from a Ci-ealkyl. In some embodiments, each R1is independently selected from methyl, ethyl or propyl, preferably methyl or ethyl, preferably methyl. In some embodiments, the functionalised polymer is a functionalised polyethylene comprising an alkoxysilyl group, preferably a trialkoxysilyl group.

[0100] The functionalised polymer may be a cross-linkable PE and / or a cross-linkable PP, preferably a cross-linkable PE. In some embodiments, the functionalised polymer is a crosslinkable PE. In some embodiments the cross-linkable PE is a silane grafted ethylene copolymer. In some embodiments the cross-linkable PE is a cross-linkable HDPE.

[0101] In some embodiments, the functionalised polymer has a density of from about 0.93 to 0.96, preferably about 0.94 g / cc, more preferably about 0.945 g / cc (as measured by ASTM method 792). In some embodiments, the functionalised polymer has a melt flow rate of about 45 g / 10 min (as measured with a load of 2.16 kg and at a temperature of 190°C in accordance with ASTM method DI 238).

[0102] Suitable functionalised polymers are commercially available or can be readily prepared by known methods. For example, suitable functionalised polymers comprising a reactive silicon based functional group may be produced using the first step of the Sioplas process, which typically involves reacted a polyethylene with a vinyl silane in the presence of a peroxide. Alternatively, the functionalised polymer may be sourced from commercial suppliers pre-functionalised with the functional group - i.e. the polymer is already functionalised and suitable for use in the invention without further modification. Many functionalised polymers pre-functionalised with the functional group and suitable for use in in the invention are commercially available.

[0103] The polymeric composite material may comprise the functionalised polymer in any suitable amount. For example, in some embodiments, the polymeric composite material may comprise the functionalised polymer in an amount of about 30% or less by weight, for example about 20% or less, 15% or less, 10% or less, 9% or less, 8% or less, 7% or less, 6% or less, or 5% or less by weight. In some embodiments, the polymeric composite material comprises the functionalised polymer in an amount of about 0.1 to 50% by weight, for example, about 0.1 to 30%, 1 to 30%, 0.1 to 20%, 1 to 20%, 0.1 to 15%, 1 to 15%, 0.1 to 10%, 1 to 10%, 0.1 to 9%, 1 to 9%, 0.1 to 8%, 1 to 8%, 0.1 to 7%, 1 to 7%, 0.1 to 6%, 1 to 6%, 0.1 to 5%, or 1 to 5% by weight. In some embodiments, the polymeric composite material, or from which the material is formed, comprises the functionalised polymer in an amount of about 0.1 to 10% by weight, for example about 1 to 10% by weight, preferably about 2 to 6%, 2 to 5% or 2 to 4% by weight, preferably 2 to 5%. In some embodiments the polymeric composite material comprises the functionalised polymer in an amount of about 2, 3, 4, or 5% by weight, preferably about 2, 3, or 4%.

[0104] In some embodiments, e.g. when the functionalised polymer comprises a reactive silicon function group, preferably the polymeric composite material comprises the functionalised polymer in an amount less than about 10% by weight, more preferably less than 7% by weight. In these embodiments, preparing the polymeric composite material from a composition comprising less than 10% by weight, more preferably less than 7% by weight, of the functionalised polymer may reduce the potential for internal or intramolecular cross-linking between the functional groups of the polymer and favour cross -linking between the functionalised polymer and reinforcement. The inventors have developed a system where, surprisingly, the functionalised polymer may be used in such relatively low amounts (compared, for example, to prior art materials comprising >90% functionalised polymer) in combination with a reinforcement while achieving desirable material properties.

[0105] The reinforcement capable of cross-linking with the functionalised polymer is a reinforcement comprising a functional group capable of reacting with the functionalised polymer to provide cross-linking between the functionalised polymer and reinforcement. As used herein, the term ‘reinforcement capable of cross-linking with the functionalised polymer’ in the contextof the cross-linkable composition (i.e. the precursor composition prior to cross-linking) refers to the reinforcement comprising a functional group capable of cross -linking with the functionalised polymer. In the context of the polymeric composite material, the term ‘reinforcement capable of cross-linking with the functionalised polymer’ refers to the same reinforcement except at least partially cross-linked to the functionalised polymer.

[0106] The reinforcement comprises a suitable material including, but not limited to, glass, a polyester, an aramid or a combination of any two or more thereof. The reinforcement material comprises one or more functional groups that is capable of reacting with the functionalised polymer to form the cross-linking. Reinforcement can be sourced pre-functionalised with the functional group (e.g. from commercial suppliers) or the functional group can be introduced as part of the process steps carried out to form the polymeric composite material. The functional group may be introduced to the reinforcement via chemical modification. The functional group may be introduced before the reinforcement is mixed with the functionalised polymer in step (ii), or during mixing the reinforcement with the functionalised polymer in step (ii). For example, in some embodiments, the reinforcement comprises glass, preferably glass fibres, and plasma is be used to at least partially coat the surface of glass with silane functional group(s) prior to mixing with the functionalised polymer. Additionally or alternatively, the functional group may be exposed by mechanical manipulation, e.g. grinding or otherwise breaking up a glass, to expose a reactive surface. For example, the reinforcement may comprise a reactive silicon based functional group, e.g. the reinforcement may comprise a sizing or a tie-layer comprising the functional group or the reinforcement itself may provide a reactive silicon site. Those persons skilled in the art will appreciate that any suitable functional groups known to form cross-linking may be useable in the invention, e.g. an epoxy group, a methacrylate group, a peroxide group or a combination of any two or more thereof.

[0107] In some embodiments, the reactive silicon based functional group is a silicon hydroxyl group (Si-OH). In some embodiments, the silicon hydroxyl group is on an exposed surface of the reinforcement. For example, in some embodiments, the reinforcement comprises glass and the silicon hydroxyl functional group is provided by an exposed surface of the glass. In some embodiments, the reinforcement comprises sized glass, preferably sized glass fibres, and the exposed glass surface is provided by incomplete coverage of the glass surface with the size. In some embodiments, the reinforcement comprises sized glass, preferably sized glass fibres, and the exposed glass surface is provided by the at least partial removal of size from a previouslyunexposed portion of the glass surface, for example during processing, for example during a mixing step in the process of the invention. In some embodiments, the reinforcement comprises sized glass, preferably sized glass fibres, and the exposed glass surface is provided by the glass reinforcement at least partially breaking and exposing a previously unexposed portion of the glass surface, for example during processing, for example during a mixing step in the process of the invention. In some embodiments, the reinforcement comprises unsized glass, for example unsized glass fibres, having exposed silicon hydroxide groups.

[0108] In some embodiments, the silicon based functional group is a silane. The silane may be introduced to the reinforcement using, for example, plasma. For example, in some embodiments, the reinforcement comprises glass, preferably glass fibres, and plasma is be used to at least partially coat the surface of glass with the silane.

[0109] In some embodiments, the reactive silicon based functional group is a group of the formula -Si(OR2)3, wherein each R2is independently H or a suitable organic group. In some embodiments, the reactive silicon based functional group is a group of the formula -Si(OR2)3, wherein each R2is independently a suitable organic group. In some embodiments, each R2is independently selected from a H, alkyl, alkenyl, cycloalkyl. In some embodiments, each R2is independently selected from a Ci-ealkyl, C2-6alkenyl or C3-ecycloalkyl. In some embodiments, each R2is independently selected from a Ci-ealkyl. In some embodiments, each R2is independently selected from methyl, ethyl or propyl, preferably methyl or ethyl, preferably methyl. In some embodiments, the reactive silicon based functional group is an alkoxysilyl group, preferably a trialkoxysilyl group.

[0110] In some embodiments, the group of the formula -Si(OR2)3 is provided by a size or other at least partial coating on the surface of the reinforcement. The number of groups of the formula -Si(OR2)3 provided by the size or other at least partial coating may vary. For example, where the groups of the formula -Si(OR2)3 react with the surface of the reinforcement when the size or other at least partial coating is applied to bond the size or at least partial coating to the surface or where the groups of the formula -Si(OR2)3 are subsequently decomposed by a processing step, then reduced or residual amounts of the groups of the formula -Si(OR2)3 may be present.

[0111] Preferably, the reinforcement comprises glass, more preferably, sized glass. When the reinforcement comprises glass, a complementary functionalised polymer is a silane graftedpolymer. The functionalised polymer comprising a reactive silicon functional group, e.g. an alkoxysilyl group, may react with the surface of the glass and form the desired cross -linking. Without wishing to be bound by theory, it is believed the silicon functional group of the polymer may react with an -OH group on the surface of the glass through a condensation mechanism. This reaction is believed to result in cross-linking between the functionalised polymer and reinforcement through a Si-O-Si bond. In some instances, the reactive silicon group is first hydrolysed, e.g. to form a silanol group, that reacts with the glass surface. If the reaction proceeds through this mechanism, there should be sufficient water present to facilitate the hydrolysis reaction. Accordingly, in some embodiments, the polymeric composite material comprises a functionalised polymer comprising a silicon group and a reinforcement comprising glass, wherein the functionalised polymer is at least partially cross-linked with reinforcement through a Si-O-Si bond.

[0112] The reinforcement has a three-dimensionality, i.e. a three-dimensional shape, which can contribute to a lattice-type structure or act as or contribute a scaffold-type structure in the cross-linked product. For example, the reinforcement may comprise comprises fibres, rods, needles, beads, flakes, particles, blocks or a combination of any two or more thereof. In some embodiments, the reinforcement is a material having an elongated shaped, e.g. fibres, rods, needles, or a combination of any two or more thereof. In some embodiments, the reinforcement comprises woven fibres and / or non-woven fibres. Preferably, the three-dimensionality is retained in the polymeric composite material.

[0113] In certain preferred embodiments, the reinforcement comprises glass fibres. In an example, typical dimensions of the glass fibre prior to processing (e.g., prior to the extrusion process) may be between about 0.5 and 5 mm in length (or may be about 1 -5 mm, or about 2-5 mm, or about 3-5 mm in length) and about 0.010 to about 0.018 mm in diameter, for example about 0.015 to about 0.018.

[0114] Suitable reinforcements are commercially available or can be readily prepared by known methods. For example, numerous types of sized glass fibres (comprising the functional group) are commercially available. Reinforcement pre-functionalised with the functional group -i.e. the reinforcement is already functionalised and suitable for use in the invention without further modification - may be sourced from numerous commercial suppliers. In certain preferred embodiments, both the functionalised polymer and the reinforcement are sourced fromcommercial suppliers pre-functionalised with the functional group. In certain preferred embodiments, the reinforcement comprises sized glass fibres, wherein the size comprises the functional group.

[0115] Examples of siloxanes used for glass sizing on polymers include but are not limited to are aminopropyltriethoxysilane (APTES), glycidoxypropyltrimethoxysilane (GPTMS), methacryloxyproyltrim ethyloxy silane MPTMS and vinyltriethoxysilane (VTES).

[0116] The polymeric composite material may comprise the reinforcement in any suitable amount. For example, in some embodiments, the polymeric composite material or cross -linkable composition comprises the reinforcement in an amount of about 30% or less by weight, for example about 20% or less, 15% or less, 10% or less, 9% or less, 8% or less, 7% or less, 6% or less, or 5% or less by weight. In some embodiments, the polymeric composite material comprises the reinforcement in an amount of about 25% or 20% or less by weight. In some embodiments, the polymeric composite material comprises the reinforcement in an amount of about 1 to 30% by weight. In some embodiments, the polymeric composite material comprises the reinforcement in an amount of about 1 to 30%, 1 to 25%, 1 to 20%, 1 to 15%, 1 to 10%, 5 to 50%, 5 to 45%, 5 to 40%, 5 to 35%, 5 to 30%, 5 to 25%, 5 to 20%, 5 to 15%, 10 to 50%, 10 to 45%, 10 to 40%, 10 to 35%, 10 to 30%, 10 to 25%, 10 to 20%, 10 to 15%, 15 to 50%, 15 to 45%, 15 to 40%, 15 to 35%, 15 to 30%, 15 to 25%, 15 to 20%, 20 to 50%, 20 to 45%, 20 to 40%, 20 to 35%, 20 to 30% or 20 to 25% by weight. In some embodiments, the polymeric composite material comprises the reinforcement in an amount of about 10 to 30% by weight, for example about 11 to 29% by weight, 12 to 28% by weight, 13 to 27% by weight, or 14 to 26% by weight, preferably about 15 to 25% by weight. In some embodiments, the polymeric composite material comprises the reinforcement in an amount of about 20% by weight.

[0117] The amount of the functionalised polymer may be selected relative to the amount of the reinforcement, and vice versa. For example, the weight ratio of the functionalised polymer to the reinforcement may be from about 30:1 to 1:30. In some embodiments, the weight ratio of the functionalised polymer to the reinforcement is from about 20:1 to 1:30, about l5:l to 1:30, about 10:1 to 1:30, about 5:1 to 1:30, about 1:1 to 1:30, about 1:1 to 1:25, about 1:1 to 1:20, about 1:1 to 1 : 15 or about 1:1 to 1:10. Preferably, the weight ratio of the functionalised polymer to the reinforcement is from about 1:2 to 1:10, about 1:3 to 1:9, about 1:4 to 1:9 or about 1:4 to 1:8.

[0118] In some embodiments, the polymeric composite material comprises at least about 5% w / w glass fibres, preferably at least about 10% w / w, for example at least about 15% w / w. In some embodiments, the extruded material comprises from about 5% to 20%, for example from about 10% to 20%, w / w glass fibres.

[0119] Fibres such as glass fibres typically break up during extrusion and / or other parts of the forming process, reducing their length. Processing parameters can be varied and / or optimised to reduce and / or minimise the amount by which the average length of the fibres is reduced during extrusion and / or forming, etc. The average length of the fibres in the layer formed from the extruded material may depend on, for example, the type of fibre, geometry of the extrusion screw, die configuration, melt pipe flow characteristics, where and how the fibres are fed or otherwise introduced into the extruder, etc. In one example, reduction in the average length of the fibres is reduced and / or minimised by avoiding the use of screen packs or other structures in the melt pipes that causes or increases the amount of turbulence on fibres in the melt. In another example, reduction in the average length of the fibres is reduced and / or minimised by feeding the fibres into the extruder at a zone in which the polymer is molten (compared to feeding the fibres in to the extruder at a zone, for example the primary feed end or cooler end of the extruder distal to (i.e. opposite to) the die, where the polymer is in a solid form, for example beads, pellets, etc., which may crush the fibres as the material is pushed through the extruder).

