US20070087180A1 - Variegated composites and related methods of manufacture - Google Patents
Variegated composites and related methods of manufacture Download PDFInfo
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- US20070087180A1 US20070087180A1 US11/544,566 US54456606A US2007087180A1 US 20070087180 A1 US20070087180 A1 US 20070087180A1 US 54456606 A US54456606 A US 54456606A US 2007087180 A1 US2007087180 A1 US 2007087180A1
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L97/00—Compositions of lignin-containing materials
- C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/249925—Fiber-containing wood product [e.g., hardboard, lumber, or wood board, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
- Y10T428/254—Polymeric or resinous material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31971—Of carbohydrate
- Y10T428/31989—Of wood
Definitions
- the invention may include one or more of the following aspects: the crystalline polymer may be at least one of polypropylene and polyethylene; the amorphous polymer may be a styrenic polymer; the outer surface may include streaks of the first color; the amorphous polymer may have a melting temperature that is substantially the same as a melting temperature of the crystalline polymer; the outer surface may be variegated; a first portion of the outer surface may have the first color and a second portion of the outer surface may have the second color; another amorphous polymer visible on the outer surface; the another amorphous polymer may have a third color different from the first color and the second color; the composite may be at least one of a building material, a decking material, and a decking board; a colorant may be blended with one of the crystalline polymer and the amorphous polymer.
- FIG. 2A is a schematic view of the composite of FIG. 1 .
- Crystalline polymer 2 may have any suitable size, shape, and/or configuration to be melted, mixed with wood fibers 3 , and/or extruded into a dimensionally stable profile. Crystalline polymer 2 may have any suitable size, shape, and/or configuration to be used in any of the apparatuses or methods disclosed in co-owned U.S. Pat. Nos. 5,851,469 and 6,527,532, co-pending and co-owned U.S. patent application Ser. No. 10/292,672 filed Nov. 12, 2002, and co-pending and co-owned U.S. patent application Ser. No. 10/668,368 filed Sep. 24, 2003, the entirety of all of which are incorporated herein by reference.
- amorphous polymers 6 generally cannot fit into the semicrystalline structures of crystalline polymers 2 (e.g., like incompatible puzzle pieces), and amorphous polymers 6 may also exhibit polarities that prevent it from being integrated into the semicrystalline structures of crystalline polymers 2 (e.g., like oil and water).
- amorphous polymer 6 has a different solubility parameter then crystalline polymer 2 .
- the polarities of amorphous polymer 6 may also allow it to retain polar pigments (e.g., which may be background color 9 ) that may not bind as well to crystalline polymer 2 which is either devoid and/or has a lower polarity than amorphous polymer 6 .
- a suitable biostabilizer may be trichlorophenoxyphenol (TCPP), examples of which may include VINYZENETM SB 30.
- TCPP biostabilizer may be dispersed throughout the crystalline polymer 2 , but preferably the amorphous polymer 6 , in any concentration suitable to prevent or reduce mold or mildew growth on the composite 1 , for example, between about 800 parts per million and about 1200 parts per million.
- the TCPP biostabilizer may have a thermal stability of about 230° C. and/or a solubility in water of about 10 parts per million.
- a still further example of a suitable biostabilizer may include zinc borate, which may be in the form of a crystalline powder having a solubility in water of about 2800 parts per million and a particle sizes between about 1-2 microns.
- the method may also include providing a core 8 and forming profile body 1 around at least a portion of core 8 .
- Core 8 may be a wood-plastic composite or any other suitable composite.
- Core 8 may have a cross-sectional area smaller than a cross-sectional area of die 19 .
- Core 8 may be fed by extruder 15 through die 19 such that core 8 advances through substantially the center of die 19 without contacting any portion of die 19 itself.
- Extruder 15 and/or die 19 may then deposit an outer surface 5 on core 8 that has more than one color (e.g., variegated and/or streaked) using one or more of the methods set forth herein.
Abstract
Embodiments of the invention include a composite. The composite includes a crystalline polymer, a plurality of wood fibers blended with the crystalline polymer, an outer surface, and an amorphous polymer visible on the outer surface. The amorphous polymer has a first color and the blend of the crystalline polymer and the plurality of wood fibers has a second color different from the first color. The invention also includes a method of manufacturing the wood-plastic composites such that one polymer is shifted in the composite relative to the other polymer.
Description
- 1. Field of the Invention
- The invention is directed to variegated wood-plastic composites and methods of manufacturing the same. For example, the surfaces of the wood-plastic composites may be variegated by varying the polymer composition of the wood-plastic composite. The invention also includes a method of manufacturing the wood-plastic composites such that one polymer is shifted in the composite relative to the other polymer.
- 2. Background of the Invention
- Wooden components are commonly used in manufacturing decks and related assemblies. Wooden components includes strings of wood fibers having various colors (e.g., rings on trees) that give the surface of the wooden component a streaked appearance. The streaked appearance imparts an aesthetically pleasing look and feel to the deck component. One disadvantage of using wooden components, however, is that the wood may be susceptible to rotting, weather, insects, and/or wear and tear, and may require the acquisition and processing of wood which may involve environmentally unfriendly processing techniques, such as the clear cutting of forests and the use of hazardous chemicals.
- A more environmentally friendly alternative to using wooden components in manufacturing decks and related assemblies is to use a wood-plastic composite made of crystalline polymers. Examples of suitable wood-plastic composites made of crystalline polymers and related methods of manufacture are disclosed in co-owned U.S. Pat. Nos. 5,851,469 and 6,527,532, co-pending and co-owned U.S. patent application Ser. No. 10/292,672 filed Nov. 12, 2002, and co-pending and co-owned U.S. patent application Ser. No. 10/668,368 filed Sep. 24, 2003, the entirety of all of which are incorporated herein by reference.
- Wood-plastic composites made of crystalline polymers, however, tend to have solid one color surfaces. This is at least partially due to the sharp melting point temperatures of crystalline polymers and the tendency of crystalline polymers to easily blend together. Thus, even if a plurality of crystalline polymers having a plurality of different colors are used to manufacture a wood-plastic composites, the plurality of different colors will blend together in the manufacturing process and the composite will emerge having a surface with one solid color. In any case, the resultant composite does not have a streaked appearance.
- An exemplary embodiment of the invention includes a composite. The composite comprises a crystalline polymer, a plurality of wood fibers blended with the crystalline polymer, an outer surface, and an amorphous polymer visible on the outer surface. The amorphous polymer has a first color and the blend of the crystalline polymer and the plurality of wood fibers has a second color different from the first color.
- In various embodiments, the invention may include one or more of the following aspects: the crystalline polymer may be at least one of polypropylene and polyethylene; the amorphous polymer may be a styrenic polymer; the outer surface may include streaks of the first color; the amorphous polymer may have a melting temperature that is substantially the same as a melting temperature of the crystalline polymer; the outer surface may be variegated; a first portion of the outer surface may have the first color and a second portion of the outer surface may have the second color; another amorphous polymer visible on the outer surface; the another amorphous polymer may have a third color different from the first color and the second color; the composite may be at least one of a building material, a decking material, and a decking board; a colorant may be blended with one of the crystalline polymer and the amorphous polymer.
