Composite materials, articles of manufacture produced therefrom, and methods for their manufacture
AssigneeElk Composite Building Products, Inc.
InventorCharles Baker
Life of this patent
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Abstract
The invention is directed to a plastic fiber article of manufacture having composite-like high strength characteristics. The article of manufacture can be in the form of a panel or board. The panel or board is constructed from low cost fiber materials, industrial grade or high thermal plastic, and other additives to protect the board or panel from ultraviolet light, fugii growth, excessive heat, fire, insect infestation, and/or weathering. The plastic fiber panel or board may be textured and colored to resemble natural wood such as cedar, walnut, or oak. The plastic fiber panel or board is stronger more durable and may be cheaper than natural wood alternative panels or boards.
Claims18
A process for forming a composite article of manufacture comprising:
- (a) adding wood fibers screened through a 20-40 mesh to an extruder mixing container;
- (b) adding fiberglass chop about ¼ inch to about 1 inch in length to the mixing container
- (c) heating the fibers of steps (a) and (b) in the mixing container to remove moisture;
- (d) contacting a hot thermal plastic additive mixture with the fibers of step (b) to produce a fiber/thermal plastic composite;
- and
- (e) contacting the fiber/thermal plastic mixture of step (d) with a die to provide shape to the fiber/thermal plastic composite and to produce the composite article of manufacture, wherein the fiber/thermal plastic composite comprises about 35% fiberglass, about 25% wood, and about 40% plastic.
Dependencies are inferred from the claim text.