Lightweight thermoplastic composite products and methods of making same
AssigneeJohns Manville
InventorsMingfu Zhang, Jieyu Hu, Lance Wang, Jawed Asrar
Life of this patent
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Abstract
A lightweight polymer-based composite product may include a polymer material body and a lightweight filler material that is embedded in the polymer. The polymer material body may be an in-situ polymerized polymer formed via casting of a reactive resin in a mold. The polymer may have a density of at least 1.0 g/cm3. The lightweight filler material may be concentrated on at least a portion of a first surface of the polymer material body. The lightweight filler material may have a density of between 0.1 and 1.0 g/cm3. The lightweight polymer-based composite product may have a density that is less than a comparable product that consists mainly of the polymer.
Claims24
A lightweight polymer-based composite product comprising:
- a first layer having a first exterior surface, the first layer comprising:
- a polymer material body formed of an in-situ polymerized polymer having a density of at least 1.0 g/cm3;
- and
- a lightweight filler material that is embedded in the polymer, wherein the lightweight filler material has a density of between 0.1 and 1.0 g/cm3;
- a second layer having a second exterior surface that is positioned opposite the first exterior surface, the second layer comprising a polymer material body formed of the in-situ polymerized polymer;
- wherein the lightweight filler material is separated from the second layer such that substantially all of the lightweight filler material is included in the first layer;
- wherein the first exterior surface includes the lightweight filler material and the second exterior surface is free of the lightweight filler material;
- wherein the second layer seamlessly transitions from the first layer due to a continuous matrix of the in-situ polymerized polymer throughout the first layer and the second layer;
- and
- wherein the first layer has a density that is less than the second layer.
A lightweight polymer-based composite product comprising:
- a polymer material body formed of an in-situ polymerized polymer, the polymer material body having a first exterior surface and a second exterior surface that is positioned opposite the first exterior surface and the polymer having a density of at least 1.0 g/cm3;
- and
- a lightweight filler material that is embedded in the polymer and that is concentrated within the polymer material body so that the lightweight filler material forms a layer on at least a portion of the first exterior surface of the polymer material body and so that the second exterior surface is free of the lightweight filler material;
- wherein the lightweight filler material has a density of between 0.1 and 1.0 g/cm3.
Dependencies are inferred from the claim text.