US5486553A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Advanced polymer/wood composite structural member
Assignee: Andersen Corp
•
Filing: 1994-04-07
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Granted: 1996-01-23
•
Expires: 2014-04-07
Abstract
Abstract A polymer and wood composite structural members can be manufactured by extruding and injection molding a composition comprising polyvinyl chloride, wood fiber and optionally a concentration of an intentionally added waste stream. Such structural members have strength, workability, fastener retention, resistance to rot and insect attack, and thermal properties sufficient to constitute an advanced composite wood replacement material. The advanced structural member can be used as a component in construction of any structure requiring sized lumber or specifically shaped wood products. In such an application, the structural members can be extruded in the shape of commonly available lumber. The structural members of the invention can also be extruded in complex shapes adapted to the assembly of windows and doors used in both residential and commercial structures. The structural members have a modulus, a coefficient of thermal expansion, a coefficient of elasticity, a compressive strength and other related properties ideal for use as a replacement for either metal or wood, window or door structural components. The preferred structural member is manufactured from a polyvinyl chloride and wood fiber composite that optionally contains an intentionally recycled impurity component. Such components comprise waste materials common in the manufacture of wood doors and windows. We have found that the cooperation between the amount of polymer material, the amount of an oriented wood fiber, and control over water content results in the improved structural properties of the composite structural members of the invention.
Inventors
- 👤 Michael J. Deaner
- 👤 Giuseppe Puppin
- 👤 Kurt E. Heikkila
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 16:55
CPC Classifications
C; C08; C08J; C08J5/00; C08J5/04; C08J5/045; B; B27; B27N; B27N3/00; B27N3/08; B27N3/28; B29; B29C; B29C48/00; B29C48/022; E; E06; E06B; E06B3/00; E06B3/04; E06B3/06; E06B3/08; E06B3/10; B29C48/001; B29C48/0018; B29C48/0022; B29C48/03; B29C48/07; B29C48/08; B29C48/09; B29C48/11; B29C48/12; B29K; B29K2027/00; B29K2105/00; B29K2105/06; B29K2105/16; B29K2105/26; B29K2711/00; B29K2711/14; C08J2327/00; C08J2327/02; C08J2327/04; C08J2327/06; Y; Y10; Y10T; Y10T428/00; Y10T428/26; Y10T428/268; Y10T428/269
Claims Analysis
Total Claims: 26
Claim 1
Independent Claim
90 words
A polymer wood thermoplastic composite structural member, suitable for use as a replacement for a wood structural member, which thermoplastic composite structural member comprises a composite member with a Youngs modulus of greater than 500,000, and a coefficient of thermal expansion less than 3×10 -5 in/in-°F. and which composite member comprises a continuous organic phase comprising about 35 to 65 wt-% of a polymer comprising vinyl chloride and, dispersed in the continuous phase, about 35 to 55 wt-% of wood fiber having an aspect ratio of at least about 2.
Claim 2
Dependent Claim
90 words
A polymer wood thermoplastic composite structural member, suitable for use as a replacement for a wood structural member, which thermoplastic composite structural member comprises a composite member with a Youngs modulus of greater than 500,000, and a coefficient of thermal expansion less than 3×10 -5 in/in-°F. and which composite member comprises a continuous organic phase comprising about 35 to 65 wt-% of a polymer comprising vinyl chloride and, dispersed in the continuous phase, about 35 to 55 wt-% of wood fiber having an aspect ratio of at least about 2.
Claim 3
Dependent Claim
20 words
The composite structural member of claim 1 wherein the coefficient of thermal expansion is about 1.5 to 2.5×10 -5 in/in-°F.
Claim 4
Dependent Claim
27 words
The composite structural member of claim 1 having a rectangular cross-section with a width greater than about 1 cm and a depth greater than about 1 cm.
Claim 5
Dependent Claim
18 words
The composite member of claim 2 having a square cross-section with a width greater than about 1 cm.
Claim 6
Dependent Claim
14 words
The composite member of claim 1 having a length greater than about 30 cm.
Claim 7
Dependent Claim
11 words
The composite member of claim 1 having a shaped member cross-section.
Claim 8
Dependent Claim
10 words
The composite member of claim 6 which comprises a jamb.
Claim 9
Dependent Claim
10 words
The composite member of claim 6 which comprises a stop.
Claim 10
Dependent Claim
10 words
The composite member of claim 6 which comprises a rail.
Claim 11
Dependent Claim
10 words
The composite member of claim 6 which comprises a casing.
