Patent US5948524A successfully refreshed from Google Patents.
US5948524A
Expired / Lapsed
US
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Advanced engineering resin and wood fiber composite
Assignee: Andersen Corp
•
Filing: 1996-01-08
•
Granted: 1999-09-07
•
Expires: 2016-01-08
Abstract
Abstract The invention relates to a composition including an engineering resin and wood fiber composite that can be used in the form of a linear extrudate or thermoplastic pellet used to manufacture structural members. The resin/wood fiber composite structural members can be manufactured in an extrusion process or an injection molding process as a linear extrudate or pellet that can have a cross-section of any arbitrary shape, or can be a regular geometric shape and have a volume of at least about 12 mm 3 . Preferably the pellet is a right cylindrical pellet having a minimum radius of about 1.5 mm and a minimum length of 1 mm weighing at least 14 mg. The invention also relates to the environmentally sensitive recycle of waste streams. The resin/wood fiber composite can contain an intentional recycle of a waste stream including polymer flakes, polymer particles, or wood fiber as well as adhesives, paint, or preservatives. The initial mixing step before extrusion of the composite material insures substantial mixing and melt contact between molten resin and wood fiber. The extruded pellet includes a useful proportion of resin, wood fiber and water. During the extrusion, water is removed intentionally to dry the material to a maximum water content of less than about 10 wt % based on the pellet weight. The pellet is then introduced into an extruder or injection molding apparatus wherein the composite pellet material is shaped into a useful cross-section.
Inventors
- 👤 Kasyap V. Seethamraju
- 👤 Michael J. Deaner
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 12:37
CPC Classifications
C; C08; C08J; C08J5/00; C08J5/04; C08J5/045; B; B29; B29B; B29B9/00; B29B9/12; B29B9/14; C08L; C08L101/00; B29K; B29K2001/00; B29K2001/08; B29K2001/12; Y; Y10; Y10T; Y10T428/00; Y10T428/25; Y10T428/253; Y10T428/29; Y10T428/2904; Y10T428/2907; Y10T428/2913; Y10T428/2933; Y10T428/2938; Y10T428/2964; Y10T428/2965; Y10T428/31504; Y10T428/31551; Y10T428/31591; Y10T428/31725; Y10T428/31779; Y10T428/31783; Y10T428/31855; Y10T428/3188
Claims Analysis
Total Claims: 53
Claim 1
Independent Claim
186 words
A resin and fiber composite thermoplastic pellet, capable of formation into a structural member, which pellet comprises a thermoplastic extrudate having a width of about 0.1 to 5 millimeters and a length of about 0.1 to 10 millimeters, the thermoplastic extrudate consisting essentially of: (a) a continuous phase comprising a thermoplastic engineering resin, comprising repeating monomer units substantially free of vinyl chloride, the resin having a surface energy greater than 40 dynes/cm, a processing temperature less than 250° C., and a moisture sensitivity such that the resin does not have a substantial reduction in melt index or molecular weight during processing in the presence of water; and (b) an effective amount of wood fiber having a minimum dimension of about 0.1 millimeter and a minimum aspect ratio of about 1.5 to provide structural properties to the composite; wherein the resin and wood fiber are mixed at elevated temperatures and pressure such that an intimate admixture is formed, the wood fibers are dispersed in the a continuous thermoplastic phase, the pellet is a recyclable thermoplastic and the composite has a Young's modulus of at least 500,000 psi.
Claim 2
Dependent Claim
186 words
A resin and fiber composite thermoplastic pellet, capable of formation into a structural member, which pellet comprises a thermoplastic extrudate having a width of about 0.1 to 5 millimeters and a length of about 0.1 to 10 millimeters, the thermoplastic extrudate consisting essentially of: (a) a continuous phase comprising a thermoplastic engineering resin, comprising repeating monomer units substantially free of vinyl chloride, the resin having a surface energy greater than 40 dynes/cm, a processing temperature less than 250° C., and a moisture sensitivity such that the resin does not have a substantial reduction in melt index or molecular weight during processing in the presence of water; and (b) an effective amount of wood fiber having a minimum dimension of about 0.1 millimeter and a minimum aspect ratio of about 1.5 to provide structural properties to the composite; wherein the resin and wood fiber are mixed at elevated temperatures and pressure such that an intimate admixture is formed, the wood fibers are dispersed in the a continuous thermoplastic phase, the pellet is a recyclable thermoplastic and the composite has a Young's modulus of at least 500,000 psi.
Claim 3
Dependent Claim
13 words
The composite of claim 1 wherein the engineering resin comprises a condensation polymer.
Claim 4
Dependent Claim
13 words
The composite of claim 2 wherein the condensation polymer comprises a polyphenylene oxide.