[0120] In some embodiments, the polymeric composite material comprises glass fibres having an average length of at least about 100 microns, for example at least about 150, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950, or 1,000 microns. In some embodiments, the polymeric composite material comprises glass fibres having an average length from about 100 to 2000, 200 to 2000, 300 to 2000, or 400 to 2000 microns, for example 400 to 1500, 400 to 1000, 500 to 2000, 500 to 1500, 500 to 1000, 600 to 2000, 600 to 1500, 600 to 1000 microns. Having glass fibres of such a length polymeric composite material after forming may allow the amount of glass fibres material to be reduced without increasing the amount of thermal expansion. The thermal expansion (i.e. coefficient of thermal expansion) of a material can be readily determined by methods known in the art.

[0121] In addition to toughening the polymeric composite material, the reinforcement may also reduce thermal expansion, hence improving stability and durability of the material when exposed to cyclical variations in heat. In some embodiments, the glass fibres align along thelength of the polymeric composite material from an extruder. As a result, the polymeric composite material is particularly stable along its length (i.e., the longest dimension of the material, which typically undergoes greatest change in length due to thermal expansion). Such properties are particularly useful for and are imparted to articles produced using the polymeric composite material, for example building products, such as a roofing cladding or siding module. For example, by restricting thermal expansion along the length of module, it is possible to reduce or avoid the use of thermal expansion gaps to prevent cupping or bowing along the length of the material, e.g. when used in a building product.

[0122] Fibres, such as glass fibres, may be aligned along the length of the material extruded from an extruder and that alignment may be retained during the forming process. This alignment of fibres along the length of the material constrains thermal expansion along the length of the material, reducing the amount of thermal expansion along the length of the material and increasing thermal expansion along the width and depth of the material in which thermal expansion is unconstrained or less constrained.

[0123] The term “aligned” (and related terms, such as “align”) as used herein with reference to the orientation of fibres in the material (or an article formed from the material) means that the fibres are substantially aligned in the direction indicated. That is, the fibers extend in length in a generally common direction with substantially increased orientation, compared to randomly aligned or oriented fibres. It should be understood that fibers may still be considered to be aligned even though a portion of the fibers may not be orientated in the generally common direction. It should also be understood that portions of certain fibers may bend curl, twist and / or the like in a non-aligned manner and that such fibers may still be considered to be aligned. In certain embodiments, at least about 55, 60, 65, 70, 75, 80, 85, 90, or 95%, of the fibres may be oriented or aligned generally in a common direction and / or at least about 55, 60, 65, 70, 75, or 80% of the linear length of at least a majority, for example more than 50, 55, 60, 65, 70, 75, or 80% of the fibres are oriented and / or aligned in a common direction.

[0124] In some embodiments, the polymeric composite material comprises one or more elastomers. As described herein, the inclusion of one or more elastomers increases ability of the extruded material to thermally expand and contract, for example in dimensions unconstrained or less constrained than other dimensions, for example of a module, without causing permanent damage to the structure of the material.

[0125] The polymeric composite material may comprise one or more additional polymer(s). These additional polymers may function as a filler and / or to modulate the material properties of the polymeric composite material. It will be apparent that the one or more additional polymer(s) can be selected from a wide range of suitable polymers. Examples of suitable polymers include, but are not limited to, polystyrene (GPPS), polyethylene terephthalate (PET), polyester methacrylate (PEM), high impact polystyrene (HIPS), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polyurethanes (PU), polyethylene (PE) including homopolymer, copolymer, block copolymer and terpolymer forms, polylactic acid (PLA), nylon (PA), acrylics (PMMA), high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), cross linked polyethylene (PEX), thermoplastic elastomer (TPE) (including an elastomeric LLDPE, elastomeric MDPE, elastomeric HDPE, or any combination of any two or more thereof), POE, thermoplastic polyolefin (TPO), thermoplastic rubber (TPR), polypropylene (PP), including homopolymer and copolymer forms, polybutylene terephthalate (PBT), styrene -acrylonitrile resin (SAN), ethylene tetrafluoroethylene (ETFE), vinyl, methacrylate copolymers, foamed polymer, polycarbonates, and a combination of any two or more thereof. Preferably, the one or more additional polymer(s) is a PE, such as a LDPE, a LLDPE, a MDPE, a HDPE or combination of any two or more thereof. In some embodiments, the one or more additional polymer is a LDPE, LLDPE, MDPE, HDPE, a TPE, a POE or any combination of any two or more thereof. In some embodiments, the one or more additional polymer is a LLDPE, MDPE, HDPE, a TPE, or any combination of any two or more thereof. In some embodiments, the TPE is an elastomeric LLDPE, elastomeric MDPE, elastomeric HDPE, or any combination of any two or more thereof.

[0126] The one or more additional polymer(s) may be selected according to the desired properties of the polymeric composite material. Those persons skilled in the art will appreciate the properties of the additional polymer(s) will depend on various factors, e.g., molecular weight, crystallinity, degree of polymerization, glass transition temperature, etc. For example, a polymer with greater crystallinity may be utilized to provide a polymeric composite material with greater rigidity. Conversely, a polymer with less crystallinity or having fewer crystalline regions (e.g. an amorphous polymer) typically is softer and more flexible.

[0127] The desired properties of the polymeric composite material, and consequently the preferred additional polymer(s), will depend on the intended application. For example, somepolymers with a high crystallinity may produce a brittle material. Such a material would be unsuitable for the purpose of preparing a hail resistant building product because the product may fracture or break when impacted by hail, and need to be replaced. For a hail-resistant building product, it is preferable to select a polymer, or combination of polymers, that will provide a tough, rigid material while also being sufficiently flexible or elastomeric to resist cracking when impacted. Thermal stability, such as stability to thermal expansion, is also a valuable property for building products to provide dimensional stability.

[0128] Another example is a building product comprising a photovoltaic (PV) cell. For this application, the product must endure prolonged exposure to the sun and, therefore, thermal stability and heat resistance are important properties. For example, if a PV cell is attached to the face of product, such as a roofing, cladding, or siding module, dimensional stability is desired to reduce imparting stress to the PV cell attached thereto. The degree of dimensional stability required for a roofing, cladding or siding module comprising such a PV cell is typically higher than a corresponding roofing, cladding or siding module without the PV cell. For example, a roofing, cladding, or siding module comprising such a PV cell may on prolonged exposure to the sun reach temperatures in excess of 90°C. By contrast, a corresponding a roofing, cladding or siding module comprising without the PV cell may only reach temperatures of about 70°C under the same conditions.

[0129] To achieve the desired properties, a combination of polymers may be utilised. For example, a tough and thermally stable HDPE may be combined with an elastomeric LLDPE that provides a degree of elongation and soft impact properties. Further, the material properties of the polymeric composite material may be modulated by varying the relative amounts of each polymer. For example, if greater rigidity is desired the relative amount of HDPE may be increased or, if greater flexibility is desired, the amount of LLDPE may be increased. In some embodiments, the one or more additional polymer is selected from a LLDPE, such as an elastomeric LLDPE, a LDPE, a MDPE, a HDPE, an elastomeric POE or a combination of any two or more thereof.

[0130] In some embodiments, the LLDPE has a density of from about 0.9 to 0.93, preferably about 0.92 g / cc, preferably about 0.924 g / cc (as measured by ASTM method D792). In some embodiments, the LLDPE has a melt flow index of about 10 to 50, preferably about 20 g / 10 min(as measured with a load of 2.16 kg and at a temperature of 190°C in accordance with ASTM method DI 238).

[0131] In some embodiments, the elastomeric LLDPE has a density of from about 0.91 to 0.93, preferably about 0.92 g / cc, more preferably about 0.920 g / cc (as measured by ASTM method D792). In some embodiments, the LLDPE has a melt flow index of about 10 to 50, preferably about 19 g / 10 min (as measured with a load of 2.16 kg and at a temperature of 190°C in accordance with ASTM method DI 238).

[0132] In some embodiments, the elastomeric POE has a density of from about 0.85 to 0.9, preferably about 0.82 g / cc , more preferably about 0.820 g / cc (as measured by ASTM method DI 505). In some embodiments, the elastomeric POE has a melt flow index of about 1 to 20 g / 10 min, preferably about 5 g / 10 min (as measured with a load of 2.16 kg and at a temperature of 190°C in accordance with ASTM method DI 238). In some embodiments, the POE is an PE copolymer, for example a random PE copolymer, preferably having the desired density and / or melt flow characteristics.

[0133] In some embodiments, the MDPE has a density of from about 0.93 to 0.96, preferably 0.94 g / cc, more preferably 0.945 g / cc (as measured by ASTM method D4883). In some embodiments, the MDPE has a melt flow index of form about 20 to 60, preferably 0.20 g / 10 min (as measured with a load of 2.16 kg and at a temperature of 190°C in accordance with ASTM method DI 238).

[0134] The additional polymer(s) is not intended to cross -link with the functionalised polymer or reinforcement. Therefore, it is preferable to select an additional polymer(s) that will not crosslink with the functionalised polymer or reinforcement under the conditions in which the polymeric composite material is prepared. Without wishing to be bound by theory, it is believed the additional polymer(s) (and any other components) may occupy the interstitial space in a three-dimensional framework formed by the cross-linked functionalised polymer and reinforcement.

[0135] Additionally or alternatively to selecting different materials with different material properties, the certain properties of the polymer, such as relative crystallinity, may be achieved during manufacture the polymeric composite material, for example by controlling the temperature, rate of cooling, rate of extrusion, shear forces, or other factors as known in the art.

[0136] The polymeric composite material may further comprise one or more additional additive(s). The additive(s) may be selected from a flame retardant, a filler, a colourant, a UV stabilizer, a thermal stabiliser, a compatibilizer, a foaming agent, a free radical scavenger, a lubricant or a slip agent, a biocide, an additional material, a surface leaching agent or inhibitor, and a combination of any two or more thereof. These additives may be selected from conventional additives known in the art and depending on the intended application of the material.

[0137] The polymeric composite material may comprise one or more flame retardants in an amount of about 1 to 35%, e.g. about 2 to 30%, 3 to 25%, 4 to 20% or 5 to 15%. Suitable flame retardants include, but are not limited to, inorganic metal compounds, preferably magnesium hydroxide or aluminium trihydroxide (ATH), halogenated materials, and any combination of two or more thereof.

[0138] Examples of suitable flame retardant inorganic metal compounds include but are not limited to metal compounds comprising magnesium (for example magnesium hydroxide), aluminum (for example ATH), zinc, tin, molybdenum, zirconium, and antimony (for example antimony trioxide, antimony pentoxide, sodium antimonate).

[0139] Examples of suitable flame retardant halogenated materials include but are not limited to halogenated polymers, for example fluoropolymer or a chlorofluoropolymers, for example ethylene tetrafluoroethylene, ethylene chlorotrifluoroethylene, polyvinylidinefluoride, polyvinylfluoride, fluorinated ethylene propylene, perfluoralkoxy, polychlorotrifluoroethylene, polyvinyl chloride, polyvinylidine chloride, tetrafluoroethylene-hexafluoropropylene-vinylidene fluoride terpolymer, fluoroethylene vinyl ether, copolymers and terpolymers of vinylidene fluoride with any of hexafluoropropylene, tetrafluoroethylene, chlorotrifluoroethylene; flame retardant brominated or chlorinated organic compounds or polymers hexabromocyclodecane, decabromodiphenyl ethane, poly(dibromostyrene), tetrabromophthalic anhydride, tetrabromophthalate diol, tetrabromophthalate ester, tetrabromobisphenol A, 2,4,6 tribromophenol, or tribromophenyl allyl ether.

[0140] The polymeric composite material may comprise one or more fillers in an amount of about 1 to 50% by weight, e.g. about 5 to 40%, 10 to 35%, or 15 to 30%. Suitable fillers include, but are not limited to, talc, calcium carbonate, mica, silica, kaolin, calcium sulphate, magnesium hydroxide, stabilizers, dolomite or a combination of any two or more thereof.

[0141] Any suitable colourant may be used. Numerous colourants suitable for use in polymeric composite materials are known in the art. The colourant(s) selected will depend on the desired colour of the polymeric composite material to be produced. In some embodiments, for example where the polymeric composite material is provided in the form of a building product, such as a roof, cladding or siding product or module, one or more colourant(s) (i.e. a single colourant or a combination of two or more different colourants, which may be coloured the same or different) may be used to provide a brown, red, black, grey, or white or other desirable colour in the polymeric composite material. The colourant may be selected from, e.g., an organic pigment, inorganic pigment or combination thereof. Suitable colourants include, but are not limited to, carbon black, a metal oxide such as titanium dioxide, a metal carbonate or a combination of any two or more thereof.

[0142] A suitable UV stabilizer is a hindered amine light stabilizer (HALS).

[0143] Suitable thermal stabilizers include, but are not limited to, a thermal stabilizer such as a phenolic or a phosphite.

[0144] Suitable compatibilizers improve the compatibility of immiscible polymers or other components and may help improve the stability of a blend of immiscible polymers.

[0145] Suitable lubricant or slip agents include, but are not limited to, an euricamide, a fatty acid amide slip additive, a fatty acid ester additive, a short-chain fluoro-polymer, zinc sterate or a combination of any two or more thereof.

[0146] In some embodiments, the biocide is silver, preferably silver nanoparticles.

[0147] The additional material may be provided as an additional filler or an additional reinforcement. Where a material is provided as an additional reinforcement, then those materials should be miscible or compatible with the polymeric composite (for example, to enable the transmission of force within the composite). In some embodiments, the additional material comprises materials having a three-dimensional shape which can contribute to a lattice-type structure or act or contribute a scaffold-type structure. In some embodiments, the additional material retains its three dimensional shape in the polymeric composite material. In some embodiments, the additional material is not meltable during the extrusion process.

[0148] In some embodiments, the additional material comprises fibres, rods, needles, beads, flakes, particles, blocks or a combination of any two or more thereof; preferably the additional material comprises fibres. In some embodiments, the additional material is a material having an elongated shaped, e.g. fibres, rods, needles, or a combination of any two or more thereof. In some embodiments, the additional material comprises woven fibres and / or non-woven fibres.

