U.S. patent application number 09/893274 was filed with the patent office on 2001-12-13 for polyolefin wood fiber composite.
This patent application is currently assigned to Andersen Corporation. Invention is credited to Deaner, Michael J., Godavarti, Shankar, Williams, Rodney K..
Application Number | 20010051243 09/893274 |
Document ID | / |
Family ID | 23129816 |
Filed Date | 2001-12-13 |
United States Patent
Application |
20010051243 |
Kind Code |
A1 |
Godavarti, Shankar ; et
al. |
December 13, 2001 |
Polyolefin wood fiber composite
Abstract
An improved composite structural member comprising a complex
profile structural member, made of a composite comprising a
polypropylene polymer and a wood fiber. The material is useful in
conventional construction applications. The complex profile, in the
form of an extruded thermoplastic composite member can be used in
residential and commercial structures as described. Preferably, the
structural member is used in the manufacture of the fenestration
components such as windows and doors. Such linear members are
designed with specifically configured cross-sectional shapes to
form structural elements in the fenestration units. Structural
elements must possess sufficient strength, thermal stability and
weatherability to permit the manufacture of a structurally sound
window unit that can be easily installed into a rough opening but
can maintain its attractive appearance and structural integrity
over the life of the window unit often twenty years or more. The
structural member comprises a hollow complex cross-section with at
least one structural web or one fastener web formed within the
component. The exterior of the extruded component has a visible
capstock layer and is shaped and adapted for installation in rough
openings. The exterior also contains shape and components capable
of supporting the elements of the fenestration unit such as a
window, sash or movable door unit. The improved polypropylene
structural members have unique advantages and can be assembled in
thermoplastic weld processes.
Inventors: |
Godavarti, Shankar;
(Maplewood, MN) ; Williams, Rodney K.; (Stacy,
MN) ; Deaner, Michael J.; (Osceola, WI) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Assignee: |
Andersen Corporation
100 Fourth Avenue North
Bayport
MN
55003
|
Family ID: |
23129816 |
Appl. No.: |
09/893274 |
Filed: |
June 27, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09893274 |
Jun 27, 2001 |
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09293618 |
Apr 16, 1999 |
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6265037 |
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Current U.S.
Class: |
428/36.9 |
Current CPC
Class: |
C08L 2205/08 20130101;
E04F 13/16 20130101; C08F 255/02 20130101; B29C 48/11 20190201;
Y10T 428/169 20150115; C08L 2666/02 20130101; C08L 2666/06
20130101; B29K 2105/06 20130101; C08L 2666/26 20130101; B29C 48/12
20190201; C08L 97/02 20130101; Y10T 428/24994 20150401; B29C 48/022
20190201; Y10T 428/139 20150115; C08L 23/10 20130101; C08L 2666/24
20130101; C08L 51/06 20130101; Y10T 428/1303 20150115; E06B 3/22
20130101; Y10T 428/1352 20150115; C08L 1/00 20130101; B29K 2711/14
20130101; C08L 23/142 20130101; C08L 23/10 20130101; C08L 23/10
20130101; Y10T 428/1383 20150115; C08L 97/02 20130101; C08L 2205/16
20130101; C08L 51/06 20130101 |
Class at
Publication: |
428/36.9 |
International
Class: |
B32B 001/08 |
Claims
We claim:
1. A weatherable, mechanically stable thin walled complex hollow
profile comprising, a composite comprising: (a) greater than about
25 wt % of a polyolefin polymer composition having a melting point
of about 145.degree. C. to 158.degree. C.; and (b) greater than
about 50 to 75 wt % of a wood fiber, the fiber having a moisture
content of less than 5000 parts of water per million parts of the
profile, a particle size of about 100 to about 2000 .mu.m and an
aspect ratio of about 1:2 to about 1:5; wherein the profile
comprises an extruded complex hollow member having a defined
support direction and a wall thickness of less than about 5 mm, the
modulus of the profile is greater than about 5.multidot.10.sup.5
psi, the heat distortion temperature of the profile in the defined
support direction is greater than about 75.degree. C. at 264 psi
(ASTM D 696).
2. The profile of claim 1 wherein the polyolefin is a maleic
anhydride grafted polypropylene and, with 1 to 100 moles maleic
anhydride, the modulus is at least about 8.multidot.10.sup.5
psi.
3. The profile of claim 1 wherein the polyolefin is polypropylene
and the modulus is at least about 10.multidot.10.sup.5 psi.
4. The profile of claim 1 selected from the group consisting of a
sill, a jamb, a stile, or a rail.
5. A unit comprising at least two profiles of claim 1 with a secure
joint between the profiles.
6. The unit of claim 4 wherein the joint is formed by thermal
welding.
7. The profile of claim 4 having a capstock layer with a thickness
of about 0.05 to 1 mm.
8. The profile of claim 1 wherein the compatibilizer comprises a
polyolefin having a molecular weight (M.sub.4) of about 5000 to
100,000 and about 1 to 100 moles of maleic anhydride per mole of
polymer.
9. The profile of claim 8 wherein the polyolefin is
polypropylene
10. The composite of claim 1 wherein the wood fiber comprises a
moisture content of about 5 to 3200 ppm and a particle size of
about 100 to 800 .mu.m and an aspect ratio of about 2 to 7.
11. The composite of claim 1 wherein the polymer has a weight
average molecular weight (Mw) of about 20,000 to 80,000.
12. A mechanically stable and thermally stable polymer/fiber
composite comprising: (a) greater than about 25 wt % of a
polyolefin polymer composition having a melt index of about 20 to
60 gm-10.sup.-1, a melting point of about 145.degree. C. to
158.degree. C.; (b) greater than about 50 to 75 wt % of a wood
fiber, the fiber having a moisture content of less than 5000 parts
of water per million parts of the fiber, a particle size of about
100 to about 2000 .mu.m and an aspect ratio of about 1:2 to about
1:5; and (c) about 20 to 35 wt % of a polymer/fiber compatibilizer;
wherein the modulus of the composite is greater than about
8.multidot.10.sup.5 psi, the compressive strength of the profile in
the defined support direction is greater than about 1200 psi.
13. The profile of claim 12 wherein the compatibilizer comprises a
polyolefin having a molecular weight (M.sub.w) of about 5000 to
100,000 and about 1 to 100 moles of maleic anhydride per mole of
polymer.
14. The composite of claim 12 having a modulus of at least about
10.multidot.10.sup.5 psi.
15. The composite of claim 12 having a modulus of at least about
12.multidot.10.sup.5 psi.
16. The composite of claim 12 wherein the wood fiber comprises a
moisture content of about 1 to 5000 ppm and a particle size of
about 100 to 2000 .mu.m and an aspect ratio of about 2 to 7.
17. The composite of claim 12 wherein the wood fiber comprises a
moisture content of about 1 to 3500 ppm and a particle size of
about 100 to 800 .mu.m and an aspect ratio of about 2 to 7.
18. The composite of claim 12 wherein the polymer is a
polypropylene has a weight average molecular weight (M.sub.w) of
about 20,000 to 80,000.
19. The composite of claim 12 wherein the polypropylene is a
poly(propylene-co-ethylene) having 0.1 to 10 wt % ethylene.
20. A mechanically stable and thermally stable polymer/fiber
composite comprising: (a) about 25 to 40 wt % of a polypropylene
polymer composition having a melt index of about 30 to 55 g-10
min.sup.-1, a melting point of about 148 to 158.degree. C., a
molecular weight (M.sub.w) of about 20,000 to 80,000 and an
ethylene content of about 0.1 to about 10 wt %; (b) about 65 to 75
wt % of a wood fiber, the fiber having a moisture content of less
than about 4000 parts of water per million parts of fiber, a
particle size of about 150 to about 800 .mu.m and an aspect ratio
of about 1:2 to about 1:5; and (c) about 0.1 to about 5 wt % of a
polymer fiber compatibilizer comprising a polypropylene polymer
having a molecular weight of about 5000 to about 50,000 having
grafted thereto maleic anhydride in an amount of about 15 to about
50 moles of maleic anhydride per mole of polymer composition;
wherein the modulus of the composite is greater than about
8.multidot.10.sup.5 psi, the HDT of the profile in the defined
support direction is greater than about 135.degree. at 264 psi.
Description
FIELD OF THE INVENTION
[0001] The invention relates to composite materials for structural
members used in commercial and residential architecture and
specifically in the manufacture or fabrication of fenestration
units such as windows and doors. The composite is made using an
extrusion process with an input of polyolefin and wood fiber to
form a composite material having improved properties. The materials
have improved processability, thermal and structural properties
when compared to metal, vinyl, or wooden components and when
compared to other polymeric or polyolefin composites. The
structural members of the invention can be used in the form of
elements used in institutional and residential construction such as
framing members, beams, sized lumber, trim, siding, shingle, jambs,
stiles, sills, tracks, sash and other components. These
applications can require a low cost, complex, thin-walled, hollow
profile structural member. The composite can be made with
intentional recycle of by-product or waste streams comprising
components used in the manufacture of the fenestration unit, if
desired.
