Abstract: The invention relates to a method for making a dimensionally stable wood-thermoplastic composite material composed of a wood component and a thermoplastic component comprising the steps of forming a wood-thermoplastic mass at a temperature above the melting temperature of the thermoplastic component. The mass is then passed through a converging die to form a shaped extrudate profile having a cross sectional shape wherein at least a part of the converging die is maintained at a substantially higher temperature than that of the mass. The profile is then fed through a low friction thermally insulating land section, the land section having the substantially the same cross sectional shape as the exit end of the converging die. The profile is then quenched in a non-oxidizing environment to form a substantially dimensionally stable outer shell around the profile, the shell having a temperature below the melting temperature of the thermoplastic component.

Abstract: A spacing tool for determining the spacing between adjacent members of a structure including a pair of perpendicular planes, the planes intersecting along a line offset from the centerline of each plane, the pair of perpendicular planes including a first planar member having a first width corresponding to a first desired spacing between adjacent members in a structure; and a second planar member having a second width corresponding to a second desired width between adjacent members in a structure, the second desired width being less than the first desired width. Each of the first and second planar members further includes a side edge, and the spacing tool further includes first and second thickness indicia positioned on the first planar member side edge and the second planar member side edge respectively. The indicia correspond to the first width and the second width.

Abstract: The invention relates to a method for making a dimensionally stable wood-thermoplastic composite material composed of a wood component and a thermoplastic component comprising the steps of forming a wood-thermoplastic mass at a temperature above the melting temperature of the thermoplastic component. The mass is then passed through a converging die to form a shaped extrudate profile having a cross sectional shape wherein at least a part of the converging die is maintained at a substantially higher temperature than that of the mass. The profile is then fed through a low friction thermally insulating land section, the land section having the substantially the same cross sectional shape as the exit end of the converging die. The profile is then quenched in a non-oxidizing environment to form a substantially dimensionally stable outer shell around the profile, the shell having a temperature below the melting temperature of the thermoplastic component.

Abstract: A method is disclosed for producing a wood-thermoplastic composite material using a high bulk density feedstock. The feedstock is formed by feeding a wood-thermoplastic mixture to a pellet mill where the bulk density thereof is increased by a significant amount. The pelletized feedstock may be stored for later formation into a finished product and may be blended as necessary to maintain product quality. The feedstock is easy to handle and transport and provides a manufacturer with a large degree of flexibility and control over the manufacturing process.