Silicate Fiber Polymer Composite

A thermoplastic composite comprising about 90 to 10 vol. % of a discontinuous fiber phase dispersed in about 10 to 90 vol. % of a continuous polymer phase:

• (a) the discontinuous phase comprising about 1 to 60 wt. % of a CaSiO3 fiber, the fiber having a length greater than about 5 microns, a diameter greater than about 3 microns and an aspect ratio greater than about 3, the fiber having about 0.1 to 5 wt. % of an exterior coating comprising an organometallic interfacial modifier, the wt. % based on the discontinuous phase;
• and
• (b) the continuous polymer phase comprising a vinyl chloride homopolymer;
• wherein the composite has a fiber packing fraction of 80-95 vol. %, a heat deflection temperature of at least 60° C. (ASTM D648), a notched IZOD impact resistance of about 0.4 to 3.0 ft-lb-in−1 (ASTM D256), a COTE of about less than 2×10−5 in/in−1/° F. (ASTM 696), a tensile modulus (ASTM D638) of greater than 700,000 psi at 72° F., a flexural modulus (ASTM D790) of greater than 700,000 psi at 72° F., a flexural strength (ASTM D790) of greater than 2,500 psi at 72° F., a tensile strength (ASTM D638) of greater than 2,000 psi at 72° F.

A thermoplastic composite comprising a discontinuous fiber phase dispersed in about 50 to 75 vol. % of a continuous polymer phase:

• (a) the discontinuous phase consisting of 10 to 50 vol. %. of a CaSiO3 fiber, the CaSiO3 fiber having a length about 55-125 microns, a diameter about 6-15 microns and an aspect ratio greater than about 20, the fibers having about 0.1 to 5 wt. % of an exterior coating comprising an organo metallic interfacial modifier, the wt. % based on the discontinuous phase;
• and
• (b) the continuous polymer phase comprising a vinyl chloride homopolymer;
• wherein the composite has a packing fraction of 80-95 vol. %, a heat deflection temperature of at least 60° C. (ASTM D648), an notched IZOD impact resistance of about 0.5 to 3.0 ft-lb-in−1 (ASTM D256), a COTE of about 2×10−6 to 2×10−5 in/in−1/° F. (ASTM 696), a tensile modulus (ASTM D638) of greater than 0.7 to 2.75 Mpsi at 72° F., a flexural modulus (ASTM D790) of greater than 0.7 to 2.7 Mpsi at 72° F., a flexural strength (ASTM D790) of 2.5 to 20 kpsi at 72° F., a tensile strength (ASTM D638) of 2 to 20 kpsi at 72° F.