U.S. patent application number 12/229744 was filed with the patent office on 2009-01-01 for system and method for making extruded, composite material.
This patent application is currently assigned to JELD-WEN, inc.. Invention is credited to Jonathan Philip Alexander, David J. Bleha, Sean Robert Broker, Randy Jon Clark, Walter B. Davis.
Application Number | 20090004315 12/229744 |
Document ID | / |
Family ID | 32175190 |
Filed Date | 2009-01-01 |
United States Patent
Application |
20090004315 |
Kind Code |
A1 |
Broker; Sean Robert ; et
al. |
January 1, 2009 |
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.
Inventors: |
Broker; Sean Robert; (Keno,
OR) ; Alexander; Jonathan Philip; (Klamath Falls,
OR) ; Bleha; David J.; (Klamath Falls, OR) ;
Clark; Randy Jon; (Klamath Falls, OR) ; Davis; Walter
B.; (Klamath Falls, OR) |
Correspondence
Address: |
NELSON MULLINS RILEY & SCARBOROUGH, LLP
1320 MAIN STREET, 17TH FLOOR
COLUMBIA
SC
29201
US
|
Assignee: |
JELD-WEN, inc.
Klamath Falls
OR
|
Family ID: |
32175190 |
Appl. No.: |
12/229744 |
Filed: |
August 26, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10285449 |
Nov 1, 2002 |
7449229 |
|
|
12229744 |
|
|
|
|
Current U.S.
Class: |
425/205 |
Current CPC
Class: |
C08L 97/02 20130101;
Y10T 428/253 20150115; B29C 48/13 20190201; B29C 48/475 20190201;
Y10T 428/24124 20150115; Y10T 428/26 20150115; B27N 3/28 20130101;
Y10T 428/24066 20150115; B29C 48/07 20190201; Y10T 428/298
20150115; Y10T 428/24994 20150401; B29C 48/12 20190201; Y10T
428/31801 20150401; C08L 97/02 20130101; C08L 2666/02 20130101 |
Class at
Publication: |
425/205 |
International
Class: |
B29C 47/50 20060101
B29C047/50 |
Claims
1. An apparatus for forming a continuous cellulosic-based composite
material comprising: a mixing chamber comprising a volume and at
least one entrance and an exit; a feeding chamber comprising a
volume, an entrance, and an exit, the entrance of the feeding
chamber being in fluid communication with the exit of the mixing
chamber; and a die comprising an entrance, an exit, a piston, a
ram, and a pressing chamber, the entrance of the die being in fluid
communication with the exit of the feeding chamber, the pressing
chamber having a volume formed by first and second platens, the
first and second platens being disposed in facing opposition to one
another and having a length extending continuously from at least
the entrance of the die to the exit of the die, the first and
second platens having a plurality of orifices and heating elements
disposed along the length, the first and second platens being
disposed in first and second positions, the first position forming
a first volume and the second position forming a second volume.
2. The apparatus according to claim 1, wherein the reciprocating
ram displaces a predetermined amount of a workpiece through the
volume of the pressing chamber at a continuous rate.
3. The apparatus according to claim 2, wherein the continuous rate
is approximately 990 pounds per hour.
4. The apparatus according to claim 3, wherein the entrance of the
die comprises an input chute.
5. The apparatus according to claim 4, wherein the workpiece is
introduced into the volume of the pressing chamber through an input
chute.
6. The apparatus according to claim 1, wherein a distance between
the first and second platens in the first position is a first
distance.
7. The apparatus according to claim 6, wherein a distance between
the first and second platens in the second position is a second
distance.
8. The apparatus according to claim 7, wherein the second distance
is greater than the first distance.
9. The apparatus according to claim 1, wherein ends of the first
and second platens in the first position are proximate the entrance
of the die.
10. The apparatus according to claim 1, wherein ends of the first
and second platens in the second position are proximate the exit of
the die.
11. The apparatus according to claim 1, wherein a spacer is
disposed between the first and second platens.
