Abstract: A composite load bearing member is provided comprising an elongated inner structural member and a thick polymeric composite outer member. An apparatus for producing the composite load bearing member is provided including devices for suspending the inner structural member within a mold cavity prior to and during injection of the polymeric composite outer member. A method of using the apparatus to produce the composite load bearing member is provided.

Abstract: A composite load bearing member is provided comprising an elongated inner structural member and a thick polymeric composite outer member. An apparatus for producing the composite load bearing member is provided including devices for suspending the inner structural member within a mold cavity prior to and during injection of the polymeric composite outer member. A method of using the apparatus to produce the composite load bearing member is provided.

Abstract: A composite load bearing member is provided comprising an elongated inner structural member and a thick polymeric composite outer member. An apparatus for producing the composite load bearing member is provided including devices for suspending the inner structural member within a mold cavity prior to and during injection of the polymeric composite outer member. A method of using the apparatus to produce the composite load bearing member is provided.

Abstract: A polymeric composite useful for producing large shaped articles such as railroad crossties comprises a filler component having minimal reinforcing/structural characteristics; and a polymer blend including at least one polymeric stiffening component, at least one polymeric density component, and at least one polymeric flexibility component. The polymer blend can include post-consumer recycled thermoplastic polymers. To produce the composite, a multistage extruder brings a blend of polymer and filler materials to an extrudable threshold without completely liquefying the polymer blend. The extruded blend is cooled within a mold to form a shaped article such as a recycled composite crosstie. Exemplary recycled composite mixtures may include composite polymer materials, such as, polypropylene, High Density Polyethylene (HDPE), High Molecular Weight Polyethylene (HMW), Low Density Polyethylene (LDPE), ABS, Ethylene Vinyl Acetate (EVA), Linear Low Density Polyethylene (LLDPE), and combinations of these polymers.

Abstract: A polymeric composite useful for producing large shaped articles such as railroad crossties comprises a filler component having minimal reinforcing/structural characteristics; and a polymer blend including at least one polymeric stiffening component, at least one polymeric density component, and at least one polymeric flexibility component. The polymer blend can include post-consumer recycled thermoplastic polymers. To produce the composite, a multistage extruder brings a blend of polymer and filler materials to an extrudable threshold without completely liquefying the polymer blend. The extruded blend is cooled within a mold to form a shaped article such as a recycled composite crosstie. Exemplary recycled composite mixtures may include composite polymer materials, such as, polypropylene, High Density Polyethylene (HDPE), High Molecular Weight Polyethylene (HMW), Low Density Polyethylene (LDPE), ABS, Ethylene Vinyl Acetate (EVA), Linear Low Density Polyethylene (LLDPE), and combinations of these polymers.

Abstract: A polymeric composite useful for producing large shaped articles such as railroad crossties comprisesa filler component having minimal reinforcing/structural characteristics; and a polymer blend including at least one polymeric stiffening component, at least one polymeric density component, and at least one polymeric flexibility component. The polymer blend can include post-consumer recycled thermoplastic polymers. To produce the composite, a multistage extruder brings a blend of polymer and filler materials to an extrudable threshold without completely liquefying the polymer blend. The extruded blend is cooled within a mold to form a shaped article such as a recycled composite crosstie. Exemplary recycled composite mixtures may include composite polymer materials, such as, polypropylene, High Density Polyethylene (HDPE), High Molecular Weight Polyethylene (HMW), Low Density Polyethylene (LDPE), ABS, Ethylene Vinyl Acetate (EVA), Linear Low Density Polyethylene (LLDPE), and combinations of these polymers.