- Another embodiment of the invention includes a composite. The composite may include a first polymer, a plurality of wood fibers blended with the first polymer, an outer surface, and a second polymer configured to resist blending with the first polymer. The composite may be manufactured such that the second polymer is deliberately visible on the outer surface. The blend of the first polymer and the plurality of wood fibers may have a first color and the second polymer may have a second color different from the first color. The second polymer may not be substantially soluble in the first polymer.
- In various embodiments, the invention may include one or more of the following aspects: the first polymer may be at least one of polypropylene and polyethylene; the second polymer may be a styrenic polymer; the outer surface may include streaks of the second color; the first polymer may have a melting temperature that is substantially the same as a melting temperature of the second polymer; the outer surface may be variegated; a first portion of the outer surface may have the first color and a second portion of the outer surface has the second color; a third polymer may be configured to resist blending with the first polymer; the composite may be manufactured such that the third polymer is deliberately visible on the outer surface; the third polymer may have a third color different from the first color and the second color; the composite may be at least one of a building material, a decking material, and a decking board; a colorant blended with one of the first polymer and the second polymer.
- A further embodiment of the invention may include a method of manufacturing a wood-plastic composite. The method may include providing a crystalline polymer, providing a plurality of wood fibers, providing an amorphous polymer, melting the crystalline polymer, melting the amorphous polymer, mixing the amorphous polymer with the crystalline polymer and the plurality of wood fibers to form a feed, and forming a profile body from the feed, the profile body including an outer surface evincing a first color and a second color different from the first color.
- In various embodiments, the invention may include one or more of the following aspects: forming streaks of the first color on the outer surface; forming streaks of the amorphous polymer on the outer surface; shifting the amorphous polymer towards the outer surface; variegating the outer surface; providing at least one of a single screw extruder and a double screw extruder; the step of extruding may include extruding the feed via the at least one of the single-screw extruder and the double screw extruder; the step of mixing may include forming the first color from the amorphous polymer and forming the second color from a blend of the crystalline polymer and the plurality of wood fibers; providing another amorphous polymer; melting the another amorphous polymer; mixing the another amorphous polymer with the amorphous polymer, the crystalline polymer, and the plurality of wood fibers; the step of extruding may include forming the profile body such that the outer surface evinces a third color different from the first color and the second color; providing a core; the step of forming the profile body may include forming the profile body around at least a portion of the core; providing a colorant; blending the colorant with one of the crystalline polymer and the amorphous polymer.
- Yet another embodiment of the invention may include a method of manufacturing a wood-plastic composite. The method may include providing a first polymer, providing a plurality of wood fibers, providing a second polymer not substantially soluble in the first polymer, melting the first polymer, melting the second polymer, mixing the second polymer with the first polymer and the plurality of wood fibers to form a feed, and forming a profile body from the feed, the profile body including an outer surface deliberately evincing a first color and a second color different from the first color.
- In various embodiments, the invention may include one or more of the following aspects: forming streaks of the first color on the outer surface; forming streaks of the first polymer on the outer surface; shifting the first polymer towards the outer surface; variegating the outer surface; providing at least one of a single screw extruder and a double screw extruder; the step of extruding may include extruding the feed via the at least one of the single-screw extruder and the double screw extruder; the step of mixing may include forming the first color from the first polymer and forming the second color from a blend of the second polymer and the plurality of wood fibers; providing a third polymer not substantially soluble in the first polymer; melting the third polymer; mixing the third polymer with the first polymer, the second polymer, and the plurality of wood fibers; the step of extruding may include forming the profile body such that the outer surface deliberately evinces a third color different from the first color and the second color; providing a core; the step of forming the profile body may include forming the profile body around at least a portion of the core; providing a colorant; blending the colorant with one of the first polymer and the second polymer.
- A yet further embodiment of the invention may include a method of manufacturing a wood-plastic composite. The method may include providing a first polymer, a plurality of wood fibers, a second polymer not substantially soluble in the first polymer, and an additive, melting the first polymer and the second polymer, blending the additive with the second polymer to form a blend, mixing the blend with the first polymer and the plurality of wood fibers to form a feed, forming a profile body with an outer surface from the feed, and shifting the blend towards the outer surface such that at least a portion of the blend is visible on the outer surface.
- In various embodiments, the invention may include one or more of the following aspects: the additive may be one or more of a pigment, a mold inhibitor, and a mildew inhibitor; the blend may substantially cover an entire side of the profile body; the additive may not be blended with either of the first polymer or the wood fibers; the additive may be soluble in the second polymer and not be soluble in the first polymer.
- Additional objects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.
- It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
- The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the invention and together with the description, serve to explain the principles of the invention.
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FIG. 1 is a perspective view of a composite according to an embodiment of the invention. -
FIG. 2A is a schematic view of the composite ofFIG. 1 . -
FIG. 2B is a top schematic view of a composite according to another embodiment of the invention. -
FIG. 2C is a top schematic view of a composite according to a further embodiment of the invention. -
FIG. 3A is a side schematic view of the composite ofFIG. 1 . -
FIG. 3B is a side schematic view of a composite according to yet another embodiment of the invention. -
FIG. 3C is a side schematic view of a composite according to still another embodiment of the invention. -
FIG. 4A is a schematic view of a process of manufacturing the composite ofFIG. 1 . -
FIG. 4B is a schematic view of a process of manufacturing a composite according to a yet further embodiment of the invention. -
FIG. 4C is a schematic view of a process of manufacturing a composite according to still another embodiment of the invention. - Reference will now be made in detail to the exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
- An exemplary embodiment of the invention includes a composite. As shown in FIGS. 1, 2A-2C, and 3A-3C, composite 1 may include a
first polymer 2, a plurality ofwood fibers 3 blended withfirst polymer 2 to form ablend 4, anouter surface 5, and asecond polymer 6 configured to resist blending with first polymer 2 (e.g.,second polymer 6 is not substantially soluble in first polymer 2).Second polymer 6 may be visible onouter surface 5.Blend 4 offirst polymer 2 andwood fibers 3 may have a first color andsecond polymer 6 may have a second color different from the first color. -
Composite 1 may be used as a decking component or any other suitable building material. For example, as shown inFIG. 1 ,composite 1 may be used as a decking board, railing, railing post, and/or decking beam. In another example, composite 1 may be used to construct any portions of homes, walkways, shelters, and/or any other desirable structure. -