[0149] Suitable materials for the additional material include, but are not limited to, a natural material, a synthetic material, a non-conductive material or a combination of any two or more thereof. In some embodiments, the additional material comprises glass fibres, glass beads, glass flakes, natural fibres such as flax, cellulose, wood fibres, wood flour, cotton, sawdust, and inorganic or polymer fibres, scrim, knits, weaves, non-woven fibres, aramids, ceramics or a combination of any two or more thereof.

[0150] The additional material, where provided as an additional reinforcement, is not intended to cross-link with the functionalised polymer. Accordingly, in such embodiments, preferably the additional material does not have a functional group that will react with the functionalised polymer under the conditions in which the polymeric composite material is prepared.

[0151] The polymeric composite material may comprise one or more compatibilizers.Compatibilizers improve the compatibility of immiscible polymers or other components and may help improve the stability of a blend of immiscible polymers.

[0152] In some embodiments, the polymeric composite material may include a regrind material. This material is a polymeric composite material of the invention, which has been processed into a particular form, for example by extrusion and molding, and then subsequently reground. The material is typically waste material produced during processing of the extruded polymeric composite material (e.g., excess material trimmed from an edge of a module formed from the polymeric composite material). The inclusion of regrind material in the polymeric composite material advantageously enables such waste material to be recycled, thereby for example reducing the total cost of materials. Any suitable amount of the regrind may be used. In some embodiments, the polymeric composite material comprises about 40% or less by weight regrind, for example 35% or less, 30% or less, 25% or less, 20% or less, 15% or less, or 10% or less by weight. Accordingly, in some embodiments, the one or more additional polymer(s) comprises or a recycled material, such as a regrind material.

[0153] In another aspect, the invention provides a polymeric composite material comprising a reaction product of a) the functionalised polymer and b) the reinforcement. The reaction product is material produced by reacting the functionalised polymer and the reinforcement to at least partially cross-link the functionalised polymer and the reinforcement as described herein.

[0154] In some embodiments, the polymeric composite material comprises:a) a functionalised polymer in an amount of about 1 to 7% by weight;b) a reinforcement in an amount of about 15 to 25% by weight;c) one or more additional polymer(s) in an amount of about 20 to 65% by weight; andwherein a) the functionalised polymer and b) the reinforcement are at least partially crosslinked.

[0155] In some embodiments, the polymeric composite material comprises:a) a silanated polyethylene in an amount of about 1 to 7% by weight;b) a reinforcement comprising glass fibres in an amount of about 15 to 25% by weight;c) one or more additional polymer(s) in an amount of about 20 to 65% by weight; andwherein a) the silanated polyethylene and b) the reinforcement are at least partially cross - linked.

[0156] In some embodiments, the polymeric composite material comprises:a) a silanated polyethylene in an amount of about 1 to 7% by weight;b) a reinforcement comprising glass fibres in an amount of about 15 to 25% by weight;c) one or more additional polymer(s) selected from a LLDPE, a LDPE, a MDPE, a HDPE or a combination of any two or more thereof in an amount of about 20 to 65% by weight; andwherein a) the silanated polyethylene and b) the reinforcement are at least partially crosslinked.

[0157] In some embodiments, the polymeric composite material is formed from crosslinkable composition comprising:a) a functionalised polymer selected from a polyethylene comprising a reactive silicon based functional group, e.g. a trialkoxysilyl group, in an amount of about 1 to 7% by weight;b) a reinforcement comprising glass fibres comprising a reactive silicon based functional group in an amount of about 15 to 25% by weight;c) one or more additional polymer(s) selected from a LLDPE, a LDPE, a MDPE, a HDPE, a POE or a combination of any two or more thereof in an amount of about 20 to 65% by weight; andwherein a) the functionalised polymer and b) the reinforcement are at least partially crosslinked.2. Cross-linkable composition

[0158] The polymeric composite material may be formed from a cross -linkable composition comprising the functionalised polymer and the reinforcement capable of cross -linking with the functionalised polymer. The cross-linkable composition is subjected to a sufficient temperature and pressure for a sufficient time to melt the functionalised polymer and cause the functionalised polymer to at least partially cross-link with the reinforcement.

[0159] The components of the cross-linkable composition may be mixed or compounded before or during this melting step. For example, the cross-linkable composition may be formed by mixing the functionalised polymer and the reinforcement, and subsequently adding the crosslinkable composition to the barrel of an extruder. Alternatively, the components of the crosslinkable composition may be added to the barrel of an extruder separately (sequentially or simultaneously) to form the cross-linkable composition in the extruder. In some embodiments, batches of components may be added into the extruder in separate feeds to form the crosslinkable composition in the extruder. In some embodiments, batches of components may be simultaneously or sequentially added into the extruder in separate feeds at different points along the length of the barrel to form the cross-linkable composition in the extruder.

[0160] The inventors have discovered it is preferable for the cross-linkable composition to comprise water when the polymeric composite material is formed from a functionalised polymer comprising a reactive silicon based functional group, e.g. a trialkoxysilyl group, and a functional reinforcement comprising glass. Without wishing to be bound by theory, it is believed the water facilitates hydrolysis of the reactive silicon functional group. Water may be added or provided to the cross-linkable composition in any suitable form. For example, water may be provided in the form of steam. In another example, water may be provided in the form of one or more additive that comprises water, for example one or more additive that comprises available water, for example an amount of residual moisture. In another example, water may be provided in the form of one or more additive that decomposes to provide water during processing, for example a mixing step of a process of the invention.

[0161] The cross-linkable composite comprises a functionalised polymer and a reinforcement, and optionally further components, as set out for the polymeric composite material above. For example, the cross-linkable composition may comprise one or more additional polymer(s) and / or one or more additional additive(s). For example, the cross-linkable composition may comprise one or more additive(s) selected from a flame retardant, a filler, a colourant, a UV stabilizer, a thermal stabiliser, a compatibilizer, a foaming agent, a free radical scavenger, a lubricant or a slip agent, a biocide, an additional material, a surface leaching agent or inhibitor, and a combination of any two or more thereof.

[0162] In some embodiments, the cross-linkable composition comprises:a) the functionalised polymer in an amount of about 1 to 7% by weightb) the reinforcement in an amount of about 15 to 25% by weightc) one or more additional polymer(s) in an amount of about 20 to 65% by weight.

[0163] In some embodiments, the cross-linkable composition comprises:a) the functionalised polymer in an amount of about 1 to 7% by weightb) the reinforcement in an amount of about 15 to 25% by weightc) one or more additional polymer(s) in an amount of about 20 to 65% by weightd) one or more fillers in an amount of about 10 to 40% by weight.

[0164] In some embodiments, the cross-linkable composition comprises:a) the functionalised polymer in an amount of about 1 to 7% by weightb) the reinforcement in an amount of about 15 to 25% by weightc) one or more additional polymer(s) in an amount of about 20 to 65% by weightd) one or more fillers in an amount of about 10 to 40% by weighte) one or more flame retardants in an amount of about 5 to 15% by weight.

[0165] In some embodiments, the cross-linkable composition comprises:a) the functionalised polymer in an amount of about 1 to 7% by weightb) the reinforcement in an amount of about 15 to 25% by weightc) the regrind in an amount of about 10 to 40% by weight.

[0166] In one aspect, the invention provides a polymeric composite material formed from a cross-linkable composition as described herein.3. Articles:

[0167] In another aspect, the invention provides an article comprising the polymeric composite material. It will be appreciated that the properties of the polymeric composite material make it suitable for use in a wide variety of articles of manufacture.

[0168] In certain specifically contemplated embodiments, the polymeric composite material may be used in the manufacture of a building product, such as a roofing, cladding, or siding product (including roofing, cladding, or siding modules), for installing onto a building surface or a coating or layer of a coating for such a product or module. Examples of suitable building products and modules are described in PCT international application numberPCT / IB2015 / 059230 (published as WO 2016 / 088026) and PCT international application number PCT / IB2018 / 051012 (published as WO2018 / 154427), the entire contents of each of which are incorporated herein by reference.

[0169] Further examples of suitable building products, such as cladding modules, for use as roofing, siding or cladding are described in New Zealand patent application number 815547 and PCT international application number PCT / IB2025 / 060462, the entire contents of each of which is incorporated herein by reference in its entirety.

[0170] It will be appreciated that such polymeric products, as described herein, may be formed of or consist or consist essentially of or comprise one or more polymeric layers, for example two or more, three or more, four or more, five or more, or six or more polymeric layers, wherein one or more of said polymeric layers may be formed or comprise or consist essentially of the polymeric composite material.

[0171] Roofing, cladding and siding products for installation onto building surfaces need to be lightweight, easy to install, weatherproof, resistant to environmental wear, aesthetically pleasing and preferably economical and efficient to manufacture. Polymeric materials are suitable candidates for roofing, cladding and siding products due to their weight, durability and cost-effectiveness.

[0172] However, consumers typically prefer the appearance of more traditional roofing, cladding or siding products, such as asphalt shingles, shingles, slates or shakes, concrete tiles, etc. Accordingly, polymeric products need to be cosmetically treated to simulate the appearance of these more traditional products. Systems and methods for manufacturing these polymeric products need to be suitably flexible, in order to be able to simulate a variety of materials.

[0173] In particular embodiments, the roofing, cladding and / or siding module contemplated herein has improved weather resistance (e.g., water resistance, hail -proofing), durability, fire resistance, flame retardant qualities and / or aesthetic qualities. In some embodiments, the method of the present invention relates to manufacturing and decorating (or coloring) a roofing, cladding or siding module out of the polymeric composite material, such that the module resembles tiles, shingles, etc., made of another type of material.

[0174] In some preferred embodiments, the present invention relates to improved methods and systems for manufacturing a roofing, cladding or siding module in a high speed and / or cost-effective and / or efficient process.

[0175] The article may consist of a single layer of the polymeric composite material.Alternatively, the article may comprise two or more layers. The multi-layers article maycomprise a layer of the polymeric composite material and one or more layers of another material, e.g. another polymeric material or other material. In some embodiments, the multi-layered article comprises two or more layers of the polymeric composite material. The different layers may comprise polymeric composite materials formulated to have different material properties.

[0176] The article may be a building product comprising a photovoltaic (PV) module or a PV cell, e.g. a photovoltaic roofing tile, cladding and / or siding module. The article may be a roofing, cladding, or siding module comprising an integrated PV. In some embodiments, the roofing, cladding, or siding module is part of a building integrated photovoltaic system (BIPV).

[0177] In some embodiments, the article is a roofing, cladding, or siding module, comprising:an underlapping region extending from a head edge of the module and an exposed region extending from a foot edge of the module, the length of the foot edge defining the length of the module,wherein the underlapping region is adapted to be substantially covered by the exposed region of an adjacent or overlapping module when installed on a building surface,wherein the module is formed of at least one layer of extruded material, wherein the layer so formed comprises:a) filler and / or reinforcement, for example at least 20%, 25%, 30%, 35%, 40%, 45%, or 50% filler and / or reinforcement, preferably at least 40% filler and / or reinforcement,b) one or more polymer(s),wherein the at least one layer of extruded material comprises the polymeric composite material of the present invention.

[0178] In some embodiments, the module comprises a plurality of formed surfaces molded along the length of the module.

[0179] In some embodiments, at least a portion of a top surface of the exposed region comprise(s) three dimensional surface features, whether as surface relief or surface texturing. In some embodiments, said portion comprises surface features resembling one of: asphalt shingle,slate, shingles, shakes, concrete tiles, stone chips, weatherboard, thatch, stone, woodgrain, metal (including but not limited to copper tiles or roofing shingles). In some embodiments, each of the formed surfaces comprises said surface features. In some embodiments, each formed surface resembles an individual tile or shingle or slate or shake within the module. In some embodiments, each formed surface resembles a set of tiles or shingles or slates or shakes within the module.

[0180] In some embodiments, such roofing, cladding or siding modules comprising a plurality of formed surfaces molded, discretely or otherwise, along the length of the module, wherein each of the formed surfaces comprises three dimensional surface features, may be prepared by a process of the invention further comprising after step (iii) and before step (iv):providing to a continuous forming machine the extruded melt of the polymeric composite material of the present invention as a feed material able to assume and retain a form after being molded between a first forming surface and a second forming surface,wherein at least the first forming surface comprises a plurality of die faces provided in sequence and configured to mold the three dimensional surface features, each of said formed surfaces to be molded by a die face, andwherein the number of die faces is either:- offset from the number of formed surfaces in each module to be formed, or- matches the number of formed surfaces in each module to be formed (for example where the formed surfaces are to be of repeating or matching surfaces).

[0181] The polymeric composite material is useful in the manufacture of various other articles. For example, in some embodiments, the article is a polymeric door or window framing or joinery. In some embodiments, the article is a tool, a piece of equipment or part thereof, such as a spade, a shovel or a fork handle or shaft, or a broom handle; a car part (internal or external), such as a bumper; a gun part, such as a stock or grip; or a crash barrier for reading or highway applications. The strength or toughness or durability characteristics of the composition described herein may find useful applicability in many applications, not least the above examples.

[0182] In some embodiments, the article is a membrane, e.g. a roofing membrane. The polymeric composite material may be formed into a membrane just as with other polymeric materials. For example, the polymeric composite material may be formed into a membrane roll via a calendaring process (e.g. with rollers).

[0183] In some embodiments, a membrane, for example a TOP membrane for roofing, may be provided. The membrane may comprise a scrim or other reinforcing layer. The membrane may be prepared by, for example, extruding a layer of material comprising the polymeric composite material of the invention on both sides of a scrim or reinforcing layer, and passing then passing through rollers to join together the layers and fully encapsulate the scrim or reinforcing layer.4. Process for preparing

[0184] The polymeric composite material may be prepared by an extrusion process.

[0185] Accordingly, in one aspect the invention provides a process for preparing a polymeric composite material, the process comprising:i. charging an extruder with a cross-linkable comprising a) a functionalised polymer and b) a reinforcement capable of cross-linking with the functionalised polymer,ii. mixing the cross-linkable composition at a temperature and a pressure and for a time sufficient to melt the functionalised polymer and cause the functionalised polymer to at least partially cross-link with the reinforcement, thereby providing a melt of the polymeric composite material,iii. extruding the melt,iv. cooling the extruded melt.

