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 - 10 . (canceled)  
   
   
       11 . A composite, comprising: 
 a first polymer;    a plurality of wood fibers blended with the first polymer to form a substantially homogenous blend;    an outer surface of the composite; and    a second polymer substantially immiscible with the first polymer;    wherein the composite includes an substantially immiscible mixture of the substantially homogenous blend and the second polymer;    wherein the outer surface of the composite is defined by the substantially immiscible mixture of the substantially homogenous blend and the second polymer;    wherein the substantially homogenous blend of the first polymer and the plurality of wood fibers has a first color and the second polymer has a second color different from the first color,    wherein the first color and the second color are separately discernible on the other outer surface.    
   
   
       12 . The composite of  claim 11 , wherein the first polymer is at least one of polypropylene and polyethylene.  
   
   
       13 . The composite of  claim 11 , wherein the second polymer is a styrenic polymer.  
   
   
       14 . The composite of  claim 11 , wherein the outer surface includes streaks of the second color.  
   
   
       15 . The composite of  claim 11 , wherein the first polymer has a melting temperature that is substantially the same as a melting temperature of the second polymer.  
   
   
       16 . The composite of  claim 11 , wherein the outer surface of the composite is variegated by the first color and the second color.  
   
   
       17 . The composite of  claim 11 , wherein a first portion of the outer surface has the first color and a second portion of the outer surface has the second color.  
   
   
       18 . The composite of  claim 11 , further comprising a third polymer substantially immiscible with the first polymer; 
 wherein the third polymer is visible on the outer surface of the composite,    wherein the third polymer has a third color different from the first color and the second color,    wherein the composite includes an substantially immiscible mixture of the substantially homogenous blend, the second polymer, and the third polymer;    wherein the outer surface of the composite is defined by the substantially immiscible mixture of the substantially homogenous blend, the second polymer, and the third polymer.    
   
   
       19 . The composite of  claim 11 , wherein the composite is at least one of a building material, a decking material, a railing component, and a decking board.  
   
   
       20 . The composite of  claim 11 , further comprising a colorant blended with one of the first polymer and the second polymer.  
   
   
       21 - 45 . (canceled)  
   
   
       46 . The composite of  claim 11 , wherein the plurality of wood fibers are substantially free of the second polymer.  
   
   
       47 . The composite of  claim 11 , wherein the second polymer of the composite is substantially free of the plurality of wood fibers.  
   
   
       48 . The composite of  claim 11 , wherein at least one of the substantially homogenous blend and the second polymer is miscibly blended with at least one of a biostabilizer and a biocide.  
   
   
       49 . The composite of  claim 11 , wherein the second polymer makes up between about 5% and about 0% of the composite by weight.  
   
   
       50 . The composite of  claim 11 , wherein the second polymer makes up about 2% of the composite by weight.  
   
   
       51 . A composite, comprising: 
 a substantially homogenous blend including a first polymer and a plurality of wood fibers; and    an substantially immiscible mixture of the substantially homogenous blend and a second polymer,    wherein the substantially homogenous blend is of a first color and the second polymer is of a second color different from the first color, and    wherein the composite includes a variegation of the first color and the second color.    
   
   
       52 . The composite of  claim 51 , wherein the first polymer is at least one of polypropylene and polyethylene.  
   
   
       53 . The composite of  claim 51 , wherein the second polymer is a styrenic polymer.  
   
   
       54 . The composite of  claim 51 , further comprising an outer surface defined by the substantially immiscible mixture including the substantially homogenous blend and the second polymer.  
   
   
       55 . The composite of  claim 54 , wherein the outer surface includes streaks of the second color.  
   
   
       56 . The composite of  claim 51 , wherein the second polymer has a melting temperature that is substantially the same as a melting temperature of the first polymer.  
   
   
       57 . The composite of  claim 54 , wherein the outer surface of the composite is variegated by the first color and the second color.  
   
   
       58 . The composite of  claim 54 , wherein a first portion of the outer surface has the first color and a second portion of the outer surface has the second color.  
   
