Structural Composition and Method

Abstract

A structural polymeric composite includes a stiffening layer. The composite is made in a continuous extrusion process in which the stiffening layer is pulled through a cross-head die as a polymer is extruded over it. The layer includes a film or textile carrier, a filler of carbon fibers, fiberglass, organic fibers or minerals forming a mat. A binder may be dispersed over the mat and a second carrier applied. The mat is subjected to heat and pressure to soften the carriers and binder so they penetrate into the interstices of the filler and binds mechanically with them and the carriers and binder bind chemically with each other to form the stiffening layer. A polymer is then extruded over the stiffening layer, which may be used flat, provided with holes or punches for composite action with the polymer, formed into a profile, or segmented to provide spaced-apart stiffening layers.

What is claimed is: 
     
         1 . A method for making a structural composite, said method comprising the steps of:
 (a) providing a first carrier;   (b) distributing filler onto said first carrier;   (c) applying a binding agent onto said filler, said binding agent being chemically compatible with said first carrier;   (d) heating said first carrier, said filler and said binding agent;   (e) pressing said first carrier, said filler, and said binding agent together, wherein said binding agent liquefies and penetrates into said filler, and wherein said binding agent and said first carrier bind physically with said filler to form a stiffening layer as said first carrier, said filler and said binding agent cool; and   (f) extruding a polymer onto said stiffening layer through a cross-head die, wherein said polymer on said stiffening layer, said polymer binding chemically with said stiffening layer, and wherein said cross-head die positions said stiffening layer with respect to said polymer to reinforce said polymer.   
     
     
         2 . The method of  claim 1 , wherein said binding agent is a second carrier. 
     
     
         3 . The method of  claim 1 , wherein said binding agent is a liquid. 
     
     
         4 . The method of  claim 1 , wherein said binding agent is granular. 
     
     
         5 . The method of  claim 1 , wherein said stiffening layer is flat and wherein said method further comprises the step of deforming said stiffening layer. 
     
     
         6 . The method of  claim 1 , further comprising the steps of:
 (a) cutting said stiffening layer into strips; and   (b) separating said strips before extruding said polymer.   
     
     
         7 . The method of  claim 6 , wherein said structural composite has a neutral axis and wherein said strips are positioned away from, and on opposing sides of, said neutral axis of said structural composite. 
     
     
         8 . The method of  claim 1 , wherein said filler includes fibers. 
     
     
         9 . The method of  claim 1 , wherein said filler includes synthetic fibers. 
     
     
         10 . The method of  claim 1 , wherein said filler includes natural fibers. 
     
     
         11 . The method of  claim 1 , wherein said filler includes minerals. 
     
     
         12 . The method of  claim 1 , wherein said polymer is polyvinyl chloride. 
     
     
         13 . A method for making a structural composite, said method comprising the steps of:
 (a) rolling out a first carrier;   (b) distributing filler onto said first carrier;   (c) rolling out a second carrier onto said said filler, said filler being between said first carrier and said second carrier;   (d) heating said first carrier and said second carrier to liquefy at least one of said first carrier and said second carrier;   (e) pressing said filler, said first carrier, and said second carrier together, wherein said first carrier and said second carrier bind together chemically and to said filler physically to form a stiffening layer as said first carrier, said filler, and said second carrier cool; and   (f) extruding a polymer with said stiffening layer through a cross-head die, wherein said polymer covers said stiffening layer, said polymer binding chemically with said first carrier and said second carrier, and wherein said cross-head die positions said stiffening layer with respect to said polymer to reinforce said polymer.   
     
     
         14 . The method of  claim 13 , wherein at least one of said first carrier and said second carrier is made of polyethylene terephthalate. 
     
     
         15 . The method of  claim 13 , wherein at least one of said first carrier and said second carrier is made of high-density polyethylene. 
     
     
         16 . A method for making a structural composite, said method comprising the steps of:
 (a) rolling out a first carrier;   (b) distributing filler onto said first carrier;   (c) dispersing a binder onto said filler;   (d) rolling out a second carrier onto said first carrier, said filler and said binder being between said first carrier and said second carrier;   (e) heating said first carrier, said second carrier and said binder to liquefy said binder;   (f) pressing said filler, said binder, said first carrier, and said second carrier together, wherein said filler, said binder, said first carrier, and said second carrier bind together to form a stiffening layer as said first carrier, said second carrier, said filler, and binder cool; and   (g) extruding a polymer onto said stiffening layer through a cross-head die, wherein said said polymer binds chemically with said first carrier and said second carrier, and wherein said cross-head die positions said stiffening layer with respect to said polymer to form a reinforced structural composite.   
     
     
         17 . The method of  claim 16 , wherein said first carrier, said second carrier and said binder are heated and pressed using at least one heated jacket roller. 
     
     
         18 . The method of  claim 16 , wherein said filler includes fibers. 
     
     
         19 . The method of  claim 16 , wherein said first carrier and said second carrier are made of polyethylene terephthalate. 
     
     
         20 . The method of  claim 16 , wherein an adhesive is applied to at least one of said first carrier and said second carrier before distributing said filler.