WO2000039207A1 - Cellulosic, inorganic-filled plastic composite - Google Patents

Cellulosic, inorganic-filled plastic composite Download PDF

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Publication number
WO2000039207A1
WO2000039207A1 PCT/US1999/030990 US9930990W WO0039207A1 WO 2000039207 A1 WO2000039207 A1 WO 2000039207A1 US 9930990 W US9930990 W US 9930990W WO 0039207 A1 WO0039207 A1 WO 0039207A1
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WO
WIPO (PCT)
Prior art keywords
composite
weight
present
range
amount
Prior art date
Application number
PCT/US1999/030990
Other languages
French (fr)
Inventor
Burch E. Zehner
Bryan K. Buhrts
Original Assignee
Crane Plastics Company Limited Partnership
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Crane Plastics Company Limited Partnership filed Critical Crane Plastics Company Limited Partnership
Priority to CA002357755A priority Critical patent/CA2357755A1/en
Priority to AU27151/00A priority patent/AU2715100A/en
Publication of WO2000039207A1 publication Critical patent/WO2000039207A1/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C08L23/06—Polyethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/34—Silicon-containing compounds
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L97/00—Compositions of lignin-containing materials
    • C08L97/02—Lignocellulosic material, e.g. wood, straw or bagasse
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/253—Cellulosic [e.g., wood, paper, cork, rayon, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2904—Staple length fiber
    • Y10T428/2907—Staple length fiber with coating or impregnation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31652—Of asbestos
    • Y10T428/31667—Next to addition polymer from unsaturated monomers, or aldehyde or ketone condensation product
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/31859—Next to an aldehyde or ketone condensation product
    • Y10T428/31862—Melamine-aldehyde
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/3188—Next to cellulosic
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/3188—Next to cellulosic
    • Y10T428/31895—Paper or wood
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31855—Of addition polymer from unsaturated monomers
    • Y10T428/3188—Next to cellulosic
    • Y10T428/31895—Paper or wood
    • Y10T428/31899—Addition polymer of hydrocarbon[s] only

Definitions

  • the application relates generally to cellulose-reinforced composites and, more particularly,
  • Cellulosic materials such as wood fiber, wood flour, sawdust, rice hulls, peanut shells, and
  • thermoplastic compounds have long been added to thermoplastic compounds to achieve a wood-like composite
  • moisture sensitivity may require predrying of the cellulose fibers and the maintenance of low moisture conditions at the time of thermoplastic processing, particularly for cellulose in powder
  • the extrusion process can cause thermal degradation of the cellulose fibers
  • the invention is a cellulosic, inorganic-filled plastic composite
  • the composite is comprised of cellulosic material, talc, and polyethylene More particularly, the cellulosic material accounts for
  • the talc is about 1% to about 20% by
  • the present invention also includes an extruded article that is produced by extruding the
  • the composite used to make the extruded article may include any of the optional or preferred features of the above-described
  • Another embodiment of the present invention is a method of extruding a cellulosic
  • the method comprises introducing a cellulosic, inorganic-filled plastic composite into an extruder
  • the composite may possess any of the
  • the present invention is a cellulosic, inorganic-filled plastic composite
  • the present invention is a cellulosic, inorganic-filled plastic composite
  • invention also includes an extruded article made from the composite as well as a method of