BACKGROUND OF THE INVENTION
[0002] In conventional construction materials and in window and
door manufacture, vinyl, vinyl composite, wood and metal components
are used in forming structural members. Most commonly siding, trim,
window or door units are typically made from extruded vinyl or
aluminum or milled wood members. Such materials and units made of
these materials, require maintenance and are often energy
inefficient. Vinyl materials have been used in forming envelopes,
profile and seal components in window units. Such vinyl materials
typically comprise a major proportion of vinyl polymer with
inorganic pigments, fillers, lubricants, etc. Extruded or injection
mold of thermoplastic materials have been used, filled and unfilled
as flexible and rigid thermoplastic materials used in seals, trims,
fasteners, and other window construction parts. Thermoplastic
polyvinylchloride has been combined with wood members in the
manufacture of PERMASHIELD.RTM. brand windows manufactured by
Andersen Corporation for many years. The technology is disclosed in
Zaninni, U.S. Pat. Nos. 2,926,729 and 3,432,885. Generally, PVC
materials is used as a cladding or coating. The PVC technology used
in making PERMASHIELD.RTM. brand windows involve extruding or
injection molding thin polyvinylchloride coating or envelope onto a
shaped wooden structural member. One useful alternative to vinyl
envelopes around wood members is a polyvinylchloride wood fiber
composite such as that disclosed in patents assigned to Andersen
Corporation including U.S. Pat. Nos. 5,406,768; 5,441,801;
5,486,553; 5,539,027; 5,497,594; 5,695,874; 5,518,677; 5,827,607
and published European Patent Application No. 586,212, and
others.
[0003] Polyolefin materials such as polyethylene and propylene,
common polyolefin compositions, have been available in a variety of
grades and forms for many years. In large part, polypropylene has
not been used in exterior applications or as exterior structural
members due to its limited structural capacity and its inability to
resist the damaging effect of weather, typically heat, light and
cold. Recently, polypropylene has been used in a variety of
applications in which the polypropylene is combined with a
reinforcing composition in a variety of ways. For example,
Shinomura, U.S. Pat. No. 3,888,810, teaches a thermoplastic
composite comprising a thermoplastic resin, fibrous materials and
preferably synthetic or natural rubbers. Jones, U.S. Pat. No.
3,917,901, teaches a conductor having an insulative layer
comprising a polyolefin-wood composite. Nakano et al., U.S. Pat.
No. 3,962,157, claim a polypropylene composition modified with a
porous filler and a free radical agent that promotes reaction
between the filler and the polymer. Laver, U.S. Pat. No. 5,516,472,
claims an apparatus and method for making a composite which forms,
internally, pellet-like strands that are then recombined to form an
extruded part. Bainbridge et al., U.S. Pat. No. 5,766,395, claim a
self-supporting composite structure in the form of a panel made by
compression molding composite materials. The prior art also
discloses a large proportion of patents that compatibilize a
combination of a polyolefin with a cellulose filler using such
materials as plasticizers, monomeric silicone containing compounds,
grafted silyl moieties on either the polymer or the filler,
polyolefin lubricants, blends of varied types of polymers in
combination with the primary polyolefin, synthetic elastomers and
rubbers, methylol phenolic modified polyolefins, blends of ethylene
polymers and polypropylene polymers, in situ polymerization of
monomers onto a fiber used in the making of a composite,
specialized fibers including polytetrafluoroethylene fibers,
expanded or otherwise specially modified polyolefins, glyoxal and
other types of thermally reactive crosslinking agents, modified
cellulosic fibers including the use of metals, crosslinking agents,
compatibilizing agents, etc. Wold, U.S. Pat. No. 5,435,954, teaches
a molding method for forming a composite into a useful article.
[0004] The polypropylene art has shown significant advancement and
sophistication in learning to obtain new physical properties from
polypropylene, various fibers and reagents or other polymers.
Representative examples of recent developments in the manufacture
of polypropylene compositions, particularly metallocene catalyst
manufactured propylene, is shown in the technical literature owned
by Montell North America Inc. For example, Malucelli et al., U.S.
Pat. No. 5,574,094, teach improved polyolefin compositions
comprising one or more crystalline materials having a melt index
higher than 20 grams-10 min.sup.-1 combined with a cellulosic
particle or fiber. Malucelli et al. disclose pelletizing such a
composite and converting such a pellet into products by way of
injection molding. Sacchetti et al., U.S. Pat. No. 5,691,264,
disclose a bimetallic metallocene catalyst containing at least one
M-.pi. bond combined with a support comprising magnesium halide in
the gas phase polymerization of an olefin such as propylene into a
structural polymeric product. In particular, these catalysts obtain
the polymerization of olefins such as propylene into high molecular
weight useful materials. The patent literature describes bimetallic
catalysts comprising a compound of titanium or vanadium supported
on a magnesium halide reactive with a metallocene compound
containing at least one cyclopentadienyl ring coordinated on a
transition metal selected from V, Ti, Zr, Hf, or mixtures thereof.
Examples of such catalysts are described in U.S. Pat. No.
5,120,696, EP-A-447070 and EP-A447071. The bimetallic catalysts can
be obtained by impregnating a silica support with a magnesium
compound of the type MgR.sub.2, wherein R is a hydrocarbon radical
and then reacting the treated support with a compound of Ti, such
as TiCl.sub.4, optionally with SiCl.sub.4 and thereafter with a
metallocene compound. Such materials are shown in EP-A-514594. Such
bimetallic catalysts obtained by these treatments and then with
other titanocenes such as dicyclopentadienyl titanium dichloride
and bis(indenyl) titanium dichloride are shown in EP-A-412750.
Similar catalysts obtained by treating carbonated compounds of
magnesium such as alkyl magnesium carbonate, with titanium
dichloride in the presence of a metallocene compound of Hf or Zr,
are known from PCT Application WO 94/03508. Bimetallic catalysts
comprising a titanium based catalyst in which the Ti compound is
supported on a Mg halide, a metallocene compound and a
poly(methylaluminoxane) (a MAO) are disclosed in EP-A-436399.
Sacchetti et al., U.S. Pat. No. 5,698,487, disclose additional
compositions and methods for preparation of metallocene catalysts
for preparing polyolefin materials. Govoni et al., U.S. Pat. No.
5,698,642, disclose a particular gas phase polymerization project
having two interconnected polymerization zones for olefin
polymerization. Sacchetti et al., U.S. Pat. No. 5,759,940, disclose
further information on the preparation of catalytic materials for
the manufacture of polyolefin materials. Additional details for
manufacturing modem metallocene catalysts are shown in U.S. Pat.
No. 4,542,199 and EP-A-129368; EP-A-185918; EP-A-485823;
EP-A485820; EP-A-51237; and U.S. Pat. Nos. 5,132,262; 5,162,278;
5,106,804. The more modern polypropylene polymeric materials show
improvement in physical properties when compared to the materials
made using the initially formulated Zigler-Natta catalytic
materials developed since the early 1960's.
[0005] Kourgli, U.S. Pat. No. 5,542,780, discloses a polypropylene
composite having an elastic modulus of about 500,000 or less. Coran
et al., U.S. Pat. No. 4,323,625, teach a polypropylene composite
having 20 wt % of a hardwood pulp and a modulus less than 200,000.
Nishibori, U.S. Pat. No. 5,725,939, teaches a wood meal
polypropylene composite with 50% polymer and a modulus less than
400,000. Beshay, U.S. Pat. No. 4,717,742, discloses an aspen pulp
polypropylene composite having 40 wt % pulp and a tensile modulus
less than 100,000. Beshay, U.S. Pat. No. 4,820,749, teaches an
aspen pulp polypropylene composite having about 40 wt % pulp and a
modulus of less than 100,000. Dehennau et al., U.S. Pat. No.
5,164,432 and Bortoluzzi et al., U.S. Pat. No. 5,215,695, show
sawdust containing composites with less than 50 wt % fiber and a
modulus less than 800,000. Malucelli et al., EP Application No.
540026, teach a wood flour polypropylene composite having 50 wt %
polymer and a modulus less than 700,000. In summary, the prior art
relating to polypropylene composites typically uses 50 wt % or less
fiber, exhibits a modulus of less than 800,000 and is not
particularly descriptive regarding manufacturing process conditions
or valuable thermal or structural properties. The industry has not
succeeded in manufacturing a high strength and thermally stable
composite. The industry has failed to prepare a complex thin-wall
profile structural member from polypropylene and a reinforcing
fiber that can show structural integrity over the life of a
fenestration unit.