Composite 1 may include afirst polymer 2 which may be acrystalline polymer 2.Crystalline polymer 2 is preferably at least one of high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), and polypropylene (PP). The polypropylene may be a homo- and/or a co-polymer polypropylene. However, any crystalline polymer may be used, such as one or more polyamides (PA), nylons, polyoxymethylenes, polybutylene terephthalates (PBT), polyethylene terephthalates (PET), and/or acetals.Crystalline polymer 2 may have any suitable size, shape, and/or configuration to be melted, mixed withwood fibers 3, and/or extruded into a dimensionally stable profile.Crystalline polymer 2 may have any suitable size, shape, and/or configuration to be used in any of the apparatuses or methods disclosed in co-owned U.S. Pat. Nos. 5,851,469 and 6,527,532, co-pending and co-owned U.S. patent application Ser. No. 10/292,672 filed Nov. 12, 2002, and co-pending and co-owned U.S. patent application Ser. No. 10/668,368 filed Sep. 24, 2003, the entirety of all of which are incorporated herein by reference. For example,crystalline polymer 2 may be in the form of a pellet, a flake, a film, and/or a scrap form. In another example,crystalline polymer 2 may range in size from reactor powder having a diameter of about 0.01650 inches to pieces of plastic having dimensions (e.g., length, width, height, depth, and/or diameter) between about 1 inch and about 100 feet. More typically, however,crystalline polymer 2 is film scrap having dimensions (e.g., length, width, height, depth, and/or diameter) between about 0.0787 inches and 0.25 inches. -
Composite 1 may include asecond polymer 6 which may be anamorphous polymer 6.Amorphous polymer 6 is preferably a styrenic polymer such as polystrene (PS). However, any amorphous polymer may be used incomposite 1, such as one or more of Impact PS, polymethylmethacrylates (PMMA), polyvinyl chlorides (PVC), acrylonitrile-butadine-styrene copolymers (ABS), thermoplastic polyurethanes (TPU), styrene acrylonitrile copolymers (SAN), polyphenyl oxide (PPO), acryla-styrene butyl-acrylate or acrylate styrene acrylonitrile (either of which may be abbreviated as ASA), and/or polycarbonates (PC). In a preferred embodiment, ABS is used.Amorphous polymer 6 may have any suitable size, shape, and/or configuration. For example,amorphous polymer 6 may be in the form of pellets and/or flakes. In a preferred embodiment,amorphous polymer 6 has a high polarity and/or decreased melt flow relative tocrystalline polymer 2. The size of theamorphous polymer 6 used may be dependent on these and other properties ofamorphous polymer 6. For example,amorphous polymer 6 may be a substantially solid chunk having dimensions (e.g., length, width, diameter, depth, and/or height) between about 0.25 inches and 0.0165 inches or may have a substantially spherical shape having an average diameter of about 0.0165 inches. - In its Solid form, polymers generally are capable of forming different structures depending on the structure of the polymer chain as well as the processing conditions. In
amorphous polymers 6, the polymer chain is substantially random and unordered in structure, while incrystalline polymers 2, the structure of the polymer backbone is a substantially regular, ordered structure such that the polymer can be tightly packed, although in general mostcrystalline polymer 2 are only semicrystalline. This is because the exact make up and details of the polymer backbone will determine whether the polymer is capable of crystallizing. For example, PVC, depending on the characteristics of its backbone, may be either crystalline (isotactic or syndiotactic structures) or amorphous (atactic structure). Accordingly, due to these differences in polymer structures,amorphous polymers 6 generally cannot fit into the semicrystalline structures of crystalline polymers 2 (e.g., like incompatible puzzle pieces), andamorphous polymers 6 may also exhibit polarities that prevent it from being integrated into the semicrystalline structures of crystalline polymers 2 (e.g., like oil and water). Thus,amorphous polymer 6 has a different solubility parameter thencrystalline polymer 2. The polarities ofamorphous polymer 6 may also allow it to retain polar pigments (e.g., which may be background color 9) that may not bind as well tocrystalline polymer 2 which is either devoid and/or has a lower polarity thanamorphous polymer 6. -
Composite 1 may include a plurality ofwood fibers 3.Wood fibers 3 may be from any type of suitable wood, for example, one or more hardwoods and/or softwoods.Wood fibers 3 may be of any suitable shape and/or size, and may be configured to be suitably blended withcrystalline polymer 2 such that a mixture orblend 4 ofwood fibers 3 andcrystalline polymer 2 appears substantially homogenous in color and/or consistency. For example,wood fibers 3 may have dimensions (e.g., length, width, depth, diameter, and/or height) ranging from about 6 inches to about 0.25 inches, all the way down to substantially spherical shapes having an average diameter of about 0.00079 inches. More typically, however,wood fibers 3 may range in size from substantially spherical shapes having an average diameter of about 0.07870 inches to substantially spherical shapes having an average diameter of about 0.007 inches. In various embodiments, thewood fibers 3 may be mixed with and/or be replaced with any suitable organic or inorganic filler material, including one or more of grass, wheat hulls, corn stocks, corn ears, nuts, nut shells, peanuts, peanut shells, walnut, walnut shells, sand, clay, dirt, and concrete. -
Second polymer 6 may resist blending with first polymer 2 (e.g.,second polymer 6 may not be soluble infirst polymer 2 and vice versa). For example, ifsecond polymer 6 is an amorphous polymer andfirst polymer 2 is a crystalline polymer, even when both polymers are in a melted state, the two polymers may resist blending with each other. Thus, whileamorphous polymer 6 may be somewhat dispersed throughoutcrystalline polymer 2,amorphous polymer 6 may not be evenly distributed or blended throughout crystalline polymer 2 (e.g.,amorphous polymer 6 may migrate to the outer surface 5). Accordingly,amorphous polymer 6 may form “clumps” and/or “pockets” incrystalline polymer 2, and thus regions ofamorphous polymer 6 may be clearly discernible in the otherwise substantially homogenous blend ofcrystalline polymer 2 andwood fibers 3. For example,amorphous polymer 6 may have a different color and/or consistency than any combination ofcrystalline polymer 2 andwood fibers 3. -
Composite 1 may have a variegated outer surface 5 (i.e., a first portion ofouter surface 5 may have a first color and a second portion ofouter surface 5 may have a second color different from the first color). For example,outer surface 5 may includestreaks 16.Streaks 16 may run in any direction, may have any size and/or shape, may be disposed in and/or on any portion ofcomposite 1, may have any configuration, and/or may have a color different from the rest ofcomposite 1. For example,streaks 16 may assist composite 1 in obtaining a more aesthetically pleasing wood-like appearance.Streaks 16 are preferably present towardouter surface 5. Any surface ofcomposite 1, for example inner surfaces ofcomposite 1, may havestreaks 16. - Due to the properties of the
amorphous polymer 6 set forth above, and especially with regard to its possible tendency to resist blending with crystalline polymers,amorphous polymer 6 may be responsible forstreaks 16 onouter surface 5 ofcomposite 1. For example, when melted and mixed withcrystalline polymer 2 and wood fiber blend,amorphous polymer 6 may be dispersed in the blend (e.g., mixed but not blended with the blend) such thatstreaks 16 correspond to the location ofamorphous polymer 6. As shown inFIG. 3A ,amorphous polymer 6 is preferably disposed towardouter surface 5 ofcomposite 1. -
Composite 1 may have anouter surface 5 that includes 50% or more of second polymer 6 (e.g., more than 50% of the surface area ofouter surface 5 ofcomposite 1 may be second polymer 6). For example, as shown inFIG. 3C substantially entire portions of outer surface 5 (e.g., one or more of the top, bottom, sides, and/or ends of composite 1) may be composed ofsecond polymer 6. Thus, in some configurations, composite 1 may appear as is if it was coextruded such thatsecond polymer 6 substantially surroundsfirst polymer 2. In such a configuration, entire portions ofouter surface 5 may appear to have substantially one color (e.g., the color ofsecond polymer 6 after it has been extruded using any of the exemplary methods set forth herein), even though composite 1 may include one or more components (e.g.,first polymer 2,wood fibers 3,blend 4,second polymer 6,background color 9, and/or blend 18) having different colors either prior to, during, or following processing. -
Amorphous polymer 6 may have a melting temperature that is substantially the same as a melting temperature ofcrystalline polymer 2, as shown in the following table:Polymer Melting Temperature Range (° C.) HDPE 125°-132° LLDPE 110°-125° LDPE 103°-110° PP-Homo 160°-175° PP-Copolymer 150°-175° PS 74°-105° ABS 88°-125° SAN 100°-200° PS-Rubber Mod. 93°-105°
Thus, for polymers listed above, non-melting mixing (e.g., mixing without blending) ofamorphous polymer 6 andcrystalline polymer 2 may occur between about 140° C. and about 180° C., depending on the exact polymers used. Thus, the present invention has the advantage that even though the polymers used (e.g.,crystalline polymer 2 and amorphous polymer 6) may have substantially the same melting temperature, the two polymers will still resist blending. - Composite i may include a