[0186] In another aspect, the invention provides a process for preparing a polymeric composite material, the process comprising:i. charging an extruder with cross-linkable composition comprising a) a functionalised polymer and b) a reinforcement capable of cross-linking with the functionalised polymer,ii. mixing the cross-linkable composition in the presence of water at a temperature and a pressure and for a time sufficient to melt the functionalised polymer and cause the functionalised polymer to at least partially cross-link with the reinforcement, thereby providing a melt of the polymeric composite material,iii. extruding the melt,iv. cooling the extruded melt.

[0187] The extrusion process may be performed with a conventional extruder as known in the art. Extruder machinery and associated equipment may be supplied, for example, from one or more of the following: Coperion, Leistritz, Milacron, KraussMaffei, JSW (Japan Steel Works), Steer, Bausano, Cowin Extrusion, Battenfeld-Cincinnati, CPM Extrusion Group. The extruder comprises a barrel and at least one screw. Preferably, the extruder is a multi-screw extruder, e.g. a twin-screw extruder. In some embodiments, the twin-screw extruder is a co-rotating twin screw extruder. In other embodiments, the twin-screw extruder is a counter-rotating twin screw extruder. Advantageously, the use of a twin-screw extruder achieves improved and more consistent mixing (e.g. distribution), dispersion, and / or homogenisation of the cross-linkable composition compared to a single-screw extruder.

[0188] Step (i) of the process comprises charging the extruder with a cross -linkable composition comprising a) a functionalised polymer and b) a reinforcement capable of crosslinking with the functionalised polymer.

[0189] As used herein, unless the context indicates otherwise, the term “charging an extruder” (and similar terms such as “charging the extruder”) means providing the ingredient, material, component, additive, mixture, composition, or other form of matter indicated within the barrel of the extruder. Charging the extruder with the cross-linkable composition may comprise adding or feeding the cross-linkable composition (as a single composition) to the extruder, for example via a single feeder. Alternatively, charging the extruder with the cross-linkable composition may comprise adding the individual materials of the cross-linkable composition to the extruder separately (simultaneously or sequentially), for example via separate feeders, such that the crosslinkable composition is provided within the barrel of the extruder. Individual components of the cross-linkable composition that are added separately, may be added, for example via feeders, disposed at different points along the length of the barrel (simultaneously or sequentially).

[0190] The pressure and temperature within the barrel and the torque of the extruder can be monitored to control the pressure, temperature, and time during the mixing step (ii).

[0191] Step (ii) of the process involves heating the cross-linkable composition at a sufficient temperature and pressure to melt the functionalised polymer and cause cross-linking with the reinforcement. For example, step (ii) may comprise mixing the composition at a temperature of at least about 80, 100, 120, 140, 160, 180, 200 or 220°C. In some embodiments, step (ii) comprises mixing the composition at a temperature less than about 300, 280, 270, 260, 250 or 240°C. In some embodiments, step (ii) comprises mixing the composition at a temperature of about 80 to 300°C, 200 to 280°C, 210 to 270°C, 220 to 260°C; preferably about 230 to 250°C. In some embodiments, step (ii) comprises mixing the composition at a temperature of about 240°C. In some embodiments, step (ii) comprises mixing the cross -linkable composition at a temperature greater than about 200°C and less than about 250°C.

[0192] Step (ii) may comprise mixing the composition at a pressure of at least about 700, 800, 900, 1,000, 1,100, 1,200, 1,300, 1,400, 1,500, 1,600, 1,700, 1,800, 1,900 or 2,000 psi. In some embodiments, step (ii) comprises mixing the composition at a pressure of at least about 1,500, 1,600, 1,700, 1,800, 1,900 or 2,000 psi. In some embodiments, step (ii) comprises mixing the composition at a pressure less than or equal to about 3,000, 2,900, 2,800, 2,700, 2,600, 2,500 or 2,400 psi. In some embodiments, step (ii) comprises mixing the composition at a pressure of about 750 to 3,000 psi, 1,000 to 3,000 psi, 1,250 to 3,000 psi, 1,500 to 3,000 psi, 1,600 to 2,900 psi, 1,700 to 2,800 psi, 1,800 to 2,600 psi, 1,900 to 2,400 psi, preferably about 2,000 to 2,200 psi. In some embodiments, step (ii) comprises mixing the composition at a pressure of about 1,500 to 3,000 psi, 1,600 to 2,900 psi, 1,700 to 2,800 psi, 1,800 to 2,600 psi, 1,900 to 2,400 psi, preferably about 2,000 to 2,200 psi. In some embodiments, step (ii) comprises mixing the crosslinkable composition at a pressure greater than about 1,800 psi and less than about 2,200 psi.

[0193] The preferred time for the mixing and extrusion steps varies depending on the nature of the cross-linkable composition. Generally, the time for mixing and extrusion steps should be long enough to allow initiation of cross-linking between the functionalised polymer and reinforcement but not so long that the material solidifies causing blockage of the extruder. In some embodiments, the time of step (ii) is at least about 1, 2, 3, 4 or 5 minutes. In some embodiments, the time of step (ii) is less than about 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 minute. In some embodiments, the time of step (ii) is about 1 to 15 minutes, 2 to 10 minutes;preferably about 3 to 7 minutes. In some embodiments, the time of step (ii) is greater than about 2 minutes and less than about 15 minutes.

[0194] In some embodiments, the residence time of the composition in step (ii) is at least about 1, 2, 3, 4 or 5 minutes. In some embodiments, the residence time of the composition in step (ii) is less than about 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 minute. In some embodiments, the residence time of the composition in step (ii) is about 1 to 15 minutes, 2 to 10 minutes; preferably about 3 to 7 minutes. In some embodiments, the residence time of the composition in step (ii) is greater than about 2 minutes and less than about 15 minutes. The term ‘residence time’ as used herein refers to the time for which the cross-linkable composition is mixed, e.g. in the barrel of the extruder, until the point at which the melted polymeric composite material is expelled, e.g. extruded from the extruder. For example, if the barrel of an extruder is charged with material to provide a cross-linkable composition in the barrel and it takes 5 minutes from the point at which the cross-linkable composition is provided in the barrel for the material to then move through the barrel and exit the extruder (in the form of a melted polymeric composite material), the residence time would be 5 minutes.

[0195] Mixing of the cross-linkable composition in the extruder may be performed in the presence of water. Performing mixing step (ii) in the presence of water is preferable when the functionalised polymer comprises a reactive silicon based functional group and the reinforcement comprises glass. This is surprising because extrusion of silane grafted polymers (e.g. PEX-B) is typically performed in the absence of water to avoid cross-linking during extrusion. The presence of water during extrusion of silane grafted polymers typically leads to excessive cross-linking, resulting in blockage of the extruder, and loss of productivity due to machine down-time while the blockage is cleared.

[0196] Accordingly, the process may further comprise charging the extruder with water. The water may be in any suitable form. For example, in some embodiments the water is provided in the form of steam. In some embodiments, the water is provided in the form of an one or more additive that comprises water. In some embodiments, the water is provided by one or more additive that decomposes to provide water during the mixing. Accordingly, in some embodiments, the extruder is charged with steam. In some embodiments, the extruder is charged with one or more additive that comprises water. In some embodiments, the one or more additive that comprises water is a filler, a flame retardant, or a combination thereof. In someembodiments, the one or more additive that comprises water is calcium carbonate, magnesium hydroxide, or a combination thereof. In such embodiments, the magnesium hydroxide and / or calcium carbonate used comprise an amount of water, typically residual moisture. For example, the magnesium hydroxide feedstock used in the examples described herein (which is made by a slurry process involving water) typically contains about 1% by weight moisture. In some embodiments, the extruder is charged with one or more additive that decomposes to provide water during the mixing. In some embodiments, the one or more additive that decomposes to provide water during the mixing is magnesium hydroxide. In some of such embodiments, an amount of the magnesium hydroxide provided decomposes during the mixing to provide water and magnesium oxide. The amount of magnesium hydroxide that decomposes is typically low, for example less than 5%, 4%, 3%, 2%, or 1% or even less based on the molar amount of the magnesium hydroxide used. It will be appreciated that generally the process is controlled such that the amount of magnesium hydroxide that decomposes does not adversely affect the flame retardant capability of the polymeric composite material, for example the ability of the polymeric composite material to meet certain industry standards for flame retardance depending on the product. Where one or more additive that comprises water or one or more additive that decomposes to provide water is used, the water provided may form steam in the barrel when exposed to the temperateure and pressure.

[0197] The process may comprise a further step of forming the extruded melt into an article having a desired three-dimensional shaped. The desired shape may be formed, at least partially, by the die from which the extruded melt exits. Additionally or alternatively, the desired shape may be formed by one or more additional steps in which the extruded melt may be shaped. For example, in some embodiments, the extruded melt is deposited into / onto a mold form surface, and held for a sufficient period of time to allow for the extruded material to cool and assume the shape of the mold form or at least be sufficiently self-supporting to then be removed from the mold form for further cooling. Articles may be molded by thermoforming, compression molding, pressing or any other suitable method of forming.

[0198] The forming step may be performed after step (iii) and before step (iv).Advantageously, in contrast to certain prior art processes, e.g. for forming PEX-B or PEX-C, in which a separate step of initiating cross-linking is carried out after extrusion, the process of the invention may be performed without the need for a separate cross -linking step after extrusion of the melt. Cross-linking between the functionalised polymer and the reinforcement is initiated andoccurs during the mixing step. Therefore, the melted polymeric composite material exiting the extruder may be formed directly into the desired three dimensional shape.

[0199] Advantageously, it has been found that the process does not require a radical initiator (e.g. a peroxide), a cross-linking catalyst (that catalyses cross-linking of the functionalised polymer and reinforcement) (e.g. a tin catalyst), or irradiation step. For example, in some embodiments when the functionalised polymer comprises a reactive silicon based functional group and the reinforcement comprises glass, the mixing step (ii) may be performed in the presence of water, which facilitates reaction and cross-linking between the functionalised polymer and reinforcement, and a radical initiator (e.g. a peroxide, such as an organic peroxide), a cross-linking catalyst (e.g. a tin catalyst), or an irradiation step is not required. For the avoidance of doubt, as used herein the term “cross-linking catalyst” in this context does not include water. Accordingly, in some embodiments, the polymeric composite material or the cross-linkable composition is substantially free of any organic peroxide, preferably substantially free of any peroxide. In some embodiments, the polymeric composite material or the crosslinkable composition is substantially free of a cross-linking catalyst, e.g. a tin catalyst. Radical initiators are known in the art. In some embodiments, the radical initiator is a peroxide, for example an organic peroxide. Cross-linking catalysts are also known in the art. In some embodiments, the cross-linking catalyst is an inorganic catalyst, an organic catalyst, or a peroxide catalyst. In some embodiments, the inorganic catalyst is an inorganic metal catalyst, for example a tin catalyst. In some embodiments, the inorganic metal catalyst is an organometal metal catalyst, for example an organotin catalyst. Examples of organotin catalysts include, but are not limited to, dibutyltin dilaurate (DBTDL), or dioctyltin dilaurate (DOTDL). In some embodiments, the organic catalyst is an anhydride catalyst, for example, maleic anhydride, succinic anhydride, or a combination thereof. In some embodiments, the anhydride catalyst is maleic anhydride. In some embodiments, the peroxide catalyst is an organic peroxide.Notwithstanding the above, it will be appreciated that a such a radical initiator, cross-linking catalyst, or irradiation step can be used in the process when desired in certain embodiments.

[0200] The article may be formed in a continuous process. In addition to the increase in productivity and reduction in cost, molding the entire length of the article in a continuous process eliminates any weld lines. This increases the durability and weather resistance of the article, and improves the appearance of the final product.

[0201] One or more additive(s) as described above may be utilised in the process for preparing the polymeric composite material.

[0202] Extruder machinery and associated equipment may be supplied, for example, from one or more of the following: Coperion, Leistritz, Milacron, KraussMaffei, JSW (Japan Steel Works), Steer, Bausano, Cowin Extrusion, Battenfeld -Cincinnati, CPM Extrusion Group.

[0203] While the extrusion process described herein may in certain embodiments be used or preferred for processing the cross-linkable composition of the invention and producing the polymeric composite materials of the invention, it will be appreciated that other processes may be used. For example, in one alternate embodiment, an injection molding process may be used for processing the cross-linkable composition of the invention and producing the polymeric composite materials of the invention. In another alternate embodiment, a compression molding process may be used for processing the cross-linkable composition of the invention and producing the polymeric composite materials of the invention.5. Product by process

[0204] In a further aspect, the invention provides a polymeric composite material obtained from a process as described herein.

[0205] The following non-limiting examples are provided to illustrate the present invention and in no way limit the scope thereof.EXAMPLES

[0206] Example 1

[0207] In a first example, the following describes a cross-linkable composition. In one form, this composition could be suitable for extrusion and subsequent forming into a roofing, cladding, or siding module, optionally which may include an integrated PV module as described herein.

[0208] The cross-linkable composition comprises:• about 40 wt.% of polymers, of which about 4 wt.% is in the form of a functionalised polymer, such as a silane functionalised PE; and• about 60 wt.% of fillers and reinforcement, of which about 25 wt. % is a reinforcement in the form of glass fibre.

[0209] The reinforcement in the form of glass fibre is capable of cross-linking with the functionalised polymer.

[0210] Example 2

[0211] In a second example, the following describes a cross-linkable composition. In one form, this composition could be suitable for extrusion and subsequent formation into a roofing, cladding, or siding module, optionally which may not include an integrated PV module.

[0212] The cross-linkable composition comprises:• about 40 wt.% of polymers, of which about 2 wt.% is in the form of a functionalised polymer, such as a silane functionalised PE; and• about 60 wt.% of fillers and reinforcement, of which about 17 wt. % is a reinforcement in the form of glass fibre.

[0213] The reinforcement in the form of glass fibre is capable of cross-linking with the functionalised polymer.

[0214] Example 3

[0215] A general procedure for a process of the invention for processing the cross -linkable compositions of the invention described in Examples 1 and 2 is as follows.