[0006] A substantial need exists for an improved polyolefin-wood
fiber composite structural material that can be extruded into a
weatherable, color stable, engineering structural member. Such a
structural member requires physical stability, color stability, a
controllable coefficient of thermal expansion and sufficient
modulus to survive in a construction installation and while exposed
to the exterior environment. The composite must be extruded or
extrudable into a shape that is a direct substitute in assembly
properties and structural properties for a wooden or extruded
aluminum member. Such materials must be extrudable into
reproducible, stable dimensions and useful cross-sections with a
low heat transmission rate, improved resistance to insect attack,
improved resistance to water absorption and rot resistance when in
use combined with hardness and rigidity that permits sawing,
milling and obtains fastening retention properties comparable to
wood members and aluminum members. Accordingly, a substantial need
exists for further developments in the manufacture of composite
members for fenestration units.
BRIEF DISCUSSION OF THE INVENTION
[0007] We have found a substantially improved polyolefin wood fiber
composite material that when extruded into structural members
provide surprisingly improved mechanical properties including:
tensile modulus, and mechanical stability (heat deflection) at
elevated temperature. Applicants have unexpectedly discovered that
"compatibilization" of acicular wood fibers having specified
moisture content provides a melt rheology conducive to production
of improved extruded, fiber reinforced structural members. A
further feature of the invention resides in applicant's recognition
that the melt rheology permits use of extrusion tooling (dies,
calibration blocks, etc.) designed for a poly(vinylchloride) (PVC)
wood fiber composite material also known as FIBREX.RTM.. Applicants
believe that the superior mechanical properties of the structural
members are due to improved wood fiber alignment and fiber-resin
compatibilization (wetting).
[0008] The polypropylene composite combines about 5 to 50 parts of
a polyolefm polyethylene or polypropylene with greater than about
50 to 90 parts of a wood fiber having an aspect ratio greater than
about 2 and a fiber size that falls between about 50 microns and
about 2000 microns. Preferably the fiber size ranges from about 100
to about 1000 microns and most preferably from about 100 to about
500 microns. The useful polyolefin material is a polyethylene or
polypropylene polymer having a melting point of about 140 to
160.degree. C., preferably about 145 to 158.degree. C. and a melt
index greater than 20 g-10 min.sup.-1 preferably about 40 to 60
g-10 min.sup.-1. The preferred polyethylene material is a
polyethylene homopolymer or copolymer with 0.01 to 10 wt. % of a
C.sub.2-16 olefin monomer. The preferred molecular weight (M.sub.w)
is about 10,000 to 60,000. The preferred polypropylene material is
a polypropylene homopolymer or copolymer with 0.01 to 10 wt % of
ethylene or a C.sub.4-16 olefin monomer or mixtures thereof. The
preferred molecular weight (M.sub.w) is about 10,000 to 60,000. The
composite is also compatibilized using a compatibilizing agent that
improves the wetting of the polymer on the fiber particle. In a
preferred mode, the wood fiber is dried as thoroughly as possible.
The useful fiber material is dried to a content of less than about
5000 parts, preferably less than 3500 parts of water per each
million parts of wood fiber (ppm) resulting in an open cell wood
fiber state in which the polypropylene polymer can then wet and
penetrate the open salt fiber structure. The combination of these
parameters in the composite results in a composite having
surprisingly improved structural properties and thermal properties.
The polypropylene-wood fiber composite was manufactured in two
stages. In the first stage, polypropylene resin and wood fiber were
fed into the compounder and pelletized. A vacuum was applied
downstream to reduce the final moisture content. Also, another
vacuum was applied in the transition box between the twin-screw
compounder and the single-screw extruder to further reduce the
moisture content and also to lower the temperature. These were
called Precursor pellets. In the second stage, the precursor
pellets and the compatibilizer were fed directly into the feed port
and pelletized. The compounded and pelletized material from the
second stage was called the Composite. Both, the biofiber and the
resin were added simultaneously for two reasons. One, to minimize
fiber degradation in the screw i.e., to maintain the fiber aspect
ratio. The resin is allowed to coat the fiber and hence act as a
lubricant. Two, incorporating the resin downstream into the hot
fiber would result in lowering of temperature and increase the
tendency of clumping leading to non-uniform distribution of the
fiber within the matrix. In the second stage, the solid
compatibilizers were added along with the precursor into the feed
port in an initial zone. The liquid compatibilizers were added
downstream into melt. Liquid compatibilizer experiments resulted in
dark samples due to discoloration and excessive heat history and
these were not pursued further. The two-stage process was also
beneficial from a moisture control point of view. More than 95% of
the initial moisture was removed in stage 1 of the process. This
moisture removal is of utmost importance for increasing the
effectiveness of the coupling agents being added in stage 2.
[0009] The general formulation parameters are as follows for the
composite.
1TABLE 1 FORMULATIONS (Parts by Weight) POLYOLEFIN COMPATIBILIZER
WOOD FIBER POLYPROPYLENE 20-50 0.01 to 5 80-greater than 50 20-45
0.1 to 4 80-55 25-35 0.5 to 3 75-65 POLYETHYLENE 20-50 0.01 to 5
80-greater than 50 20-45 0.1 to 4 80-55 25-35 0.5 to 3 75-65
[0010] Preferred polypropylene is available in different forms
including homopolymer, random copolymer and impact copolymers. The
ethylene content in random copolymers varies from 2-5% and from
5-8% in impact copolymers. The ethylene portion is responsible for
imparting the impact strength while the propylene portion imparts
the rigidity. Typical DroDerties of these two types of polymers are
given in Table 2. Higher impact strength copolymers tend to lose
some stiffness or rigidity. Montell polypropylene random copolymer
SV-258 resin was identified and used as the base polymer for all
experiments in this phase.
[0011] We have also developed a weatherable, mechanically stable,
thin-walled complex, hollow profile material. The term
"thin-walled" contemplates a profile having an open internal hollow
structure. The structure is surrounded by a thin wall having a
thickness dimension of about 1 to about 10 millimeters, preferably
about 2 to 8 millimeters. Any internal support webs or fastener
anchor locations have a wall thickness of about 5 to 8 mm. The
profile is manufactured from a composite comprising an improved
polypropylene polymer composition and wood fiber. The wood fiber is
a specially prepared material having controlled moisture content,
particle size and aspect ratio. The resulting structural member is
extruded into a complex hollow profile having a defined support
direction. The modulus of the profile is about 8.multidot.10.sup.5
psi. The compressive strength of the profile in the defined support
directions greater than about 1.2.multidot.10.sup.3 psi. Such
profiles can be assembled into a useful unit in institutional or
residential real estate construction. The profiles can be joined
using a variety of adhesive and welding joining techniques for
forming a secure joint between profile members. The modulus of the
profile is about 5.5 gigapascals. The compressive strength of the
profile in the defined support directions is greater than about 8.8
gigapascals. The profile, can optionally include a weatherable
capstock material that has a stable color and appearance defined as
less than a Delta E value of less than two 2 Hunter Lab units upon
60 months of accelerated weathering as determined by ASTM D2244
Section 6.3 (after exposure per Section 7.9.1.1). Such profiles can
be assembled into a useful unit in institutional or residential
real estate construction. The profiles can be joined using a
variety of adhesive and welding joining techniques for forming a
secure joint between profile members. The profile can have a
capstock layer with a thickness of about 0.05 to 1 mm, preferably
about 0.1 to 0.5 millimeters coextruded on any visible exterior
portion or the entire exterior portion of the profile. The capstock
can cover greater than 20% of the exterior area, 20 to 80% of the
exterior area or virtually 100% of the exterior area, depending on
the application of the profile. The profile can have a capstock
layer with a thickness of about 0.05 to 1 mm, preferably about 0.1
to 0.5 millimeters coextruded on any visible exterior portion or
the entire exterior portion of the profile. The capstock can cover
greater than 20% of the exterior area, 20 to 80% of the exterior
area or virtually 100% of the exterior area, depending on the
application of the profile.
[0012] For the purpose of the patent application, the term "aspect
ratio" indicates an index number obtained by dividing the length of
the fiber by its width. Molecular weights disclosed in this patent
application are weight average molecular weights (M.sub.w). The
physical parameters of the materials made in this application are
measured using ASTM methods which are disclosed throughout the
application. The term complex profile is intended to mean an
extruded thermoplastic article having a hollow internal structure.
Such structure includes a complex exterior surface geometry or
structure, at least one support web providing mechanical stability
in a defined support direction. Alternatively the complex profile
structure can comprise one, or more fastener anchor means or
locations to improve assembly or installation. The term defined
support direction is intended to mean a direction of force or a
line of strain opposing the force derived from the environment.
Examples of such force includes the force of a step upon a
threshold, the force of closing a sash, the force of gravity, wind
load forces and forces rising from the anisotropic stress resulting
from the non-planar installation of the unit.
BRIEF DESCRIPTION OF FIGURE
[0013] FIG. 1 shows a portion of a extruded complex hollow profile
for a window sash. The sash is an extruded polypropylene wood fiber
composite having a capstock. The sash has at least two support
directions, one for gravity and a second for wind load. The profile
comprises a complex external surface features, for glazing and
frame, and a complex internal structure.