third polymer 7. For example,third polymer 7 may be an amorphous polymer.Third polymer 7 may be the same amorphous polymer assecond polymer 6, or may be a different amorphous polymer.Third polymer 7 may have the same color assecond polymer 6, or may have a different color.Third polymer 7 may behave similarly tosecond polymer 6. For example,third polymer 7 may formstreaks 16 onouter surface 5 ofcomposite 1 that have a color different from the rest ofouter surface 5. Thus, composite 1 may have a plurality of streaks against a base background color ofcomposite 1, with afirst set 16A ofstreaks 16 having a first color andsecond set 16B ofstreaks 16 having a second color different from the first color. One of ordinary skill in the art would realize that composite 1 may include any suitable number of crystalline polymers, wood fiber types, and/or amorphous polymers. In the example where amorphous polymers cover substantially entire portions of composite 1 (e.g., as set forth inFIG. 3C ),composite 1 may still evince more than color, for example, one color may correspond to the presence ofamorphous polymer 6 on some portions ofouter surface 5 while another color may correspond to the presence ofamorphous polymer 7 on other portions ofouter surface 5. - As shown in
FIG. 3B , composite 1 may include acore 8.Core 8 may have any suitable size, shape, configuration, and/or composition.Core 8 may be configured to impart strength or any other suitable property tocomposite 1.Core 8 may itself be a wood-plastic composite. The mixture ofcrystalline polymer 2,amorphous polymer 6, and/orwood fibers 3 may be disposed aroundcore 8 and/or integrated (e.g., fused) withcore 8. -
Composite 1 may include abackground color 9 and/or pigment.Background color 9 may be configured to color one or more ofcrystalline polymer 2,amorphous polymer 6,amorphous polymer 7, and/orwood fibers 3. For example,background color 9 may be processed withcrystalline polymer 2 and/orwood fiber 3 such thatbackground color 9 permeatescrystalline polymer 2 and/orwood fiber 3 and forms blend 4 (e.g.,background color 9 may permeate associate/engage with portions of the polymer chain of crystalline polymer 2). However,blend 4 may then be processed withamorphous polymer 6 in a suitable manner such thatbackground color 9 does not substantially permeateamorphous polymer 6. For example, the processing ofblend 4 andamorphous polymer 6 may occur at a lower temperature than the processing ofbackground color 9,crystalline polymer 2, and/orwood fiber 3. In another example, the aforementioned structures of the respective polymer chains ofcrystalline polymer 2 andamorphous polymer 6 may be substantially incompatible and/or resistant to blending (e.g., at any temperature). Accordingly,background color 9 may substantially remain attached to/withincrystalline polymer 2 and/orblend 4 and not appreciably permeateamorphous polymer 6. - In various embodiments,
background color 9 may be added toamorphous polymer 6 in addition to and/or instead ofcrystalline polymer 2, and any of the aforementioned characteristics may be applicable to amorphous polymer 6 (e.g., becauseamorphous polymer 6 andcrystalline polymer 2 are configured to resist blending,background color 9 will substantially remain associated withamorphous polymer 6 and not crystalline polymer 2). Indeed, addingbackground color 9 toamorphous polymer 6 and then mixing amorphous polymer 6 (which already has been mixed with background color 9) with either a colored oruncolored blend 4 is the preferred embodiment.Background color 9 may have a polarity that increases the likelihood thatbackground color 9 will remain associated withamorphous polymer 6. (e.g.,background color 9 andamorphous polymer 6 may have polarities that may cause them to be attracted to each other like magnets with opposing polarities) and not become associated with crystalline polymer 2 (e.g.,background color 9 andcrystalline polymer 2 may have polarities that may cause them to repel each other like magnets with substantially the same polarities). - In another embodiment, composite 1 may include another material, compound, and/or additive intermixed with at least one of
crystalline polymer 2 andamorphous polymer 6, for example, in substantially the same way asbackground color 9 is intermixed with at least one ofcrystalline polymer 2 andamorphous polymer 6 as set forth herein, and especially in the previous paragraph. For example, the another material may include a compound that, either on its own or when mixed with at least one ofcrystalline polymer 2 andamorphous polymer 6, causes at least portions of composite 1 (and preferablyouter surface 5 of composite 1) to be resistant to molding and/or mildewing (e.g., keeps the level of microorganisms, mildew, and/or mold in and/or on a composite 1 lower than about 0.1 parts per million). An example of such a material may include a dichloro-octyl-isothiazolone (DCOIT) biostabilizer (e.g., biocide), such as certain grades of VINYZENE™ manufactured by ROHM AND HAAS™ (or other isothiazolones), however, any other suitable material (e.g., biostabiliter or biocide) that prevents and/or reduces molding and/or mildewing either alone or when mixed with at least one ofcrystalline polymer 2 andamorphous polymer 6 is also acceptable. Examples of acceptable methods for determining whether a particular material (e.g., biostabilizer, biocide) suitably prevents and/or reduces mold and/or mildew oncomposite 1 may include American Association for Testing Materials (ASTM™) standards ASTM™ D-1413-99 SOIL-BLACK, ASTM™ D-4445-91 SAP STAIN, ASTM™ E-1428-99 PINK STAIN, ASTM™ G-21-96 MIXED FUNGI, ASTM™ D-5583-00 SINGLE CULTURE, and/or MILITARY STANDARD 810-E HUMIDITY CHAMBER, and/or their equivalents. Indeed, in any of the embodiments set forth herein, the another material, such as the DCOIT biostabilizer, may be substituted forbackground color 9 and may exhibit any of the properties ofbackground color 9 relative to thecrystalline polymer 2,amorphous polymer 6, and/orblend 4 in any portion of the process. - The DCOIT biostabilizer (examples of which may include VINYZENE™ IT 4000 Series, VINYZENE™ IT 4010 Series, and VINYZENE™ SB 27, all of which are manufactured by ROHM AND HAAS™) may be dispersed throughout the
crystalline polymer 2, but preferably theamorphous polymer 6, in any concentration suitable to prevent or reduce mold or mildew growth on thecomposite 1, for example, between about 800 parts per million and about 2000 parts per million and/or between about 1000 parts per million and 1200 parts per million. The DCOIT biostabilizer may have a thermal stability of about 220° C. and/or a solubility in water of about 6 parts per million. - Another example of a suitable biostabilizer may be 10.10′-oxybisphenoxarsine (OBPA), examples of which may include VINYZENE™ BP 5-2 Series, VINYZENE™ BP 5-5 Series,
VINYZENE™ SB 1, andVINYZENE™ SB 1 Series. The OBPA biostabilizer may be dispersed throughout thecrystalline polymer 2, but preferably theamorphous polymer 6, in any concentration suitable to prevent or reduce mold or mildew growth on thecomposite 1, for example, between about 200 parts per million and about 500 parts per million. The OBPA biostabilizer may have a thermal stability of about 300° C. and/or a solubility in water of about 6 parts per million. - A further example of a suitable biostabilizer may be octyl-isothiazoline (OIT), examples of which may include VINYZENE™ IT 3000 Series, VINYZENE™ IT 3010 Series, VINYZENE™ IT 3025 DIDP, and
VINYZENE™ SB 8. The OIT biostabilizer may be dispersed throughout thecrystalline polymer 2, but preferably theamorphous polymer 6, in any concentration suitable to prevent or reduce mold or mildew growth on thecomposite 1, for example, between about 800 parts per million and about 1200 parts per million. The OIT biostabilizer may have a thermal stability of about 220° C. and/or a solubility in water of about 500 parts per million. - Yet another example of a suitable biostabilizer may be trichlorophenoxyphenol (TCPP), examples of which may include VINYZENE™ SB 30. The TCPP biostabilizer may be dispersed throughout the
crystalline polymer 2, but preferably theamorphous polymer 6, in any concentration suitable to prevent or reduce mold or mildew growth on thecomposite 1, for example, between about 800 parts per million and about 1200 parts per million. The TCPP biostabilizer may have a thermal stability of about 230° C. and/or a solubility in water of about 10 parts per million. - A yet further example of a suitable biostabilizer includes biostabilizers that prevent and/or reduce the growth of any of the following exemplary fungi, bacteria, and/or actinomycetes on composite 1: Altemaria, Aureobasidium, Curvularia, Aspergillus, Penicillium, Fusarium, Bigrospora, Chaetomium, Gliocladium, Helminthsporium, and/or all of the subspecies of the aforementioned fungi, bacteria, and/or actinomycetes.
