Variegated composites and related methods of manufacture

Abstract

Embodiments of the invention include a composite. The composite includes a crystalline polymer, a plurality of wood fibers blended with the crystalline polymer, an outer surface, and an amorphous polymer visible on the outer surface. The amorphous polymer has a first color and the blend of the crystalline polymer and the plurality of wood fibers has a second color different from the first color. The invention also includes a method of manufacturing the wood-plastic composites such that one polymer is shifted in the composite relative to the other polymer.

1 - 20 . (canceled)  
   
   
       21 . A method of manufacturing a wood-plastic composite including a profile body, comprising: 
 providing a crystalline polymer;    providing a plurality of wood fibers;    providing an amorphous polymer;    melting the crystalline polymer;    melting the amorphous polymer;    first mixing the crystalline polymer and the plurality of wood fibers to form a substantially homogenous feed;    second mixing the amorphous polymer with the substantially homogenous feed of the crystalline polymer and the plurality of wood fibers to form a heterogeneous feed; and    forming the profile body from the heterogeneous feed, the profile body including an outer surface evincing a first color associated with the amorphous polymer and a second color associated with the substantially homogenous feed, the second color being different from the first color.    
   
   
       22 . The method of  claim 21 , further comprising forming streaks of the first color on the outer surface.  
   
   
       23 . The method of  claim 21 , further comprising forming streaks of the amorphous polymer on the outer surface.  
   
   
       24 . The method of  claim 21 , further comprising shifting the amorphous polymer towards the outer surface.  
   
   
       25 . The method of  claim 21 , further comprising variegating the outer surface.  
   
   
       26 . The method of  claim 21 , further comprising providing at least one of a single screw extruder and a double screw extruder, 
 wherein the step of forming includes extruding the heterogeneous feed via the at least one of the single-screw extruder and the double screw extruder.    
   
   
       27 . The method of  claim 21 , wherein the step of second mixing includes forming the first color from the amorphous polymer and forming the second color from the substantially homogenous feed including the crystalline polymer and the plurality of wood fibers.  
   
   
       28 . The method of  claim 21 , further comprising providing another amorphous polymer; 
 melting the another amorphous polymer; and    mixing the another amorphous polymer with the amorphous polymer and the substantially homogenous feed including the crystalline polymer and the plurality of wood fibers,    wherein the step of forming includes forming the profile body such that the outer surface evinces a third color associated with the another amorphous polymer different from the first color and the second color.    
   
   
       29 . The method of  claim 21 , further comprising providing a core, wherein the step of forming the profile body includes forming the profile body around at least a portion of the core.  
   
   
       30 . The method of  claim 21 , further comprising providing a colorant having a third color different from the first color and the second color; and 
 blending the colorant with one of the crystalline polymer and the amorphous polymer so as to turn the one of the crystalline polymer and the amorphous polymer the third color.    
   
   
       31 . A method of manufacturing a wood-plastic composite including a profile body, comprising: 
 providing a first polymer;    providing a plurality of wood fibers;    providing a second polymer not substantially soluble in the first polymer;    melting the first polymer;    melting the second polymer;    first mixing the second polymer and the plurality of wood fibers to form a substantially homogenous feed;    second mixing the first polymer with the substantially homogenous feed to form a heterogeneous feed; and    forming the profile body from the heterogeneous feed, the profile body including an outer surface evincing a first color associated with the first polymer and a second color associated with the substantially homogenous feed, the second color being different from the first color.    
   
   
       32 . The method of  claim 31 , further comprising forming streaks of the first color on the outer surface.  
   
   
       33 . The method of  claim 31 , further comprising forming streaks of the first polymer on the outer surface.  
   
   
       34 . The method of  claim 31 , further comprising shifting the first polymer towards the outer surface.  
   
   
       35 . The method of  claim 31 , further comprising variegating the outer surface.  
   
   
       36 . The method of  claim 31 , further comprising providing at least one of a single screw extruder and a double screw extruder, 
 wherein the step of forming includes extruding the heterogeneous feed via the at least one of the single-screw extruder and the double screw extruder.    
   
