Abstract: Foamed and solid, flax-filled composites. The flax filler may be used as a substitute for wood fiber, wood flour, and other cellulosic fillers in synthetic wood composites. The flax filler may be present in an amount up to about 55% by weight of an exemplary solid composite. In an exemplary foamed composite, the flax filler may be present in an amount up to about 40% by weight.

Abstract: An extrudable wood composite which includes cellulosic material and a powdered thermoplastic material.

Abstract: The present invention relates to a system and a method for cooling extruded and molded materials. The present invention is especially useful to thoroughly cool an extrudate by releasing a cooling fluid in a hollow portion of the extrudate. Hollows may be created in order to reduce material, weight, and/or processing time. A fluid below about 80 degrees Fahrenheit is released into the hollow so as to cool the material and to assist in solidification. Increases in production line throughput may result by rapidly cooling the molded material. Other uses for the present invention include injection molding, compression molding, gas assist molding, and co-extrusion.

Abstract: The present invention is a continuous in-line compounding and extrusion system that does not require pre-dried wood flour or pelletized feed stock of cellulosic/polymer composite materials in order to produce net shapes from cellulosic/polymer composite materials. A preferred embodiment of the present invention utilizes automated loss-in-weight feeders to dispense wood flour and all of the other cellulosic/polymer composite materials into a compounder. The compounder blends the cellulosic/polymer composite materials into a composite melt. The composite melt is continuously devolitalized as it travels through the compounder, a transition chute, and a finish extruder. The composite melt is then forced through a profile die which is fitted to the finish extruder in order to achieve a net shape.

Abstract: The present invention is a system and process for drying and extruding a cellulosic compound. The compound materials are provided to a mixer in a desired ratio. The compound materials are then mixed together. Thereafter, the compound materials can be stored in a non-controlled environment until needed. When it is time to extrude the compound materials, the compound materials are transferred to a dryer at a location remote from the mixer. The dryer has a surface area enabling the compound materials to be sufficiently spread out for drying. The compound materials are substantially uniformly dried to a desired level in the dryer. The compound materials are then transferred to an extruder to be formed into a final net shape.

Abstract: A panel for use in siding is disclosed. The panel has a cement core in a shape defining the panel of the siding, and a plastic film layer attached to the cement core. The plastic film layer is either a polymer or a copolymer of vinyl chloride. The panel may also have an adhesive layer which adheres the plastic film layer to the cement core. The cement core may contain fiber reinforcement.

Abstract: An extruded wood simulative material is described which includes a high degree of cellulosic material content and begins with powdered thermoplastic material.

Abstract: The present invention is a cellulosic, inorganic-filled plastic composite. The composite includes about 30% to about 70% by weight of the composite of cellulosic material, about 1% to about 20% by weight of the composite of talc, and about 25% to about 40% by weight of the composite of polyethylene. An extruded article and a method of making the cellulosic, inorganic-filled plastic composite are also disclosed.

Abstract: A cellulosic composite comprising: (a) at least one cellulosic material present in an amount in the range of from about 50% to about 75% by weight of the composite, (b) at least one polyvinyl chloride material present in an amount in the range of from about 25% to about 50% by weight of the composite, and (c) at least one polar thermosetting material present in an amount in the range of from about 0% to about 4% by weight of the composite is disclosed. An extruded article made form the cellulose composite and a method of making the cellulose composite are also disclosed.

Abstract: A system of compression molding a synthetic wood formulation into a commercially useable synthetic wood component is described. Surprising results are achieved when the dry formulation is placed under heat and pressure. Many different components may be made using the present invention, such as by example, wood-like trim components for the housing construction industry.

Abstract: A deck plank comprising a substantially flat top surface made preferably from a wood replacement material having a first edge and a second edge, and may also have a tongue attached to the first edge and a groove attached to the second edge, the tongue and the groove each extending in a plane below the top surface downward from the top, the tongue being adapted to fit with a groove of an adjacent plank. The tongue and the groove are shaped so that a space is maintained between a portion of the tongue and a portion of the groove of the adjacent plank when the tongue is placed adjacent to the groove of the adjacent plank. A number of the deck planks can be used to make a deck.

Abstract: An extrusion process is described for the extrusion of a synthetic wood material. The process includes a significantly higher compression ratio through which the extruded product must pass. The higher compression ratio results in significantly improved product qualities.

Abstract: A cellulosic composite comprising: (a) at least one cellulosic material present in an amount in the range of from about 50% to about 75% by weight of the composite, (b) at least one polyvinyl chloride material present in an amount in the range of from about 25% to about 50% by weight of the composite, and (c) at least one polar thermosetting material present in an amount in the range of from about 0% to about 4% by weight of the composite is disclosed. An extruded article made form the cellulose composite and a method of making the cellulose composite are also disclosed.

Abstract: A process is disclosed for manufacturing a thermoplastic panel or piece having a resilient injection molded portion. The panel or piece of the present invention may be used in a variety of applications such as to provide sealing ends on thermoplastic panels or to create resiliently closeable passages in thermoplastic panels through which wires and other objects may be passed while maintaining an even surface appearance of the baseboard panel. Other uses include attaching one or more thermoplastic pieces together.

Abstract: A deck plank comprised of a wood replacement material. The deck plank includes a top surface, a first leg, and a second leg. The top surface has a first end portion and a second end portion. The first leg is attached to the first end portion, and the second leg is attached to the second end portion. The first leg extends downward from the top surface, and it has a tongue and an outer surface. The tongue has a first limb and a second limb which are joined together to define a recess. The outer surface defines a channel that extends along the tongue. The second leg also extends downward from the top surface, and it has an upper portion and a lower portion. The upper portion and the lower portion define a groove, and the tongue is adapted to fit with a groove of an adjacent, substantially similar deck plank.

Abstract: A cellulosic composite comprising: (a) at least one cellulosic material present in an amount in the range of from about 50% to about 75% by weight of the composite, (b) at least one polyvinyl chloride material present in an amount in the range of from about 25% to about 50% by weight of the composite, and (c) at least one polar thermosetting material present in an amount in the range of from about 0% to about 4% by weight of the composite is disclosed. An extruded article made form the cellulose composite and a method of making the cellulose composite are also disclosed.

Abstract: The present invention is a thermoplastic panel or piece having a resilient injection molded portion. The panel or piece of the present invention may be used in a variety of applications such as to provide sealing ends on thermoplastic panels or to create resiliently closable passages in thermoplastic panels through which wires and other objects may be passed while maintaining an even surface appearance of the baseboard panel. Other uses include attaching one or more thermoplastic pieces together. The invention also includes a method for making the subject thermoplastic panel or piece.

Abstract: A process is descripted in which an article of manufacture may be produced which includes a renewable surface on a synthetic wood composite substrate.

Abstract: The present invention pertains to a polymeric sealing/spring strip and method of producing same. The polymeric sealing/spring strip of the present invention has several various embodiments which are based upon the incorporation of silicone rubber. Some of the embodiments are based on the formation of a resilient silicone rubber surface to provide a sealing/spring contact with an opposing surface period. Other embodiments of the invention incorporate the silicone rubber in such way as to utilize its resilient properties to produce a sealing/spring strip which has improved mechanical resilience properties. The method of the present invention allows the production of a sealing/spring strip in accordance with the present invention by using extrusion techniques.