12. The apparatus according to claim 1, wherein the spacer has a
first end and a second end, the first end proximate the entrance of
the die and the second end proximate the exit of the die, the first
end of the spacer having a first thickness and the second end of
the spacer having a second thickness.
13. The apparatus according to claim 12, wherein the second
thickness is greater than the first thickness.
14. The apparatus according to claim 1, wherein the first volume is
greater than the second volume.
15. The apparatus according to claim 1, wherein the piston is
disposed proximate the entrance of the die and opposite the exit of
the die.
16. The apparatus according to claim 5, wherein the piston is
positioned substantially perpendicular to the input chute.
17. The apparatus according to claim 16, wherein the ram is coupled
to the piston.
18. The apparatus according to claim 17, wherein the ram comprises
a face, the face contacting the workpiece.
19. The apparatus according to claim 18, wherein the face comprises
a serrated edge.
20. The apparatus according to claim 18, wherein the face comprises
a flat edge.
21. The apparatus according to claim 3, wherein the piston exerts a
force on the workpiece substantially planar to the length of the
first and second platens.
22. The apparatus according to claim 21, wherein the force of the
piston displaces the workpiece toward the exit of the die at the
continuous rate.
23. The apparatus according to claim 2, wherein the first and
second platens compress the workpiece to a substantially uniform
density.
24. The apparatus according to claim 23, wherein the density is in
a range between approximately 27 and approximately 36 pounds per
cubic foot.
25. The apparatus according to claim 1, wherein the first and
second platens each have a thickness, wherein the plurality of
orifices are formed through the thickness of the first and second
platens.
26. The apparatus according to claim 1, further comprising: a
hopper comprising a volume, an entrance, an exit, and a screw
feeder disposed proximate the exit of the hopper, the exit of the
hopper being in fluid communication with one of the entrances of
the mixing chamber; and a resin injector comprising at least one
tank and a regulating valve, the regulating valve being in fluid
communication with another one of the entrances of the mixing
chamber.
27. The apparatus according to claim 26, wherein the hopper further
comprises a screen having a plurality of orifices, the orifices
each having a diameter.
28. The apparatus according to claim 27, wherein the diameter is in
a range between approximately one-eighth of an inch and
approximately three-eighths of an inch.
29. The apparatus according to claim 27 further comprising: a
cyclone having an entrance, an exit, and a middle portion, the
middle portion being disposed between the entrance and the exit of
the cyclone and including at least one magnet, the exit of the
cyclone being in fluid communication with the entrance of the
hopper, wherein cellulosic material is directed from the entrance
of the cyclone to the exit of the cyclone passing through the
middle portion, whereby the at least one magnet removes ferrous
material from the cellulosic material.
Description
CROSS-REFERENCE TO RELATED PATENTS AND PATENT APPLICATIONS
[0001] This application is a divisional application of U.S. patent
application Ser. No. 10/285,449 filed Nov. 1, 2002, which is
incorporated by reference herein in its entirety.
NOTICE OF COPYRIGHT PROTECTION
[0002] A portion of the disclosure of this patent document and its
figures contain material subject to copyright protection. The
copyright owner has no objection to the facsimile reproduction by
anyone of the patent document, but otherwise reserves all
copyrights whatsoever.
FIELD OF INVENTION
[0003] The invention disclosed herein relates to composite
materials in general, and more particularly, to an apparatus for
and method of making an extruded, cellulosic-based composite
material.
BACKGROUND
[0004] Manufacturing processes invariably result in material waste
for a variety of reasons, such as imperfections in raw materials
and errors made during production. Material waste has increasingly
become an economic burden for manufacturers of wood products, such
as doors and windows. In the past, wood waste from doors,
cardboard, particleboard, and wood pallets was either disposed of
in landfills or burned. The steady increase in fees for landfill
disposal and increasingly stringent air-quality regulations have
made traditional methods of waste disposal problematic for
manufacturers of wood products.
[0005] Conventional alternatives to landfill disposal and burning
are inadequate. One alternative is to place any one of a variety of
pollution-control devices in the exhaust path of a wood-burning
plant. However, the cost of such devices is expensive, and for
small manufacturers, these expenses can quickly become
cost-prohibitive. The cost of burning waste can also include
governmental permit fees, as well as the cost of ensuring
compliance with environmental regulations.