- Still another example of a suitable biostabilizer (e.g., biocide) includes biostabilizers having one or more of the following features: substantially non-toxic; safe and environmentally friendly; broad spectrum; compatibility with formulation; leach and ultraviolet resistant; has sufficient thermal stability; and ease of use and handling.
- A still further example of a suitable biostabilizer may include zinc borate, which may be in the form of a crystalline powder having a solubility in water of about 2800 parts per million and a particle sizes between about 1-2 microns.
- Other examples of suitable biostabilizers (e.g., biocides) and methods for determining suitable. biostabilizers for wood-plastic and other composites were disclosed in a presentation entitled Maintaining the Aesthetic Quality of WPC Decking with Isothiazolone Biocide by Peter Dylingowski, which was presented on May 20, 2003 at the 7th International Conference on Wood-Fiber Plastic Composites, the entirety of which is incorporated herein by reference.
- An exemplary embodiment of the invention includes a method of manufacturing a wood-plastic composite. As shown in
FIGS. 4A-4C , the method may include providing afirst polymer 2, providing a plurality ofwood fibers 3, providing asecond polymer 6 configured to resist blending withfirst polymer 2, meltingfirst polymer 2, meltingsecond polymer 6, mixingsecond polymer 6 withfirst polymer 2 andwood fibers 3 to form afeed 10, and forming aprofile body 1.Profile body 1 may include anouter surface 5 deliberately evincing a first color and a second color different from the first color.Profile body 1 may also include anouter surface 5 being substantially composed ofsecond polymer 6, with a cross-sectional profile ofprofile body 1 showing that a layer ofsecond polymer 6 may be substantially disposed aroundblend 4 offirst polymer 2 andwood fibers 3. -
First polymer 2 may include acrystalline polymer 2.Crystalline polymer 2 is preferably at least one of high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE), and polypropylene (PP), however, any crystalline polymer may be used incomposite 1, such as one or more polyamides (PA), nylons, polyoxymethylenes, polybutylene terephthalates (PBT), polyethylene terephthalates (PET), and/or acetals.First polymer 2 may be provided in any suitable form (e.g., pellets, flakes, sheets, etc.) to be melted, mixed withwood fibers 3, and/or extruded into a dimensionally stable profile.First polymer 2 may have any suitable size, shape, and/or configuration to be used in any of the apparatuses or methods disclosed in co-owned U.S. Pat. Nos. 5,851,469 and 6,527,532, co-pending and co-owned U.S. patent application Ser. No. 10/292,672 filed Nov. 12, 2002, and co-pending and co-owned U.S. patent application Ser. No. 10/668,368 filed Sep. 24, 2003, the entirety of all of which are incorporated herein by reference.First polymer 2 may be processed prior to extruding thefeed 10 using any suitable method. For example,first polymer 2 may be chopped, purified, shredded, heated, and/or demoistured. In various embodiments,first polymer 2 may be heated (e.g., by shear friction with the apparatus or by the application of external thermal energy) to completely melt, partially melt, and/or improve processability. -
Crystalline polymers 2 may be selected because they have a specific color (e.g., be mixed with a certain color dye) and/or composition (e.g., allowsbackground color 9 to suitable permeate its structure). However, because crystalline polymers 2 (and/or its additives such as background color 9) tend to blend and form a substantially homogenous color, the specific colors and/or compositions ofcrystalline polymers 2 used in the process need not be tightly controlled. Some specific dyes may affect the resulting color ofprofile body 1 more than other dyes. One of ordinary skill in the art may controlcrystalline polymers 2 input into the process in order to achieve the desired resultant color forouter surface 5. Moreover, the resultant color ofcrystalline polymers 2 after processing (e.g., heating and/or extrusion) may be different from the initial colors ofcrystalline polymers 2.Crystalline polymer 2 may have any suitable size, shape, and/or configuration, exemplary parameters for which have already been set forth herein. -
Second polymer 6 may include an amorphous polymer.Amorphous polymer 6 is preferably a styrenic polymer such as polystrene (PS), however, any amorphous polymer may be used incomposite 1, such as one or more of Impact PS, polymethylmethacrylates (PMMA), polyvinyl chlorides (PVC), acrylonitrile-butadine-styrene copolymers (ABS), thermoplastic polyurethanes (TPU), styrene acrylonitrile copolymers (SAN), polyphenyl oxide (PPO), acryla-styrene butyl-acrylate or acrylate styrene acrylonitrile (either of which may be abbreviated as ASA), and/or polycarbonates (PC).Second polymer 6 may be provided in any suitable form (e.g., pellets, flakes, sheets, films, etc.)Second polymer 6 may be processed prior to extruding thefeed 10 using any suitable method. For example,second polymer 6 may be chopped, shredded, heated, purified, and/or demoistured. In another example, background color may be added tosecond polymer 6, and thensecond polymer 6 may introduced into a processing apparatus, such asextruder 15, substantially cold (e.g., without processing) to be mixed withblend 4 and/or into the processing apparatus as close to the extruder die 19 of the processing apparatus as possible to be extruded withblend 4. -
Amorphous polymer 6 used may be selected based on its color and/or composition.Amorphous polymer 6 may have an initial color and/or resultant color that is different from the initial color and/or resultant color of the one or more crystalline polymers (with or without wood fibers 3) thatamorphous polymer 6 is being mixed with. For example,crystalline polymers 2, after processing (with or withoutwood fibers 3 and/or background color 9), may result in a substantially gray color, whileamorphous polymer 6, after processing, may result in a substantially black color.Amorphous polymer 6 may have any suitable size, shape, and/or configuration. For example,amorphous polymer 6 may be provided in flake or pellet form. -
Crystalline polymer 2 and/oramorphous polymer 6 may be melted using any suitable method. For example,crystalline polymer 2 and/oramorphous polymer 6 may be heated using in an external heat source (e.g., a flame in a heater 13) or may be heated through kinetic energy (e.g., by passing through abarrel 12 with arotating screw 11, or passing through extruder die 19).Crystalline polymer 2 and/oramorphous polymer 6 may be melted at any point in the composite manufacturing process prior to formingprofile body 1.Crystalline polymer 2 and/oramorphous polymer 6 may be heated separately and/or together. In a preferred embodiment,crystalline polymer 2 and/or wood-fibers 3 may be heated and blended to formblend 4.Crystalline polymer 2 may be heated substantially throughoutcrystalline polymer 2 and/or enough to improve processability (e.g., mixing and/or blending). -
