System and method for making extruded, composite material

Abstract

Systems and methods for making a material composition are disclosed. The method includes mixing a thermoset polymer, a petroleum distillate, a release agent, and a catalyst to form an admixture. A cellulosic material is mixed with the admixture to form a generally homogenous furnish. The system includes a mixing chamber, a feeding chamber, and a die. The die includes a pressing chamber, which has a volume formed by first and second platens. The platens are in facing opposition to one another and have a length extending continuously from an entrance to an exit of the die. The platens have a plurality of orifices and heating elements disposed along the length. The platens are disposed in first and second positions. The first position forms a first volume and the second position forms a second volume.

1 . A method of making a material composition comprising:
 mixing a thermoset polymer, a petroleum distillate, a release agent, and a catalyst, thereby forming an admixture; and   mixing a cellulosic material with the admixture, thereby forming a generally homogenous furnish, the thermoset polymer being present in the furnish in an amount of approximately 6 to approximately 10 percent by weight.   
     
     
         2 . The method according to  claim 1  further comprising:
 heating the furnish to a temperature of at least 212 degrees F., whereby a water vapor is formed in the furnish; and   releasing the water vapor from the furnish.   
     
     
         3 . The method according to  claim 2  further comprising compressing the furnish to an average density of between approximately 27 and approximately 36 pounds per cubic foot. 
     
     
         4 . The method according to  claim 3  further comprising introducing the furnish into a die, the die having a length and continuously displacing the furnish along the length of the die at a predetermined rate. 
     
     
         5 . The method according to  claim 4 , wherein the rate is approximately 990 pounds per hour. 
     
     
         6 . The method according to  claim 1 , wherein forming the homogenous furnish comprises:
 introducing the admixture into a chamber;   introducing the cellulosic material into the chamber; and   maintaining the chamber at a temperature at approximately 65 degrees F.   
     
     
         7 . The method according to  claim 1 , wherein the cellulosic material is present in the furnish in the amount of approximately 83 to approximately 93.5 percent by weight. 
     
     
         8 . The method according to  claim 1 , wherein the petroleum distillate is present in the furnish in the amount of approximately 0 to approximately 2 percent by weight. 
     
     
         9 . The method according to  claim 15 , wherein the release agent is present in the furnish in the amount of approximately 0.03 to approximately 0.5 percent by weight. 
     
     
         10 . The method according to  claim 1 , wherein the catalyst is present in the furnish in the amount of approximately 0.5 to approximately 3 percent by weight. 
     
     
         11 . The method according to  claim 1 , wherein the cellulosic material is comprised of discrete wood particles. 
     
     
         12 . The method according to  claim 11 , wherein each of the discrete wood particles has a diameter of less than approximately one-eighth of an inch. 
     
     
         13 . The method according to  claim 1 , wherein the thermoset polymer is comprised of a melamine urea formaldehyde resin. 
     
     
         14 . The method according to  claim 1 , wherein the petroleum distillate is comprised of an emulsified wax. 
     
     
         15 . The method according to  claim 1 , wherein the release agent is comprised of a modified fatty oil. 
     
     
         16 . The method according to  claim 1 , wherein the catalyst is comprised of an ammonium chloride. 
     
     
         17 . The method of  claim 11 , wherein each of the discrete wood particles has a diameter of less than approximately three-eighths of an inch.