[0006] An alternative to disposing of the waste is to find another
market for the waste material. One potential market is animal
bedding. However, animal bedding requires generally homogenous and
nontoxic material. Wood waste from manufacturing processes can
often include ferrous materials and painted products, which can be
harmful to animals. Thus, animal bedding is often not an adequate
solution. Another potential market is fill material for
construction sites. The construction industry utilizes fill for a
variety of purposes, such as raising elevations. However, the
demand for fill material is inconsistent, which means that
manufacturers would be forced to keep an inventory of waste when
there is no adequate demand. Keeping any sort of inventory is
generally expensive, and thus, this option does not offer
sufficient economic advantages over disposal.
[0007] Another alternative to disposing of wood waste is to utilize
the wood waste to manufacture composite components. Various methods
for utilizing wood waste to make certain wood-based composite
materials, such as certain particleboards and fiberboards, is well
known in the art. However, the equipment currently available to
manufacture such composite materials is relatively expensive, and
therefore is cost-prohibitive for most small and specialty
manufacturers. Moreover, currently-available wood extrusion
processes require generally uniform--that is, size, shape, weight,
moisture content, and material type--raw materials. Often, wood
waste from manufacturing processes is not uniform. Moreover, the
product produced by such conventional methods typically has a
density that is non-uniform.
SUMMARY OF THE INVENTION
[0008] The present invention includes systems and methods for
making extruded composite material, and products made therefrom.
One embodiment of the present invention provides for a method of
making a material composition that includes mixing a thermoset
polymer, a petroleum distillate, a release agent, and a catalyst to
form an admixture. Preferably, the thermoset polymer is present in
the furnish in an amount of approximately 6 to approximately 10
percent by weight. The method also includes mixing the admixture
with a cellulosic material to form a generally homogenous
furnish.
[0009] Another embodiment of the method includes introducing the
furnish into a die having a length. The method further includes
heating the furnish in the die to a temperature of at least 212
degrees F., forming a water vapor in the furnish, and releasing the
water vapor from the furnish and the die.
[0010] One embodiment of the present invention provides an
apparatus for forming a continuous cellulosic-based composite
material that includes a mixing chamber, a feeding chamber, and a
die. The mixing chamber includes a volume and at least one entrance
and one exit. The feeding chamber includes a volume, an entrance,
and an exit. The entrance of the feeding chamber is in fluid
communication with the exit of the mixing chamber.
[0011] The die includes an entrance, an exit, a piston, a ram, and
a pressing chamber. The entrance of the die is a fluid
communication with the exit of the feeding chamber. The pressing
chamber has a volume formed by first and second platens. The first
and second platens are in facing opposition to one another and have
a length extending continuously from at least the entrance of the
die to the exit of the die. The first and second platens have a
plurality of orifices and heating elements disposed along the
length. The first and second platens are disposed in first and
second positions. The first position forms a first volume and the
second position forms a second volume.
[0012] One embodiment of the present invention provides a material
composition that includes a cellulosic material, a thermoset
polymer being present in the composition in an amount of
approximately 6 to approximately 10 percent by weight, a petroleum
distillate, a release agent, and a catalyst. The composition has a
generally uniform density. In an embodiment, the cellulosic
material includes discrete wood particles having a diameter of less
than approximately one-eighth of an inch. In other embodiment, the
cellulosic material includes discrete wood particles having a
diameter of less than approximately three-eighths of an inch. The
cellulosic material is present in the composition in an amount of
approximately 83 to approximately 93.5 percent by weight. In an
embodiment, the thermoset polymer is a melamine urea formaldehyde
resin. The petroleum distillate is present in the composition in an
amount of approximately 0 to approximately 2 percent by weight. The
release agent can be present in the composition in an amount of
approximately 0.03 to approximately 0.5 percent by weight. The
catalyst can be present in the composition in an amount of
approximately 0.5 to approximately 3 percent by weight: In an
embodiment, the composition has a density in a range between
approximately 27 and approximately 36 pounds per cubic foot
(pcf).
