Agglomerated filler for composite materials

A method for forming a composite material, the method comprising:

• mixing a thermoplastic elastomer and solid pieces of a filler concentrate to form a mixture, the filler concentrate comprising:
• a solid polymer;
• and
• a filler;
• heating the mixture to:
• at least partially melt the solid polymer to release the particles of the filler from the solid pieces of the filler concentrate;
• and
• melt the thermoplastic elastomer to enable the particles of the filler to diffuse throughout the thermoplastic elastomer to form a liquid composite blend;
• forming the liquid composite blend into a desired shape;
• and
• cooling the liquid composite blend to form the composite material in the desired shape.

A method of forming an agglomerate, comprising:

• introducing a solid polymer into an agglomerator in an amount of about 1 part, by weight, to about 10 parts, by weight;
• introducing a filler into the agglomerator in an amount of about 90 parts, by weight, to about 99 parts, by weight;
• mixing the solid polymer and the filler in the agglomerator, heat generated by mixing softening the solid polymer to enable the solid polymer to bond to the filler;
• and
• forming the agglomerates including:
• the solid polymer comprising about 1% to about 10% of the weight of each agglomerate;
• and
• the filler comprising about 90% to about 99% of the weight of each agglomerate.