Thermoplastic composite building product having continuous fiber reinforcement

Abstract

The present invention relates to a decking product, such as railing, fencing, posts and decking, made in part from commingled continuous filaments of glass fibers and polymeric fibers. The commingled fibers can be consolidated into a composite reinforcement or final profile, and can be used in the form of bulk molding compound pellets. The consolidation of the commingled fibers into a composite reinforcement can be made in-situ, during in-line extrusion of the final end product, profile, or extrudate, or prepared as a tape or rod and later incorporated into an off-line extrusion of final product. The bulk molding pellets can be used solely or diluted with an addition of polymeric material for extrusion, co-extrusion, or compression molding, for example.

1 . A thermoplastic composite decking material comprising: a molded thermoplastic composite profile made substantially from a bulk molding compound containing commingled glass fibers and consolidated thermoplastic fibers, wherein the thermoplastic fibers used to make said bulk molding compound are selected from the group consisting essentially of polyethylene, polypropylene, and polyester.  
   
   
       2 . The decking material of  claim 1 , further comprising a wood grain.  
   
   
       3 . The decking material of  claim 2  wherein said wood grain is slip resistant.  
   
   
       4 . The decking material of  claim 1 , wherein said glass fibers are substantially at least one half inch in length.  
   
   
       5 . The decking material of  claim 1 , wherein said glass fibers comprise about 10-40 wt. % of said decking material.  
   
   
       6 . The decking material of  claim 1 , wherein said decking material comprises a UV stabilizer and exhibits a custom color.  
   
   
       7 . The decking material of  claim 6 , wherein said custom color is a dark color.  
   
   
       8 . The decking material of  claim 1 , wherein the bulk molding compound includes about 20%-80% glass fiber content, or is diluted with an addition of polymeric pellets to a glass fiber content of 10%-20% in the final product.  
   
   
       9 . The decking material of  claim 8 , wherein the thermal expansion and contraction of said decking product is controlled by the use of said bulk molding compound.  
   
   
       10 . The decking material of  claim 9 , wherein said decking material is a walking panel or plank, incorporating a molded-in spacer or spacer hole.  
   
   
       11 . A polymer composite fencing or railing material comprising: 
 a composite reinforcement comprising filaments of fibers substantially oriented in at least a first direction substantially continuously along the entire length of said fencing or railing material, and disposed within a thermoplastic matrix; and    a capstock polymeric material disposed substantially over and in direct contact with said composite reinforcement;    said fencing or railing material being resistant to heat deformation and corrosion.    
   
   
       12 . The fencing or railing material of  claim 11  wherein at least said capstock has a dark color.  
   
   
       13 . The fencing or railing material of  claim 12  wherein said heat deformation resistance includes resistance to bowing due to expansion and contraction of said fencing or railing material when exposed to sunlight.  
   
   
       14 . The fencing or railing material of  claim 13  wherein said composite reinforcement and said capstock are observably discrete portions of said fencing or railing material.  
   
   
       15 . The fencing or railing material of  claim 11 , wherein said composite reinforcement comprises about 20 wt. % fiber content.  
   
   
       16 . The fencing or railing material of  claim 15  wherein said fibers comprise one or more of: glass, aramid, or carbon fibers.  
   
   
       17 . The fencing or railing material of  claim 11  wherein said fibers comprise continuous glass filaments, said thermoplastic matrix comprises polypropylene, and said capstock comprises high molecular weight polyethylene (HMPE).  
   
   
       18 . The fencing or railing material of  claim 11  in which the fencing or railing material is in the form of a fence, rail, post, or fencing or railing component.  
   
   
       19 . The fencing or railing material of  claim 11  further comprising a secondary group of fibers oriented in a second direction.  
   
   
       20 . A polymer composite fencing component comprising: 
 a composite reinforcement comprising continuous filaments of high strength fibers oriented substantially in at least a first longitudinal direction within a thermoplastic matrix; and    a thermoplastic capstock polymeric material, which is itself adherent to the thermoplastic of said composite reinforcement, said capstock polymeric material disposed substantially over and in contact with said composite reinforcement;    said fencing component being resistant to corrosion and heat deformation due to exposure to sunlight.    
   
   
       21 . The fencing component of  claim 20  wherein said composite reinforcement comprises one or more of: roving, fabric or tape.  
   
   
       22 . The fencing component of  claim 21  wherein said fabric comprises a uni-directional, multi-axial or woven material.  
   
   
       23 . The fencing component of  claim 20  wherein said composite reinforcement comprises a pultrusion.  
   
   
       24 . The fencing component of  claim 20  wherein said polymeric matrix comprises polypropylene, said fibers comprise continuous glass filaments, and said capstock comprises high molecular weight polyethylene (HMPE).  
   
   
       25 . The fencing component of  claim 20  wherein said component has a dark color and a span of at least about 8 feet.  
   
   
       26 . A polymer composite fencing component comprising: 
 a composite reinforcement comprising continuous glass filaments of fibers substantially oriented in at least a first direction within a pultruded thermoplastic polymeric matrix, said composite reinforcement having a higher tensile strength than aluminum; and    a thermoplastic capstock polymeric material having a dark color disposed substantially over and bonded directly to said composite reinforcement;    said fencing component being corrosion resistant to chemical gasses or acids and resistant to bowing due to expansion and contraction of said fencing or railing material upon exposure to sunlight.    
   
   
       27 . The fencing component of  claim 26  wherein said fibers are oriented in substantially only said first direction for substantially the entire length of said fencing or railing material.  
   
   
       28 . The fencing component of  claim 26  wherein said capstock is directly bonded to said composite reinforcement without additional adhesive or surface treatment.  
   
   
       29 . A substantially maintenance free polymer composite ornamental rail or fence component comprising: 
 a thermoplastic matrix composite comprising high strength glass filaments disposed substantially continuously along the entire length of said rail or fence component; and    a thermoplastic capstock polymeric material having a dark color disposed substantially over and in direct contact with said composite reinforcement, said rail or fence component being substantially stabilized when exposed to uneven contraction and expansion forces, despite a difference in heat buildup on its surface due to sunlight.    
   
   
       30 . The component of  claim 29  wherein said polymer of said polymeric matrix composite and said capstock both contain the same thermoplastic resin.  
   
   
       31 . The component of  claim 29  wherein said composite is a pultrusion.  
   
   
       32 . A process of making a building component comprising: 
 (a) commingling continuous glass and polymeric fibers, wherein said polymeric fibers are selected from the group comprising polyethylene, polypropylene, and polyester;    (b) consolidating said commingled glass and polymeric fibers into a reinforcement; and    (c) disposing a polymeric layer at least partially over and in bonding contact with said reinforcement, said polymeric layer forming the profile for said fencing or railing component.    
   
   
       33 . The process of  claim 32 , wherein said disposing step (c) comprises extruding said polymeric layer over said reinforcement.  
   
   
       34 . The process of  claim 32  wherein said consolidating step (b) comprises pultruding said commingled glass and polymeric fibers.  
   
   
       35 . A process of making a fencing or railing component comprising: 
 (a) commingling continuous glass and polymeric fibers, wherein said polymeric fibers are selected from the group comprising polyethylene, polypropylene, and polyester;    (b) forming said commingled continuous glass and polymeric fibers into a bulk molding compound; and    (c) compression molding said bulk molding compound into a fencing or railing component profile.