[0013] An advantage of the present invention can be to provide a
homogenous composite material composition.
[0014] One advantage of the present invention can be to utilize
non-uniform raw waste materials for the composite material
composition.
[0015] An advantage of the present invention can be to reduce the
amount of waste disposed of in landfills or burned by using waste
wood to form a composite material.
[0016] Another advantage of the present invention can be to provide
a uniform, high density composite material composition.
[0017] Yet another advantage of the present invention can be to
provide composite material composition that is an effective sound
barrier.
[0018] A further advantage of the present invention can be to
provide an inexpensive apparatus for manufacturing a composite
material composition.
[0019] Yet a further advantage of the present invention can be to
provide for drying a composite admixture integral to the
apparatus.
[0020] Another advantage of the present invention can be to use the
material for components in hollow-core wood doors.
[0021] Additional advantages of embodiments of the invention are
set forth in the detailed description that follows and will become
more apparent to those skilled in the art upon examination of the
following.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The accompanying drawings, which are incorporated herein and
constitute part of this specification, assist in illustrating
embodiments of the invention.
[0023] FIG. 1 is a schematic of an apparatus for forming a
continuous cellulosic-based composite material according to an
embodiment of the invention.
[0024] FIG. 2A is a top plan view of a first platen of the
apparatus of FIG. 1.
[0025] FIG. 2B is a side view of the first platen of the apparatus
of FIG. 1.
[0026] FIG. 2C is a bottom plan view of the first platen of the
apparatus of FIG. 1.
[0027] FIG. 2D is a cross-sectional view at line 2D-2D in FIG.
2C.
[0028] FIG. 2E is a cross-sectional view at line 2E-2E in FIG.
2C.
[0029] FIG. 2F is a cross-sectional view at line 2F-2F in FIG.
2A.
[0030] FIG. 3A is a top plan view of a second platen of the
apparatus of FIG. 1.
[0031] FIG. 3B is a side view of the second platen of the apparatus
of FIG. 1.
[0032] FIG. 3C is a side view of a platen spacer of the apparatus
of FIG. 1.
[0033] FIG. 3D is a top plan view of the platen spacer of the
apparatus of FIG. 1.
[0034] FIG. 3E is a cross-sectional view at line 3E-3E in FIG.
3A.
[0035] FIG. 3F is a cross-sectional view at line 3F-3F in FIG.
3A.
[0036] FIG. 4A is a side view of a ram and cylinder assembly of the
apparatus of FIG. 1
[0037] FIG. 4B is a side view of the ram of the apparatus of FIG.
1.
[0038] FIG. 4C is another side view of the ram of the apparatus of
FIG. 1.
[0039] FIG. 5 is a flowchart of a process of using the apparatus in
FIG. 1.
[0040] FIG. 6 is a front view of a door using the material
composition produced by the process of FIG. 5.
DETAILED DESCRIPTION
[0041] The present invention includes systems and methods for
making extruded composite material, and products made therefrom.
FIG. 1 shows one embodiment of a system for making extruded
composite material according to the present invention. Referring to
FIG. 1, a schematic of an apparatus 100 for forming a continuous
cellulosic-based composite material according to an embodiment of
the invention is shown. The apparatus 100 shown includes a mixing
chamber 200, a feeding chamber 300, and a die 400. The mixing
chamber 200 includes a volume 210, a first entrance 220, a second
entrance 230, an exit 240, and an auger 270. A homogenous furnish
(not shown), which includes a cellulosic material (not shown) and
an admixture (not shown), is formed in the volume 210 of the mixing
chamber 200. The admixture includes a thermoset polymer, a
petroleum distillate, a release agent, and a catalyst.
Alternatively, any suitable thermoset polymer, petroleum
distillate, release agent, and catalyst can be used.