[0014] FIG. 2 shows a cross-section of a second extruded complex
hollow profile for a residential siding component. The siding
component is an extruded polypropylene wood fiber composite that
can have a capstock if needed on the exterior surface. The siding
unit requires impact strength to resist the effects of impact in
the horizontal direction and also requires sufficient structural
integrity to survive installation.
[0015] FIG. 3 is a graph demonstrating the surprising melt flow
properties, measured at 190.degree. C., of the polypropylene wood
fiber composite. Combining a major proportion of fiber with a
polypropylene thermoplastic component provides melt flow and
viscosity similar to known production parameters for profile
extrusion with a PVC wood fiber composite in which the composite
comprises about 60 parts by weight of PVC and about 40 parts by
weight of wood fiber. Even with the use of substantially different
proportions of materials, a useful and extrudable thermoplastic
material results. This melt flow viscosity lends itself to
extrusion using well understood temperature and pressure
profiles.
DETAILED DISCUSSION OF THE INVENTION
[0016] The invention resides in an advanced composite and in a thin
wall complex hollow profile manufactured from a polyolefin
preferably polypropylene/wood fiber composite material. The
composite has improved mechanical, chemical and weatherability
properties rendering it ideal for use in institutional and
residential construction materials. The profile can be used in
virtually any structural or trim application.
[0017] The composite, comprising a polyolefin, preferable
polypropylene, combined with the wood fiber materials preferred for
use in the invention, have improved impact resistance, improved
flexural and tensile moduli, improved heat distortion temperature,
and reduced brittle character. Newer polyolefin, polyethylene or
polypropylene are made using metallocene catalyst technology.
Metallocene catalysts are typically single sited catalysts (i.e.,
they have one or more identical active sites per molecule). Such
catalyst consistency results in improved molecular weight
distribution and stereochemical structure. Syndiotactic
polypropylene is now being produced commercially using metallocene
catalysts. These catalysts are organometallic compounds with a
sandwich-like spacial arrangement consisting of a transition metal
(iron, titanium, zirconium, etc.) situated between two cyclic
organic compounds such as a dicyclopentadienyl or a bridged ring
structure. The first metallocenes used for polymerization showed
activity but the hydrolysis of trimethylaluminum into
methylalumoxane resulting in a much more highly active metallocene
catalyst. Chiral, bridged metallocene catalysts have also been
prepared in catalytic materials that are highly active and
selective. Current metallocene catalyst systems commonly use
zirconium dichlorite (ZrCl.sub.2) as the transition metal complex
with a cyclopentadiene moiety as the organic compound and an
aluminoxane such as MaO as a cocatalyst. The improved polyolefin,
polyethylene or polypropylene resins having improved
microstructure, molecular weight and other properties can be
produced using these catalysts.
[0018] Polyethylenes made using the current metallocene catalyst
technology exhibit increased rigidity, uniform molecular structure,
improved heat or thermal properties and improved toughness. The
improved uniform polyethylene molecular structures minimize
polydispersion or distribution ratios, M.sub.w.backslash.M.sub.n of
about 3-6. Overall, the improved polyethylenes have a molecular
weight of about 10,000 to 80,000, a melt index of about 20 to 60
g-10 min.sup.-1 and improved processability.
[0019] Polypropylenes made using current metallocene catalyst
technology exhibit increased rigidity and transparency, higher heat
distortion temperature, improved impact strength and toughness even
at winter extremes with low extractable residues. Due to the
uniformity of the polypropylene chains, metallocene catalyzed
polypropylene has a very narrow (compared to Zigler-Natta
polypropylene) minimum distribution ratio, M.sub.w/M.sub.n of about
3-6. This narrow molecular weight distribution results in low shear
sensitivity of the polypropylene resin and provides low melt
elasticity, elongation and viscosity in extrusion processes. The
melting point of metallocene polypropylene (147-158.degree. C.;
297-316.degree. F.) is generally lower than of conventional
Zigler-Natta polypropylene (160-170.degree. C.; 320-338.degree. F.)
and can be tailored for specific applications using the appropriate
catalyst. The preferred polypropylene materials used for the
composites of this invention comprise a polypropylene having a
molecular weight (M.sub.w) of about 20,000 to 100,000, a melt index
of about 40 to 60 g-10 min.sup.-1 and improved extrusion
processability.
[0020] The improved polyolefin materials of the invention can
comprise either a polypropylene copolymer wherein the polymer
comprises a major proportion of propylene combined with a minor
proportion (typically less than 50 wt %, most commonly between
about 0.1 and 10 wt %) of a second monomer which can comprise
ethylene or a C.sub.4-16 monomer material. Such copolymers often
have improved processability, flexibility and compatibility.
Preferred ethylene copolymers can comprise a major proportion of
ethylene and a minor proportion (typically less than 50 wt %,
preferably about 0.1 to about 10 wt %) of a C.sub.3-18 monomer.
These polyethylenes similarly have improved properties over the
prior art.
[0021] Wood fiber, in terms of abundance and suitability, can be
derived from either soft woods or evergreens or from hard woods
commonly known as broadleaf deciduous trees. Soft woods are
generally preferred for fiber manufacture because the resulting
fibers are longer, contain high percentages of lignin and lower
percentages of hemicellulose than hardwoods. While soft wood is the
primary source of fiber for the invention, additional fiber make-up
can be derived from a number of secondary or fiber reclaim sources
including hard woods, bamboo, rice, sugar cane, and recycled fibers
from newspapers, boxes, computer printouts, etc. However, the
primary source for wood fiber used in the process of this invention
comprises the wood fiber by-product of sawing or milling softwoods
commonly known as sawdust or milling tailings. Such wood fiber has
a regular, reproducible shape and aspect ratio. The fibers based on
a random selection of about 100 fibers are commonly greater than 50
.mu.m in length, greater than 10 .mu.m in thickness and commonly
have an aspect ratio of at least 1.8. The fibers are 50 .mu.m to
2000 .mu.m in length, preferably 100 to 1000 .mu.m in length, most
preferably about 100 to 500 .mu.m in length. The fiber is a dry
fiber and comprises less than about 5000 ppm water, preferably less
than about 3500 ppm water, based on the fiber. Several key
characteristics were identified and the following were considered
in this study including particle size distribution, hard or soft
wood, moisture content and fiber morphology. Particle size
distribution is the most critical variable of all. The fiber aspect
ratio influences the final composite properties significantly.
Therefore, in order to study this effect, three different wood
fiber sizes i.e., less than 140 mesh (80.mu.), less than 80 mesh
(200.mu.) and standard wood fiber less than 30 but larger than 80
(900 to 200.mu.), were chosen. Traditionally, Andersen Windows
Corp. has been using softwood (loblolly pine wood) and therefore
the same species was used in this study. All three wood fiber types
had an initial moisture content ranging between 6.7-6.9%.
[0022] The preferred fiber for use in this invention are fibers
derived from comminuting wood fiber or from processes common in the
manufacture of windows and doors. Wooden members are commonly
ripped or sawed to size in a cross grain direction to form
appropriate lengths and widths of wood materials. The by-product of
such sawing operations is a substantial quantity of sawdust. In
shaping a regular shaped piece of wood into a useful milled shape,
wood is commonly passed through machines which selectively remove
wood from the piece leaving the useful shape. Such milling
operations produce substantial quantities of sawdust or mill
tailing by-products. Lastly, when shaped materials are cut to size
and mitered joints, butt joints, overlapping joints, mortise and
tenon joints are manufactured from pre-shaped wooden members,
substantial waste trim is produced. Such large trim pieces are
commonly cut and machined to convert the larger objects into wood
fiber having dimensions approximating sawdust or mill tailing
dimensions. The wood fiber sources of the invention can be blended
regardless of particle size and used to make the composite.
[0023] Wood fiber, in terms of abundance and suitability, can be
derived from either softwoods or evergreens or from hard woods
commonly known as broadleaf deciduous trees. Softwoods are
generally preferred for fiber manufacture because the resulting
fibers are longer, contain high percentages of lignin and lower
percentages of hemicellulose than hardwoods. While soft wood is the
primary source of fiber for the invention, additional fiber make-up
can be derived from any number of available sources such as
hardwood fiber ground newsprint, magazines, books, cardboard, wood
pulps (mechanical, stone ground, chemical, mechanical-chemical,
bleached or unbleached, sludge, waste fines), and various
agricultural wastes (rice hulls, wheat, oat, barley and oat chaff,
coconut shells, peanut shells, walnut shells, straw, corn husks,
con stalks, jute, hemp, bagasse, bamboo, flax, and kenaff).
However, the primary source for wood fiber used in the process of
this invention comprises the wood fiber by-product of sawing or
milling softwoods commonly known as sawdust or milling tailings.