  • the present invention replaces a portion of the cellulosic material with an inorganic filler
  • the present invention includes a cellulosic, inorganic-filled plastic composite
  • the cellulosic material is preferably present in an amount in the range from about 40% to
  • the talc is preferably present in an amount in the range from about 5% to about
  • the polyethylene is preferably high density
  • polyethylene and it is preferably present in an amount in the range from about 25% to about 35%
  • the combination of the at least one cellulosic material and the talc is preferably present in an amount in the range from about 50% to about 80% by weight of the composite, and more preferably from about 55% by weight to about 65% by weight
  • the cellulosic material is selected from wood fiber, seed husks, ground rice
  • the cellulosic material is wood
  • wood fiber It should be recognized that wood fiber is available in different forms Other specific
  • cellulosic material examples include sawdust, alfalfa, wheat pulp, wood chips, wood particles, ground wood, wood flour, wood flakes, wood veneers, wood laminates, paper, cardboard, straw,
  • cellulosic material of the present invention may be any cellulosic material of the present invention.
  • One preferred composite is comprised of about 50% to about 55% by weight of the composite of wood fiber, about 5% to about 10% by weight of the composite of talc, and about
  • composite is comprised of about 50% to about 55% by weight of the composite of wood fiber
  • the invention also includes an extruded article produced by extruding the cellulosic,
  • the invention also includes a method of extruding the
  • the method comprises introducing the composite as described above into an extruder, melting the composite, extruding the composite through a profile die to form a
  • the composite of the present invention may include additives
  • additives include lubricants, process aids, cross-linking agents, accelerators,
  • linking agents include polyurethanes, such as isocyanates, phenolic resins, unsaturated polyesters, and epoxy resins
  • the polyethylene is mixed with the dried wood fiber, talc, stabilizers, lubricants, and process aids in a low intensity mixer such as a ribbon
  • the mixture is preferably melted and processed in a conical, twin screw, counter- rotating extruder with a vent (for example, a Model CM80 extruder by Cincinnati Milacron)
  • a vent for example, a Model CM80 extruder by Cincinnati Milacron
  • force feed hopper (i e , a crammer) is preferred to feed the mixture into the extruder, although
  • hoppers e g , a gravity feed hopper
  • a vacuum is preferably applied
  • the extruder preferably forces the
  • the operating temperatures for the first two stages of the extruder may be about 380° F,
  • the die temperature is preferably about 350° F, and the screw temperature is preferably about 360° F
  • the die may be varied to obtain optimum results for a particular extrusion
  • the die design is preferably streamlined with a compaction ratio of between about 2 1 to
  • the die system includes an extended die land
  • the extended die is preferred that the die system includes an extended die land
  • land preferably provides the necessary back pressure to obtain a uniform melt, as well as
  • the resultant product has an appearance similar to wood and may be sawed, sanded, shaped, turned, fastened and/or finished in the same manner as natural wood.
  • composites filled only with cellulosic material show higher compound bulk density, higher extrusion rates, and less sensitivity to porosity
  • composites of the present invention also show reduced moisture sensitivity in the extruded shape
  • the inorganic filler is readily available
  • the inorganic filler typically does not require special drying, maintenance, or processing conditions