[0042] The volume 210 of the mixing chamber 200 is formed by a
plurality of mixing chamber walls 260. The auger 270 is disposed
proximate the exit 240 of the mixing chamber 200. The auger 270
forms the homogenous furnish by blending the cellulosic material
and the admixture, i.e., directly contacting the cellulosic
material and the admixture. The mixing chamber 200 includes a
chiller 250. Preferably the chiller 250 is disposed separate from
the volume 210 of the mixing chamber 200. Alternatively, the
chiller 250 can be formed integrally with the volume 210 of the
mixing chamber 200.
[0043] The feeding chamber 300 includes a volume 310, an entrance
320, and an exit 330. The entrance 320 of the feeding chamber 300
is in fluid communication with the exit 240 of the mixing chamber
200. The auger 270 mechanically conveys the homogenous furnish
through the mixing chamber 200 to the exit 240 of the mixing
chamber. The furnish is gravity-fed to the entrance 320 of the
feeding chamber 300. Alternatively, any other suitable conveying
means can be used.
[0044] The die 400 includes an input chute 410, an output channel
420, a piston 430, a ram 460, and a pressing chamber 440. The
pressing chamber 440 has a volume 442. The volume 442 of the
pressing chamber 440 is formed by a first platen 470 and a second
platen 480. Alternatively, there can be more than two platens. The
first platen 470 and the second platen 480 are in facing opposition
to one another and each have a length extending continuously from
at least the input chute 410 to the output channel 420. In one
embodiment, the length of the first platen 470 and the second
platen 480 is 12 feet. Alternatively, the platens 470 and 480 can
be formed of a series of smaller plates disposed along a length of
the pressing chamber 440. Preferably, the first platen 470 and the
second platen 480 are formed of ASTM A36 steel plate.
Alternatively, the first platen 470 and the second platen 480 can
be formed of any other suitable grade of steel.
[0045] Referring now to FIG. 2A, a top view of the first platen 470
is shown. In one embodiment, the first platen 470 is 12 feet long,
four feet wide, and three inches thick. Alternatively, any other
suitable dimensions can be used. The first platen 470 includes a
top surface 471. Disposed throughout the top surface 471 is a
plurality of orifices 472. The orifices 472 are formed through the
entire thickness of the first platen 470. Preferably, the orifices
472 are formed by drilling through the first platen 470.
Alternatively, the orifices 472 can be molded in the first platen
470. A diameter of the orifices 472 are in a range between 0.30
inches and 0.60 inches. The orifices 472 permit vapor to escape the
die 400 through the first platen 470. Disposed substantially along
a perimeter is a plurality of bolt holes 494.
[0046] Disposed along a side surface of the first platen 470 is a
plurality of hinges 473. Preferably, the hinge 473 is welded to the
side surface of the first platen 470. Alternatively, the hinge 473
can be attached by fastening or the hinge 473 can be formed
integrally with the first platen 470. FIG. 2F shows a side view of
one of the hinges 473 in a cross-sectional view of the first platen
470 taken at line 2F-2F in FIG. 2A.
[0047] In an embodiment, the hinge 473 projects six-and-one-half
inches from the side surface of the first platen 470. The thickness
of each of the hinges 473 is three-quarters of an inch. The hinges
473 are generally flush with the top surface 471 of the first
platen 470. An attaching orifice 479 is formed in a lower portion
of each of the hinges 473. A diameter of the attaching orifice 479
is preferably eleven-sixteenths of an inch.
[0048] Referring now to FIG. 2B, a side view of the first platen
470 is shown. The first platen 470 includes a plurality of match
drilled holes 474. As shown in FIG. 2B, the match drilled holes 474
are drilled into a side surface 475 of the first platen 470. The
match drilled holes 475 are formed by a series of four minor
diameters forming a square-like shape and a major diameter disposed
in a center of the square. Preferably, the plurality of match
drilled holes 474 is 20. The major diameter of each of the match
drilled holes 474 is drilled entirely from the side surface 475 to
an opposite side surface (not shown). In an embodiment, the major
diameter of the match drilled holes 474 is one inch and the minor
diameters of the match drilled holes 474 are one-half an inch.
Alternatively, any other suitable dimensions can be used for the
major and minor diameters of the match drilled holes 474. The match
drilled holes 474 supply hot oil to the first platen 470 to heat
the furnish in the die 400 (described in more detail below).
