US6015611A
Expired / Lapsed
US
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Advanced polymer wood composite
Assignee: Andersen Corp
•
Filing: 1998-10-26
•
Granted: 2000-01-18
•
Expires: 2018-10-26
Abstract
Abstract A composition in the form of pellets comprising a thermoplastic and wood fiber composite material suitable for forming structural members as a replacement for wood in the manufacture of doors and windows. The composite has less than about 10 wt % water based on pellet weight and a Young's modulus of at least about 500,000. Structural members are typically formed from the composite in an extrusion or an injection molding process.
Inventors
- 👤 Michael J. Deaner
- 👤 Joseph Puppin
- 👤 Kurt E. Heikkila
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 16:34
CPC Classifications
C; C08; C08L; C08L97/00; C08L97/02; B; B27; B27N; B27N3/00; B27N3/007; B27N3/08; B27N3/28; B29; B29B; B29B9/00; B29B9/12; B29B9/14; C08J; C08J11/00; C08J11/04; C08J11/06; C08J5/00; C08J5/04; C08J5/045; C08J5/047; C08J5/06; C08L27/00; C08L27/02; C08L27/04; C08L27/06; B29K; B29K2311/00; B29K2311/14; C08J2327/00; C08J2327/02; C08J2327/04; C08J2327/06; C08K; C08K7/00; C08K7/02; C08L101/00; C08L2205/00; C08L2205/03; Y; Y02; Y02W; Y02W30/00; Y02W30/50; Y02W30/62; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249924; Y10T428/249925; Y10T428/25; Y10T428/253; Y10T428/26; Y10T428/29; Y10T428/2904; Y10T428/2907; Y10T428/2913; Y10T428/2933; Y10T428/2938; Y10T428/2964; Y10T428/2965; Y10T428/2982; Y10T428/2991; Y10T428/2998; Y10T428/31504; Y10T428/31551; Y10T428/31591; Y10T428/31725; Y10T428/31779; Y10T428/31783; Y10T428/31855; Y10T428/3188; Y10T428/31884; Y10T428/31891; Y10T428/31895; Y10T428/31906
Claims Analysis
Total Claims: 54
Claim 1
Independent Claim
144 words
A composite thermoplastic pellet, capable of formation into a structural profile or member, which pellet consists essentially of a thermoplastic cylindrical extrudate having a width of about 1 to 5 mm, a length of about 1 to 10 mm, the thermoplastic pellet composite composition consisting essentially of: (a) about 40 to 70 wt. % a thermoplastic polymer comprising vinyl chloride; and (b) about 30 to 50 wt. % of wood fiber having a minimum aspect ratio of about 1.8 to provide structural properties to the composite; wherein the polymer wood fiber are mixed at elevated temperature and pressure such that the fiber comprises less than about 8 wt-% water, the pellet comprises an intimate admixture of wood fiber dispersed throughout the continuous thermoplastic polymer phase, the pellet is a recyclable thermoplastic and the composite has a Young's modulus of at least about 800,000 psi.
Claim 2
Dependent Claim
144 words
A composite thermoplastic pellet, capable of formation into a structural profile or member, which pellet consists essentially of a thermoplastic cylindrical extrudate having a width of about 1 to 5 mm, a length of about 1 to 10 mm, the thermoplastic pellet composite composition consisting essentially of: (a) about 40 to 70 wt. % a thermoplastic polymer comprising vinyl chloride; and (b) about 30 to 50 wt. % of wood fiber having a minimum aspect ratio of about 1.8 to provide structural properties to the composite; wherein the polymer wood fiber are mixed at elevated temperature and pressure such that the fiber comprises less than about 8 wt-% water, the pellet comprises an intimate admixture of wood fiber dispersed throughout the continuous thermoplastic polymer phase, the pellet is a recyclable thermoplastic and the composite has a Young's modulus of at least about 800,000 psi.
Claim 3
Dependent Claim
20 words
The composition of claim 1 wherein the composite has a coefficient of thermal expansion of less than 1.8·10 -5 in/in-F°.
Claim 4
Dependent Claim
18 words
The composition of claim 1 wherein the composite has a Young's modulus of greater than about 1,000,000 psi.
Claim 5
Dependent Claim
20 words
The composition of claim 3 wherein the composite has a coefficient of thermal expansion of less than 1.8·10 -5 in/in-F°.
Claim 6
Dependent Claim
19 words
The composition of claim 1 wherein the polymer occupies greater than 50% of the interior volume of the fiber.
Claim 7
Dependent Claim
19 words
The composition of claim 1 wherein the polymer occupies greater than 70% of the interior volume of the fiber.
Claim 8
Dependent Claim
14 words
The composition of claim 1 wherein the polymer comprises a polyvinyl chloride polymer alloy.
Claim 9
Dependent Claim
18 words
The composition of claim 1 wherein the wood fiber comprises a by-product of milling or sawing wooden members.
Claim 10
Dependent Claim
11 words
The composition of claim 8 wherein the wood fiber comprises sawdust.
