Thermoplastic composite building material and method of making same

Abstract

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

1 - 30 . Canceled.  
     
     
         31 . A method of making a polymer composite decking member comprising; 
 (a) providing commingled glass fibers and thermoplastic fibers, said thermoplastic fibers having an ASTM D1238 melt index of at least about 2;    (b) heating said thermoplastic fibers and said glass fibers to at least partially melt said thermoplastic fibers and consolidate said thermoplastic fibers with said glass fibers;    (c) forming said consolidated glass fibers and thermoplastic fibers in a tool to form a shaped decking member; and    (d) cooling said shaped decking member whereby said cooled and shaped decking member has a flexural modulus of at least about 400,000 PSI.    
     
     
         32 . A method of making a polymer composite decking member, comprising: 
 (a) providing glass fibers and a thermoplastic resin, said thermoplastic resin having an ASTM D1238 melt index of at least about 2;    (b) heating said glass fibers and said thermoplastic resin to at least partially melt said thermoplastic resin;    (c) forming said glass fibers and said at least partially melted thermoplastic resin in a tool to form a decking member; and    (d) cooling said decking member;    said cooled decking member having a flexural modulus of at least about 400,000 PSI.    
     
     
         33 . The method of  claim 32 , wherein said heating step (b), forming step (c), or both, comprise compression molding.  
     
     
         34 . The method of  claim 32 , wherein said heating step (b), forming step (c), or both, comprise a pultrusion process.  
     
     
         35 . The method of  claim 32 , wherein said providing step (a) comprises providing a bulk thermoplastic resin containing chopped glass fibers.  
     
     
         36 . The method of  claim 32 , wherein said providing step (a) comprises providing commingled thermoplastic and glass filaments, and said heating step (b) at least partially consolidates said commingled thermoplastic and glass filaments prior to said forming step (c).  
     
     
         37 . The method of  claim 32 , wherein said forming step (c) is conducted under pressure.  
     
     
         38 . The method of  claim 32 , wherein said providing step (a) provides a first thermoplastic resin comprising glass filaments and a second thermoplastic resin which is compatible with said first thermoplastic resin.  
     
     
         39 . The method of  claim 38 , wherein said first thermoplastic resin comprises continuous glass filaments, and said second thermoplastic resin comprises chopped glass fibers.  
     
     
         40 . A method of installing a polymer composite decking construction comprising: 
 (a) providing a first polymer composite decking component having a top planar surface, a bottom surface, a pair of longitudinal sides, and a pair of transverse ends, said first polymer composite decking including at least one aperture located in at least one of its longitudinal sides, and a spacer having a pin for mating with said aperture of said first polymer composite decking member, said spacer disposed between said first polymer composite decking member and a second adjacent polymer composite decking member for providing a uniform spacing between said first polymer composite decking member and said second adjacent polymer composite decking member;    (b) inserting a fastener through said spacer and into a substructure joist, whereby said fastener is at least partially concealed by said first polymer composite decking member and said second adjacent polymer composite decking member.    
     
     
         41 . The method of  claim 40  wherein said second adjacent polymer composite decking member also has an aperture disposed on a longitudinal side thereof which faces said first polymer composite decking member, said spacer having a second pin for mating with said aperture of said second adjacent polymer composite decking member.  
     
     
         42 . The method of  claim 40 , wherein said first polymer composite decking member comprises glass fibers disposed within a thermoplastic matrix, said first polymer composite decking member having a flexural modulus of at least about 400,000 PSI.  
     
     
         43 . The method of  claim 40 , wherein each of said first polymer composite decking member and said second adjacent polymer composite decking member have a cavity located along a bottom surface thereof.  
     
     
         44 . A fencing component, comprising: a polymer composite including glass fibers and a thermoplastic matrix, said thermoplastic matrix containing: polyethylene, polypropylene, HMPE or a combination thereof; said fencing component having at least about 10 wt. % glass fibers and a flexural modulus of at least about 400,000 PSI and said thermoplastic matrix having a melt index of at least about 2, as measured in accordance with the ASTM D1238 test method.  
     
     
         45 . The fencing component of  claim 44 , wherein said component forms a portion of a rail or post.  
     
     
         46 . The fencing component of  claim 45 , wherein said component forms a rail of more than an eight foot span.  
     
     
         47 . The fencing component of  claim 49  wherein said polymer composite is embedded into at least one strategic location within a basic polymeric material.  
     
     
         48 . A fencing rail or post component comprising: a polymer composite including glass fibers disposed within a thermoplastic matrix, said thermoplastic matrix containing: polyethylene, polypropylene, HMPE, or a combination thereof, said rail or post component having a flexural modulus at least about 400,000 PSI.  
     
     
         49 . The component of  claim 48  wherein said polymer composite is disposed within a second polymeric material.  
     
     
         50 . The component of  claim 48 , wherein said component has a dark color.  
     
     
         51 . The component of  claim 50 , wherein said component has a capstock layer disposed thereon.  
     
     
         52 . The component of  claim 50 , wherein said component has at least 10% of the final product.