[0049] Referring now to FIG. 2C, a bottom view of the first platen
470 is shown. The first platen 470 includes a bottom surface 476.
Disposed along the bottom surface 476 of the first platen 470 are a
plurality of grooves 477. The grooves 477 are disposed
substantially parallel to one another and extend nearly the entire
distance from the side surface 475 to the opposite side surface.
Preferably, the grooves 477 can be machined into the bottom
surface. Alternatively, the grooves 477 can be etched or molded in
the bottom surface 476. Disposed within the grooves 477 are the
orifices 472. Referring now to FIG. 2D, a cross-sectional view
taken along line 2D-2D in FIG. 2C shows a typical detail of the
orifices 472. The orifice 472 shown in FIG. 2D extends through the
first platen 470 from the top surface 471 to the bottom surface
476.
[0050] In one embodiment, an infeed 478 is disposed in the top
surface 471. The infeed 478 is generally rectangular in shape and
extends substantially from the side surface 475 to the opposite
side surface. A cross-sectional view of the infeed 478 taken along
line 2E-2E in FIG. 2C is shown in FIG. 2E. The infeed 478 extends
through the entire thickness of the first platen 470. Preferably, a
width of the steam vent 478 is five inches. Alternatively, any
other shape and dimensions can be used. The infeed 478 allows
furnish to enter the die 400.
[0051] Referring now to FIG. 3A, a top view of the second platen
480 is shown. In one embodiment, the second platen 480 is 12 feet
long, four feet wide, and three inches thick. Alternatively, any
other suitable dimensions can be used. The second platen 480
includes a top surface 481. Disposed throughout the top surface 481
is a plurality of orifices 482. The orifices 482 are formed through
the entire thickness of the second platen 480. Preferably, the
diameter of the orifices 482 are in a range between 0.30 inches and
0.60 inches. A cross section of the second platen 480 taken along
line 3E-3E in FIG. 3A shows one of the orifices 482 in FIG. 3E. The
orifices 482 permit vapor to escape the die 400 through the second
platen 480. A plurality of grooves 484 are disposed along the
bottom surface 481 of the second platen 480. The grooves 484 are
disposed substantially parallel to one another and extend nearly
the entire distance from a side surface 485 to an opposite side
surface (not shown). The plurality of orifices 482 are disposed
within the grooves 484. A plurality of hinges 483 are disposed
along a side surface of the second platen 480. The details of the
hinges 483 are materially similar to the hinges 473 and will not be
described in detail. The hinges 483 are shown in FIG. 3F. The
hinges 473 and 483 interlock to secure the first and second platens
470 and 480 together. The hinges 473 and 483 can be interlocked
together by a nut and bolt or any other suitable securing
means.
[0052] Referring now to FIG. 3B, a side view of the second platen
480 is shown. Preferably, the second platen 480 is three inches
thick. The second platen 480 includes a plurality of match drilled
holes 486. The match drilled holes 486 are drilled into the side
surface 485 from the side surface 485 to the opposite side surface.
The match drilled holes 486 supply hot oil to the second platen 480
to heat the furnish in the die 400 (described in more detail
below). The structure of the match drilled holes 486 in the second
platen 480 is similar in material respect to the match drilled
holes 474 of the first platen 470, and thus will not be described
in detail.
[0053] Referring now to FIGS. 3C and 3D, a platen spacer 490 is
shown. Preferably, the length of the platen spacer 490 corresponds
to the length of the first and second platens 470 and 480, i.e., 12
feet. Alternatively, the length of the platen spacer 490 can be
different than the length of the first and second platens 470 and
480. A width of the platen spacer 490 is preferably
six-and-seven-eighths inches. Alternatively, the width of the
platen spacer 490 can be approximately six-and-seven-eighths inches
or any other suitable thickness. In one embodiment, a thickness of
the platen spacer 490 is tapered. At an end 492 of the platen
spacer 490 proximate the output channel 420, the thickness is
preferably 1.19 inches. At an end 491 of the platen spacer 490
proximate the infeed 478, the thickness is preferably 1.11 inches.