[0216] Addition of the materials of the cross-linkable composition of the invention is staged. Loaders are activated. Using a series of loss in weight feeder systems, the materials are fed into a twin-screw extruder so as to provide within the barrel of the extruder the cross -linkable composition of the invention. The materials are progressively moved through the barrel of the extruder to an extruder head. Temperature within the barrel is maintained at greater than about 200°C and less than about 250°C. Pressure within the barrel is maintained at greater than about 1,800 psi and less than about 2,200 psi. The material is processed through the barrel of the extruder to provide for a residence time of greater than about 2-3 mins and less than about 15 mins.

[0217] The twin-screw extruder may operate in a co-rotating or a counter-rotating methodology.

[0218] The extruder could include gravimetric or loss in weight feeders, side feeders, screen changers, melt pumps and dies. Component materials can be metered into the barrel system and / or side feeders, and during the processing through the extruder, the polymers are melted and compounded with the other materials of the composition and fully homogenised to provide consistent distribution, dispersion, viscosity, and temperature throughout the extrudate.

[0219] Material exiting from the extruder die (as extrudate) can be shape-formed by the die and by the ‘downstream’ equipment. For example, the exiting material or extrudate can be deposited into / onto a mold form surface, and held for a sufficient period of time to allow for the extruded material to cool and assume the shape of the mold form or at least be sufficiently self-supporting to then be removed from the mold form for further cooling.

[0220] In one example, the extrudate is deposited onto mold forms and formed into a module, such as a cladding module in the form of a roofing or siding module to be used as a cladding module for a building. However, it will be appreciated that this is one example of a possible end product, and a multitude of other end products could be formed which may wish to take advantage of the resultant bulk material characteristics provided by the invention as disclosed herein.

[0221] Example 4

[0222] Polymeric composite materials of the invention were prepared from cross -linkable compositions of the invention containing about 2% or about 4% by weight of a functionalised polymer, such as a silane functionalised PE. The 4% by weight composition was based on the composition set forth in Example 1. The 2% composition was based on the composition set forth in Example 2.

[0223] A polymeric composite material comprising 0% functionalised polymer was also prepared. The polymeric composite material comprising 0% functionalised polymer was based on to the composition set forth in Example 2 but contained no functionalised polymer.

[0224] The three polymeric composite materials were subjected to tensile testing in accordance with ASTM D638 and flexural testing in accordance with ASTM D790. The resultsare shown in tables 1 and 2, respectively. Based on the data obtained from testing these three polymeric composite materials, test results for a polymeric composite material comprising about 6% by weight of the functionalised polymer were extrapolated.

[0225] The data show that the use of relatively low amounts of the functionalised polymer led to significant changes in the tensile and flexural properties tested.

[0226] Table 1 : Tensile testing results

[0227] * Data extrapolated based on data obtained for other polymeric composite materials tested.

[0228] Table 2: Flexural testing results

[0229] * Data extrapolated based on data obtained for other polymeric composite materials tested.

[0230] Example 5

[0231] An infrared spectrum of a polymeric composite material formed from a cross -linkable composition according to the invention comprising a silane functionalised PE and reinforcement in the form of glass fibre (comprising sizing) was obtained.

[0232] The spectrum includes characteristic peaks at the following wavelengths (cm4): 1055-1081 (Si-O-Si), 843 (Si-O-Si), 2918 (C-H), 2850 (C-H), 1470 (C-H), 1378 (C-H), and 720 (C-H). The Si-O-Si peaks at 1081 and 843 are characteristic of the silane functionalisation and the C-H peaks listed are characteristic of PE.