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.

Description

CELLULOSIC, INORGANIC-FILLED PLASTIC COMPOSITE
This application claims the benefit of U S Provisional Application No 60/113,987, filed December 28, 1998
BACKGROUND AND SUMMARY OF THE INVENTION The application relates generally to cellulose-reinforced composites and, more particularly,
to a cellulosic, inorganic-filled plastic composite
There is a very high demand for wood products Although wood is a renewable resource,
it takes many years for trees to mature Consequently, the supply of wood suitable for use in construction is decreasing Therefore, there is a need to develop alternatives to the use of wood in construction
Cellulosic materials, such as wood fiber, wood flour, sawdust, rice hulls, peanut shells, and
the like, have long been added to thermoplastic compounds to achieve a wood-like composite
providing reinforcement, reduced coefficient of expansion, and cost reduction Process methods have been developed to enable blends containing materials having low bulk density (i e , powders)
and poor flow characteristics to be fed at commercially acceptable rates Blends of this type can
be extruded through dies of the appropriate configuration to produce building product type
shapes previously made from wood For example, U S Patent Nos 3,908,902, 4,091,153,
4,686,251, 4,708,623, 5,002,713, 5,055,247, 5,087,400, and 5,151,238 relate to processes for
producing wood-like composites
A major limitation of cellulosic fillers is the moisture sensitivity of cellulose fibers This
moisture sensitivity may require predrying of the cellulose fibers and the maintenance of low moisture conditions at the time of thermoplastic processing, particularly for cellulose in powder
form In addition, the moisture sensitivity of the cellulose fibers requires the exercise of special
care during extrusion to ensure cellulosic encapsulation and/or protection against moisture
absorption to avoid moisture deterioration of the cellulosic fibers Furthermore, the extrusion process can cause thermal degradation of the cellulose fibers
In light of these shortcomings, there is a need for a cellulosic composite with improved
moisture resistance characteristics Another need exists for a cellulosic composite that is less susceptible to thermal degradation A need also exists for an improved cellulosic composite that
includes inorganic fillers Yet another need exists for a cellulosic, inorganic-filled composite that can be used as a substitute for natural wood, particle board, wafer board, and the like
The present invention satisfies some or all of these needs One embodiment of the present
invention is a cellulosic, inorganic-filled plastic composite The composite is comprised of cellulosic material, talc, and polyethylene More particularly, the cellulosic material accounts for
about 30% to about 70% by weight of the composite, the talc is about 1% to about 20% by
weight of the composite, and the polyethylene is about 25% to about 40% by weight of the
composite
The present invention also includes an extruded article that is produced by extruding the
aforementioned cellulosic, inorganic-filled plastic composite The composite used to make the extruded article may include any of the optional or preferred features of the above-described
composite
Another embodiment of the present invention is a method of extruding a cellulosic,
inorganic-filled plastic composite profile The method comprises introducing a cellulosic, inorganic-filled plastic composite into an extruder The composite may possess any of the
optional or preferred features of the above-described cellulosic, inorganic-filled plastic composite The composite is then melted and extruded through a profile die to form a profile The profile is
then cooled to achieve a final net shape
In addition to the novel features and advantages mentioned above, other objects and
advantages of the present invention will be readily apparent from the following description of the
preferred embodiments
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS The present invention is a cellulosic, inorganic-filled plastic composite The present
invention also includes an extruded article made from the composite as well as a method of
extruding the composite to form a profile
The present invention replaces a portion of the cellulosic material with an inorganic filler In broadest terms, the present invention includes a cellulosic, inorganic-filled plastic composite
comprising about 30% by weight 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
The cellulosic material is preferably present in an amount in the range from about 40% to
about 60%) by weight of the composite, and more preferably from about 45% by weight to about
55% by weight The talc is preferably present in an amount in the range from about 5% to about
15% by weight of the composite In addition, the polyethylene is preferably high density
polyethylene, and it is preferably present in an amount in the range from about 25% to about 35%
by weight of the composite The combination of the at least one cellulosic material and the talc is preferably present in an amount in the range from about 50% to about 80% by weight of the composite, and more preferably from about 55% by weight to about 65% by weight
Preferably, the cellulosic material is selected from wood fiber, seed husks, ground rice
hulls, newspaper, kenaf, and coconut shells More preferably, the cellulosic material is wood
fiber It should be recognized that wood fiber is available in different forms Other specific
examples of cellulosic material include sawdust, alfalfa, wheat pulp, wood chips, wood particles, ground wood, wood flour, wood flakes, wood veneers, wood laminates, paper, cardboard, straw,
cotton, peanut shells, bagass, plant fibers, bamboo fiber, palm fiber, or any other similar materials
