Method of producing composite members having increased strength

Inactive Publication Date: 2007-03-01
ECOPURO LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0034] Glass spheres or ceramic spheres have enormous compression strength in comparison to the foam cells created by blowing agents. Therefore, the addition of micro spheres will not only provide the ability to tailor the CTE of the foam but it will replace low compression strength cell structures with higher strength cell structures.
[0035] The incorporation of chop fibers adds dramatic cross structural strength throughout the foam. Applicant's mechanical model analysis clearly illustrates an increased strength of materials resulting from the presence of core material regardless of the mechanical structure. The analysis was directed to extruded PVC. Some of the extruded PVC members were filled with chopped fibers and some were not. The chopped fibers increased strength of the structural member and decreased the CTE. The additives of selected fillers to the foam core materials illustrate similar characteristics. Selecting appropriate materials for a composite is complicated because composites are not homogeneous materials. However, composites are required to function as a homogeneous structure without structural deviation. The models clearly show how reinforcing fibers increases load b

Problems solved by technology

The cross-section of the members may also be very complex, including internal support structures and/or having an irregular periphery.
One drawback associated with existing extruded composite structural building materials is that existing materials lack the strength necessary to directly compete with or replace structural wood, e.g., various sized wood beams, i.e., 2×4, 2×6, 2×8, 4×4, 4×6, 4×8, etc.
However, composite materials typically still require wood support structures for structural strength.
The addition of wood particles to plastic also results in some undesirable characteristics.
For example, wood particles may rot and are susceptible to fungal attack, wood particles can absorb moisture, wood particles are on the surface of a WPC member can be destroyed by freeze and thaw cycling, wood particles are susceptible to absorbing environmental staining, e.g., from tree leaves, wood particles can create pockets if improperly distributed in a WPC material, which may result in a failure risk that cannot be detected by visual inspection, and wood particles create manufacturing difficulties in maintaining consistent colors because of the variety of wood species color absorption is not consistent.
As a result, the wood particles on the surface tend to undergo environmental bleaching.
Con

Method used

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  • Method of producing composite members having increased strength
  • Method of producing composite members having increased strength
  • Method of producing composite members having increased strength

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Embodiment Construction

[0052] Before explaining the present invention in detail, it is important to understand that the invention is not limited in its application to the details of the embodiments and steps described herein. The invention is capable of other embodiments and of being practiced or carried out in a variety of ways. It is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation.

[0053] Referring now to FIG. 1, a cross-section of prior art extrusion die 10 is shown. Extrusion die 10 includes external die element 12 and internal die elements 14 that define die walls 16. Die walls 16 define channels 18 through which a molten material is forced. Once the molten material is forced out of the die 10, the material cools, resulting in an extruded member, e.g., extruded member 19, shown in cross-section in FIG. 2.

[0054] Referring now to FIG. 3, an improved extrusion die 20 is shown. Extrusion die 20 includes external die element 22...

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Abstract

This invention relates to extruded composite materials specifically focusing on the increasing load bearing capacity and the overall strength of composites. Injectable conformable structural core materials are used to replace foam cells inside extruded composite materials thereby increasing the overall load bearing stability and strength. The core materials are tailored to have a desired CTE with respect to the structural materials. The core materials may also incorporate fibers and solid structural fillers for increasing the strength of the composite member. The objective is to enable composite materials to have the highest structural load bearing capability possible so that these technologies can be used as the replacement of wood, in aerospace applications and for other purposes.

Description

CROSS REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit of U.S. Provisional Application No. 60 / 709,628, which application was filed with the Patent and Trademark Office on Aug. 19, 2005, which application is hereby incorporated by reference.FIELD OF THE INVENTION [0002] This invention relates generally to structures having structural core materials inside of a composite matrix. More particularly, the invention relates to extruded composite building materials having a selected core material tailored to increase the strength of the extruded member. BACKGROUND OF THE INVENTION [0003] An extrusion process is one of the most economic methods of manufacturing to produce engineering structural materials. Typically, an extrusion process is used to manufacture lengths of extruded members having a uniform cross-section. The cross-section of the members may be of various simple shapes such as circular, annular, or rectangular. The cross-section of the members may also...

Claims

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Application Information

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IPC IPC(8): B29C47/06B29C47/12B29C47/92B05D5/00B05D3/12B29C44/20B29C48/07B29C48/11B29C48/12B29C48/30B29C48/92
CPCB29C44/128B29C44/186B29C44/3411B29L2031/60B29C47/12B29C47/128B29K2105/04B29C47/0028B29C48/11B29C48/304B29C2948/92561B29C2948/926B29C2948/92761B29C2948/92952B29C2948/9298B29C48/07B29C48/12B05D3/12B05D5/00B29C44/20
Inventor JOHNSON, WILLIAM L. SR.
Owner ECOPURO LLC
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