Claim 11
Dependent Claim
13 words
The composition of claim 1 wherein the composite additionally comprises a compatibilizing agent.
Claim 12
Dependent Claim
18 words
The composition of claim 1 wherein the polymer has a molecular weight (M w ) of about 90,000±50,000.
Claim 13
Dependent Claim
18 words
The composition of claim 1 wherein the polymer comprises a copolymer having a molecular weight of about 88,000±10,000.
Claim 14
Dependent Claim
37 words
The composition of claim 1 wherein the wood fiber has a fiber width of up to about 1.5 mm, a fiber length of up to about 10 mm and a aspect ratio of about 2 to 7.
Claim 15
Dependent Claim
17 words
The composition of claim 1 wherein the water comprises about 0.01 to 5 wt-% of the pellet.
Claim 16
Dependent Claim
13 words
The composition of claim 1 wherein the polymer comprises a polyvinyl chloride homopolymer.
Claim 17
Dependent Claim
16 words
The composition of claim 1 wherein the wood fiber has an aspect ratio of about 6.
Claim 18
Dependent Claim
122 words
A polymer and wood fiber thermoplastic composite composition capable of formation into a structural profile or member, the thermoplastic extrudate composite composition consisting essentially of: (a) about 40 to 70 wt. % a thermoplastic polymer comprising vinyl chloride; and (b) about 30 to 50 wt. % of wood fiber having a minimum aspect ratio of about 1.8 to provide structural properties to the composite; wherein the polymer wood fiber are mixed at elevated temperature and pressure such that the fiber comprises less than about 8 wt-% water, the pellet comprises an intimate admixture of wood fiber dispersed throughout the continuous thermoplastic polymer phase, the pellet is a recyclable thermoplastic and the composite has a Young's modulus of at least about 800,000 psi.
Claim 19
Dependent Claim
122 words
A polymer and wood fiber thermoplastic composite composition capable of formation into a structural profile or member, the thermoplastic extrudate composite composition consisting essentially of: (a) about 40 to 70 wt. % a thermoplastic polymer comprising vinyl chloride; and (b) about 30 to 50 wt. % of wood fiber having a minimum aspect ratio of about 1.8 to provide structural properties to the composite; wherein the polymer wood fiber are mixed at elevated temperature and pressure such that the fiber comprises less than about 8 wt-% water, the pellet comprises an intimate admixture of wood fiber dispersed throughout the continuous thermoplastic polymer phase, the pellet is a recyclable thermoplastic and the composite has a Young's modulus of at least about 800,000 psi.
Claim 20
Dependent Claim
20 words
The composition of claim 17 wherein the composite has a coefficient of thermal expansion of less than 1.8·10 -5 in/in-F°.
Claim 21
Dependent Claim
18 words
The composition of claim 17 wherein the composite has a Young's modulus of greater than about 1,000,000 psi.
Claim 22
Dependent Claim
20 words
The composition of claim 19 wherein the composite has a coefficient of thermal expansion of less than 1.8·10 -5 in/in-F°.
Claim 23
Dependent Claim
13 words
The composition of claim 17 wherein the polymer comprises a polyvinyl chloride copolymer.
Claim 24
Dependent Claim
14 words
The composition of claim 17 wherein the polymer comprises a polyvinyl chloride polymer alloy.
Claim 25
Dependent Claim
18 words
The composition of claim 17 wherein the wood fiber comprises a by-product of milling or sawing wooden members.
Claim 26
Dependent Claim
11 words
The composition of claim 17 wherein the wood fiber comprises sawdust.
Claim 27
Dependent Claim
13 words
The composition of claim 17 wherein the composition additionally comprises a compatibilizing agent.
Claim 28
Dependent Claim
18 words
The composition of claim 17 wherein the polymer has a molecular weight (M w ) of about 95,000±50,000.
Claim 29
Dependent Claim
21 words
The composition of claim 17 wherein the polymer comprises a copolymer has a molecular weight (M w ) of about 88,000±10,000.
Claim 30
Dependent Claim
37 words
The composition of claim 17 wherein the wood fiber has a fiber width of up to about 1.5 mm, a fiber length of up to about 10 mm and a aspect ratio of about 2 to 7.
Claim 31
Dependent Claim
17 words
The composition of claim 17 wherein the water comprises about 0.01 to 5 wt-% of the pellet.
Claim 32
Dependent Claim
16 words
The composition of claim 17 wherein the wood fiber has an aspect ratio of about 6.
Claim 33
Dependent Claim
95 words
A polymer and wood fiber composite capable of formation into a structural member, which composite comprises a cylindrical linear extrudate having a radius of about 1 to 5 mm; the linear extrudate composition comprising: (a) about 45 to 70 wt-% of a polymer comprising vinyl chloride; (b) about 30 to 50 wt-% of wood fiber having a minimum thickness of 1 mm and a minimum length of 3 mm and an aspect ratio of about 1.8; (c) less than about 8 wt-% water; and wherein the wood fiber is dispersed throughout a continuous polymer phase.
