Abstract
Polyester composite tiles (PCT) are synthesized from PET and fabricated by compression molding using micro-marble clusters as filler. Identical PCTs are also fabricated by using commercially available polyester resin to compare properties. Three batches of marble clusters with different size distributions are used to assess the effect of filler particle size on mechanical properties. Tiles prepared using finer marble grades yield consistently higher flexural strength and stiffness values regardless of the synthesized or commercial polyester resin. However, the flexural strength and stiffness of the tiles prepared with commercial polyester are observed to be on average 1.8 and 2.5 fold higher, respectively. Prospects of improving mechanical properties are explored by reinforcing PC tiles with randomly oriented, discontinuous glass fibers. This is achieved by placing a single layer of glass fiber mat on the top and bottom tile surface. Presence of fiber mats leads to the formation of a graded particle size distribution across the mat thickness when the coarse grade marble dust is used. This distribution resulted in significant improvements in flexural strength, stiffness and overall toughness of the tiles. The improvements observed in PCTs prepared with synthesized polyester resin surpassed the improvements in their counterparts prepared with commercial polyester. In fact, the flexural strength of the glass fiber mat reinforced PCTs prepared with synthesized and commercial polyester resin are observed to be statistically identical.