   
       37 . The method of  claim 31 , wherein the step of second mixing includes forming the first color from the first polymer and forming the second color from the substantially homogenous feed including the second polymer and the plurality of wood fibers.  
   
   
       38 . The method of  claim 31 , further comprising providing a third polymer not substantially soluble in the second polymer; 
 melting the third polymer; and    mixing the third polymer with the first polymer and the substantially homogenous feed including the second polymer and the plurality of wood fibers,    wherein the step of forming includes forming the profile body such that the outer surface deliberately evinces a third color associated with the third polymer different from the first color and the second color.    
   
   
       39 . The method of  claim 31 , further comprising providing a core, wherein the step of forming the profile body includes forming the profile body around at least a portion of the core.  
   
   
       40 . The method of  claim 31 , further comprising providing a colorant having a third color different from the first color and the second color; and 
 blending the colorant with one of the first polymer and the second polymer so as to turn the one of the first polymer and the second polymer the third color.    
   
   
       41 . A method of manufacturing a wood-plastic composite including a profile body, comprising: 
 providing a first polymer, a plurality of wood fibers, a second polymer not substantially soluble in the first polymer, and an additive;    melting the first polymer and the second polymer;    first blending the additive with the second polymer to form a substantially homogenous blend;    second blending the first polymer and the plurality of wood fibers to form a substantially homogenous feed;    mixing the substantially homogenous blend with the substantially homogenous feed of the first polymer and the plurality of wood fibers to form a heterogeneous feed;    forming the profile body with an outer surface from the heterogeneous feed; and    shifting the substantially homogenous blend towards the outer surface such that at least a portion of the substantially homogenous blend is visible on the outer surface.    
   
   
       42 . The method of  claim 41 , wherein the additive is one or more of a pigment, a mold inhibitor, a microorganism growth inhibitor, and a mildew inhibitor.  
   
   
       43 . The method of  claim 41 , wherein the substantially homogeneous blend substantially covers an entire side of the profile body.  
   
   
       44 . The method of  claim 41 , wherein the additive is not blended with either of the first polymer or the wood fibers.  
   
   
       45 . The method of  claim 41 , wherein the additive is soluble in the second polymer and not soluble in the first polymer.  
   
   
       46 . The method of  claim 21 , further comprising preventing the plurality of wood fibers from being dispersed throughout the amorphous polymer during the step of second mixing.  
   
   
       47 . The method of  claim 31 , further comprising preventing the plurality of wood fibers from being dispersed throughout the first polymer during the step of second mixing.  
   
   
       48 . The method of  claim 41 , further comprising preventing the plurality of wood fibers from being dispersed throughout the first polymer during the step of mixing.  
   
   
       49 . The method of  claim 21 , wherein providing the amorphous polymer includes providing enough of the amorphous polymer so as to result in the profile body including between about 0% and about 5% of the amorphous polymer by weight.  
   
   
       50 . The method of  claim 31 , wherein providing the first polymer includes providing enough of the first polymer so as to result in the profile body including between about 0% and about 5% of the first polymer by weight.  
   
   
       51 . The method of  claim 41 , wherein providing the first polymer includes providing enough of the first polymer so as to result in the profile body including between about 0% and about 5% of the first polymer by weight.  
   
   
       52 . The method of  claim 21 , wherein providing the amorphous polymer includes providing enough of the amorphous polymer so as to result in the profile body including about 2% of the amorphous polymer by weight.  
   
   
       53 . The method of  claim 31 , wherein providing the first polymer includes providing enough of the first polymer so as to result in the profile body including about 2% of the first polymer by weight.  
   
   
       54 . The method of  claim 41 , wherein providing the first polymer includes providing enough of the first polymer so as to result in the profile body including about 2% of the first polymer by weight.  
   
   
       55 . The method of  claim 21 , wherein the amorphous polymer is one of a polystyrene and polycarbonate.  
   
   
       56 . The method of  claim 31 , wherein the amorphous polymer is one of a polystyrene and polycarbonate.  
   
   
       57 . The method of  claim 41 , wherein the amorphous polymer is one of a polystyrene and polycarbonate.