Claim 34
Dependent Claim
95 words
A polymer and wood fiber composite capable of formation into a structural member, which composite comprises a cylindrical linear extrudate having a radius of about 1 to 5 mm; the linear extrudate composition comprising: (a) about 45 to 70 wt-% of a polymer comprising vinyl chloride; (b) about 30 to 50 wt-% of wood fiber having a minimum thickness of 1 mm and a minimum length of 3 mm and an aspect ratio of about 1.8; (c) less than about 8 wt-% water; and wherein the wood fiber is dispersed throughout a continuous polymer phase.
Claim 35
Dependent Claim
13 words
The composition of claim 31 wherein the polymer comprises a polyvinyl chloride homopolymer.
Claim 36
Dependent Claim
13 words
The composition of claim 31 wherein the polymer comprises a polyvinyl chloride copolymer.
Claim 37
Dependent Claim
15 words
The composition of claim 33 wherein the copolymer has a molecular weight of about 88,000±10,000.
Claim 38
Dependent Claim
18 words
The composition of claim 31 wherein the wood fiber comprises a by-product of milling or sawing wooden members.
Claim 39
Dependent Claim
11 words
The composition of claim 35 wherein the wood fiber comprises sawdust.
Claim 40
Dependent Claim
15 words
The composition of claim 35 wherein the polymer has a molecular weight of about 95,000±50,000.
Claim 41
Dependent Claim
13 words
The composition of claim 31 wherein the composition additionally comprises a compatiblizing agent.
Claim 42
Dependent Claim
37 words
The composition of claim 31 wherein the wood fiber has a fiber width of about 0.3 to 1.5 mm, a fiber length of about 1 to 10 mm and a aspect ratio of about 2 to 7.
Claim 43
Dependent Claim
17 words
The composition of claim 31 wherein the water comprises about 0.01 to 5 wt-% of the pellet.
Claim 44
Dependent Claim
102 words
A composite composition, capable of extrusion into a dimensionally stable structural member, which composition comprises: (a) about 40 to 70 wt-% of a polymer comprising vinyl chloride; (b) about 30 to 50 wt-% of wood fiber having a minimum width of 0.3 mm and a minimum length of 1 mm and an aspect ratio of greater than about 1.8; (c) about 0.01 to 25 wt-% of an intentionally recycled impurity comprising thermoplastic polymer, an adhesive, a paint, a thermoplastic resin or mixtures thereof; and (d) less than about 10 wt-% water; wherein the wood fiber is dispersed throughout a continuous polymer phase.
Claim 45
Dependent Claim
102 words
A composite composition, capable of extrusion into a dimensionally stable structural member, which composition comprises: (a) about 40 to 70 wt-% of a polymer comprising vinyl chloride; (b) about 30 to 50 wt-% of wood fiber having a minimum width of 0.3 mm and a minimum length of 1 mm and an aspect ratio of greater than about 1.8; (c) about 0.01 to 25 wt-% of an intentionally recycled impurity comprising thermoplastic polymer, an adhesive, a paint, a thermoplastic resin or mixtures thereof; and (d) less than about 10 wt-% water; wherein the wood fiber is dispersed throughout a continuous polymer phase.
Claim 46
Dependent Claim
13 words
The composition of claim 41 wherein the polymer comprises a polyvinyl chloride homopolymer.
Claim 47
Dependent Claim
15 words
The composition of claim 42 wherein the polymer has a molecular weight of about 95,000±50,000.
Claim 48
Dependent Claim
13 words
The composition of claim 41 wherein the polymer comprises a polyvinyl chloride copolymer.
Claim 49
Dependent Claim
15 words
The composition of claim 44 wherein the copolymer has a molecular weight of about 88,000±10,000.
Claim 50
Dependent Claim
18 words
The composition of claim 41 wherein the wood fiber comprises a by-product of milling or sawing wooden members.
Claim 51
Dependent Claim
11 words
The composition of claim 41 wherein the wood fiber comprises sawdust.
Claim 52
Dependent Claim
37 words
The composition of claim 41 wherein the wood fiber has a fiber width of about 0.3 to 1.5 mm, a fiber length of about 1 to 10 mm and a aspect ratio of about 2 to 7.
Claim 53
Dependent Claim
19 words
The composition of claim 41 wherein the concentration of water comprises about 0.01 to 3.5 wt-% of the composition.
Claim 54
Dependent Claim
61 words
The composition of claim 41 wherein the intentionally recycled impurity comprises about 0 to 5 wt-% of a hot melt adhesive composition, about 0 to 5 wt-% of a paint and about 0.01 to 15 wt-% of recycled polyvinyl chloride cladding, wherein the cladding comprises about 9.0 to 99.9 wt-% polyvinyl chloride and about 0.01 to 2 wt-% of a pigment.
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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) | 2003-01-17 | 2003-07-19 | 2004-01-18 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2007-01-17 | 2007-07-19 | 2008-01-18 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2011-01-17 | 2011-07-19 | 2012-01-18 | $7700.00 | Window Closed / Lapsed |