[0233] The following numbered items define particular aspects of the present invention:1. A polymeric composite material formed from a cross -linkable composition comprising a) a functionalised polymer and b) a reinforcement capable of cross-linking with the functionalised polymer; wherein in the polymeric composite material the functionalised polymer is at least partially cross-linked with the reinforcement.2. A polymeric composite material comprising a functionalised polymer at least partially cross-linked with a reinforcement.3. A polymeric composite material comprising a reaction product of a) a functionalised polymer and b) a reinforcement capable of cross-linking with the functionalised polymer, wherein in the reaction product the functionalised polymer is at least partially crosslinked with the reinforcement.4. A cross-linkable composition for forming a polymeric composite material comprising a) a functionalised polymer and b) a reinforcement capable of cross-linking with the functionalised polymer.5. A process for preparing a polymeric composite material, the process comprising:i. providing in a container a cross-linkable composition comprising a) a functionalised polymer and b) a reinforcement capable of cross-linking with the functionalised polymer,ii. mixing the cross-linkable composition in the container at a temperature and a pressure and for a time sufficient to melt the functionalised polymer and cause the functionalised polymer to at least partially cross-link with the reinforcement, thereby providing a melt of the polymeric composite material,iii. expelling the melt from the container,iv. cooling the expelled melt.6. A process for preparing a polymeric composite material, the process comprising:i. charging an extruder with a cross-linkable composition comprising a) a functionalised polymer and b) a reinforcement capable of cross-linking with the functionalised polymer,ii. mixing the cross-linkable composition at a temperature and a pressure and for a time sufficient to melt the functionalised polymer and cause the functionalised polymer to at least partially cross-link with the reinforcement, thereby providing a melt of the polymeric composite material,iii. extruding the melt,iv. cooling the extruded melt.7. A process for preparing a polymeric composite material, the process comprising:i. charging an extruder with cross-linkable composition comprising a) a functionalised polymer and b) a reinforcement capable of cross-linking with the functionalised polymer,ii. mixing the cross-linkable composition in the presence of water at a temperature and a pressure and for a time sufficient to melt the functionalised polymer and cause the functionalised polymer to at least partially cross-link with the reinforcement, thereby providing a melt of the polymeric composite material,iii. extruding the melt,iv. cooling the extruded melt.The polymeric composite material of any one of items 1 to 3, the cross-linkable composition of item 4, or the process of any one of items 5 to 7, wherein the polymeric composite material is an extruded polymeric composite material, an injection molded polymeric composite material or a compression molded polymeric composite material.The polymeric composite material of any one of items 1 to 3 and 8, the cross-linkable composition of item 4 or 8, or the process of any one of items 5 to 8, wherein the functionalised polymer comprises a reactive silicon based functional group.The polymeric composite, the cross-linkable composition or the process of item 9, wherein the reactive silicon based functional group is a group of the formula -Si(OR1)3, wherein each R1is independently H or a suitable organic groupThe polymeric composite, the cross-linkable composition or the process of item 10, wherein the reactive silicon based functional group is a group of the formula -Si(OR1)3, wherein R1is independently a suitable organic group.The polymeric composite, the cross-linkable composition or the process of item 10, wherein each R1is independent selected from a H, alkyl, alkenyl, cycloalkyl; preferably, each R1is independently selected from a Ci-ealkyl, C2-ealkenyl or C3-ecycloalkyl.The polymeric composite, the cross-linkable composition or the process of item 10 or 11, wherein each R1is independently selected from a Ci-ealkyl.The polymeric composite, the cross-linkable composition or the process of item 10 or 11, wherein each R1is independently selected from methyl, ethyl or propyl, preferably methyl or ethyl, preferably methyl.The polymeric composite, the cross-linkable composition or the process of any one of items 10 to 14, wherein the reactive silicon based functional group is an alkoxysilyl group, preferably a trialkoxysilyl group.The polymeric composite material of any one of items 1 to 3 and 8 to 15, the crosslinkable composition of any one of items 4 and 8 to 15, or the process of any one of items 5 to 15, wherein the functionalised polymer is a functionalised polyolefin; preferably, the functionalised polymer is a functionalised polyethylene, e.g. a low-density polyethylene(LDPE), medium-density polyethylene (MDPE), high density polyethylene (HDPE), a polyolefin elastomer (POE) or combination of any two or more thereof.The polymeric composite material of any one of items 1 to 3 and 8 to 16, the crosslinkable composition of any one of items 4 and 8 to 16, or the process of any one of items 5 to 16, wherein the functionalised polymer is a functionalised polyolefin comprising a reactive silicon based functional group.The polymeric composite material of any one of items 1 to 3 and 8 to 17, the crosslinkable composition of any one of items 4 and 8 to 17, or the process of any one of items 5 to 17, wherein the functionalised polymer is a functionalised polyolefin comprising a reactive silicon based functional group of the formula -Si(OR1)3, wherein each R1is independently H or a suitable organic group, preferably wherein each R1is independently a suitable organic group.The polymeric composite material of item 18, the cross-linkable composition of item 18, or the process of item 18, wherein each R1is independent selected from a H, alkyl, alkenyl, cycloalkyl.The polymeric composite material of item 18 or 19, the cross-linkable composition of item 18 or 19, or the process of item 18 or 19, wherein each R1is independently selected from a Cnealkyl, C2-ealkenyl or C3-ecycloalkyl; preferably, each R1is independently selected from a Ci-ealkyl.The polymeric composite material of any one of items 18 to 20, the cross-linkable composition of any one of items 18 to 20, or the process of any one of items 18 to 20, wherein each R1is independently selected from methyl, ethyl or propyl, preferably methyl or ethyl, preferably methyl.The polymeric composite material of any one of items 1 to 3 and 8 to 21, the crosslinkable composition of any one of items 4 and 8 to 21, or the process of any one of items 5 to 21, wherein the functionalised polymer is a functionalised polyethylene comprising an alkoxysilyl group, preferably a trialkoxysilyl group.The polymeric composite material of any one of items 1 to 3 and 8 to 22, the crosslinkable composition of any one of items 4 and 8 to 22, or the process of any one of items5 to 23, wherein the polymeric composite material or the cross-linkable composition comprises the functionalised polymer in an amount of about 30% or less by weight, for example about 20% or less, 15% or less, 10% or less, 9% or less, 8% or less, 7% or less, 6% or less, or 5% or less by weight.The polymeric composite material of any one of items 1 to 3 and 8 to 23, the crosslinkable composition of any one of items 4 and 8 to 23, or the process of any one of items 5 to 23, wherein the polymeric composite material or the cross-linkable composition comprises the functionalised polymer in an amount of about 0.1 to 30% by weight, for example about 0.5 to 30%, 1 to 30%, 0.1 to 20%, 0.5 to 20%, 1 to 20%, 0.1 to 15%, 0.5 to 15%, 1 to 15%, 0.1 to 10%, 0.5 to 10%, 1 to 10%, 0.1 to 9%, 0.5 to 9%, 1 to 9%, 0.1 to 8%, 0.5 to 8%, 1 to 8%, 0.1 to 7%, 0.5 to 7%, 1 to 7%, 0.1 to 6%, 0.5 to 6%, 1 to 6%, 0.1 to 5%, 0.5 to 5%, 1 to 5%, 2 to 10%, 2 to 9%, 2 to 8%, 2 to 7%, 2 to 6%, 2 to 5%, or 2 to 4% by weight.The polymeric composite material of any one of items 1 to 3 and 8 to 24, the crosslinkable composition of any one of items 4 and 8 to 24, or the process of any one of items 5 to 24, wherein the polymeric composite material or the cross-linkable composition comprises the functionalised polymer in an amount of about 0.1 to 10% by weight, for example about 1 to 10%, 1 to 9%, 1 to 8%, 1 to 7%, 1 to 6%, 1 to 5%, or 1 to 4% by weight, preferably about 2 to 6%, 2 to 5% or 2 to 4% by weight, more preferably 2 to 5%.The polymeric composite material of any one of items 1 to 3 and 8 to 25, the crosslinkable composition of any one of items 4 and 8 to 25, or the process of any one of items 5 to 25, wherein the polymeric composite material or the cross-linkable composition comprises the functionalised polymer in an amount of about 2, 3, 4, or 5% by weight, preferably about 2, 3, or 4%.The polymeric composite material of any one of items 1 to 3 and 8 to 26, the crosslinkable composition of any one of items 4 and 8 to 26, or the process of any one of items 5 to 26, wherein the functionalised polymer is a cross-linkable PE and / or a cross-linkable PP.The polymeric composite material, the cross-linkable composition or the process of item 27, wherein the cross-linkable PP is a silane grafted propylene copolymer.The polymeric composite material, the cross-linkable composition or the process of item 27, wherein the functionalised polymer is a cross-linkable PE.The polymeric composite material, the cross-linkable composition or the process of item 27 or 29, wherein the cross-linkable PE is a silane grafted ethylene copolymer.The polymeric composite material, the cross-linkable composition or the process of any one of items 27, 29 and 30, wherein the cross-linkable PE is a cross-linkable HDPE.The polymeric composite material, the cross-linkable composition or the process of any one of items 27, 29 and 30, wherein the cross-linkable PE is a cross-linkable MDPE.The polymeric composite material of any one of items 1 to 3 and 8 to 32, the crosslinkable composition of any one of items 4 and 8 to 32, or the process of any one of items 5 to 32, wherein the functionalised polymer has a density of from about 0.90 to 0.96, preferably 0.93 to 0.96, more preferably about 0.93 g / cc (as measured by ASTM method 792).The polymeric composite material of any one of items 1 to 3 and 8 to 33, the crosslinkable composition of any one of items 4 and 8 to 33, or the process of any one of items 5 33, wherein the functionalised polymer has a melt flow rate of from about 20 to 50, preferably 20 to 40, more preferably about 20 g / 10 min (as measured with a load of 2.16 kg and at a temperature of 190°C in accordance with ASTM method DI 238).The polymeric composite material of any one of items 1 to 3 and 8 to 34, the crosslinkable composition of any one of items 4 and 8 to 34, or the process of any one of items 5 to 34, wherein a functional group capable of cross-linking with the functionalised polymer may be introduced to the reinforcement via chemical modification.The polymeric composite material of any one of items 1 to 3 and 8 to 35, the crosslinkable composition of any one of items 4 and 8 to 35, or the process of any one of items 5 to 35, wherein a functional group capable of cross-linking with the functionalised polymer may be exposed by mechanical manipulation to expose a reactive surface.The polymeric composite material of any one of items 1 to 3 and 8 to 36, the crosslinkable composition of any one of items 4 and 8 to 36, or the process of any one of items5 to 36, wherein a functional group capable of cross-linking with the functionalised polymer may be exposed by grinding or otherwise breaking up the reinforcement to expose a reactive surface.The polymeric composite material of any one of items 1 to 3 and 8 to 37, the crosslinkable composition of any one of items 4 and 8 to 37, or the process of any one of items 5 to 37, wherein the reinforcement may comprise a sizing or a tie-layer comprising a functional group or the reinforcement itself may provide a functional group.The polymeric composite material of any one of items 1 to 3 and 8 to 38, the crosslinkable composition of any one of items 4 and 8 to 38, or the process of any one of items 5 to 38, wherein the reinforcement comprises a reactive silicon based functional group, an epoxy group, a methacylate group, a peroxide group or a combination of any two or more thereof.The polymeric composite material of any one of items 1 to 3 and 8 to 39, the crosslinkable composition of any one of items 4 and 8 to 39, or the process of any one of items 5 to 39, wherein the reinforcement comprises a reactive silicon based functional group.The polymeric composite material, the cross-linkable composition or the process of item 40, wherein the reactive silicon based functional group is a silicon hydroxide group.The polymeric composite material, the cross-linkable composition or the process of item 40, wherein the reactive silicon based functional group is a group of the formula -Si(OR2)3, wherein each R2is independently H or a suitable organic group, preferably wherein each R2is independently a suitable organic group.The polymeric composite material, the cross-linkable composition or the process of item 42, wherein each R2is independently selected from a H, alkyl, alkenyl, cycloalkyl.The polymeric composite material, the cross-linkable composition or the process of item 42, wherein each R2is independently selected from a Ci-ealkyl, C2-ealkenyl or C3-ecycloalkyl.The polymeric composite material, the cross-linkable composition or the process of item 42, wherein each R2is independently selected from a Ci-ealkyl.The polymeric composite material, the cross-linkable composition or the process of item 42, wherein each R2is independently selected from methyl, ethyl or propyl.The polymeric composite material, the cross-linkable composition or the process of any one of items 42, wherein the reactive silicon based functional group is an alkoxysilyl group, preferably a trialkoxysilyl group.The polymeric composite material of any one of items 1 to 3 and 8 to 47, the crosslinkable composition of any one of items 4 and 8 to 47, or the process of any one of items 5 to 47, wherein the reinforcement comprises materials having a three-dimensional shape.The polymeric composite material, the cross-linkable composition or the process of item 48, wherein the reinforcement retains its three dimensional shape in the polymeric composite material.The polymeric composite material of any one of items 1 to 3 and 8 to 49, the crosslinkable composition of any one of items 4 and 8 to 49, or the process of any one of items 5 to 49, wherein the reinforcement is not meltable during the extrusion process.The polymeric composite material of any one of items 1 to 3 and 8 to 50, the crosslinkable composition of any one of items 4 and 8 to 50, or the process of any one of items 5 to 50, wherein the reinforcement comprises glass, a polyester, an aramid or a combination of any two or more thereof.The polymeric composite material of any one of items 1 to 3 and 8 to 51, the crosslinkable composition of any one of items 4 and 8 to 51, or the process of any one of items 5 to 51, wherein the reinforcement comprises fibres, rods, needles, beads, flakes, particles, blocks or a combination of any two or more thereof; preferably the reinforcement comprises fibres.The polymeric composite material of any one of items 1 to 3 and 8 to 52, the crosslinkable composition of any one of items 4 and 8 to 52, or the process of any one of items 5 to 52, wherein the reinforcement is a material having an elongated shaped, e.g. fibres, rods, needles, or a combination of any two or more thereof.The polymeric composite material of any one of items 1 to 3 and 8 to 53, the cross-linkable composition of any one of items 4 and 8 to 53, or the process of any one of items 5 to 53, wherein the reinforcement comprises woven fibres and / or non-woven fibres.The polymeric composite material of any one of items 1 to 3 and 8 to 54, the crosslinkable composition of any one of items 4 and 8 to 54, or the process of any one of items 5 to 54, wherein the reinforcement comprises glass fibres.The polymeric composite material of any one of items 1 to 3 and 8 to 51, the crosslinkable composition of any one of items 4 and 8 to 51, or the process of any one of items 5 to 51, wherein the reinforcement comprises ground glass.The polymeric composite material of any one of items 1 to 3 and 8 to 55, the crosslinkable composition of any one of items 4 and 8 to 55, or the process of any one of items 5 to 55, wherein the reinforcement comprises sized glass, preferably sized glass fibres.The polymeric composite material of any one of items 1 to 3 and 8 to 55, the crosslinkable composition of any one of items 4 and 8 to 55, or the process of any one of items 5 to 55, wherein the reinforcement comprises glass, preferably glass fibres, comprising a reactive silicon based functional group.The polymeric composite material of any one of items 1 to 3 and 8 to 58, the crosslinkable composition of any one of items 4 and 8 to 58, or the process of any one of items 5 to 58, wherein the polymeric composite material or cross-linkable composition comprises the reinforcement in an amount of about 30% or less by weight, for example about 20% or less, 15% or less, 10% or less, 9% or less, 8% or less, 7% or less, 6% or less, or 5% or less by weight.The polymeric composite material of any one of items 1 to 3 and 8 to 59, the crosslinkable composition of any one of items 4 and 8 to 59, or the process of any one of items 5 to 59, wherein the polymeric composite material or cross-linkable composition comprises the reinforcement in an amount of about 25% or less or 20% or less by weight.The polymeric composite material of any one of items 1 to 3 and 8 to 60, the crosslinkable composition of any one of items 4 and 8 to 60, or the process of any one of items 5 to 60, wherein the polymeric composite material or cross-linkable composition comprises the reinforcement in an amount of about 1 to 30% by weight, for exampleabout 1 to 25%, 1 to 20%, 1 to 15%, 1 to 10%, 5 to 30%, 5 to 25%, 5 to 20%, 5 to 15%, 10 to 30%, 10 to 25%, 10 to 20%, 10 to 15%, 15 to 30%, 15 to 25%, 15 to 20%, 20 to 30%, or 20 to 25% by weight.The polymeric composite material of any one of items 1 to 3 and 8 to 61, the crosslinkable composition of any one of items 4 and 8 to 61, or the process of any one of items 5 to 61, wherein the polymeric composite material or cross-linkable composition comprises the reinforcement in an amount of about 10 to 30% by weight, for example about 11 to 29% by weight, 12 to 28% by weight, 13 to 27% by weight, or 14 to 26% by weight, preferably about 15 to 25% by weight.The polymeric composite material of any one of items 1 to 3 and 8 to 62, the crosslinkable composition of any one of items 4 and 8 to 62, or the process of any one of items 5 to 62, wherein the polymeric composite material or cross-linkable composition comprises the reinforcement in an amount of about 20% by weight.The polymeric composite material of any one of items 1 to 3 and 8 to 63, the crosslinkable composition of any one of items 4 and 8 to 63, or the process of any one of items 5 to 63, wherein the functionalised polymer is a functionalised polyethylene comprising a reactive silicon based functional group, such as a group of the formula -Si(OR1)3, preferably wherein each R1is independently selected from a Ci-ealkyl, and the reinforcement comprises glass, preferably glass fibres.The polymeric composite material of any one of items 1 to 3 and 8 to 64, the crosslinkable composition of any one of items 4 and 8 to 64, or the process of any one of items 5 to 64, wherein the functionalised polymer is a functionalised polyethylene comprising a reactive silicon based functional group, such as a group of the formula -Si(OR1)3, preferably wherein each R1is independently selected from a Ci-ealkyl, and the reinforcement comprises glass, preferably glass fibres, comprising a reactive silicon based functional group, such as a group of the formula -Si(OR1)3, preferably wherein each R1is independently selected from a Ci-ealkyl.The polymeric composite material of any one of items 1 to 3 and 8 to 65, the crosslinkable composition of any one of items 4 and 8 to 65, or the process of any one of items 5 to 65, wherein the functionalised polymer is a functionalised polyethylene comprising areactive silicon based functional group, and the reinforcement comprises glass, preferably glass fibres, comprising a reactive silicon based functional group and, in the polymeric composite material, the functionalised polymer is at least partially cross -linked with the reinforcement through a Si-O-Si bond.The polymeric composite material of any one of items 1 to 3 and 8 to 66, the crosslinkable composition of any one of items 4 and 8 to 66, or the process of any one of items 5 to 66, wherein the weight ratio of the functionalised polymer to the reinforcement is from about 30:1 to 1:30; preferably, the weight ratio of the functionalised polymer to the reinforcement is from about 20:1 to 1:30, about 15:1 to 1:30, about 10:1 to 1:30, about 5:1 to 1:30, about 1:1 to 1:30, about 1:1 to 1:25, about 1:1 to 1:20, about 1:1 to 1:15 or about 1:1 to 1:10.The polymeric composite material of any one of items 1 to 3 and 8 to 67, the crosslinkable composition of any one of items 4 and 8 to 67, or the process of any one of items 5 to 67, wherein the weight ratio of the functionalised polymer to the reinforcement is from about 1:2 to 1:10, about 1:3 to 1:9, about 1:4 to 1:9 or about 1:4 to 1:8.The polymeric composite material of any one of items 1 to 3 and 8 to 68, the crosslinkable composition of any one of items 4 and 8 to 68, or the process of any one of items 5 to 68, wherein the cross-linkable composition comprises water; preferably, the crosslinkable composition comprises sufficient water to facilitate a reaction between the functionalised polymer and the reinforcement.The polymeric composite material of any one of items 1 to 3 and 8 to 69, the crosslinkable composition of any one of items 4 and 8 to 69, or the process of any one of items 5 to 69, wherein the water is provided in the form of steam.The polymeric composite material of any one of items 1 to 3 and 8 to 69, the crosslinkable composition of any one of items 4 and 69, or the process of any one of items 5 to 69, wherein the water is provided in the form of one or more additive that comprises water.The polymeric composite material, the cross-linkable composition or the process of item 71, wherein the one or more additive that comprises water is a filler, a flame retardant, or a combination thereof.The polymeric composite material, the cross-linkable composition or the process of item 71, wherein the one or more additive that comprises water is calcium carbonate, magnesium hydroxide, or a combination thereof.The polymeric composite material of any one of items 1 to 3 and 8 to 73, the crosslinkable composition of any one of items 4 and 8 to 73, or the process of any one of items 5 to 73, wherein the water is provided in the form of one or more additive that decomposes to provide water during processing, for example during a mixing step of a process of the invention.The polymeric composite material, the cross-linkable composition or the process of item 74, wherein the one or more additive that decompose to provide water is magnesium hydroxide.The polymeric composite material of any one of items 1 to 3 and 8 to 75, the crosslinkable composition of any one of items 4 and 8 to 75, or the process of any one of items 5 to 75, wherein the polymeric composite material or the