Composite board and method
AssigneeSub-Tank Renewal Systems, Inc.
InventorRichard W. Tock
Life of this patent
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Abstract
A composite board is produced by the method of blending a cellulosic filler having sufficient extractable organic content and an expandable thermoplastic polymer, adding a tacifier agent during blending for producing a pre-blown mixture, heating the mixture in a mold to a temperature above the glass transition temperature of the polymer for a period of time sufficient to permit expansion of the beads and bonding of the expanded beads with the cellulosic filler to thereby form a composite board. The board may be laminated by a solvent based adhesive or a thermal insult coating so as to form rigid macro-voids between the laminate and the composite board surface.
Claims28
A molded foam composite board, comprising:
- (a) from about 40 parts by weight to about 90 parts by weight of a thermoplastic polymer comprising vinyl monomers having a blown density of from about 1 to about 3 lb m/ft.sup.3 ;
- (b) from about 1 part by weight to about 60 parts by weight lignocellulosic filler providing extractable plasticizer compounds, said filler comprising from about 10 to about 25% cellulose content, from about 30 to about 45% lignin content and from about 7 to about 13% ash content so that upon being blown the surface of said polymer is plasticized by said compounds for thereby increasing interfacial bonding between the expanded polymer and said filler;
- and,
- (c) tacifier agent of from about 1 part by weight to about 2 parts by weight of said polymer.
A molded foam composite board comprising:
- (a) from about 40 parts by weight to about 90 parts by weight of thermoplastic polymer comprising vinyl monomers having a blown density of from about 1 to about 3 lb m/ft.sup.3 ;
- (b) from about 1 part by weight to about 60 parts by weight lignocellulosic filler providing extractable plasticizer compounds, said filler comprising from about 10 to about 25% cellulose content, from about 30 to about 45% lignin content and from about 7 to about 13% ash content, so that upon expansion the surface of said polymer is thereby plasticized for promoting interfacial bonding between the expanded polymer and said filler;
- (c) tacifier agent of from about 1 part by weight to about 2 parts by weight of said polymer;
- and,
- (d) at least one surface of said board having a laminate applied thereto.
A molded foam composite board comprising:
- (a) from about 40 parts by weight to about 90 parts by weight of a thermoplastic polymer comprising vinyl monomers having a blown density of from about 1 to about 3 lb m/ft.sup.3 ;
- (b) from about 30 parts by weight to about 60 parts by weight cotton gin by-product waste;
- and,
- (c) tacifier agent of from about 1 part by weight to about 2 parts by weight of said polymer.
Dependencies are inferred from the claim text.