Wood fibers 3 may be from any type of suitable wood, for example, one or more hardwoods and/or softwoods.Wood fibers 3 may also be mixed with and/or replaced by any organic or inorganic filler such as those set forth herein.Wood fibers 3 may be of any suitable shape and/or size, and may be configured to be suitably blended withcrystalline polymer 2 such that a mixture ofwood fibers 3 andcrystalline polymer 2 appears substantially homogenous in color.Wood fibers 3 may be processed prior to formingprofile body 1 using any suitable method. For example,wood fibers 3 may be chopped, shredded, heated, purified, and/or demoisturized.Wood fibers 3 may be dried prior to being blended withcrystalline polymer 2 to formblend 4. In some cases, pieces ofwood fiber 3 may be discernible inblend 4, however,wood fiber 3 will still typically have the same homogenous color as the rest ofblend 4. -
Crystalline polymer 2 may be blended in aprocessor 13 withwood fibers 3 such thatblend 4 is substantially homogenous. For example,blend 4 may have one substantially solid color and/or have a substantially uniform consistency.Blend 4 may be formed using any suitable method.Crystalline polymer 2 andwood fibers 3 may be blended by placing them together either before, during, or aftercrystalline polymer 2 and/orwood fibers 3 are dried.Crystalline polymer 2 andwood fibers 3 may be blended using applied heat and/or mechanical agitation. Such blending may be accomplished by an extruder, high shear device, and/or a low shear mixer with or without the application of heat. -
Second polymer 6 may be mixed withfirst polymer 2 andwood fibers 3 to form afeed 10 in any suitable order, any suitable ratio, and using any suitable method. For example,first polymer 2,second polymer 6, and plurality ofwood fibers 3 may be mixed as they are advanced by one ormore screws 11 in abarrel 12 and/or extruded throughdie 19.Second polymer 6 may be mixed withfirst polymer 2 andwood fibers 3 at any time prior to extruding the feed and in any relative order. For example,first polymer 2 may be blended withwood fibers 3, the blend may be heated, and thensecond polymer 6 may be added to the blend. In another example,first polymer 2,second polymer 6, andwood fibers 3 may be combined at substantially the same time and mixed simultaneously.Second polymer 6 may be mixed withfirst polymer 2 andwood fibers 3 such that the mixture does not blend. For example, the mixture may be heated to a temperature that allows mixing but not blending. - In another example,
second polymer 6 may be added to blend 4 to formfeed 10 just prior to extrudingfeed 10 through extruder die 19. Thus, heating ofsecond polymer 6 may only occur just after introducingsecond polymer 6 intoblend 4 and/or during extrusion offeed 10 through extruder die 19. Accordingly,second polymer 6 may experience less of a heat history than any offirst polymer 2,wood fibers 3, and/orblend 4, which may assist in preventing blending. - In a further example, the structures (e.g., crystalline structures, lack of crystalline structures, polymer backbones, polarity, compositions, etc.) of
first polymer 2 andsecond polymer 6 may assist in preventing thepolymers first polymer 2,second polymer 6, andwood fibers 3 are listed herein, however, generally, the percentage offirst polymer 2 will exceed the percentage ofsecond polymer 6. - In various embodiments, composite 1 may include between about 100% and about 20% of
crystalline polymer 2, between about 5% and about 0% ofamorphous polymer 6, and between about 0% and about 80% wood fiber or other filler. In a preferred embodiment, composite 1 may include between about 60% and about 53% ofcrystalline polymer 2, about 2% ofamorphous polymer 6, and between about 45% and about 38% wood fiber or other filler - Besides having a more natural, smooth, non-monolithic, and/or three-dimensional looking surface,
composites 1 discussed herein may have other advantages. For example, composite 1 may be less susceptible to mold and mildew and/or may be more durable.Crystalline polymer 2 andamorphous polymer 6 do not blend incomposites 1. Accordingly, the minor component (in this case, amorphous polymer 6) may migrate to theouter surface 5 ofcomposite 1. When the minor component migrates toouter surface 5 ofcomposite 1, the minor component may tend to coat at least portions of outer surface 5 (e.g., top, bottom, and/or side surfaces) with a polymer rich coating that does not absorb moisture, and thus allowsouter surface 5 to resist molding and/or mildewing. Moreover, additional additives, such as mold and mildew resistant compounds (e.g., DCOIT biostabilizers or other suitable anti-fungi.bacteria materials/compounds, examples of which are set forth herein, or other materials having other desirable properties for composite 1), may be added toamorphous polymer 6 at any point before or during the manufacturing process ofcomposite 1. During the addition of the additive toamorphous polymer 6, the additive andamorphous polymer 6 may be processed so as to substantially disperse the additive through the matrix ofamorphous polymer 6. Once again, becauseamorphous polymer 6 may migrate toouter surface 5 ofcomposite 1,amorphous polymer 6 with mildew resistant additives (or other materials) may coat at least portions ofouter surface 5. Some exemplary reasons whyamorphous polymer 6 may migrate towardouter surface 5 ofcomposite 1 are set forth herein, and especially below. - This type of delivery of the mold and mildew resistant materials and/or compounds, examples of which are set forth herein, (or other compounds with other desirable properties) to specific portions of
composite 1 may have many advantages. For example, the compounds themselves may be relatively expensive and/or including too much of the compound incomposite 1 may compromise some structural and/or aesthetic properties ofcomposite 1. Thus, there may be a need to minimize the amount of the compound incomposite 1 by delivering the compound to portions of the composite 1 where the compound may be most effective. In the case of mildew and/or mold resistant compounds (examples of which are set forth herein), such compounds may be most effective on at least portions ofouter surface 5 ofcomposite 1. Accordingly, because the properties (e.g., crystalline structure, solubility, or other properties like or similar to those set forth herein) of first polymer 2 (e.g., crystalline polymer) and second polymer 6 (e.g., amorphous polymer) causessecond polymer 6, when extruded, to migrate away from first polymer 2 (e.g., with or without wood fibers 3) and/or towardouter surface 5 ofcomposite 1,second polymer 6 may be used as a vehicle to deliver desirable compounds on and/or towardouter surface 5. In some cases, if the property of the compound is desirable along large portions ofouter surface 5, thensecond polymer 6 with the desirable compound may be disposed along entire portions ofouter surface 5, for example, as set forth inFIG. 3C . -
Profile body 1 with anouter surface 5 may be formed using any suitable method. For example, the mixture including first polymer 2 (e.g., crystalline polymer), second polymer 6 (e.g., amorphous polymer), andwood fibers 3 may be extruded through a die 19 to formprofile body 1.Feed 10 may be extruded using either a single screw extruder or a double screw extruder to formprofile body 1.Feed 10 may also be formed intoprofile body 1 using any suitable method. -