Claim 5
Dependent Claim
13 words
The composite of claim 2 wherein the condensation polymer comprises a polybutylene terephthalate.
Claim 6
Dependent Claim
13 words
The composite of claim 2 wherein the condensation polymer comprises a polyethylene naphthalate.
Claim 7
Dependent Claim
13 words
The composite of claim 2 wherein the condensation polymer comprises cellulose acetate butyrate.
Claim 8
Dependent Claim
21 words
The composite of claim 2 wherein the condensation polymer has a melt flow index of about 1 to 10 gm/10 min.
Claim 9
Dependent Claim
14 words
The composite of claim 7 wherein the pellet comprises about 0.01 to 7% water.
Claim 10
Dependent Claim
12 words
The composite of claim 2 wherein the resin comprises a thermoplastic polyurethane.
Claim 11
Dependent Claim
13 words
The composite of claim 1 wherein the engineering resin comprises a vinyl polymer.
Claim 12
Dependent Claim
14 words
The composite of claim 10 wherein the vinyl polymer comprises a copolymer comprising styrene.
Claim 13
Dependent Claim
12 words
The composite of claim 11 wherein the copolymer comprises acrylonitride and styrene.
Claim 14
Dependent Claim
13 words
The composite of claim 11 wherein the copolymer comprises acrylonitrile, butadiene and styrene.
Claim 15
Dependent Claim
36 words
The composite of claim 10 wherein the vinyl polymer comprises an acrylic polymer having repeating units derived from a monomer selected from the group consisting of acrylic acid, methacrylic acid, methylacrylate, methylmethacrylate, acrylamide and mixtures thereof.
Claim 16
Dependent Claim
29 words
The composite of claim 10 wherein the vinyl polymer has a processing temperature less than 235° C. and a melt flow index of about 0.1 to 20 gm/10 min.
Claim 17
Dependent Claim
22 words
The composite of claim 10 wherein the polymer is a polyacetal with a melt flow of about 0.001 to 0.1 gm/10 min.
Claim 18
Dependent Claim
29 words
The composite of claim 1 wherein the wood fiber comprises a by-product of milling or sawing wooden members and the pellet comprises less than about 10 wt % water.
Claim 19
Dependent Claim
24 words
The composite of claim 1 wherein the composite additionally comprises an agent that promotes the compatibility of the engineering resin and the wood fiber.
Claim 20
Dependent Claim
28 words
The composite of claim 1 wherein the wood fiber has a fiber length of about 0.1 to 2 millimeters and an aspect ratio of about 2 to 7.
Claim 21
Dependent Claim
31 words
The composite of claim 1 wherein the pellet comprises a right circular cylinder having a radius of about 0.1 to 5 mm and a length of about 0.1 to 10 mm.
Claim 22
Dependent Claim
26 words
The composite of claim 1 wherein the polymer comprises an additive selected from a lubricant, an antioxidant, a pigment, a thermal stabilizer, or a mixture thereof.
Claim 23
Dependent Claim
18 words
The composite of claim 1 wherein the aspect ratio of said wood fiber is at least about 1.8.
Claim 24
Dependent Claim
17 words
The composite of claim 1 wherein the composite has a Young's modulus of at least 600,000 psi.
Claim 25
Dependent Claim
18 words
The composite of claim 1 wherein the composite has a Young's modulus of at least 1×10 6 psi.
Claim 26
Dependent Claim
12 words
The composite of claim 1 wherein the resin comprises a polyvinylidene fluoride.
Claim 27
Dependent Claim
12 words
The composite of claim 1 wherein the resin comprises a polymer alloy.
Claim 28
Dependent Claim
17 words
The composite of claim 26 wherein the polymer alloy comprises a polycarbonate resin and an acrylonitrile-butadiene-styrene resin.
Claim 29
Dependent Claim
167 words
A resin and fiber thermoplastic composite, capable of formation into a structural member, which composite comprises a thermoplastic engineering resin and fiber, the composite consisting essentially of: (a) a continuous phase of a thermoplastic engineering resin, comprising repeating monomer units substantially free of vinyl chloride, the resin having a surface energy greater than 40 dynes/cm, a processing temperature less than 250° C., and a moisture sensitivity such that the resin does not have a substantial reduction in either melt index or molecular weight during processing in the presence of water; and (b) an effective amount of wood fiber having a minimum dimension of about 0.1 millimeter and a minimum aspect ratio of about 1.5 to provide structural properties to the composite; wherein the resin and wood fiber are mixed at elevated temperatures and pressure such that an intimate admixture is formed, the wood fibers disperse throughout a continuous thermoplastic resin phase, the pellet is recyclable and the composite has a Young's modulus of at least 500,000 psi.
