US4818604A
Expired / Lapsed
US
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Composite board and method
Assignee: Sub-Tank Renewal Systems Inc
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Filing: 1987-03-27
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Granted: 1989-04-04
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Expires: 2007-03-27
Abstract
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.
Inventors
- 👤 Richard W. Tock
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 19:08
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/22; C08J9/228; C08J9/236; B; B27; B27N; B27N3/00; B27N3/005; B29; B29C; B29C44/00; B29C44/34; B29C44/36; B29C44/38; B29C44/44; B29C44/445; C08J9/0061; B29K; B29K2025/00; B29K2105/00; B29K2105/06; B29K2105/16; C08J2300/00; C08J2300/22; C08J2325/00; C08J2325/02; C08J2325/04; C08J2325/06; C08J2497/00; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249953; Y10T428/249987; Y10T428/249991; Y10T428/249992; Y10T428/249993; Y10T428/25; Y10T428/253; Y10T428/31504; Y10T428/31652; Y10T428/31659; Y10T428/31855; Y10T428/3188
Claims Analysis
Total Claims: 31
Claim 1
Independent Claim
135 words
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 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.
Claim 2
Dependent Claim
135 words
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 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.
Claim 3
Dependent Claim
30 words
A composite board as in claim 1, wherein: (a) said thermoplastic polymer chosen from the group consisting of polystyrene, poly (methyl methacrylate), poly (vinyl chloride), poly (vinylidine chloride) and polyacrylonitrile.
Claim 4
Dependent Claim
24 words
A composite board as in claim 1, wherein: (a) said polymer to said filler content having a preferred ratio of 50-50 parts by weight.
Claim 5
Dependent Claim
21 words
A composite board as in claim 1, wherein: (a) said cellulosic filler having an extractable organic content of at least 70%.
Claim 6
Dependent Claim
31 words
A composite board as in claim 1, wherein: (a) said cellulosic filler chosen from the group consisting of cotton gin by-product waste, sawdust, shredded paper, ground corn cobs and milo stubble.
Claim 7
Dependent Claim
25 words
A composite board as in claim 5, wherein: (a) said filler comprising flakes, fibres and granules of from about 10 to about 30 mesh size.
Claim 8
Dependent Claim
33 words
A composite board as in claim 6, wherein: (a) said filler having a total content of about 80 parts by weight 16 mesh size and about 20 parts by weight 30 mesh size.
Claim 9
Dependent Claim
37 words
A composite board as in claim 1, wherein: (a) said tacifier agent having a sufficiently low viscosity so as to promote adherence of said filler and said polymer during blending and to promote adhesive bonding during molding.
Claim 10
Dependent Claim
22 words
A composite board as in claim 1, wherein: (a) said tacifier chosen from the group consisting of silane polyester and poly glycol.
Claim 11
Dependent Claim
22 words
A composite board as in claim 1, further comprising: (a) from about 6 to about 10 parts by weight flame retardant material.
Claim 12
Dependent Claim
16 words
A composite board as in claim 10, wherein: (a) said flame retardant material is ammonium phosphate.
Claim 13
Dependent Claim
28 words
A composite board as in claim 1, wherein: (a) said board has a density of from about 5 lb m/ft 3 to about 60 lb m/ft 3 .
Claim 14
Dependent Claim
143 words
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 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.
Claim 15
Dependent Claim
143 words
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 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.
Claim 16
Dependent Claim
16 words
A composite board as in claim 13, wherein: (a) said laminate is a solvent based adhesive.
Claim 17
Dependent Claim
18 words
A composite board as in claim 14, wherein: (a) said adhesive comprising unsaturated polyesters containing a styrene monomer.
Claim 18
Dependent Claim
15 words
A composite board as in claim 13, wherein: (a) said laminate is a thermal insult.
Claim 19
Dependent Claim
14 words
A composite board as in claim 16, wherein: (a) said thermal insult comprising asphalt.
Claim 20
Dependent Claim
30 words
A composite board as in claim 13, wherein: (a) said thermoplastic polymer chosen from the group consisting of polystyrene, poly (methryl methacrylate), poly (vinyl choride), poly (vinyladine chloride) and polyacrylontrile.
Claim 21
Dependent Claim
31 words
A composite board as in claim 13, wherein: (a) said cellulosic filler chosen from the group consisting of cotton gin by-product waste, sawdust, shredded paper, ground corn cobs and milo stubble.
Claim 22
Dependent Claim
78 words
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 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.
Claim 23
Dependent Claim
78 words
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 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.
Claim 24
Dependent Claim
30 words
A composite board as in claim 20, wherein: (a) said thermoplastic polymer chosen from the group consisting of polystyrene, poly (methyl methacrylate), poly (vinyl chloride), poly (vinyladine chloride) and polyacrylonitrile.
Claim 25
Dependent Claim
23 words
A composite board as in claim 20, wherein: (a) said polymer to said filler content having a ratio of 50-50 parts by weight.
Claim 26
Dependent Claim
28 words
A composite board as in claim 20, wherein: (a) said cotton gin by-product waste comprising flakes, fibers and granules of from about 10 to about 30 mesh size.
Claim 27
Dependent Claim
36 words
A composite board as in claim 23, wherein: (a) said cotton gin by-product waste having a total content of about 80 parts by weight 16 mesh size and about 20 parts by weight 30 mesh size.
Claim 28
Dependent Claim
40 words
A composite board as in claim 20, wherein: (a) said tacifier agent having a sufficiently low viscosity so as to promote adherence of said cotton gin by-product waste and said polymer during blending and to promote adhesive bonding during molding.
Claim 29
Dependent Claim
22 words
A composite board as in claim 20, wherein: (a) said tacifier chosen from the group consisting of silane polyester and poly glycol.
Claim 30
Dependent Claim
22 words
A composite board as in claim 20, further comprising: (a) from about 6 to about 10 parts by weight flame retardant material.
Claim 31
Dependent Claim
16 words
A composite board as in claim 27, wherein: (a) said flame retardant material is ammonium phosphate.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-04-03 | 1992-10-03 | 1993-04-04 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-04-03 | 1996-10-03 | 1997-04-04 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-04-03 | 2000-10-03 | 2001-04-04 | $7700.00 | Window Closed / Lapsed |