   
       59 . The composite of  claim 51 , wherein the substantially immiscible mixture includes another second polymer different from the second polymer, 
 wherein the another second polymer is substantially immiscible with the substantially homogenous blend, and    wherein the another second polymer has a third color different from the first color and the second color.    
   
   
       60 . The composite of  claim 51 , wherein the composite is at least one of a building material, a decking material, a railing component, and a decking board.  
   
   
       61 . The composite of  claim 51 , further comprising a colorant blended with one of the first polymer and the second polymer, 
 wherein the colorant has a color different from a color of the one of the first polymer and second polymer, and    wherein a substantially homogenous blend of the colorant and the one of the first polymer and second polymer has the color of the colorant.    
   
   
       62 . The composite of  claim 51 , wherein the plurality of wood fibers are substantially free of the second polymer.  
   
   
       63 . The composite of  claim 51 , wherein the second polymer of the composite is substantially free of the plurality of wood fibers.  
   
   
       64 . The composite of  claim 51 , wherein at least one of the substantially homogenous blend and the second polymer is miscibly blended with at least one of a biostabilizer and a biocide.  
   
   
       65 . The composite of  claim 51 , wherein the second polymer makes up between about 5% and about 0% of the composite by weight.  
   
   
       66 . The composite of  claim 51 , wherein the second polymer makes up about 2% of the composite by weight.  
   
   
       67 . A composite, comprising: 
 an substantially immiscible mixture of a first polymer and a second polymer; and    a plurality of wood fibers dispersed throughout the first polymer,    wherein the first polymer is of a first color and the second polymer is of a second color different from the first color, and    wherein the second polymer is substantially free of the plurality of wood fibers.    
   
   
       68 . The composite of  claim 67 , wherein the first polymer is at least one of polypropylene and polyethylene.  
   
   
       69 . The composite of  claim 67 , wherein the second polymer is a styrenic polymer.  
   
   
       70 . The composite of  claim 67 , further comprising an outer surface defined by the substantially immiscible mixture of the first polymer and the second polymer.  
   
   
       71 . The composite of  claim 70 , wherein the outer surface includes streaks of the second color.  
   
   
       72 . The composite of  claim 67 , wherein the second polymer has a melting temperature that is substantially the same as a melting temperature of the first polymer.  
   
   
       73 . The composite of  claim 70 , wherein the outer surface of the composite is variegated.  
   
   
       74 . The composite of  claim 70 , wherein a first portion of the outer surface has the first color and a second portion of the outer surface has the second color.  
   
   
       75 . The composite of  claim 67 , wherein the substantially immiscible mixture includes another second polymer different from the second polymer, 
 wherein the another second polymer is substantially immiscible with the first polymer, and    wherein the another second polymer has a third color different from the first color and the second color.    
   
   
       76 . The composite of  claim 67 , wherein the composite is at least one of a building material, a decking material, a railing component, and a decking board.  
   
   
       77 . The composite of  claim 67 , further comprising a colorant blended with one of the first polymer and the second polymer, 
 wherein the colorant has a color different from a color of the one of the first polymer and second polymer,    wherein a substantially homogenous blend of the colorant and the one of the first polymer and second polymer has the color of the colorant.    
   
   
       78 . The composite of  claim 67 , wherein at least one of the first polymer and the second polymer is miscibly blended with at least one of a biostabilizer and a biocide.  
   
   
       79 . The composite of  claim 67 , wherein the second polymer makes up between about 5% and about 0% of the composite by weight.  
   
   
       80 . The composite of  claim 67 , wherein the second polymer makes up about 2% of the composite by weight.  
   
   
       81 . The composite of  claim 13 , wherein the second polymer is one of a polycarbonate and a polystyrene.  
   
   
       82 . The composite of  claim 53 , wherein the second polymer is one of a polycarbonate and a polystyrene.  
   
   
       83 . The composite of  claim 69 , wherein the second polymer is one of a polycarbonate and a polystyrene.