Fiber Polymer Composite

Abstract

The claimed material relates to a fiber and polymer composite having enhanced modulus, viscoelastic and rheological properties.

We claim: 
     
         1 - 33 . (canceled) 
     
     
         34 . An extruded thermoplastic composite material comprising:
 (i) about 10 to 80 wt. % of a polymer phase comprising a thermoplastic polymer with a density of less than about 1.9 g-m −2 : and   (ii) about 20 to 90 wt. %. % of a dispersed particulate phase consisting essentially of greater than 50 vol. % of a reinforcing cellulosic fiber and the balance comprising at least 5 vol. % of a mineral particulate or a glass particulate, the dispersed phase comprising about 0.2-6 wt. % of a coating of at least one interfacial modifier to form a mixture; and   
       wherein the composite material has a Young's modulus of greater than 700 Mpa and the interfacial modifier provides a coating on the dispersed particulate that can form a close association between the particulate and polymer and covalent bonding between fiber, particulate and polymer are not formed. 
     
     
         35 . The composite of  claim 34  wherein the polymer comprises polyvinyl chloride, and the particulate comprises a cellulosic fiber and a hollow glass sphere. 
     
     
         36 . The composite of  claim 34  wherein the fiber comprises a wood fiber. 
     
     
         37 . The composite of  claim 34  wherein the glass particulate is a hollow glass sphere. 
     
     
         38 . An extruded thermoplastic composite structural member comprising:
 (i) about 10 to 80 wt. % of a polymer phase comprising a thermoplastic polymer with a density of less than 1.9 g-m −2 : and   (ii) about 20 to 90 wt. % of a dispersed particulate phase consisting essentially of greater than 50 vol. % of a reinforcing cellulosic fiber and the balance comprising at least 5 vol. % of a mineral particulate or a glass particulate, the dispersed phase comprising about 0.2-6.00 wt. % of a coating of at least one interfacial modifier to form a mixture; and wherein the composite material has a Young's modulus of greater than 700 MPa; and the interfacial modifier provides a coating on the dispersed particulate that can form a close association between the particulate and polymer and covalent bonding between fiber, particulate and polymer are not formed.   
     
     
         39 . The structural member of  claim 38  comprising a decking member, an extruded panel, and a fencing member. 
     
     
         40 . The composite of  claim 38  forming at least two extruded panels and joinery features. 
     
     
         41 . The composite of  claim 38  comprising a fenestration opening. 
     
     
         42 . The composite of  claim 38  wherein the fiber comprises a wood fiber. 
     
     
         43 . The composite of  claim 38  wherein there is a major proportion of cellulosic fiber and a minor proportion of a glass fiber. 
     
     
         44 . The composite of  claim 38  wherein there are at least two packing fractions of the fiber comprising the cellulosic fiber and the glass fiber. 
     
     
         45 . The composite of  claim 38  wherein the packing fraction of the fiber comprising the cellulosic fiber is greater than the packing fraction comprising the glass fiber.