cross-linkable composition further comprises one or more additional polymer(s).The polymeric composite material, the cross-linkable composition or the process of item 76, wherein the one or more additional polymer(s) is a thermoplastic polymer.The polymeric composite material, the cross-linkable composition or the process of item 76, wherein the one or more additional polymer(s) is a polystyrene (GPPS), polyethylene terephthalate (PET), polyester methacrylate (PEM), high impact polystyrene (HIPS), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polyurethanes (PU), polyethylene (PE) including homopolymer, copolymer, block copolymer and terpolymer forms, polylactic acid (PLA), nylon (PA), acrylics (PMMA), high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), cross linked polyethylene (PEX), thermoplastic elastomer (TPE) (including an elastomeric LLDPE, elastomeric MDPE, elastomeric HDPE, or any combination of any two or more thereof), POE, thermoplastic polyolefin (TPO), thermoplastic rubber (TPR), polypropylene (PP), including homopolymer and copolymer forms, polybutylene terephthalate (PBT), styrene-acrylonitrile resin (SAN), ethylene tetrafluoroethylene (ETFE), vinyl, methacrylate copolymers, foamed polymer,polycarbonates, or a combination of any two or more thereof, preferably wherein the one or more additional polymer(s) is a polystyrene (GPPS), polyethylene terephthalate (PET), polyester methacrylate (PEM), high impact polystyrene (HIPS), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polyurethanes (PU), polyethylene (PE) including homopolymer, copolymer, block copolymer and terpolymer forms, polylactic acid (PLA), nylon (PA), acrylics (PMMA), high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), cross linked polyethylene (PEX), thermoplastic elastomer (TPE), thermoplastic polyolefin (TPO), thermoplastic rubber (TPR), polypropylene (PP), including homopolymer and copolymer forms, polybutylene terephthalate (PBT), styrene-acrylonitrile resin (SAN), ethylene tetrafluoroethylene (ETFE), vinyl, methacrylate copolymers, foamed polymer, polycarbonates, or a combination of any two or more thereof.The polymeric composite material, the cross-linkable composition or the process of item 76, wherein the one or more additional polymer(s) is a polyolefin.The polymeric composite material, the cross-linkable composition or the process of item 76, wherein the one or more additional polymer(s) is a polyethylene, e.g. a low-density polyethylene (LDPE), a linear low-density polyethylene (LLDPE), medium-density polyethylene (MDPE), high density polyethylene (HDPE), TPE (such as an elastomeric LLDPE, elastomeric MDPE, elastomeric HDPE, or any combination of any two or more thereof), POE, or combination of any two or more thereof; preferably a low-density polyethylene (LDPE), medium-density polyethylene (MDPE), high density polyethylene (HDPE) or combination of any two or more thereof.The polymeric composite material, the cross-linkable composition or the process of any one of items 78 to 86, wherein the one or more additional polymer(s) does not cross-link with the functionalised polymer or the reinforcement during the extrusion process.The polymeric composite material of any one of items 1 to 3 and 8 to 89, the crosslinkable composition of any one of items 4 and 8 to 89, or the process of any one of items 5 to 89, wherein the polymeric composite material or the cross-linkable composition further comprises one or more additive(s) selected from a flame retardant, a filler, a colourant, a UV stabilizer, a thermal stabiliser, a compatibilizer, a foaming agent, a freeradical scavenger, a lubricant or a slip agent, a biocide, an additional material, a surface leaching agent or inhibitor, and a combination of any two or more thereof.The polymeric composite material, the cross-linkable composition or the process of item 90, wherein the flame retardant is an inorganic metal compound, preferably magnesium hydroxide or aluminium trihydroxide (ATH), a halogenated material, or any combination of two or more thereof.The polymeric composite material, the cross-linkable composition or the process of item 90, wherein the filler is talc, calcium carbonate, mica, silica, kaolin, calcium sulphate, magnesium hydroxide, stabilizers, dolomite or a combination of any two or more thereof.The polymeric composite material, the cross-linkable composition or the process of item 90, wherein the colourant is an organic pigment, an inorganic pigment or a combination thereof; preferably wherein the colourant is carbon black, a metal oxide such as titanium dioxide, a metal carbonate or a combination of any two or more thereof, preferably carbon black, titanium dioxide or a combination thereof.The polymeric composite material, the cross-linkable composition or the process of item 90, wherein the UV stabilizer is a hindered amine light stabilizer (HALS).The polymeric composite material, the cross-linkable composition or the process of item 90, wherein the thermal stabilizer is a phenolic or a phosphite.The polymeric composite material, the cross-linkable composition or the process of item 90, wherein the lubricant or slip agent is an euricamide, a fatty acid amide slip additive, a fatty acid ester additive, a short-chain fluoro-polymer, zinc stearate or a combination of any two or more thereof.The polymeric composite material, the cross-linkable composition or the process of item 90, wherein the biocide is silver, preferably silver nanoparticles.The polymeric composite material, the cross-linkable composition or the process of item 90, wherein the additional material is provided as an additional filler or additional reinforcement.The polymeric composite material, the cross-linkable composition or the process of item98, wherein the additional material comprises materials having a three-dimensional shape.The polymeric composite material, the cross-linkable composition or the process of item 99, wherein the additional material retains its three dimensional shape in the polymeric composite material.The polymeric composite material, the cross-linkable composition or the process of any one of items 98 to 100, wherein the additional material is not meltable during the extrusion process.The polymeric composite material, the cross-linkable composition or the process of any one of items 98 to 101, wherein the additional material comprises fibres, rods, needles, beads, flakes, particles, blocks or a combination of any two or more thereof; preferably the additional material comprises fibres.The polymeric composite material, the cross-linkable composition or the process of item 102, wherein the additional material is a material having an elongated shaped, e.g. fibres, rods, needles, or a combination of any two or more thereof.The polymeric composite material, the cross-linkable composition or the process of item 103, wherein the additional material comprises woven fibres and / or non-woven fibres.The polymeric composite material, the cross-linkable composition or the process of any one of items 98 to 104, wherein the additional material comprises a natural material, a synthetic material, a non-conductive material or a combination of any two or more thereof.The polymeric composite material, the cross-linkable composition or the process of any one of items 98 to 105, wherein the additional material comprises glass fibres, glass beads, glass flakes, natural fibres such as flax, cellulose, wood fibres, wood flour, cotton, sawdust, and inorganic or polymer fibres, scrim, knits, weaves, non-woven fibres, aramids, ceramics or a combination of any two or more thereof.The polymeric composite material of any one of items 1 to 3 and 8 to 106, the crosslinkable composition of any one of items 4 and 8 to 106, or the process of any one ofitems 5 to 106, wherein the polymeric composite material or the cross-linkable composition is substantially free of any organic peroxide, preferably substantially free of any peroxide.100. The polymeric composite material of any one of items 1 to 3 and 8 to 107, the cross-linkable composition of any one of items 4 and 8 to 107, or the process of any one of items 5 to 107, wherein the polymeric composite material or the cross-linkable composition is substantially free of a cross-linking catalyst, e.g. a tin catalyst.101. The polymeric composite material of any one of items 1 to 3 and 8 to 108, the cross-linkable composition of any one of items 4 and 8 to 108, or the process of any one of items 5 to 108, wherein the polymeric composite material comprises a polyolefin and a reinforcement comprising glass, preferably glass fibres; wherein the polyolefin comprises a silane group cross-linked to the glass by a Si-O-Si bond.102. The polymeric composite material of any one of items 1 to 3 and 8 to 109, the cross-linkable composition of any one of items 4 and 8 to 109, or the process of any one of items 5 to 109, wherein the polymeric composite material has one or more tensile properties, when measured by Tensile ASTM D638, selected from:a) a Youngs modulus (MD) of at least about 800 MPa;b) a Youngs modulus (TD) of at least about 200 MPa;c) a tensile strength (MD) of at least about 10 MPa; andd) a tensile strength (TD) of at least about 5 MPa.103. The polymeric composite material of any one of items 1 to 3 and 8 to 110, the cross-linkable composition of any one of items 4 and 8 to 110, or the process of any one of items 5 to 110, wherein the polymeric composite material has one or more tensile properties when measured by Tensile ASTM D638 selected from:a) a Youngs modulus (MD) of at least about 900, 1,000, 1,100, 1,200, 1,300, 1,400, 1,500, 1,600, 1,700, 1,800, 1,900, 2,000, 2,100, 2,200, 2,300, 2,400, 2,500, 2,600, 2,700, 2,800, 2,900 or 3,000 MPa, preferably at least about 900, 1,000, 1,100, 1,200, 1,300, 1,400, 1,500 MPa;b) a Youngs modulus (TD) of at least about 300, 400, 500, 600, 700, 800, 900 or 1,100 MPa;c) a tensile strength (MD) of at least about 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27 or 28 MPa; andd) a tensile strength (TD) of at least about 6, 10, 11, 12, 13, 14, 15, 16, 17, 18 or 19 MPa.104. The polymeric composite material, the cross-linkable composition or the process of item 110 or 111 , wherein the polymeric composite material has two or more tensile properties as defined above.105. The polymeric composite material, the cross-linkable composition or the process of item 110 or 111 , wherein the polymeric composite material has three or more tensile properties as defined above.106. The polymeric composite material, the cross-linkable composition or the process of item 110 or 111 , wherein the polymeric composite material has four tensile properties as defined above.107. The polymeric composite material of any one of items 1 to 3 and 8 to 114, the cross-linkable composition of any one of items 4 and 8 to 114, or the process of any one of items 5 to 114, wherein the polymeric composite material has one or more flexural properties when measured by Flexural ASTMD790, selected from:a) a Youngs modulus (MD) of at least about 1,100 MPa;b) a Youngs modulus (TD) of at least about 400 MPa;c) a flex stress at 5% (MD) of at least about 20 MPa; andd) a flex stress at 5% (TD) of at least about 11 MPa.108. The polymeric composite material of any one of items 1 to 3 and 8 to 115, the cross-linkable composition of any one of items 4 and 8 to 115, or the process of any one of items 5 to 115, wherein the polymeric composite material has one or more flexural properties when measured by Flexural ASTMD790, selected from:a) a Youngs modulus (MD) of at least about 1,200, 1,300 or 1,400 MPa;b) a Youngs modulus (TD) of at least about 450, 500, 550, 600 or 650 MPa;c) a flex stress at 5% (MD) of at least about 25, 30, 35, 40, 45, 50 or 55 MPa; andd) a flex stress at 5% (TD) of at least about 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25 or 26 MPa.109. The polymeric composite material, the cross-linkable composition or the process of item 115 or 116, wherein the polymeric composite material has two or more flexural properties as defined above.110. The polymeric composite material, the cross-linkable composition or the process of item 115 or 116, wherein the polymeric composite material has three or more flexural properties as defined above.111. The polymeric composite material, the cross-linkable composition or the process of item 115 or 116, wherein the polymeric composite material has four flexural properties as defined above.112. The polymeric composite material of any one of items 1 to 3 and 8 to 119, the cross-linkable composition of any one of items 4 and 8 to 119, or the process of any one of items 5 to 119, wherein the polymeric composite material has a coefficient of thermal expansion (MD) of about 3.81 x 10'5or less, for example about 3.81 x 10'5.113. The polymeric composite material of any one of items 1 to 3 and 8 to 120, the cross-linkable composition of any one of items 4 and 8 to 120, or the process of any one of items 5 to 120, wherein the polymeric composite material has a coefficient of thermal expansion (TD) of about 1.18x1 O'4or less, for example about 1.18x1 O'4.114. The polymeric composite material of any one of items 1 to 3 and 8 to 121, the cross-linkable composition of any one of items 4 and 8 to 121, or the process of any one of items 5 to 121, wherein the functionalised polymer is at least partially cross-linked with the reinforcement prior to forming an article having a desired three-dimensional shape from the polymeric composite material.. The process of claim 5, wherein the container in step (i) is a barrel of an extruder or a barrel of an injection molding device.. The polymeric composite material of any one of items 1 to 3 and 8 to 123, the cross-linkable composition of any one of items 4 and 8 to 123, or the process of any one of items 5 to 123, wherein the polymeric composite material is an extruded polymeric composite material and after extrusion the material is not subjected to any step for initiating further cross-linking of the functionalised polymer with the reinforcement.. The polymeric composite material of any one of items 1 to 3 and 8 to 124, the cross-linkable composition of any one of items 4 and 8 to 124, or the process of any one of items 5 to 124, wherein the polymeric composite material is an injection molded polymeric composite material or a compression molded polymeric composite material and after conveying the material into a mold is not subjected to any step for initiating further cross-linking of the functionalised polymer with the reinforcement.. The process of any one of items 5 to 125, wherein step (ii) comprises mixing the cross-linkable composition at a temperature of at least about 80, 100, 120, 140, 160, 180, 200 or 220°C.. The process of any one of items 5 to 126, wherein step (ii) comprises mixing the cross-linkable composition at a temperature less than about 300, 280, 270, 260, 250 or 240°C.. The process of any one of items 5 to 127, wherein step (ii) comprises mixing the cross-linkable composition at a temperature of about 80 to 300°C, 200 to 280°C, 210 to 270°C, 220 to 260°C; preferably about 230 to 250°C.. The process of any one of items 5 to 128, wherein step (ii) comprises mixing the cross-linkable composition at a temperature of about 240°C.. The process of any one of items 5 to 129, wherein step (ii) comprises mixing the cross-linkable composition at a temperature greater than about 200° C and less than about 250°C.. The process of any one of items 5 to 130, wherein step (ii) comprises mixing thecross-linkable composition at a pressure of at least about 700, 800, 900, 1,000, 1,100, 1,200, 1,300, 1400, 1,500, 1,600, 1,700, 1,800, 1,900 or 2,000 psi, preferably at least about 1,500, 1,600, 1,700, 1,800, 1,900 or 2,000 psi.. The process of any one of items 5 to 131, wherein step (ii) comprises mixing the cross-linkable composition at a pressure less than about 3,000, 2,900, 2,800, 2,700, 2,600, 2,500 or 2,400 psi.. The process of any one of items 5 to 132, wherein step (ii) comprises mixing the cross-linkable composition at a pressure of about 750 to 3,000 psi, 1,000 to 3, 000 psi, 1,250 to 3,000 psi, 1,500 to 3,000 psi, 1,600 to 2,900 psi, 1,700 to 2,800 psi, 1,800 to 2,600 psi, 1,900 to 2,400 psi, preferably about 1,500 to 3,000 psi, 1,600 to 2,900 psi, 1,700 to 2,800 psi, 1,800 to 2,600 psi, 1,900 to 2,400 psi, preferably about 2,000 to 2,200 psi, more preferably about 2,000 to 2,200 psi.. The process of any one of items 5 to 133, wherein step (ii) comprises mixing the cross-linkable composition at a pressure greater than about 1,800 psi and less than about 2,200 psi.. The process of any one of items 5 to 134, wherein step (ii) comprises mixing the cross-linkable composition at a temperature greater than about 200° C and less than about 250°C and a pressure greater than about 1,800 psi and less than about 2,200 psi.. The process of any one of items 5 to 135, wherein the time of step (ii) is at least about 1, 2, 3, 4 or 5 minutes.. The process of any one of items 5 to 136, wherein the time of step (ii) is less than about 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 minute.. The process of any one of items 5 to 137, wherein the time of step (ii) is about 1 to 15 minutes, 2 to 10 minutes; preferably about 3 to 7 minutes.. The process of any one of items 5 to 138, wherein the time of step (ii) is greater than about 2 minutes and less than about 15 minutes.. The process of any one of items 5 to 135, wherein the residence time of the composition in step (ii) is at least about 1, 2, 3, 4 or 5 minutes.. The process of any one of items 5 to 135, wherein the residence time of the composition in step (ii) is less than about 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 minute.. The process of any one of items 5 to 135, wherein the residence time of the composition in step (ii) is about 1 to 15 minutes, 2 to 10 minutes; preferably about 3 to 7 minutes.. The process of any one of items 5 to 135, wherein the residence time of the composition in step (ii) is greater than about 2 minutes and less than about 15 minutes.. The process of any one of items 6 to 143, wherein the extruder comprises a barrel and at least one screw.. The process of any one of items 6 to 143, wherein the extruder is a twin screw extruder.. The process of item 145, wherein the twin-screw extruder is a co-rotating twin screw extruder.. The process of item 145, wherein the twin-screw extruder is a counter-rotating twin screw extruder.. The process of any one of items 6 to 147, wherein charging the extruder with the cross-linkable composition comprises adding the functionalised polymer and the reinforcement to extruder together (i.e. adding a cross-linkable composition of the invention).. The process of any one of items 6 to 148, wherein charging the extruder with the cross-linkable composition comprises adding the functionalised polymer and the reinforcement to the extruder separately (simultaneously or sequentially).. The process of any one of items 6 to 149, wherein charging the extruder with the cross-linkable composition comprises adding the functionalised polymer and the reinforcement to the extruder separately at different points located along the length of the barrel.. The process of any one of items 6 to 150, wherein charging the extruder with the cross-linkable composition comprises adding the functionalised polymer and the reinforcement to the extruder simultaneously and separately at different points located along the length of the barrel.. The process of claim 5, wherein providing the cross-linkable composition in the container comprises adding the functionalised polymer and the reinforcement to a barrel of an extruder or an injection moulding device together (i.e. adding a cross -linkable composition of the invention).. The process of claim 5, wherein providing the cross-linkable composition in the container comprises adding the functionalised polymer and the reinforcement to a barrel of an extruder or an injection molding device separately (simultaneously or sequentially).. The process of claim 5, wherein providing the cross-linkable composition in a container comprises adding the functionalised polymer and the reinforcement to a barrel of an extruder or an injection molding device at different points located along the length of the barrel.. The process of claim 5, wherein providing the cross-linkable composition in the container comprises adding the functionalised polymer and the reinforcement to a barrel of an extruder or an injection molding device simultaneously and separately at different points located along the length of the barrel.. The process of any one of items 6 to 155, wherein the process further comprises charging the extruder with water.. The process of item 156, wherein the amount of water is sufficient to facilitate a reaction between the functionalised polymer and the reinforcement.. The process of item 156 or 157, wherein the water is provided in the form of one or more additive that comprises water, for example one or more additive that comprise available water, for example residual moisture.. The process of item 156 or 157, wherein the water is provided by one or more additive that decomposes to provide water during the mixing.. The process of item 156 or 157, wherein the extruder is charged with water in the form of steam.. The process of item 156 or 157, wherein the extruder is charged with one or more additive that comprises water.. The process of item 161, wherein the one or more additive that comprises water is a filler, a flame retardant, or a combination thereof.. The process of item 161, wherein the one or more additive that comprises water is calcium carbonate, magnesium hydroxide, or a combination thereof; and / or wherein the extruder is charged with one or more additive that decompose to provide water during the mixing.. The process of item 161, wherein the one or more additive that decompose to provide water is magnesium hydroxide.. The process of any one of items 6 to 164, wherein the process further comprises after step (iii) forming the extruded melt into an article having a desired three-dimensional shape.. The process of any one of items 6 to 165, wherein the process further comprises after step (iii) forming the melt into an article having a desired three-dimensional shape with injection molding or compression molding, preferably compression molding.. The process of any one of items 6 to 166, wherein the process does not comprise after step (iii) any step for initiating further cross-linking of the functionalised polymer with the reinforcement, or at least no steps actively taken to initiate or carry on cross -linking.. A polymeric composite material obtained by a process of any one of items 6 to 167.. An article comprising the polymeric composite material of any one of items 1 to 3 and 8 to 125.. The article of item 169, wherein the article is a building product.163. The article of item 170, wherein the building product is a roof, cladding or siding product, e.g. a roof, cladding or siding module.164. The article of item 170 or 171, wherein the building product is a hail-resistant roof, cladding or siding module.165. The article of item 170, wherein the article or building product is a photovoltaic module.166. The article of item 170, wherein the article or building product is a roof, cladding or siding module comprising an integrated photovoltaic module.167. The article of any one of items 169 to 174, wherein the article comprises one or more layers, e.g., two or more layers.168. The article of any one of items 169 to 174, wherein the article comprises a first layer comprising the polymeric composite material and a second layer comprising a polymeric material.169. The article of any one of items 169 to 174, wherein the article comprises a first layer comprising the polymeric composite material and a second layer comprising a polymeric composite material.