Claim 12
Dependent Claim
10 words
The composite member of claim 6 which comprises a sill.
Claim 13
Dependent Claim
10 words
The composite member of claim 6 which comprises a stile.
Claim 14
Dependent Claim
11 words
The composite member of claim 6 which comprises a grill component.
Claim 15
Dependent Claim
10 words
The composite member of claim 6 which comprises a track.
Claim 16
Dependent Claim
14 words
The composite member of claim 14 wherein the track comprises a window sash track.
Claim 17
Dependent Claim
13 words
The composite member of claim 14 wherein the track comprises a door track.
Claim 18
Dependent Claim
77 words
A polymer wood composite sill, suitable for use as a replacement for a wood sill, which composite sill comprises an elongated thermoplastic extrudate having a Youngs modulus of greater than 500,000, and a coefficient of thermal expansion between 1.5 and 3.01×10 -5 in/in-°F., and which composite member comprises about 35 to 65 wt-% of a polymer comprising vinyl chloride and about 35 to 55 wt-% of wood fiber having an aspect ratio of at least about 2.
Claim 19
Dependent Claim
77 words
A polymer wood composite sill, suitable for use as a replacement for a wood sill, which composite sill comprises an elongated thermoplastic extrudate having a Youngs modulus of greater than 500,000, and a coefficient of thermal expansion between 1.5 and 3.01×10 -5 in/in-°F., and which composite member comprises about 35 to 65 wt-% of a polymer comprising vinyl chloride and about 35 to 55 wt-% of wood fiber having an aspect ratio of at least about 2.
Claim 20
Dependent Claim
30 words
The sill of claim 17 wherein the composite comprises about 50 to 65 wt-% of a polymer comprising a vinyl chloride and about 35 to 50 wt-% of wood fiber.
Claim 21
Dependent Claim
87 words
A polymer wood composite stile, suitable for use as a replacement for a wood stile, which composite stile comprises an elongated thermoplastic extrudate having a Youngs modulus of greater than 500,000, and a coefficient of thermal expansion between 1.5 and 3.0×10 -5 in/in-°F., and which composite member comprises a continuous organic phase comprising about 35 to 65 wt-% of a polymer comprising vinyl chloride and, dispersed in the continuous phase, about 35 to 55 wt-% of wood fiber having an aspect ratio of at least about 2.
Claim 22
Dependent Claim
87 words
A polymer wood composite stile, suitable for use as a replacement for a wood stile, which composite stile comprises an elongated thermoplastic extrudate having a Youngs modulus of greater than 500,000, and a coefficient of thermal expansion between 1.5 and 3.0×10 -5 in/in-°F., and which composite member comprises a continuous organic phase comprising about 35 to 65 wt-% of a polymer comprising vinyl chloride and, dispersed in the continuous phase, about 35 to 55 wt-% of wood fiber having an aspect ratio of at least about 2.
Claim 23
Dependent Claim
21 words
The stile of claim 19 wherein the composite comprises about 50 to 65 wt-% of a polymer comprising a vinyl chloride.
Claim 24
Dependent Claim
12 words
The stile of claim 19 wherein the modulus is greater than 800,000.
Claim 25
Dependent Claim
88 words
A polymer wood composite rail, suitable for use as a replacement for a wood rail, which composite rail comprises an elongated thermoplastic extrudate having a Youngs modulus of greater than 7.5'10 5 and a coefficient of thermal expansion between 1.5 and 3.0×10 -5 in/in-°F. and which composite member comprises a continuous organic phase comprising about 35 to 65 wt-% of a polymer comprising vinyl chloride and, dispersed in the continuous phase, about 35 to 55 wt-% of wood fiber having an aspect ratio of at least about 2.
Claim 26
Dependent Claim
88 words
A polymer wood composite rail, suitable for use as a replacement for a wood rail, which composite rail comprises an elongated thermoplastic extrudate having a Youngs modulus of greater than 7.5'10 5 and a coefficient of thermal expansion between 1.5 and 3.0×10 -5 in/in-°F. and which composite member comprises a continuous organic phase comprising about 35 to 65 wt-% of a polymer comprising vinyl chloride and, dispersed in the continuous phase, about 35 to 55 wt-% of wood fiber having an aspect ratio of at least about 2.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1999-01-22 | 1999-07-24 | 2000-01-23 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2003-01-22 | 2003-07-24 | 2004-01-23 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2007-01-22 | 2007-07-24 | 2008-01-23 | $7700.00 | Window Closed / Lapsed |