Those skilled in the art should recognize that the cellulosic material of the present invention may
be any suitable combination of different types of cellulosic material
One preferred composite is comprised of about 50% to about 55% by weight of the composite of wood fiber, about 5% to about 10% by weight of the composite of talc, and about
30% to about 40% by weight of the composite of high density polyethylene Another preferred
composite is comprised of about 50% to about 55% by weight of the composite of wood fiber,
about 10% to about 15% by weight of the composite of talc, and about 25% to about 30% by
weight of the composite of high density polyethylene
The invention also includes an extruded article produced by extruding the cellulosic,
inorganic-filled plastic composite The invention also includes a method of extruding the
composite to form a profile The method comprises introducing the composite as described above into an extruder, melting the composite, extruding the composite through a profile die to form a
profile, and cooling the profile The following charts help to illustrate the optional and preferred features of the composite of the present invention
Ingredient Range (by weight) Preferred Range (by Most Preferred Range weight) (by weight)
Cellulosic Material 30 - 70 % 40 - 60% 45 - 55% Talc 1 - 20% 5 - 15%
Polyethylene 25 - 40% 25 - 35% Combination of 50 - 80% 55 - 65% Cellulosic Material and Talc
Two preferred composites are
Ingredient Amount (by weight) Amount (by weight)
Wood fiber 50 - 55% 50 - 55%
Talc 5 - 10% 10 - 15%
High Density Polyethylene 30 - 40% 25 - 30%
Additives 0 - 10% 0 - 10%
As indicated above, the composite of the present invention may include additives
Examples of additives include lubricants, process aids, cross-linking agents, accelerators,
inhibitors, enhancers, compatibilizers, stabilizers, blowing agents, foaming agents, and other
additives known in the art Common commercial lubricants known in the plastics processing industry, both external and internal, can be used Examples of lubricants which can be used
include calcium stearate, zinc stearate, esters, paraffin wax, and amide wax Examples of cross-
linking agents include polyurethanes, such as isocyanates, phenolic resins, unsaturated polyesters, and epoxy resins
A preferred embodiment of the composite can be made as follows The wood fiber is
preferably dried to between about 0 5% to about 3% in moisture content, and more preferably between about 1% and about 2% moisture by weight The polyethylene is mixed with the dried wood fiber, talc, stabilizers, lubricants, and process aids in a low intensity mixer such as a ribbon
blender The mixture is preferably melted and processed in a conical, twin screw, counter- rotating extruder with a vent (for example, a Model CM80 extruder by Cincinnati Milacron) A
force feed hopper (i e , a crammer) is preferred to feed the mixture into the extruder, although
other types of hoppers (e g , a gravity feed hopper) may be used A vacuum is preferably applied
to the vent to further reduce the moisture in the extrudate The extruder preferably forces the
composite through a die or die system to obtain a final profile shape
The operating temperatures for the first two stages of the extruder may be about 380° F,
while the last two stages, which are located after the vent, may be about 350° F The die temperature is preferably about 350° F, and the screw temperature is preferably about 360° F
Nevertheless, those skilled in the art should recognize that the temperatures of the extruder and
the die may be varied to obtain optimum results for a particular extrusion
The die design is preferably streamlined with a compaction ratio of between about 2 1 to
about 4 1 It is preferred that the die system includes an extended die land The extended die
land preferably provides the necessary back pressure to obtain a uniform melt, as well as
compaction and shaping of the melt
The resultant product has an appearance similar to wood and may be sawed, sanded, shaped, turned, fastened and/or finished in the same manner as natural wood The resultant
product is resistant to rot and decay as well as termite attack The resultant product may be used,
for example, as decorative moldings inside or outside of a house, picture frames, furniture, porch
decks, window moldings, window components, door components, roofing systems, and any other type of use where structural requirements do not exceed the physical properties of the resultant
material
Composites made according to the present invention offer several advantages over
composites filled only with cellulosic material For example, composites of the present invention show higher compound bulk density, higher extrusion rates, and less sensitivity to porosity The
composites of the present invention also show reduced moisture sensitivity in the extruded shape
as well as reduced smoke and flame spread In addition, the inorganic filler is readily available,
and it has easily defined properties Moreover, the inorganic filler typically does not require special drying, maintenance, or processing conditions
The preferred embodiments herein disclosed are not intended to be exhaustive or to unnecessarily limit the scope of the invention The preferred embodiments were chosen and
described in order to explain the principles of the present invention so that others skilled in the art may practice the invention Having shown and described preferred embodiments of the present invention, those skilled in the art will realize that many variations and modifications may be made to affect the described invention Many of those variations and modifications will provide the
same result and fall within the spirit of the claimed invention It is the intention, therefore, to limit
the invention only as indicated by the scope of the claims

