Abstract: A panel comprised of at least one connector that facilitates connection with an adjacent panel. An exemplary embodiment of a panel may be comprised of a female connector and a male connector such that the male connector may be inserted in a female connector of an adjacent, substantially similar panel. The female connector may include a ridge, and the male connector may include a flange. An exemplary embodiment of a panel assembly may be formed when a male connector of one panel is inserted in a female connector of another panel such that the flange of the male connector slides over the ridge of the female connector to interlock the panels.

Abstract: A panel comprised of at least one connector that facilitates connection with an adjacent panel. An exemplary embodiment of a panel may be comprised of a female connector and a male connector such that the male connector may be inserted in a female connector of an adjacent, substantially similar panel. The female connector may include a ridge, and the male connector may include a flange. An exemplary embodiment of a panel assembly may be formed when a male connector of one panel is inserted in a female connector of another panel such that the flange of the male connector slides over the ridge of the female connector to interlock the panels.

Abstract: A panel comprised of at least one connector that facilitates connection with an adjacent panel. An exemplary embodiment of a panel may be comprised of a female connector and a male connector such that the male connector may be inserted in a female connector of an adjacent, substantially similar panel. The female connector may include a ridge, and the male connector may include a flange. An exemplary embodiment of a panel assembly may be formed when a male connector of one panel is inserted in a female connector of another panel such that the flange of the male connector slides over the ridge of the female connector to interlock the panels.

Abstract: Methods of manufacturing a composite lattice structure made of cellulosic, inorganic, and/or polymer materials are disclosed. The unique lattice is weather-resistant and low-maintenance and may be used for ornamental gardening trellises, overhead outdoor patio or deck coverings, window lattices, privacy fences, garden fences, ornamental skirting or façades such as around the bottom of an elevated deck or porch, and other suitable functions.

Abstract: A component such as a siding panel comprised of a PVC/wood flour composite. Another embodiment is a component such as a siding panel that is made from a PVC/CPE/wood flour composite. The cellulosic composite may be extruded through a die and then bent into the shape of the component. Optionally, a reinforcement backer (e.g., an expanded polystyrene foam panel) may be adhered to the cellulosic composite siding.

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 directing a cooling fluid toward a surface of the extrudate (e.g., an interior surface that defines a hollow portion of an extrudate). Hollows may be created in order to reduce material, weight, and/or processing time. A cooling fluid is diverted toward the surface of the extrudate so as to cool the material and assist in solidification. A baffle may serve to divert the cooling fluid in the desired direction. In another example, the extrudate may be partially or totally immersed in a liquid cryogenic fluid. Increases in production line throughput may result by rapidly cooling the molded material. In addition, the more efficient cooling may be achieved with a lesser amount of the cooling fluid, and the velocity and temperature of the cooling fluid may be reduced.

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: The present invention is a component having a synthetic wood layer that is secured to a foamed polymer layer. The foamed polymer layer is comprised of a polymer selected from the group consisting of high density polyethylene, polypropylene, polyvinyl chloride, low density polyethylene, chlorinated polyvinyl chloride, acrylonitrile butadiene styrene, ethyl-vinyl acetate, and polystyrene. The component can be used for a variety of different purposes such as fencing, furniture, cabinets, storage devices, lawn edging, flower boxes, flooring, roofing, wall covering, building siding, basement flooring, basement wall covering, interior and exterior decorative house moldings, crown moldings, chair rails, picture frames, porch decks, deck railings, window moldings, window components, door components, door moldings, various other lawn and garden uses, various other below grade uses, and various other indoor and outdoor uses.

Abstract: A method of manufacturing a component in which a cellulosic material is mixed with a plastic material to form a cellulosic reinforced plastic composite. The cellulosic reinforced plastic composite is then formed into irregular shaped granules, such as by grinding. The granules are then molded into the component.

