System and method for making extruded, composite material

Abstract

Systems and methods for making a material composition are disclosed. The method includes mixing a thermoset polymer, a petroleum distillate, a release agent, and a catalyst to form an admixture. A cellulosic material is mixed with the admixture to form a generally homogenous furnish. The system includes a mixing chamber, a feeding chamber, and a die. The die includes a pressing chamber, which has a volume formed by first and second platens. The platens are in facing opposition to one another and have a length extending continuously from an entrance to an exit of the die. The platens have a plurality of orifices and heating elements disposed along the length. The platens are disposed in first and second positions. The first position forms a first volume and the second position forms a second volume.

Description

CROSS-REFERENCE TO RELATED PATENTS AND PATENT APPLICATIONS[0001]This application is a divisional application of U.S. patent application Ser. No. 10 / 285,449 filed Nov. 1, 2002, which is incorporated by reference herein in its entirety.NOTICE OF COPYRIGHT PROTECTION[0002]A portion of the disclosure of this patent document and its figures contain material subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document, but otherwise reserves all copyrights whatsoever.FIELD OF INVENTION[0003]The invention disclosed herein relates to composite materials in general, and more particularly, to an apparatus for and method of making an extruded, cellulosic-based composite material.BACKGROUND[0004]Manufacturing processes invariably result in material waste for a variety of reasons, such as imperfections in raw materials and errors made during production. Material waste has increasingly become an economic burden for manufactur...

AI Technical Summary

Benefits of technology

[0014]One advantage of the present invention can be to utilize non-uniform raw waste materials for the composite material composition.

[0015]An advantage of the present invention can be to reduce the amount of waste disposed of in landfills or burned by using waste wood to form a composite material.

[0016]Another advantage of the present invention can be to provide a uniform, high density composite material composition.

[0017]Yet another advantage of the present invention can be to provide composite material composition that is an effective sound barrier.

[0018]A further advantage of the present invention can be to provide an inexpensive apparatus for manufacturing a composite material composition.

[0019]Yet a further advantage of the present invention can be to provide for drying a composite admixture integral to the apparatus.

Problems solved by technology

Manufacturing processes invariably result in material waste for a variety of reasons, such as imperfections in raw materials and errors made during production.

Material waste has increasingly become an economic burden for manufacturers of wood products, such as doors and windows.

The steady increase in fees for landfill disposal and increasingly stringent air-quality regulations have made traditional methods of waste disposal problematic for manufacturers of wood products.

Conventional alternatives to landfill disposal and burning are inadequate.

However, the cost of such devices is expensive, and for small manufacturers, these expenses can quickly become cost-prohibitive.

The cost of burning waste can also include governmental permit fees, as well as the cost of ensuring compliance with environmental regulations.

However, animal bedding requires generally homogenous and nontoxic material.

Wood waste from manufacturing processes can often include ferrous materials and painted products, which can be harmful to animals.

Thus, animal bedding is often not an adequate solution.

However, the demand for fill material is inconsistent, which means that manufacturers would be forced to keep an inventory of waste when there is no adequate demand.

Keeping any sort of inventory is generally expensive, and thus, this option does not offer sufficient economic advantages over disposal.

However, the equipment currently available to manufacture such composite materials is relatively expensive, and therefore is cost-prohibitive for most small and specialty manufacturers.

Often, wood waste from manufacturing processes is not uniform.

Moreover, the product produced by such conventional methods typically has a density that is non-uniform.

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