Such wood fiber has a regular, reproducible shape and aspect ratio.
The fibers based on a random selection of about 100 fibers are
commonly greater than 50 micrometers in length, greater than 10
micrometers in thickness and commonly have an aspect ratio of at
least 1.8. The fibers are 50 micrometers to 2000 micrometers in
length, preferably 100 to 1000 micrometers in length, most
preferably about 100 to 500 micrometers in length. The fibers are 3
to 25 micrometers in thickness with an aspect ratio between 2 and
50, preferably 2.5 to 40 or as necessary to provide a fiber of
useful length.
[0024] As disclosed in greater detail hereinbelow, the improved
thermal and mechanical properties including impact strength of the
inventive structural members increase as lengths of the wood fibers
used to prepare the composite material are increased. In the
inventive structural members, wood fibers act as reinforcing fibers
as opposed to fillers. Applicant's believe that the transition from
filler to reinforcing fiber takes place above 80-mesh fiber size.
Maximum strength is achieved when the fiber length exceeds the
critical load transfer length. In this case, the fiber fails before
the polyolefin matrix or the "compatibilized" interface between
fiber and matrix. When the fiber length is less than the critical
length, failure generally takes place either at the interface or in
the continuous polyolefin matrix. The critical load transfer length
is described by Stokes and Evens, Fundamentals of Interfacial
Engineering, Wiley-VCH, New York, (1997), Chapter 7 and Matthews
and Rawlings, Composite Materials: Engineering and Science, Chapman
& Hall, London, (1994), pp 297-321 the disclosures of which are
hereby incorporated by reference. Since the desirable thermal and
mechanical properties provided by the invention are related to long
fibers. it is important to minimize fiber breakage in the various
unit operations used to extrude the composite. When completely dry,
wood fibers become brittle and subject to breakage in the shear
fields during compounding. Therefore the wood fiber moisture should
exceed 40 ppm, preferably 100 ppm. As disclosed below, when wood
fiber moisture is too high chemical bonding between fiber and
compatibilizer is minimized and the improved properties
characterizing the invention are not achieved. Therefore wood fiber
moisture should be in the range of from 40 to 40,000 ppm,
preferably from 100 to 10,000 ppm, and more preferably from 500 to
5,000 ppm, and most preferably from 1,000 to 3,500 ppm.
[0025] Coupling, compatibilizing, or mixing agents can be added to
the polyolefin material. These additives can be added in an amount
of from about 0.01 to about 20 wt %, preferably about 0.1 to about
10 wt % to preferably from about 0.2 to 5 wt % to achieve
improvements in the physical, mechanical and thermal
characteristics of the materials. Examples of such compatabilizerss
include titanium alcoholates, esters of phosphoric, phosphorous,
phosphonic and silicic acids, metallic salts and esters of
aliphatic, aromatic and cycloaliphatic acids, ethylene/acrylic or
methacrylic acids, ethylene/esters of acrylic or methacrylic acid,
ethylene/vinyl acetate resins, styrene/maleic anhydride resins or
esters thereof, acrylonitrilebutadiene styrene resins,
methacrylate/butadiene styrene resins (MBS), styrene acrylonitrile
resins (SAN), butadieneacrylonitrile copolymers and particularly
polyethylene or polypropylene modified polymers. Such polymers are
modified by a reactive group including polar monomers such as
maleic anhydride or esters, acrylic or methacrylic acid or esters,
vinylacetate, acrylonitrile, and styrene. Virtually any
olefinically reactive residue that can provide a reactive
functional group on a modified polyolefin polymer can be useful in
the invention. Preferred compatibilizers comprise a polyolefin such
as a polyethylene or polypropylene having a molecular weight that
ranges from about 5000 to about 100,000. Each polymer of the
compatibilizing agent can be modified from about 5 to about 100
residues per mole of the polymer. Preferred compatibilizers
comprise either a modified polypropylene or a modified polyethylene
modified with maleic anhydride residues. The most preferred
compatibilizer comprises a maleic anhydride modified polypropylene.
The preferred material has a molecular weight that ranges from
about 5000 to about 60,000 and has from about 5 to 50 moles of
maleic anhydride per mole of polymer. The composites of the
invention can also contain conventional additive materials
including lubricants, antioxidants, dyes, stabilizing agents and
other materials common for maintaining the molecular weight or
stabilizing the overall material to thermal or mechanical
degradation. Coupling agents were selected based on their coupling
mechanisms. Epolene polymers from Eastman Chemicals (Epolene-E43,
G3003, and G3015) and Questron KA 805 from Montell were identified
as the maleic anhydride grafted polypropylene agents. These
function through covalent bonding mechanism. Titanate/Zirconate
(LICA 12 and LICA 38) based coupling agents from Kenrich Chemicals
were identified for their emulsion based compatibilizing mechanism.
Lupasol FG and Lupasol G20 waterfree from BASF were chosen for
hydrogen bonding mechanism. The parameters of interest in case of
Epolene and Questron coupling agents were: Molecular weight and
Acid number. In case of LICA 12 and 38, parameters of interest were
physical form and particle size and shape. In case of Lupasol,
viscosity, moisture content and molecular weight were the
parameters considered. Tables 3 and 4 lists properties of all
compatibilizers.
[0026] Coupling, compatibilizing, or mixing agents can be added to
the polyolefin material. These additives can be added in an amount
of from about 0.01 to about 20 wt %, preferably about 0.1 to about
10 wt % to preferably from about 0.2 to 5 wt % to achieve
improvements in the physical, mechanical and thermal
characteristics of the materials. Such compatibilizing agent can
include both organic and inorganic fillers. Examples of such
fillers include titanium alcoholates, esters of phosphoric,
phosphorous, phosphonic and silicic acids, metallic salts and
esters of aliphatic, aromatic and cycloaliphatic acids,
ethylene/acrylic or methacrylic acids, ethylene/esters of acrylic
or methacrylic acid, ethylene/vinyl acetate resins, styrene/maleic
anhydride resins or esters thereof, acrylonitrilebutadiene styrene
resins, methacrylate/butadiene styrene resins (MBS), styrene
acrylonitrile resins (SAN), butadieneacrylonitrile copolymers and
particularly polyethylene or polypropylene modified polymers. Such
polymers are modified by a reactive group including polar monomers
such as maleic anhydride or esters, acrylic or methacrylic acid or
esters, vinylacetate, acrylonitrile, and styrene. Virtually any
olefinically reactive residue that can provide a reactive
functional group on a modified polyolefin polymer can be useful in
the invention. Preferred compatibilizers comprise a polyolefin such
as a polyethylene or polypropylene having a molecular weight that
ranges from about 1000 to about 100,000, preferably 5,000 to about
80,000, more preferably from about 30,000 to about 60,000. Each
polymer of the compatibilizing agent can be modified from about 5
to about 100 residues per mole of the polymer, preferably from
about 10 to about 50 residues per mole. Preferred compatibilizers
comprise either a modified polypropylene or a modified polyethylene
modified with maleic anhydride residues. The most preferred
compatibilizer comprises a maleic anhydride modified polypropylene
having a molecular weight of from about 5000 to about 60,000 and
from about 5 to 50 moles of maleic anhydride per mole of
polymer.
[0027] Applicant's believe that the most preferred maleic anhydride
compatibiliziers react (through ring-opening reactions) with
hydroxyl groups on the surfaces of the wood fibers to form esters
linkages that chemically bond the compatibilizer to the surface of
the reinforcing wood fiber. Chemical bonding contributes to the
improved thermal and mechanical properties of structural members
derived from the composite material by maximizing fiber-matrix
interface shear strength (as disclosed by Stokes and Evens, supra).
Since excess moisture can prematurely hydrolyze the anhydride ring
to maleic acid before the formation of ester linkages, bonding is
not effective in the presence of excessive amounts of moisture. On
the other hand, when the wood fibers are too dry they become
brittle and tend break during compounding and extrusion processing
to form both the precursor (also known as masterbatch) and finished
composite used to form the structural members. As disclosed above,
when the fiber length drops below the critical length it acts as a
filler instead of a reinforcing fiber degrading the improved
thermal and mechanical properties characteristic of the inventive
structural members. In summary, the improved thermal and mechanical
properties observed in the inventive structural members results
when the: wood fiber reinforcing properties are maximized (fiber
length exceeds the critical load transfer length), compatibilizer
chemically bonds wood fiber to a portion of the polyolefin matrix
(maximizing-fiber matrix interface shear strength), and wood fiber
moisture is in the preferred range during the unit operations used
to extrude the composite material used in the structural
members.
[0028] Compatibilizers were necessary to improve the strength of
the composite material. The natural incompatibility between the two
phases; hydrophilic wood-fiber with the hydrophobic polymer matrix
results in a weak interface between the fiber and the matrix.
Further, the presence of strong intermolecular hydrogen bonds
between the fibers leads to poor dispersion of the fibers in the
matrix. Coupling these two materials through chemical bonding is an
effective way in overcoming these problems.