Abstract: The present invention relates to a system and method for directing a fluid through a die. One embodiment of the present invention is especially useful to thoroughly cool an extrudate by directing a cooling fluid toward a surface of the extrudate (e.g., an interior surface that defines a hollow portion of an extrudate). In another embodiment of the present invention, a fluid may be directed through a die for forming a layer or portion of a product. More particularly, a fluid may be directed through a die to form an external or core layer of a product from a foamed or unfoamed material including, but not limited to, a cellulosic-filled plastic composite. For example, the present invention includes a system and method for through the die foaming of extruded products.

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 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 directing a cooling fluid toward a surface of the extrudate (e.g., an interior surface that defines a hollow portion of an extrudate). Hollows may be created in order to reduce material, weight, and/or processing time. A cooling fluid is diverted toward the surface of the extrudate so as to cool the material and assist in solidification. A baffle may serve to divert the cooling fluid in the desired direction. Increases in production line throughput may result by rapidly cooling the molded material. In addition, the more efficient cooling may be achieved with a lesser amount of the cooling fluid, and the velocity and temperature of the cooling fluid may be reduced. Other uses for the present invention include injection molding, compression molding, gas assist molding, and co-extrusion.

Abstract: A cellulose/polyolefin pellet comprising polyolefin material and cellulosic material. The pellet may be concentrated such that it contains less than about 20% by weight of the polyolefin material and at least about 55% by weight of the cellulosic material. The pellet may be shipped to a remote manufacturing location where it may be blended with additional polyolefin material to make a synthetic wood component.

Abstract: The present invention relates to a system and a method for cooling extruded and molded materials. The present invention is especially useful to cool the hollows found in many extrudates. Hollows may be created in order to reduce material, weight and/or processing time. A fluid below about 40 degrees Fahrenheit is released into the hollow so as to cool the material and to assist in solidification. Additionally, the exterior of the molded material may be subjected to the cooling fluid so as to cool the material and to assist in solidification. Cooling may be further augmented by conventional methods such as a water bath. 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: A cellulose/polyolefin pellet comprising polyolefin material and cellulosic material. The pellet may be concentrated such that it contains less than about 20% by weight of the polyolefin material and at least about 55% by weight of the cellulosic material. The pellet may be shipped to a remote manufacturing location where it may be blended with additional polyolefin material to make a synthetic wood component.

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: 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 directing a cooling fluid toward a surface of the extrudate (e.g., an interior surface that defines a hollow portion of an extrudate). Hollows may be created in order to reduce material, weight, and/or processing time. A cooling fluid is diverted toward the surface of the extrudate so as to cool the material and assist in solidification. A baffle may serve to divert the cooling fluid in the desired direction. Increases in production line throughput may result by rapidly cooling the molded material. In addition, the more efficient cooling may be achieved with a lesser amount of the cooling fluid, and the velocity and temperature of the cooling fluid may be reduced. Other uses for the present invention include injection molding, compression molding, gas assist molding, and co-extrusion.

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: A method of manufacturing a sacrificial limb for a deck plank provides a deck plank that is comprised of a wood replacement material. The deck plank has a tongue that is adapted to fit with a groove of an adjacent deck plank. A channel is cut in the tongue of the deck plank. The channel is adapted to induce the tongue to fracture when expansion of the wood replacement material causes sufficient pressure between the tongue and the groove of the adjacent deck plank. As a result, expansion and contraction of the deck plank material preferably does not cause the deck to buckle.

Abstract: The present invention is a component having a synthetic wood layer that is secured to a foamed polymer layer. The foamed polymer layer is comprised of a polymer selected from the group consisting of high density polyethylene, polypropylene, polyvinyl chloride, low density polyethylene, chlorinated polyvinyl chloride, acrylonitrile butadiene styrene, ethyl-vinyl acetate, and polystyrene. The component can be used for a variety of different purposes such as fencing, furniture, cabinets, storage devices, lawn edging, flower boxes, flooring, roofing, wall covering, building siding, basement flooring, basement wall covering, interior and exterior decorative house moldings, crown moldings, chair rails, picture frames, porch decks, deck railings, window moldings, window components, door components, door moldings, various other lawn and garden uses, various other below grade uses, and various other indoor and outdoor uses.