Foil or film laminated enhanced natural fiber/polymer composite

Abstract

A natural fiber/polymer composite product that includes a core (preferably with a textured surface) and a film or pigment surface layer applied to that textured core surface. The core comprises at least one natural fiber and at least one polymer intimately admixed together to form a composite.

1 . A natural fiber/polymer composite product comprising,: 
 (a) a core comprising at least one natural fiber and at least one polymer intimately admixed together, said core comprising a mechanically or chemically prepared surface; and    (b) at least one layer on said mechanically or chemically prepared core surface, said layer comprising either: a) a film layer laminated onto said mechanically or chemically prepared core surface; or b) a layer that has been hot stamped from a foil onto said mechanically or chemically prepared core surface.    
   
   
       2 . A natural fiber/polymer composite product comprising, 
 (a) a core comprising at least one natural fiber and at least one polymer intimately admixed together, and    (b) at least one layer hot stamped from a foil onto a surface of said core.    
   
   
       3 . A natural fiber/polymer composite product comprising, 
 (a) a core comprising at least one natural fiber and at least one polymer intimately admixed together; and    (b) at least one layer laminated onto a surface of said core.    
   
   
       4 . A natural fiber/polymer composite product formed by, 
 (a) first extruding at least one natural fiber and at least one polymer to form a composite core having a smooth surface;    (b) providing a mechanical or chemical preparation to said surface of said core; and    (c) performing a process to add at least one layer to said mechanical or chemical prepared surface by a process, said process being film lamination or hot stamping of the layer from a foil to the core surface.    
   
   
       5 . The composite product  claim 1  in which said polymer is a thermoplastic.  
   
   
       6 . The composite product of  claim 5  in which the polymer comprises polyvinyl chloride, polyethylene, polypropylene, ABS, or styrene.  
   
   
       7 . The composite product  claim 1  in which the layer is a pattern that has been transferred from to the core surface from a foil by hot stamping.  
   
   
       8 . The composite product of  claim 1  in which the layer is a pattern on a film that is laminated to the core surface.  
   
   
       9 . The composite product of  claim 1  comprising more than one of the layers.  
   
   
       10 . The composite product of  claim 1  in which the core comprises by weight less than 92% but greater than 25% polymer.  
   
   
       11 . The composite product of  claim 1  in which the core comprises by weight less than 75% but greater than 8% natural fiber  
   
   
       12 . The composite product of any of  claim 1  in which the layer is essentially free of abrasive material.  
   
   
       13 . The composite product of  claim 1  in which the layer provides visual enhancements and surface design to mimic natural or man made material surface.  
   
   
       14 . The composite product of  claim 1  in which the layer comprises a material that deflects or reflects ultraviolet radiation away from the core to enhance product resistance to ultraviolet radiation.  
   
   
       15 . The composite product of  claim 14  in which the core comprises a UV resistant pigment.  
   
   
       16 . The composite product of  claim 1  in which the core, the layer, or both comprises a substance that resists mold and/or mildew.  
   
   
       17 . The composite product of  claim 1  in which the layer is a first layer on a first core surface and the product comprises a second layer on a core surface opposite the first core surface.  
   
   
       18 . The composite product of any of  claim 1  in which the layer reduces water absorption as determined either by at least a 10% reduction either in weight gain or physical expansion of the product as compared to the core without the layer, wherein weight gain or physical expansion are measured by either the room temperature or elevated temperature test methods of ASTM D1037-99.  
   
   
       19 . The composite product of any of  claim 1  in which the product exhibits extractive bleeding from the natural fiber in the composite core when subject to moisture that is at least 10% less than the extractive bleeding of the core without the layer, as determined by analysis of tannins, tannic acid and their derivative in a water solution.  
   
   
       20 . The composite product of any of  claim 1  in which the layer controls surface temperature by a minimum of 3% as measured using ASTM D4803-97.  
   
   
       21 . The composite product of any of  claim 1  in which the layer increases wear resistance at least 10% compared to the core without the layer, as measured by ASTM D968-93 Standard Methods for Abrasion Resistance tests.  
   
   
       22 . The composite product of any of  claim 1  in which the layer provides an increase in strength and stiffness compared to the core without the layer, as measured by ASTM D790-03 Standard Test Method for Flexural Properties.  
   
   
       23 . The composite product of any of  claim 1  in which the layer exhibits color inconsistency of less than 1 ΔE as demonstrated by ASTM E805-01a Standard Method.  
   
   
       24 . The composite product of any of  claim 1  in which the layer reduces color fade or change from environmental exposure, as compared to the core without the layer, by a minimum of 20% as measured by ASTM D6864-03ae1 Standard Specification.