[0029] The polypropylene compositions of the invention, in
particular, a capstock layer coextruded onto the surface of all or
a portion of the polypropylene composite profile can contain a
colorant or pigment. Colorants are pigments or dyes. Dyes are
commonly organic compound soluble in the plastic forming a neutral
molecular solution. They produce bright intense colors and are
transparent. Pigments are generally insoluble in the plastic. The
color results from the dispersion of fine particles (in the range
of about 0.01 to about 1 .mu.m) throughout the resin. They produce
opacity or at least some translucence in the final product.
Pigments can be organic or inorganic compounds and are viable in a
variety of forms including dry powders, color concentrates, liquids
and precolor resin pellets. Most common inorganic pigments include
oxides, sulfides, chromates, and other complexes based on heavy
metal such as cadmium, zinc, titanium, lead, molybdenum, iron and
others. Ultamarines are typically sulfide-silicate complexes
containing sodium and aluminum. Often pigments comprise mixtures of
two, three or more oxides of iron, barium, titanium, antimony,
nickel, chromium, lead, and others in known ratios. Titanium
dioxide is a widely used and known bright white thermally stable
inorganic pigment. Organic pigments are also known including azo or
diasazo pigments, pyrazolone pigments, and others including
permanent red 2B, nickel azo yellow, litho red, and pigment
scarlet. The preferred reinforcing fiber for the polypropylene
composite profiles of the invention is wood fiber. However, other
reinforcing fibers are useful in practicing the invention. Such
fibers include but not limited to other cellulosic or natural
fibers, for example, cotton, wool, jute, kenaff, bamboo; synthetic
fibers for example, polyester, aramide (NYLONTM); inorganic fibers
(chopped or long), for example, glass fibers, carbon fiber, ceramic
fibers.
[0030] The composition may also contain conventional components:
fillers for example, titanium dioxide, silica, alumina,
silica/alumina, silica/magnesia, calcium silicate, talc, calcium
carbonate, barium/calcium sulfate, mica, Wollastonite, Kaolin,
glass beads, glass flakes, glass microspheres, ceramic microspheres
(Zeeospheres.TM.) and the like; lubricants such as higher fatty
acids and paraffin waxes; oxidation stabilizers; UV stabilizers;
antistatic agents; antioxidants; fire retardants dyes; pigments
plasticizers mold release agents; extrusion mold release agents and
the like. These additive components can be blended and introduced
into the extruder device with the polymer materials.
[0031] Capstocks useful in practicing the invention are available
under the tradename ASTRYN.TM. from Montel
Formulations
[0032] A preferred polyolefin wood fiber formulation for use in
this invention is shown in the following table:
2TABLE 2 FORMULATIONS (Parts by Weight) Polyolefin COMPATIBILIZER
WOOD FIBER.sup.3 POLYPROPYLENE.sup.1 20 to 50 0.01 to 5 80 to
greater than 50 20 to 45 0.1 to 4 80 to 55 25 to 35 0.5 to 3 75 to
65 POLYETHYLENE.sup.2 20 to 50 0.01 to 5 80 to greater than 50 20
to 45 0.1 to 4 80 to 55 25 to 35 0.5 to 3 75 to 65 .sup.1Molecular
weight (M.sub.W) about 60,000, polydispersion about 5, m.p. about
150.degree. C., melt index about 48 g-10 min.sup.-1. Optional
copolymer with 0.01 to 10 wt % ethylene. .sup.2Homopolymer,
Molecular weight (M.sub.W) 70,000, polydispersion 4, melt index 45
g-10 min.sup.-1. .sup.3Prepared pine fiber; moisture 1000-5000 ppm
on fiber; fiber length 100-500.mu. with an aspect ratio about 2 to
5.
Extrusion Processing
[0033] The following description of the blending of the
formulations, extrusion of the materials and formation of the
materials in an appropriate thin walled hollow profile dye is an
understanding of the processing conditions required for making a
successful complex hollow profile structure.
[0034] The preferred polypropylene wood fiber composite materials
have been discovered to have the following unique properties. The
following shows the manufacture of an improved structural material
and demonstrate its utility as a stable high strength structural
member.
[0035] The following examples illustrate the advance in structural
properties including tensile modulus and Gardener impact and an
improvement in heat properties such as heat distortion temperature
and coefficient of thermal expansion. The examples illustrate the
invention and suggest the best mode.
PREPARATION OF EXAMPLES
[0036] A series of polypropylene wood fiber composite materials
were prepared. Polymer in the table shown below was used with wood
fiber in an extruder. Extrusion conditions are shown below. The
first pass extrusion without compatibilizer was made to incorporate
the polymer and wood fiber into a thermoplastic composite. The
initial composite was then blended with a compatibilizer material
and a second extrusion pass (the conditions are shown below) to
form a composite material that was tested for its structural and
heat behavioral properties. In Examples 1 through 7, about 70 parts
of wood fiber was combined with about 30 parts of polypropylene.
The wood fiber had a particle size of between 100 and 1000 microns
and either a reactive organic compatibilizer or a reactive
organometallic compatibilizer was used. In Example 1, 8 and 15, no
compatibilizer was used. In Example 2, 9 and 16, a 9000 M.sub.w
molecular weight polypropylene with about 45 maleic anhydride units
per mole was used as a compatibilizer (Eastman E43). In Examples 3,
10 and 17, a similar compatibilizer was used except the molecular
weight was 5200 and the maleic acid number was 8 (Eastman G3003).
In Examples 4, 11 and 18, a similar compatibilizer was used except
the molecular weight was 4200 and the maleic acid number was 15
(Eastman G3015). In Examples 5, 12 and 19, the MFI was 50 g-10
min.sup.-1 (Montell KA805) and the maleic acid content was 1 mole
%. In Examples 6, 7, 13, 14, 20 and 21, a titanate, ICA12, LICA38
compatibilizer was used. In all the examples, the compatibilizer
was used.
3TABLE 3 Polymer/Wood Fiber = 30/20, Fiber About 100 to 1000 .mu.
3200 ppm Water EX- First Pass AMPLE (Control) 1 2 3 4 5 6 7 Tensile
-- 6.45 8.23 9.12 11.26 8.21 7.26 8.2 Modulus (.times.10.sup.5)
Gardener 15.4 17 12.5 12.5 16.5 8.8 -- -- Impact (in-lbs.) HDT 268
-- 93 -- -- -- -- -- -- (psi @_.degree. C.)
[0037]
4TABLE 4 Polymer/Wood Fiber = 30/20, Fiber About 150 to 1000 .mu.
3200 ppm Water EXAMPLE Control 8 9 10 11 12 13 14 Tensile -- 7.9
7.9 11.0 7.5 8.3 6.4 8.4 Modulus (.times.10.sup.5) Gardener 18.2
13.5 10.5 13.7 26.1 17.5 -- -- Impact (in-lbs.) HDT 268 -- 88 -- --
-- -- -- -- (psi @_.degree. C.)
[0038]
5TABLE 5 Polymer/Wood Fiber = 30/20, Fiber About 150 to 500 .mu.
3200 ppm Water EXAMPLE Control 15 16 17 18 19 20 21 Tensile -- 8.1
9.2 8.1 10.1 7.6 10.0 7.06 Modulus (.times.10.sup.5) Gardener 11.8
10.2 12.5 12.8 25.7 12.5 11.1 7.5 Impact in-lbs. HDT 268 -- 90 130
-- -- -- -- -- (psi @_.degree. C.)
[0039] A tensile modulus was measured and should be at least
8.multidot.10.sup.5 preferably at least 10.multidot.10.sup.5 psi.
Gardener impact was measured. Heat distortion temperature was
measured and should be at least 135.degree. C. preferably
150.degree. C. @ 264 psi. An examination of the data of Table 1
indicates that a careful selection of polypropylene and wood fiber
content, an appropriate compatibilizer at an optimum concentration
and a preferred wood fiber size, an aspect ratio produces a
surprisingly useful composite. The control and first passed
materials without compatibilizer have tensile modulus that ranges
from about 3.3.times.10.sup.-5 to about 8.times.10.sup.-5 while the
materials of the invention achieve a tensile modulus that exceeds
10.0.times.10.sup.5. A substantial increase and a modulus that is
sufficient to provide an indication that the materials are
sufficiently stable in a structural mode to withstand the rigors of
manufacture installation and use. Further, the unmodified materials
have a Gardener impact that is, at most, about 12 in-lbs. The
compatibilized materials have a Gardener impact that exceeds 12 and
achieves an impact strength of greater than 20 in-lbs. Further, the
thermal properties of these materials are surprising. The heat
distortion temperature of the first passed control materials and
the materials of Examples 1, 8 and 15 have a heat distortion
temperature of less than about 90.degree. C. The heat distortion
temperature of Example 16 is 130.degree. C. showing a substantial
improvement in thermal properties. In summary, the thermal
properties and other than Gardener impact structural properties of
these materials are clearly surprising when compared to prior art
polypropylene composites.