Claim 30
Dependent Claim
167 words
A resin and fiber thermoplastic composite, capable of formation into a structural member, which composite comprises a thermoplastic engineering resin and fiber, the composite consisting essentially of: (a) a continuous phase of a thermoplastic engineering resin, comprising repeating monomer units substantially free of vinyl chloride, the resin having a surface energy greater than 40 dynes/cm, a processing temperature less than 250° C., and a moisture sensitivity such that the resin does not have a substantial reduction in either melt index or molecular weight during processing in the presence of water; and (b) an effective amount of wood fiber having a minimum dimension of about 0.1 millimeter and a minimum aspect ratio of about 1.5 to provide structural properties to the composite; wherein the resin and wood fiber are mixed at elevated temperatures and pressure such that an intimate admixture is formed, the wood fibers disperse throughout a continuous thermoplastic resin phase, the pellet is recyclable and the composite has a Young's modulus of at least 500,000 psi.
Claim 31
Dependent Claim
13 words
The composite of claim 28 wherein the engineering resin comprises a condensation polymer.
Claim 32
Dependent Claim
13 words
The composite of claim 29 wherein the condensation polymer comprises a polyphenylene oxide.
Claim 33
Dependent Claim
13 words
The composite of claim 29 wherein the condensation polymer comprises a polybutylene terephthalate.
Claim 34
Dependent Claim
13 words
The composite of claim 29 wherein the condensation polymer comprises a polyethylene naphthalate.
Claim 35
Dependent Claim
14 words
The composite of claim 29 wherein the condensation polymer comprises a cellulose acetate butyrate.
Claim 36
Dependent Claim
21 words
The composite of claim 29 wherein the condensation polymer has a melt flow index of about 1 to 10 gm/10 min.
Claim 37
Dependent Claim
13 words
The composite of claim 28 wherein the engineering resin comprises a vinyl polymer.
Claim 38
Dependent Claim
14 words
The composite of claim 35 wherein the vinyl polymer comprises a copolymer comprising styrene.
Claim 39
Dependent Claim
12 words
The composite of claim 36 wherein the copolymer comprises acrylonitrile and styrene.
Claim 40
Dependent Claim
13 words
The composite of claim 36 wherein the copolymer comprises acrylonitrile, butadiene and styrene.
Claim 41
Dependent Claim
29 words
The composite of claim 35 wherein the vinyl polymer has a processing temperature less than 236° C. and a melt flow index of about 0.1 to 20 gm/10 min.
Claim 42
Dependent Claim
36 words
The composite of claim 28 wherein the engineering resin comprises an acrylic polymer having repeating units derived from a monomer selected from the group consisting of acrylic acid, methacrylic acid, methylacrylate, methylmethacrylate, acrylamide and mixtures thereof.
Claim 43
Dependent Claim
29 words
The composite of claim 28 wherein the wood fiber comprises a by-product of milling or sawing wooden members and the pellet comprise less than about 10 wt % water.
Claim 44
Dependent Claim
24 words
The composite of claim 28 wherein the composite additionally comprises an agent that promotes the compatibility of the engineering resin and the wood fiber.
Claim 45
Dependent Claim
28 words
The composite of claim 28 wherein the wood fiber has a fiber length of about 0.1 to 2 millimeters and an aspect ratio of about 2 to 7.
Claim 46
Dependent Claim
22 words
The composite of claim 28 wherein the polymer is a polyacetal with a melt flow of about 0.001 to 0.1 gm/10 min.
Claim 47
Dependent Claim
14 words
The composite of claim 28 wherein the pellet comprises about 0.01 to 7% water.
Claim 48
Dependent Claim
27 words
The composite of claim 28 wherein the resin additionally comprises an additive selected from a lubricant, an antioxidant, a pigment, a thermal stabilizer, or a mixture thereof.
Claim 49
Dependent Claim
18 words
The composite of claim 28 wherein the aspect ratio of said wood fiber is at least about 1.8.
Claim 50
Dependent Claim
17 words
The composite of claim 28 wherein the composite has a Young's modulus of at least 600,000 psi.
Claim 51
Dependent Claim
18 words
The composite of claim 28 wherein the composite has a Young's modulus of at least 1×10 6 psi.
Claim 52
Dependent Claim
12 words
The composite of claim 28 wherein the resin comprises a polyvinylidene chloride.
Claim 53
Dependent Claim
12 words
The composite of claim 28 wherein the resin comprises a thermoplastic polyurethane.
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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) | 2002-09-06 | 2003-03-08 | 2003-09-07 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2006-09-06 | 2007-03-08 | 2007-09-07 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2010-09-06 | 2011-03-08 | 2011-09-07 | $7700.00 | Window Closed / Lapsed |