Capped component and method for forming
AssigneeTimberTech Limited
InventorsBryan K. Buhrts, Burch E. Zehner, William G. Taylor, Scott A. Haemmerle, Brett Harris
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Abstract
A method of manufacturing a component comprised of a substrate layer and a cap layer. In one exemplary embodiment, multiple co-extruded wood composite components may be formed simultaneously. In another exemplary embodiment, a component may have a substrate layer comprised of cellulosic material. The cap layer may also include cellulosic filler and at least one streaker. The resulting component may serve a variety of different uses. For example, the component may be used in railing systems such as for decks, porches, fences, stairs, or other suitable applications.
Claims20
A coextruded component comprising:
- a substrate layer comprising:
- (a) cellulosic material in an amount between about 30% by weight to about 70% by weight of said substrate material;
- and
- (b) polyethylene material in an amount between about 30% by weight to about 70% by weight of said substrate material, said polyethylene material comprising polyethylene resin;
- and
- a cap layer secured to said substrate layer, said cap layer comprising:
- (a) cellulosic material in an amount between about 20% by weight and about 70% by weight of said cap layer;
- (b) polyethylene resin in an amount between about 20% by weight and about 70% by weight of said cap layer;
- and
- (c) at least one streaker in a total amount between about 0.01% by weight and about 20% by weight of said cap layer.
A coextruded deck board comprising:
- a substrate layer comprising:
- (a) cellulosic material in an amount between about 40% by weight to about 60% by weight of said substrate material;
- and
- (b) polyethylene material in an amount between about 30% by weight to about 60% by weight of said substrate material, said polyethylene material comprising polyethylene resin;
- and
- a cap layer secured to said substrate layer, said cap layer comprising:
- (a) cellulosic material in an amount between about 40% by weight and about 45% by weight of said cap layer;
- (b) polyethylene resin in an amount between about 30% by weight and about 35% by weight of said cap layer;
- and
- (c) at least one streaker in a total amount between about 0.01% by weight and about 10% by weight of said cap layer.
A method of forming a cellulosic composite component, said method comprising:
- providing an extrusion system comprising:
- a plurality of extruders;
- and
- at least one die system;
- providing a substrate material to a first extruder of said extruders, said substrate material comprising:
- (a) cellulosic material in an amount between about 30% by weight to about 70% by weight of said substrate material;
- and
- (b) polyethylene material in an amount between about 30% by weight to about 70% by weight of said substrate material, said polyethylene material comprising polyethylene resin;
- and
- providing a cap layer material to a second extruder of said extruders, said cap layer material comprising:
- (a) cellulosic material in an amount between about 20% by weight and about 70% by weight of said cap layer;
- (b) polyethylene resin in an amount between about 20% by weight and about 70% by weight of said cap layer;
- and
- (c) at least one streaker in a total amount between about 0.01% by weight and about 20% by weight of said cap layer;
- extruding said substrate material;
- co-extruding said cap layer material onto at least a portion of said substrate material;
- forming a flow of said substrate material and said cap layer material;
- and
- forcing said flow through said at least one die system to form at least one component.
Dependencies are inferred from the claim text.