DETAILED DESCRIPTION OF THE FIGURES
[0040] FIG. 1 shows a cross-section of an extruded sash profile
100. The complex hollow profile, or structural member has a complex
surface feature or features, is covered with a capstock 102
coextruded onto the exterior of the profile 100 on all exposed or
visible surfaces. The interior surface 110 contains the capstock
102 layer. In a window sash, the common loads experienced by the
sash is a load caused by the force of gravity and a separate
important load caused by wind loadings. The support direction of
the wind load 101b and the support direction for the gravity load
101a is exerted onto the profile. The extruded profile 100 is used
in the manufacture of sash window structures by incorporating a
glass unit into a surface feature comprising a window location 103
wherein it is adhesively installed. The sash is installed in a
frame in which the sash can move vertically on a frame guide. The
sash is inserted on the frame guide (not shown) using a surface
feature comprising a sash area 104 and weatherstrip 105 to form a
weather-tight sliding area. The capstock 102 is not extruded to
cover the entirety of the profile. The uncovered composite material
111 is shown on the profile with no capstock layer. The edge 106 of
the capstock 102 covers the composite material 111 but reveals the
composite material at an edge 106 or 107. The hollow profile is
made with internal hollow areas 108a, 108b and 108c within the
profile defining the dimension of the thin walled hollow profile
structure 100. The hollow profile additionally comprises support
webs 109a and 109b within the profile 100 providing support in the
wind load direction.
[0041] FIG. 2 shows a cross-section of a typical thin walled
complex hollow profile structure that can be used as a siding
member in residential construction. The siding member 200 is
typically installed by placing the member on a rough building
surface by contacting the installation site 205 of the member 200
with the installation surface. The member 200 is then attached by
inserting a fastener such as a screw through fastener aperture 202.
Adhesives can also be used to affix the siding member 200 onto the
rough surface in contact with side 205. The member 200 is designed
to appear to be standard wood based clapboard siding. The
appearance of a complete installation comprising multiple courses
of siding members 200 reveal only the clapboard side 201 to the
observer. Clapboard side 201 can have a capstock layer 210 if
needed. When installed, a starter course of the siding 200 is
installed on the entire length of a rough side. A second course is
then installed in which installation edge 205 is inserted into a
space 208 defined by flange 206 and base 207 which interlocks to
form a tight structural siding unit. The siding unit 200 comprises
a thin walled complex profile extrusion due to the presence of the
internal structural webs 203 and 204 and as a result of the
installation edge 209 and the installation space 208 defined by
base 207 with 206.
[0042] FIG. 3 is a plot of the magnitude of the complex
viscosity.sup.1 (measured at 190.degree. C. in Pascal seconds on
the ordinate) as a function of shear rate (in reciprocal seconds on
the abscissa). The data demonstrates the surprising melt flow
characteristics of the polypropylene copolymer composite materials.
Melt flow viscosity of the polypropylene homopolymer and copolymer
is quite similar and is shown in FIG. 3 and identified as the lower
pair of lines in the melt flow exhibit. The melt flow
characteristics of the homopolymer and copolymer are compared to
the melt flow characteristics of a PVC thermoplastic composition.
This PVC composition is free of wood fiber and has substantially
different melt flow characteristics as shown by the substantially
different location of the plot of the melt flow properties of the
materials. Surprisingly, the melt flow characteristics of the
polypropylene wood fiber composite is substantially similar to the
melt flow properties of the polyvinylchloride resin material and is
substantially similar to the PVC wood fiber composite materials.
Based on our experience with the PVC wood fiber composite, we
expected the melt flow properties of the material to be more
similar to the melt flow properties of the polypropylene material
shown in the Figure. The similarity in melt flow properties of the
polypropylene composite is a surprise. .sup.1 The complex viscosity
is measured using dynamic analysis as disclosed in ASTM D4065 and
Rauwendaal, Polymer Extrusion, Hanser. Munich, (1994), pp 201-204
the disclosures of which are hereby incorporated by reference. The
complex viscosity contains more information about the melt rheology
(storage and loss modulii) of the polyolefin-wood fiber composite
material than is shown in FIG. 3.
[0043] The tensile strength, tensile modulus, Gardener impact, and
oxidation induction time (OIT) results were tested. The composition
of the composite studied is 30% polypropylene and 70% wood fiber.
Tensile strength and tensile modulus increase with increase in wood
fiber size. The tensile strength values for 140 mesh, 80 mesh and
-30/+80 wood fiber sizes are, 1525 psi, 2030 psi and 3390 psi,
respectively. Similarly, the modulus increases from 552,450 psi to
813,000 psi. This is due to the fact that the fiber length exceeds
the critical length about 0.5 to 1 mm, preferably about 0.9 to 1 mm
required for a reinforcing fiber. We believe this transition takes
place above 80-mesh fiber size. Fiber lengths below this size tend
to behave more as fillers rather than reinforcing fibers. The
effect of wood fiber size on impact strength is important. Impact
strength was measured using Gardener Impact test at room
temperature. With increasing fiber size, composite impact strength
decreased. This because larger fiber size provides a higher stress
concentration where the crack can be initiated easily. The impact
strength for 140 mesh and -30/80 mesh is 17 in-lbs and 10 in-lbs,
respectively. Oxidation Induction Time (OIT) results. OIT
experiments were carried out under two conditions -air and oxygen.
The OIT decreased from 101 min to 28 min as fiber size was
increased from 140 mesh to -30/80 in air. This is because with
increasing wood fiber size, the volume of unfilled regions within
polymer increases and the residual gases present help accelerate
the degradation. However, this phenomena would need to be confirmed
further. The density of the composite did not follow any trends.
The density values varied around 1.1.+-.0.1 g/cc for all wood fiber
sizes. This because the wood fiber is compressed to a maximum
density during compounding, that can be sustained by the cell
walls. Since the cell wall density is independent of particle size,
the final density of all fiber sizes is same.
[0044] Heat distortion temperature was tested. The HDT increases
from 95.degree. C. to 105.degree. C. as fiber size is increased
from 140 mesh to -30/+80 mesh.
[0045] Viscosity was measured using RDA II. Moisture present, if
any, was seen to behave as an internal lubricant and thus reduce
the viscosity. Brabender fusion bowl was also used to test the
effect of moisture on torque. With an increase in fiber size,
torque values are lowered. The decrease in torque with increasing
fiber size supports the theory of increasing volume of unfilled
regions within the polymer and the behavior of moisture as an
internal lubricant. The data also shows the effect of moisture
content within a given fiber size. In case of 140 mesh, lowering
the initial moisture content from 4000 ppm to 2400 ppm, increased
the equilibrium torque by 75%.
[0046] Different types of compatibilization mechanisms were used to
couple the wood fiber to the polymer backbone. The list of
compatibilizers used and their characteristics can be found
below:
6 Coupling Agent/ Property E 43 G3003 G3015 KA 805 Acid number 45 8
15 1% by wt Mol. Wt (Mw) 9100 52000 47000 xxx Density (g/cc) 0.93
0.91 0.91 0.9 Viscosity (cP) 400 60000 25000 xxx MFI (g/10 m)
50
[0047] Of these, the Epolene (Eastman Chemicals) and Questron
(Montell) compatibilizers are maleic anhydride grafted
polypropylenes (MA-g-PP) and these 5 couple the wood fiber to the
polymer backbone through esterification reaction. The hydroxyl
groups of cellulose and lignin link to the anhydride groups of the
MA-g-PP through the formation of primary linkage i.e., esters or
through secondary linkages i.e., hydrogen bonding. Epolene coupling
agents are: E43, G3003, G3015. The two variables of interest among
these compatibilizers are; molecular weight and functionality.
Functionality is expressed as an acid number of the polymer and is
indicative of the number of active sites present on the coupling
agent for bonding to the wood fiber. The molecular weight is
indicative of the degree of the entanglement that can occur between
the coupling agent and the polymer. In general therefore, a higher
molecular weight and a high acid number coupling agent are
desirable.
[0048] It was seen that with increasing molecular weight of the
Epolene coupling agents, physical properties including tensile
strength and modulus, flexural strength and modulus increased and
impact strength increased (Table 1). The molecular weight of
Epolene coupling agents increases in the order:
E43<G3015<G3003, while the acid number follows the opposite
trend. In case of 140 mesh and -30/80 mesh wood fiber sizes,
increasing the molecular weight from 9100 to 47000 increased the
tensile modulus from around 920,000 psi to over a 1000,000 psi. The
effectiveness of Epolene coupling agents can be attributed to
increased wettability of wood fiber by polypropylene matrix,
improved dispersion and better adhesion between the two phases. The
strong intermolecular fiber-fiber hydrogen bonding is diluted
leading to better dispersion of the fibers. Studies have shown that
hydrogen bonds are decreased when the hydroxyl groups in cellulose
are esterified. The physical properties improved almost by a factor
of 3.times. over the base material (i.e., composite having no
compatibilizers). Thermal properties also showed an increase of
nearly 40-50% over the base material. Of all the MA-g-PP agents,
Epolene G 3015 was seen to provide the best combination of
properties. This compatibilizer has the ideal combination of a high
molecular weight and a relatively high acid number.
