Andersen Corporation

Giuseppe Puppin

Kurt E Heikkila

Michael J Deaner

The invention relates to a composite comprising a thermoplastic resin and a glass fabric that can be used in the form of a linear extrudate as a structural member or as a repair unit. The resin glass fiber composite structural member can be manufactured in an extrusion process. The linear extrudate can have a cross-section of any arbitrary shape or can be a regular geometric shape. The profile is made by first preforming the glass fabric into a useful shape, combining the preform fabric with melt resin and extruding the resin and glass fiber in a useful shape. When contacted with melt resin, the glass fiber becomes intimately contacted with and substantially coated with the melt resin.

Thermoplastic resin and fiberglass fabric composite and method

The invention relates to a composite comprising a thermoplastic resin and a glass fabric that can be used in the form of a linear extrudate as a structural member or as a repair unit. The resin glass fiber composite structural member can be manufactured in an extrusion process. The linear extrudate can have a cross-section of any arbitrary shape or can be a regular geometric shape. The profile is made by first performing the glass fabric into a useful shape, combining the preform fabric with melt resin and extruding the resin and glass fiber in a useful shape. When contacted with melt resin, the glass fiber becomes intimately contacted with and substantially coated with the melt resin.

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.

Advanced polymer wood composite

The invention relates to a composition or pellet comprising a polyvinyl chloride homopolymer and wood fiber composite that can be used in the form of a linear extrudate or thermoplastic pellet to manufacture structural members. The fiber in the pellet or extrudate is of a particular dimension that lends enhanced modulus to the composition or pellet formed. The extruded pellet comprises a consistent proportion of polymer, wood fiber and water.

The invention relates to a method for forming a composition comprising a thermoplastic composite in the form of a linear profile extrudate. Such a profile comprises a structural member having improved tensile strength, flex modulus, impact resistance and other improved structural properties. The invention involves a unique extruder configuration having a change in direction for the resin and fiber that optimizes the composite strength by promoting the random orientation of the fibers resulting in improved structural properties. Further, because of the change in direction, the extruder can include a cooling feature that cools the profile interior as the profile leaves the exit die thus increasing the physical properties, productivity and quality of the product.

Resin and wood fiber composite profile extrusion method

The invention relates to a thermoplastic composite material consisting essentially of a thermoplastic polymer and a wood fiber. The composite can be used in the form of a linear extrudate or a thermoplastic pellet to manufacture structural members. The linear extrudate or pellet can have any arbitrary cross-section or can be a regular geometric shape. Typically the thermoplastic polyvinyl chloride polymer and the wood fiber are combined and extruded in the form of a pellet. The pellet can be then taken, placed in an extruder and extruded in the form of a structural member. The composite material of the invention can be used to form structural members having high modulus (greater than about 500,000 psi). The thermoplastic structural members of the invention can then be recycled to form new thermoplastic.

A polyvinyl chloride and wood composite pellet by extrusion. The polyvinyl chloride and wood fiber are introduced into the extruder at a ratio of approximately 6:4 by weight, respectively. The polyvinyl chloride is melted and blended with the wood fiber so that the interstitial voids of the wood fiber are filled with polyvinyl chloride. After being extruded through a die, the molten material is cut into pellets having a bulk density of preferably between 0.7 to 0.8 gm/mm.sup.3.

Advanced polymer/wood composite pellet process

A process for making a polyvinyl chloride and wood composite pellet by extrusion. The polyvinyl chloride and wood fiber are introduced into the extruder at a ratio of approximately 6:4 by weight, respectively. The polyvinyl chloride is melted and blended with the wood fiber so that the interstitial voids of the wood fiber are filled with polyvinyl chloride. After being extruded through a die, the molten material is cut into pellets having a bulk density of preferably between 0.7 to 0.8 gm/mm.sup.3.

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.

Advanced polymer/wood composite structural member

A method and apparatus for repairing laminated material or cracked material includes preheated molds (30 and 130) which have cavities (34 and 134) shaped to generally conform to a given shape of a workpiece (20). Clamps (40, 41 and 42) apply pressure to the molds, and thereby the workpiece. In a preferred embodiment, the mold (30) has an auxiliary cavity (35). Adhesive may be injected into the mold cavity (134) to repair a delaminated workpiece and a patch adhesive to the mold cavity (34) to repair a crack.

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Bayport, MN, United States of America

Giuseppe Puppin