Claims

WHAT IS CLAIMED IS
1 A cellulosic, inorganic-filled plastic composite comprising
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
2 The cellulosic, inorganic-filled plastic composite according to claim 1, wherein the
cellulosic material is present in an amount in the range from about 40% to about 60% by weight of the composite
3 The cellulosic, inorganic-filled plastic composite according to claim 1, wherein the
cellulosic material is present in an amount in the range from about 45% to about 55% by weight of the composite
4 The cellulosic, inorganic-filled plastic composite according to claim 1, wherein the talc is present in an amount in the range from about 5% to about 15% by weight of the composite
5 The cellulosic, inorganic-filled plastic composite according to claim 1, wherein the
polyethylene is present in an amount in the range from about 25% to about 35% by weight of the
composite
6 The cellulosic, inorganic-filled plastic composite according to claim 1, wherein the
combination of the cellulosic material and the talc is present in an amount in the range from about
50% to about 80% by weight of the composite
7 The cellulosic, inorganic-filled plastic composite according to claim 1, wherein the
combination of the cellulosic material and the talc is present in an amount in the range from about 55% to about 65% by weight of the composite 8 The cellulosic, inorganic-filled plastic composite according to claim 1, wherein the cellulosic material is selected from wood fiber, seed husks, ground rice hulls, newspaper, kenaf, and coconut shells
9 The cellulosic, inorganic-filled plastic composite according to claim 1, wherein the
polyethylene is high density polyethylene
10 The cellulosic, inorganic-filled plastic composite according to claim 1, wherein the
cellulosic material is wood fiber present in an amount in the range from about 50% to about 55% by weight of the composite, wherein the talc is present in an amount in the range from about 5%
to about 10% by weight of the composite, and wherein the polyethylene is high density
polyethylene present in an amount in the range from about 30% to about 40% by weight of the composite
11 The cellulosic, inorganic-filled plastic composite according to claim 1, wherein the cellulosic material is wood fiber present in an amount in the range from about 50% to about 55%
by weight of the composite, wherein the talc is present in an amount in the range from about 10%
to about 15% by weight of the composite, and wherein the polyethylene is high density
polyethylene present in an amount in the range from about 25% to about 30% by weight of the composite
12 An extruded article, said article produced by extruding a cellulosic, inorganic-filled plastic
composite, the composite comprising
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 13 An extruded article according to claim 12, wherein the cellulosic material is present in an amount in the range from about 40% to about 60% by weight of the composite
14 An extruded article according to claim 12, wherein the cellulosic material is present in an
amount in the range from about 45% to about 55% by weight of the composite
15 An extruded article according to claim 12, wherein the talc is present in an amount in the range from about 5% to about 15% by weight of the composite
16 An extruded article according to claim 12, wherein the polyethylene is present in an amount in the range from about 25% to about 35% by weight of the composite
17 An extruded article according to claim 12, wherein the combination of the cellulosic
material and the talc is present in an amount in the range from about 50% to about 80% by weight
of the composite
18 An extruded article according to claim 12, wherein the combination of the cellulosic
material and the talc is present in an amount in the range from about 55% to about 65% by weight
of the composite 19 An extruded article according to claim 12, wherein the at least one cellulosic material is selected from wood fiber, seed husks, ground rice hulls, newspaper, kenaf, and coconut shells
20 An extruded article according to claim 12, wherein the polyethylene is high density
polyethylene
21 An extruded article according to claim 12, wherein the cellulosic material is wood fiber
present in an amount in the range from about 50% to about 55% by weight of the composite, wherein the talc is present in an amount in the range from about 5% to about 10% by weight of the composite, and wherein the polyethylene is high density polyethylene present in an amount in the range from about 30% to about 40% by weight of the composite
22 An extruded article according to claim 12, wherein the cellulosic material is wood fiber
present in an amount in the range of from about 50% to about 55% by weight of the composite, wherein the talc is present in an amount in the range from about 10% to about 15% by weight of the composite, and wherein the polyethylene is high density polyethylene present in an amount in the range from about 25% to about 30% by weight of the composite
23 A method of extruding a cellulosic, inorganic-filled plastic composite profile, the method comprising
introducing a cellulosic, inorganic-filled plastic composite into an extruder, the cellulosic, inorganic-filled plastic composite comprising
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 melting the cellulosic, inorganic-filled plastic composite,
extruding the melted cellulosic, inorganic-filled plastic composite through a profile die to form a profile, and
cooling the profile
24 A method according to claim 23, wherein the cellulosic material is present in an amount in the range from about 40% to about 60% by weight of the composite
25 A method according to claim 23, wherein the cellulosic material is present in an amount in
the range from about 45% to about 55% by weight of the composite 26 A method according to claim 23, wherein the talc is present in an amount in the range
from about 5% to about 15% by weight of the composite
27 A method according to claim 23, wherein the polyethylene is present in an amount in the range from about 25% to about 35% by weight of the composite
28 A method according to claim 23, wherein the combination of the cellulosic material and
the talc is present in an amount in the range from about 50% to about 80% by weight of the composite
29 A method according to claim 23, wherein the combination of the cellulosic material and the talc is present in an amount in the range from about 55% to about 65% by weight of the
composite
30 A method according to claim 23, wherein the cellulosic material is selected from wood fiber, seed husks, ground rice hulls, newspaper, kenaf, and coconut shells
31 A method according to claim 23, wherein the polyethylene is high density polyethylene
32 A method according to claim 23, wherein the cellulosic material is wood fiber present in
an amount in the range from about 50% to about 55% by weight of the composite, wherein the
talc is present in an amount in the range from about 5% to about 10% by weight of the composite, and wherein the polyethylene is high density polyethylene present in an amount in the range from about 30% to about 40% by weight of the composite
33 A method according to claim 23, wherein the cellulosic material is wood fiber present in
an amount in the range of from about 50% to about 55% by weight of the composite, wherein the
talc is present in an amount in the range from about 10% to about 15% by weight of the composite, and wherein the polyethylene is high density polyethylene present in an amount in the range from about 25% to about 30% by weight of the composite.
PCT/US1999/030990 1998-12-28 1999-12-28 Cellulosic, inorganic-filled plastic composite WO2000039207A1 (en)

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