[0049] Titanate and zirconate coupling agents (Kenrich
Petrochemicals, Inc) were also evaluated. These function by
modifying the surface of the fiber enabling it to bond to the
polymer. Two coupling agents were evaluated. These were: LICA 12
and LICA 38. These were fed separately along with precursor pellets
into the feed throat simultaneously. Of the two titanate coupling
agents used, LICA 38 was found to be better than LICA 12. However,
overall their performance in increasing the composite physical
properties was not significant. Addition of these coupling agents
lowered impact strength. The tensile and flexural properties
improved marginally only at longer fiber lengths. The advantages
are its reduced torque resulting in higher feedrates. The
disadvantages include pre-blending and careful handling.
[0050] Lupasol G20 waterfree and FG (BASF) were the other two
coupling agents evaluated. It was seen that the product was very
dark due to discoloration and excessive heat generation from the
chemical reaction. These two coupling agents were not used in
further experiments. No results are available for these agents.
7TABLE 6 Comparative Properties of Commercial Montell
polypropylenes Property Impact copolymer Random Copolymer Melt flow
(g/10 m) 2.0 1.2 Tensile elongation 8 10 (psi) Flexural modulus
140000 180000 (psi) Notched izod No break 3.0 impact (ft-lb/in)
Tensile strength 3200 4000 (psi) HDT (F, 264 psi) 180 x
[0051] In the following Tables 7, 9 and 10 composites are prepared
as described above. Tables 7-9 show processing conditions while
Table 10 shows the properties of the resulting composite.
8TABLE 7 80 mesh fiber Feedrate Screw Speed SME BT (zone 1-5)
Sample Compatibilizer (lb/hr) (rpm) % Torque (kJ/kg Vacuum
(.degree. C.) 1 None 40 250 50 450 4 146-156-172-164 2 E 43 40 250
50 450 4 147-166-168-162 3 G 3003 40 250 50 450 4 146-141-169-161 4
G 3015 40 250 47 423 4 149-152-172-163 5 KA 805 40 250 51 459 4
148-151-170-163 6 Lica 12 40 450 37 600 x 141-144-165-155 7 Lica 38
40 450 36 584 x 142-158-159-153 8 PR8515 40 250 64 577 x
146-149-165-161 Screw Temp Screw Speed Barrel Temp Melt Temp Die
Temp Die Pressure Cutter Speed Sample (.degree. C.) (rpm) (.degree.
C.) (.degree. C.) (.degree. C.) (psi) Setting 1 150 67 150 160 161
1380-1390 6 2 150 66 149 153 161 1200-1360 6 3 150 66 150 152 160
1320-1350 6 4 150 66 149 153 160 1260-1580 6 5 150 66 149 153 161
1390-1450 6 6 150 67 144 230 158 1390-1480 6 7 150 66 145 154/225
156 1340-1390 8 8 150 60 144 207 156 770-1530 6.5
[0052]
9TABLE 8 140 Mesh Fiber Feedrate Screw Speed SME BT (zone 1-5)
Sample Compatibilizer (lb/hr) (rpm) % Torque (kJ/kg Vacuum
(.degree. C.) 9 None 40 250 46 414 5 149-152-161-168 10 E 43 40 250
44 396 5 146-153-163-170 11 G 3003 40 250 49 441 4 145-157-173-165
12 G 3015 40 250 48 432 4 148-153-170-164 13 KA 805 40 250 50 450 4
147-155-171-164 14 Lica 12 40 450 37 600 x 141-142-158-151 15 Lica
38 40 450 36 584 x 141-143-157-155 Screw Temp Screw Speed Barrel
Temp Melt Temp Die Temp Die Pressure Cutter Speed Sample (.degree.
C.) (rpm) (.degree. C.) (.degree. C.) (.degree. C.) (psi) Setting 9
150 60 151 154 150 1250-1540 6 10 150 63 150 153 156 970-1140 6 11
150 65 149 150 161 1330-1390 6 12 150 65 150 151 161 1350-1420 6 13
150 65 150 151 161 1375-1385 6 14 150 66 148 230 158 1060-1230 6 15
150 60 144 153 156 1220-1250 8
[0053]
10TABLE 9 -30 +80 Mesh Fiber Feedrate Screw Speed SME BT (zone 1-5)
Sample Compatibilizer (lb/hr) (rpm) % Torque (kJ/kg Vacuum
(.degree. C.) '16 None 40 250 47 423 8 149-151-170-162 17 E 43 40
250 46 414 4 149-149-168-161 18 G 3003 40 250 50 450 4
149-150-170-161 19 G 3015 40 250 50 450 4 147-152-173-164 20 KA 805
40 250 50 450 4 151-146-168-160 21 Lica 12 40 450 37 600 x
141-146-171-156 22 Lica 38 40 450 34 551 x 142-143-158-153 Screw
Temp Screw Speed Barrel Temp Melt Temp Die Temp Die Pressure Cutter
Speed Sample (.degree. C.) (rpm) (.degree. C.) (.degree. C.)
(.degree. C.) (psi) Setting 16 150 66 151 154 160 1310-1370 6 17
149 66 149 154 161 1010-1230 6 18 150 66 150 153 161 1220-1240 6 19
150 66 151 152 162 1290 6 20 150 66 149 148 163 1220-1380 6 21 150
66 145 (230 from T) 158 1400 6 22 150 65 124/151 148/220 156
950-1380 6
[0054]
11TABLE 10 Effect of wood fiber.sup.2 and compatibilizers on PP-WF
composites Flex- Gar- HDT ural Tensile Tensile dener (.degree. C.,
Modu- Flexural Compat- Strength Modulus impact 264 lus Strength
ibilizer (psi) (psi) (in-lb) psi) (psi) (psi) 400 to 900.mu. Wood
fiber: 700.mu. -30/+80 ave.. None 3390 813000 10.2 90 686000 4930 E
43 4300 920000 12.5 136 699000 7300 G 3003 4600 810000 12.8 128
726000 7930 G 3015 5600 1013000 25.7 133 630000 9350 KA 805 4400
765000 12.5 136 707000 7300 Lica 12 1420 999000 11.1 x 376000 2500
Lica 38 2100 706000 7.5 x 598000 4000 Wood fiber- About 80 mesh
200.mu. None 2030 792000 13.5 88 498000 3700 E 43 5050 797000 10.5
133 735000 8640 G 3003 5060 1098000 13.7 125 674000 8630 G 3015
6200 753000 26.1 135 636000 11000 KA 805 4730 830000 17.5 132
726000 8350 Lica 12 1775 639000 14.6 x 554000 3200 Lica 38 2420
840000 7.4 x 724000 4400 Wood About Fiber140mesh 100.mu. None 1525
645000 17 93 475000 3000 E 43 3910 823000 12.5 124 664000 6800 G
3003 3690 912000 12.5 132 691000 6494 G 3015 4960 1126000 16.5 131
665000 9000 KA 805 3240 821000 8.8 116 661000 5700 Lica 12 2100
726000 12.9 x 597000 3900 Lica 38 2350 820000 11.4 x 672000 4400
.sup.2The screening processes used to segregate wood fibers produce
rather broad size distributions; therefore the fiber lengths
associated with mesh sizes given above are approximate. As
discussed hereinabove, it is the long fibers that contribute most
to the improvement in thermal and mechanical properties. 140 mesh
(about 100 micrometers); 80 mesh (about 200 micrometers) -30/+80
mesh (about 700 micrometers, range about 400 to about 900
micrometers)
[0055] The above results of physical property testing of the
compatibilizer polypropylene wood fiber composites show a
significant advantage in tensile modulus and flexural modulus. The
composites achieve 800,000 to 1.0 million psi tensile modulus and
700,000-800,000 flexural modulus. High Gardener Impact values are
achieved along with excellent heat distortion temperatures ranging
from about 125 to 140.degree. C. at 264 psi. Such a result is a
substantial improvement over prior art composites and over
composites with conventional polymer technology.
12 TABLE 11 Method Property Instrument ASTM Tensile Instron D 3039
properties Flexural Instron D 790 properties Impact strength
Gardener D 4226 Heat Distortion Aspen hot air oven Temp Rheological
RDA Density Pycnometer
[0056] While the above discussion, examples and data provide a
means for understanding the operability of the invention, the
invention can be made in a variety of formats without departing
from the spirit and basic scope of the inventive concept.
Accordingly, the invention is found in the claims hereinafter
appended.
* * * * *