Outer surface 5 ofprofile body 1 may be variegated.Streaks 16 may be formed onouter surface 5 ofprofile body 1. For example, ifcrystalline polymer 2 andamorphous polymer 6 are mixed, the chemical properties of the two polymers and/or the processing conditions (e.g., temperature, extrusion rate, mixing rate that the two polymers are subjected to) may prevent them from blending with each other and forming a homogenous color. Accordingly, “clumps” or “pockets” ofamorphous polymer 6 may be dispersed throughcrystalline polymer 2 and vice versa. As the mixture ofamorphous polymer 6 and crystalline polymer 2 (with or without wood fibers 3) is extruded through thedie 19,amorphous polymer 6 may tend to go towardsouter surface 5 ofprofile body 1, for example, due the pressures exerted onfeed 10 during extrusion. In another example, due to the molecular structure of bothcrystalline polymer 2 andamorphous polymer 6, the polymer chain ofamorphous polymer 6 cannot interlock easily with the polymer chain and/or matrix ofcrystalline polymer 2. Accordingly,amorphous polymer 6 may tend to separate from the polymer matrix ofcrystalline polymer 2 and go toouter surface 5 so as to form its own solid polymer matrix ofamorphous polymer 6. Asamorphous polymer 6 reachessurface 5, becauseamorphous polymer 6 may have a different initial color and/or different resultant color as the rest of profile body 1 (i.e.,blend 4 ofcrystalline polymer 2 and wood fibers 3),streaks 16 ofamorphous polymer 6 may be readily discernible onouter surface 5.Streaks 16 may be generally perpendicular to a cross-section ofdie 19 through whichprofile body 1 is extruded. However,streaks 16 may be in any direction, and have any other shape and/or configuration, for example, similar to those set forth inFIGS. 2A-2C . - In another example, entire portions of
outer surface 5 may be composed ofamorphous polymer 6, for example, as shown inFIG. 3C . In such an example, the processing may have been such thatamorphous polymer 6 forms “clumps” or “pockets” (e.g., as set forth in the previous paragraph) around substantially all ofblend 4 so as to form a substantially solid matrix around blend 4 (e.g., with or without wood fibers 3). Any suitable proportions ofamorphous polymer 6,crystalline polymer 2, wood-fibers 3,blend 4, blend 18,background color 9, and another other material or compound set forth herein are contemplated as being discernible onouter surface 5. - The method may also include providing another
amorphous polymer 7, melting anotheramorphous polymer 7, and mixing anotheramorphous polymer 7 withamorphous polymer 6,crystalline polymer 2, and/orwood fibers 3. With the addition of additionalamorphous polymer 7, the step of extruding may include formingprofile body 1 such thatouter surface 5 deliberately evinces a third color different from the first color and the second color due to additionalamorphous polymer 7. - Another
amorphous polymer 7 may be selected because its initial color and/or resultant color may be different from an initial color and/or resultant color of one or more ofcrystalline polymer 2 and/orwood fibers 3. Anotheramorphous polymer 7 may processed and/or behave similarly to otheramorphous polymers 6, thus,streaks 16B of anotheramorphous polymer 7 may be formed onouter surface 5 ofprofile body 1.Streaks 16B from anotheramorphous polymer 7 may be of a color different from either the base color ofprofile body 1 and/or the color ofstreaks 16A fromamorphous polymer 6. - As shown in
FIG. 4B , the method may also include providing acore 8 and formingprofile body 1 around at least a portion ofcore 8.Core 8 may be a wood-plastic composite or any other suitable composite.Core 8 may have a cross-sectional area smaller than a cross-sectional area ofdie 19.Core 8 may be fed byextruder 15 throughdie 19 such thatcore 8 advances through substantially the center ofdie 19 without contacting any portion ofdie 19 itself.Extruder 15 and/or die 19 may then deposit anouter surface 5 oncore 8 that has more than one color (e.g., variegated and/or streaked) using one or more of the methods set forth herein. Thevariegated surface 5 may be bonded tocore 8 using any suitable method, for example, whenvariegated surface 5 is co-extruded ontocore 8, a portion ofcore 8 may melt and intermix withvariegated surface 5 such thatcore 8 and thevariegated surface 5 are substantially fused. Accordingly, the resultant product may be a building material with acore 8 having a wood-plastic composite having a deliberately variegatedouter surface 5 formed around it. Such a resultant product may be desirable, for example, to impart strength to the component (e.g., by providing a core component having a high strength such as aluminum or steel). - The method also may include the use of a
background color 9. As shown inFIG. 4B ,background color 9 may be added tocrystalline polymer 2 and/or wood fiber 3 (e.g., blend 4) to impart a color to blend 4 different from an initial color ofblend 4,crystalline polymer 2, and/orwood fiber 3.Background color 9,crystalline polymer 2,wood fibers 3, and/orblend 4 may be processed byprocessor 13 using any suitable apparatus and/or method to formresultant blend 4.Resultant blend 4 may then be transferred toextruder 15 and processed withamorphous polymer 6 to formprofile body 1 withstreaks 16 or other variations ofouter surface 5 as set forth herein.Background color 9 may be added to any step of the process and/or any component or subcomponent of the process at any time prior to extrusion throughdie 19. - In a preferred embodiment, as shown in
FIG. 4C ,background color 9 may be added toamorphous polymer 6 to impart a color toamorphous polymer 6 different from an initial color ofamorphous polymer 6.Background color 9 and/oramorphous polymer 6 may be processed byprocessor 17 using any suitable apparatus and/or method to formresultant blend 18 ofamorphous polymer 6 andbackground color 9.Resultant blend 18 may then be transferred toextruder 15 and processed withcrystalline polymer 2,wood fibers 3, and/orblend 4 to formprofile body 1 withstreaks 16 or other variations ofouter surface 5 as set forth herein. Once again,background color 9 may be added to any step of the process and/or any component or subcomponent of the process at any time prior to extrusion throughdie 19. - One of ordinary skill in the art will recognize that some aspects of the invention may be multiplied so as to form different embodiments of the invention. For example, there may be a plurality of crystalline polymers, a plurality of types of wood fibers, and/or a plurality of amorphous polymers used.
- One of ordinary skill of art will further recognize that some of the aspects of set forth herein may be combined with other aspects set forth herein to form different embodiments of the invention. For example, composite 1 with streaks having multiple colors may also include a core.
- One of ordinary skill in the art will also recognize that some of the aspects set forth herein may be removed to form different embodiments of the invention. For example,
crystalline polymer 2 and wood fibers need not be blended prior to mixing them withamorphous polymer 6. - Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.