[0234] It is not the intention to limit the scope of the invention to the abovementioned examples only. As would be appreciated by a skilled person in the art, many variations are possible without departing from the scope of the invention as set out in the accompanying claims. All headings used herein are for convenience only.

Claims

CLAIMS1. A process for preparing a polymeric composite material, the process comprising:

1. charging an extruder with cross-linkable composition comprising a) a functionalised polymer and b) a reinforcement capable of cross-linking with the functionalised polymer,ii. mixing the cross-linkable composition in the presence of water at a temperature and a pressure and for a time sufficient to melt the functionalised polymer and cause the functionalised polymer to at least partially cross-link with the reinforcement, thereby providing a melt of the polymeric composite material,iii. extruding the melt,iv. cooling the extruded melt,wherein the cross-linkable composition comprises the functionalised polymer in an amount of about 30% or less by weight and the reinforcement in an amount of about 30% or less by weight.

2. The process of claim 1, wherein the polymeric composite material is an extruded polymeric composite material, an injection molded polymeric composite material or a compression molded polymeric composite material.

3. The process of claim 1 or 2, wherein the functionalised polymer comprises a reactive silicon based functional group.

4. The process of claim 3, wherein the reactive silicon based functional group is a group of the formula -Si(OR1)3, wherein each R1is independently H or a suitable organic group.

5. The process of claim 4, wherein each R1is independent selected from a H, alkyl, alkenyl, cycloalkyl; preferably, each R1is independently selected from a Ci-ealkyl, C2-6alkenyl or Ca-ecycloalkyl.

6. The process of claim 4 or 5, wherein each R1is independently selected from a Ci-ealkyl.

7. The process of any one of claims 4 to 6, wherein the reactive silicon based functional group is an alkoxysilyl group, preferably a trialkoxysilyl group.

8. The process of any one of claims 1 to 7, wherein the functionalised polymer is a functionalised polyolefin; preferably, the functionalised polymer is a functionalised polyethylene, e.g. a low-density polyethylene (LDPE), medium-density polyethylene (MDPE), high density polyethylene (HDPE), a polyolefin elastomer (POE) or combination of any two or more thereof.

9. The process of any one of claims 1 to 8, wherein the polymeric composite material or the cross-linkable composition comprises the functionalised polymer in an amount of about 20% or less, 15% or less, 10% or less, 9% or less, 8% or less, 7% or less, 6% or less, or 5% or less by weight.

10. The process of any one of claims 1 to 9, wherein the polymeric composite material or the cross-linkable composition comprises the functionalised polymer in an amount of about 0.1 to 30% by weight, for example about 0.5 to 30%, 1 to 30%, 0.1 to 20%, 0.5 to 20%, 1 to 20%, 0.1 to 15%, 0.5 to 15%, 1 to 15%, 0.1 to 10%, 0.5 to 10%, 1 to 10%, 0.1 to 9%, 0.5 to 9%, 1 to 9%, 0.1 to 8%, 0.5 to 8%, 1 to 8%, 0.1 to 7%, 0.5 to 7%, 1 to 7%, 0.1 to 6%, 0.5 to 6%, 1 to 6%, 0.1 to 5%, 0.5 to 5%, 1 to 5%, 2 to 10%, 2 to 9%, 2 to 8%, 2 to 7%, 2 to 6%, 2 to 5%, or 2 to 4% by weight.

11. The process of any one of claims 1 to 10, wherein the polymeric composite material or the cross-linkable composition comprises the functionalised polymer in an amount of about 0.1 to 10% by weight, for example about 1 to 10%, 1 to 9%, 1 to 8%, 1 to 7%, 1 to 6%, 1 to 5%, or 1 to 4% by weight, preferably about 2 to 6%, 2 to 5% or 2 to 4% by weight, more preferably 2 to 5%.

12. The process of any one of claims 1 to 11, wherein the functionalised polymer is a crosslinkable PE and / or a cross-linkable PP.

13. The process of claim 12, wherein the functionalised polymer is a cross -linkable PE.

14. The process of claim 12 or 13, wherein the cross-linkable PE is a silane grafted ethylene copolymer.

15. The process of any one of claims 12 to 14, wherein the cross-linkable PE is a cross- linkable HDPE.

16. The process of any one of claims 12 to 14, wherein the cross-linkable PE is a crosslinkable MDPE.

17. The process of any one of items 1 to 16, wherein the reinforcement comprises a reactive silicon based functional group, an epoxy group, a methacylate group, a peroxide group or a combination of any two or more thereof.

18. The process of any one of claims 1 to 17, wherein the reinforcement comprises a reactive silicon based functional group.

19. The process of claim 18, wherein the reactive silicon based functional group is a silicon hydroxide group.

20. The process of claim 18, wherein the reactive silicon based functional group is a group of the formula -Si(OR2)3, wherein each R2is independently H or a suitable organic group.

21. The process of claim 20, wherein each R2is independently selected from a H, alkyl, alkenyl, cycloalkyl.

22. The process of claim 20 or 21, wherein each R2is independently selected from a Ci- ealkyl.

23. The process of any one of claims 17 to 20, wherein the reactive silicon based functional group is an alkoxysilyl group, preferably a trialkoxysilyl group.

24. The process of any one of claims 1 to 23, wherein the reinforcement comprises glass, a polyester, an aramid or a combination of any two or more thereof.

25. The process of any one of claims 1 to 24, wherein the reinforcement comprises fibres, rods, needles, beads, flakes, particles, blocks or a combination of any two or more thereof; preferably the reinforcement comprises fibres.

26. The process of any one of claims 1 to 25, wherein the reinforcement a material having an elongated shaped, e.g. fibres, rods, needles, or a combination of any two or more thereof.

27. The process of any one of claims 1 to 26, wherein the reinforcement comprises woven fibres and / or non-woven fibres.

28. The process of any one of claims 1 to 27, wherein the reinforcement comprises glass fibres.

29. The process of any one of claims 1 to 27, wherein the reinforcement comprises sized glass, preferably sized glass fibres.

30. The process of any one of claims 1 to 28, wherein the reinforcement comprises glass, preferably glass fibres, comprising a reactive silicon based functional group.

31. The process of any one of claims 1 to 30, wherein the polymeric composite material or cross-linkable composition comprises the reinforcement in an amount of about 20% or less, 15% or less, 10% or less, 9% or less, 8% or less, 7% or less, 6% or less, or 5% or less by weight.

32. The process of any one of claims 1 to 31, wherein the polymeric composite material or cross-linkable composition comprises the reinforcement in an amount of about 1 to 30% by weight, for example about 1 to 25%, 1 to 20%, 1 to 15%, 1 to 10%, 5 to 30%, 5 to 25%, 5 to 20%, 5 to 15%, 10 to 30%, 10 to 25%, 10 to 20%, 10 to 15%, 15 to 30%, 15 to 25%, 15 to 20%, 20 to 30%, or 20 to 25% by weight.

33. The process of any one of claims 1 to 32, wherein the polymeric composite material or cross-linkable composition comprises the reinforcement in an amount of about 10 to 30% by weight, for example about 11 to 29% by weight, 12 to 28% by weight, 13 to 27% by weight, or 14 to 26% by weight, preferably about 15 to 25% by weight.

34. The process of any one of claims 1 to 33, wherein the functionalised polymer is a functionalised polyethylene comprising a reactive silicon based functional group, and the reinforcement comprises glass, preferably glass fibres, comprising a reactive silicon based functional group and, in the polymeric composite material, the functionalised polymer is at least partially cross-linked with the reinforcement through a Si-O-Si bond.

35. The process of any one of claims 1 to 34, wherein the weight ratio of the functionalised polymer to the reinforcement is from about 30:1 to 1 :30; preferably, the weight ratio ofthe functionalised polymer to the reinforcement is from about 20:1 to 1 :30, about 15:1 to 1:30, about 10:1 to 1:30, about 5:1 to 1:30, about 1:1 to 1:30, about 1:1 to 1:25, about 1:1 to 1 :20, about 1 : 1 to 1 : 15 or about 1:1 to 1:10.

36. The process of any one of claims 1 to 35, wherein the weight ratio of the functionalised polymer to the reinforcement is from about 1 :2 to 1:10, about 1 :3 to 1 :9, about 1 :4 to 1:9 or about 1:4 to 1:8.

37. The process of any one of claims 1 to 36, wherein the cross-linkable composition comprises water; preferably, the cross-linkable composition comprises sufficient water to facilitate a reaction between the functionalised polymer and the reinforcement.

38. The process of any one of claims 1 to 37, wherein the water is provided in the form of steam.

39. The process of any one of claims 1 to 37, wherein the water is provided in the form of one or more additive that comprises water.

40. The process of claim 39, wherein the one or more additive that comprise water is a filler, a flame retardant, or a combination thereof; or wherein the one or more additive that comprise water is calcium carbonate, magnesium hydroxide, or a combination thereof.

41. The process of any one of claims 1 to 37, wherein the water is provided in the form of one or more additive that decomposes to provide water during processing, for example during a mixing step of a process of the invention; optionally wherein the one or more additives that decompose to provide water is magnesium hydroxide.

42. The process of any one of claims 1 to 41, wherein the polymeric composite material or the cross-linkable composition further comprises one or more additional polymer(s).

43. The process of claim 42, wherein the one or more additional polymer(s) is a thermoplastic polymer.

44. The process of claim 42, wherein the one or more additional polymer(s) is a polyolefin.

45. The process of claim 42, wherein the one or more additional polymer(s) is a polyethylene, e.g. a low-density polyethylene (LDPE), medium-density polyethylene(MDPE), high density polyethylene (HDPE) or combination of any two or more thereof.

46. The process of any one of claims 42 to 45, wherein the one or more additional polymer(s) does not cross-link with the functionalised polymer or the reinforcement during the extrusion process.

47. The process of any one of claims 1 to 46, wherein the polymeric composite material or the cross-linkable composition further comprises one or more additive(s) selected from a flame retardant, a filler, a colourant, a UV stabilizer, a thermal stabiliser, a compatibilizer, a foaming agent, a free radical scavenger, a lubricant or a slip agent, a biocide, an additional material, a surface leaching agent or inhibitor, and a combination of any two or more thereof.

48. The process of any one of claims 1 to 47, wherein the polymeric composite material or the cross-linkable composition is substantially free of any organic peroxide, preferably substantially free of any peroxide.

49. The process of any one of claims 1 to 48, wherein the polymeric composite material or the cross-linkable composition is substantially free of a cross-linking catalyst, e.g. a tin catalyst.

50. The process of any one of claims 1 to 49, wherein the polymeric composite material is an extruded polymeric composite material and after extrusion the material is not subjected to any step for initiating further cross-linking of the functionalised polymer with the reinforcement.

51. The process of any one of claims 1 to 50, wherein step (ii) comprises mixing the crosslinkable composition at a temperature of about 80 to 300°C, 200 to 280°C, 210 to 270°C, 220 to 260°C, or 230 to 250°C or about 240°C.

52. The process of any one of claims 1 to 51, wherein step (ii) comprises mixing the crosslinkable composition at a pressure of about 750 to 3,000 psi, 1,000 to 3, 000 psi, 1,250 to 3,000 psi, 1,500 to 3,000 psi, 1,600 to 2,900 psi, 1,700 to 2,800 psi, 1,800 to 2,600 psi, 1,900 to 2,400 psi, preferably about 2,000 to 2,200 psi.

53. The process of any one of claims 1 to 52, wherein step (ii) comprises mixing the cross-linkable composition at a temperature greater than about 200°C and less than about 250°C and a pressure greater than about 1,800 psi and less than about 2,200 psi.

54. The process of any one of claims 1 to 53, wherein the time of step (ii) is about 1 to 15 minutes, 2 to 10 minutes; preferably about 3 to 7 minutes.

55. The process of any one of claims 1 to 54, wherein the extruder comprises a barrel and at least one screw, wherein the extruder is a twin screw extruder.

56. The process of any one of claims 1 to 55, wherein the process further comprises after step (iii) forming the melt into an article having a desired three-dimensional shape with injection molding or compression molding.

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