Claims (38)
1-20. (canceled)
21. A method of manufacturing a wood-plastic composite including a profile body, comprising:
providing a crystalline polymer;
providing a plurality of wood fibers;
providing an amorphous polymer;
melting the crystalline polymer;
melting the amorphous polymer;
first mixing the crystalline polymer and the plurality of wood fibers to form a substantially homogenous feed;
second mixing the amorphous polymer with the substantially homogenous feed of the crystalline polymer and the plurality of wood fibers to form a heterogeneous feed; and
forming the profile body from the heterogeneous feed, the profile body including an outer surface evincing a first color associated with the amorphous polymer and a second color associated with the substantially homogenous feed, the second color being different from the first color.
22. The method of claim 21 , further comprising forming streaks of the first color on the outer surface.
23. The method of claim 21 , further comprising forming streaks of the amorphous polymer on the outer surface.
24. The method of claim 21 , further comprising shifting the amorphous polymer towards the outer surface.
25. The method of claim 21 , further comprising variegating the outer surface.
26. The method of claim 21 , further comprising providing at least one of a single screw extruder and a double screw extruder,
wherein the step of forming includes extruding the heterogeneous feed via the at least one of the single-screw extruder and the double screw extruder.
27. The method of claim 21 , wherein the step of second mixing includes forming the first color from the amorphous polymer and forming the second color from the substantially homogenous feed including the crystalline polymer and the plurality of wood fibers.
28. The method of claim 21 , further comprising providing another amorphous polymer;
melting the another amorphous polymer; and
mixing the another amorphous polymer with the amorphous polymer and the substantially homogenous feed including the crystalline polymer and the plurality of wood fibers,
wherein the step of forming includes forming the profile body such that the outer surface evinces a third color associated with the another amorphous polymer different from the first color and the second color.
29. The method of claim 21 , further comprising providing a core, wherein the step of forming the profile body includes forming the profile body around at least a portion of the core.
30. The method of claim 21 , further comprising providing a colorant having a third color different from the first color and the second color; and
blending the colorant with one of the crystalline polymer and the amorphous polymer so as to turn the one of the crystalline polymer and the amorphous polymer the third color.
31. A method of manufacturing a wood-plastic composite including a profile body, comprising:
providing a first polymer;
providing a plurality of wood fibers;
providing a second polymer not substantially soluble in the first polymer;
melting the first polymer;
melting the second polymer;
first mixing the second polymer and the plurality of wood fibers to form a substantially homogenous feed;
second mixing the first polymer with the substantially homogenous feed to form a heterogeneous feed; and
forming the profile body from the heterogeneous feed, the profile body including an outer surface evincing a first color associated with the first polymer and a second color associated with the substantially homogenous feed, the second color being different from the first color.
32. The method of claim 31 , further comprising forming streaks of the first color on the outer surface.
33. The method of claim 31 , further comprising forming streaks of the first polymer on the outer surface.
34. The method of claim 31 , further comprising shifting the first polymer towards the outer surface.
35. The method of claim 31 , further comprising variegating the outer surface.
36. The method of claim 31 , further comprising providing at least one of a single screw extruder and a double screw extruder,
wherein the step of forming includes extruding the heterogeneous feed via the at least one of the single-screw extruder and the double screw extruder.
37. The method of claim 31 , wherein the step of second mixing includes forming the first color from the first polymer and forming the second color from the substantially homogenous feed including the second polymer and the plurality of wood fibers.
38. The method of claim 31 , further comprising providing a third polymer not substantially soluble in the second polymer;
melting the third polymer; and
mixing the third polymer with the first polymer and the substantially homogenous feed including the second polymer and the plurality of wood fibers,
wherein the step of forming includes forming the profile body such that the outer surface deliberately evinces a third color associated with the third polymer different from the first color and the second color.
39. The method of claim 31 , further comprising providing a core, wherein the step of forming the profile body includes forming the profile body around at least a portion of the core.
40. The method of claim 31 , further comprising providing a colorant having a third color different from the first color and the second color; and
blending the colorant with one of the first polymer and the second polymer so as to turn the one of the first polymer and the second polymer the third color.
41. A method of manufacturing a wood-plastic composite including a profile body, comprising:
providing a first polymer, a plurality of wood fibers, a second polymer not substantially soluble in the first polymer, and an additive;
melting the first polymer and the second polymer;
first blending the additive with the second polymer to form a substantially homogenous blend;
second blending the first polymer and the plurality of wood fibers to form a substantially homogenous feed;
mixing the substantially homogenous blend with the substantially homogenous feed of the first polymer and the plurality of wood fibers to form a heterogeneous feed;
forming the profile body with an outer surface from the heterogeneous feed; and
shifting the substantially homogenous blend towards the outer surface such that at least a portion of the substantially homogenous blend is visible on the outer surface.
42. The method of claim 41 , wherein the additive is one or more of a pigment, a mold inhibitor, a microorganism growth inhibitor, and a mildew inhibitor.
43. The method of claim 41 , wherein the substantially homogeneous blend substantially covers an entire side of the profile body.
44. The method of claim 41 , wherein the additive is not blended with either of the first polymer or the wood fibers.
45. The method of claim 41 , wherein the additive is soluble in the second polymer and not soluble in the first polymer.
46. The method of claim 21 , further comprising preventing the plurality of wood fibers from being dispersed throughout the amorphous polymer during the step of second mixing.
47. The method of claim 31 , further comprising preventing the plurality of wood fibers from being dispersed throughout the first polymer during the step of second mixing.
48. The method of claim 41 , further comprising preventing the plurality of wood fibers from being dispersed throughout the first polymer during the step of mixing.
49. The method of claim 21 , wherein providing the amorphous polymer includes providing enough of the amorphous polymer so as to result in the profile body including between about 0% and about 5% of the amorphous polymer by weight.
50. The method of claim 31 , wherein providing the first polymer includes providing enough of the first polymer so as to result in the profile body including between about 0% and about 5% of the first polymer by weight.
51. The method of claim 41 , wherein providing the first polymer includes providing enough of the first polymer so as to result in the profile body including between about 0% and about 5% of the first polymer by weight.
52. The method of claim 21 , wherein providing the amorphous polymer includes providing enough of the amorphous polymer so as to result in the profile body including about 2% of the amorphous polymer by weight.
53. The method of claim 31 , wherein providing the first polymer includes providing enough of the first polymer so as to result in the profile body including about 2% of the first polymer by weight.
54. The method of claim 41 , wherein providing the first polymer includes providing enough of the first polymer so as to result in the profile body including about 2% of the first polymer by weight.
55. The method of claim 21 , wherein the amorphous polymer is one of a polystyrene and polycarbonate.
56. The method of claim 31 , wherein the amorphous polymer is one of a polystyrene and polycarbonate.
57. The method of claim 41 , wherein the amorphous polymer is one of a polystyrene and polycarbonate.
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Also Published As
Publication number | Publication date |
---|---|
US7410687B2 (en) | 2008-08-12 |
MXPA06014301A (en) | 2007-05-04 |
US20060068215A2 (en) | 2006-03-30 |
US20050271872A1 (en) | 2005-12-08 |
US20070087181A1 (en) | 2007-04-19 |
US20050271889A1 (en) | 2005-12-08 |
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