In the embodiment, the thickness of the platen spacer 490 is 1.11
inches for six feet from end 491; the thickness of the spacer 490
then increases gradually to 1.19 inches over the next two feet, and
remains at 1.19 inches to the end 492. Alternatively, any other
suitable dimensions and configurations can be provided. For
example, in another embodiment, the thickness of the platen spacer
490 at the end 492 can be 1.75 inches. In this other embodiment,
the thickness of the platen spacer 490 can be 1.67 inches at the
end 491 and for six feet from the end 491. Alternatively, the
platen spacer 490 can be any other suitable thicknesses. The platen
spacer 490 can also have a constant thickness along its entire
length.
[0054] In an embodiment, the spacer 490 is disposed between the top
surface 481 of the second platen 480 and the bottom surface 476 of
the first platen 470. Preferably, a plurality of bolts (not shown)
join the first platen 470, the second platen 480, and the spacer
490 through the plurality of bolt holes 494. As the spacer 490 is
attached to the first and second platens 470 and 480, the first and
second platens 470 and 480 conform to the spacer 490. Preferably,
there are two spacers 490. One spacer 490 is disposed along side
surfaces 475 and 485 and the opposite side surfaces. The spacers
490 also prevent furnish from escaping through sides of the die
400.
[0055] Preferably, the first and second platens 470 and 480 are
separated by the spacer 490. Due to the taper of the spacer 490,
the distances between the platens 470 and 480 vary, and thus, the
volume 442 of the pressing chamber 440 varies as well. In a
position proximate the input chute 410, the platens form a first
volume (not shown) of the pressing chamber 440. In a second
position proximate the output channel 420, the platens form a
second volume (not shown) of the pressing chamber 440. The first
volume is less than the second volume. Preferably, the minimum
distance between the platens 470 and 480 is 1.11 inches--the
thickness of the spacer 490 at end 491. Preferably, the maximum
distance between the platens 470 and 480 is 1.19 inches--the
thickness of the spacer 490 at end 492. Alternatively, any other
suitable distances between the platens 470 and 480 can be provided.
For example, the maximum distance between the first and second
platens 470 and 480 can be 1.75 inches. This maximum distance
between the platens 470 and 480 can be proximate the output channel
420. In another embodiment, the distance between the platens 470
and 480 can be uniform through the length of the pressing chamber
400. The furnish is compressed as it is displaced from the input
chute 410 to the output channel 420.
[0056] The first and second platens 470 and 480 include a plurality
of heating elements 450 disposed along the length of the first and
second platens 470 and 480. Each heating element 450 is formed by a
number of the plurality of match drilled holes 474 and 486.
Preferably, each heating element 450 is formed by five of the match
drilled holes 474 in the first platen 470 and five of the match
drilled holes 486 in the second platen 480. Preferably, the heating
elements 450 supply hot oil to the platens 470 and 480.
Alternatively, the heating elements 450 can be formed of any
suitable heating element, including electric resistance-type
heaters. The preferably five heating elements 450 can be controlled
with respect to temperature by increasing or decreasing the major
diameter of the match drilled holes 474 and 486. As described
above, the preferred major diameter is one inch. The heating
element 450 proximate the infeed 478 is preferably maintained at a
temperature in a range between 13 approximately 340 degrees F. and
approximately 360 degrees F. The heating element 450 proximate the
output channel 420 is preferably maintained at a temperature in a
range between approximately 360 degrees F. and 380 degrees F. The
heating elements 450 between these two extremes are maintained at a
temperature between the extremes of the temperature ranges
described above. The heating elements 450 transfer sufficient heat
to the homogenous furnish in the die 400 to vaporize water in the
furnish, i.e., to at least 212 degrees F.
[0057] The heating elements 450 shown are provided with hot oil by
a hot oil pump 452. The hot oil pump 452 preferably includes an
integral hot oil reservoir (not shown) and an integral hot oil
heater (not shown). Alternatively, the hot oil pump 452 can be
connected to a stand-alone (i.e., separate) hot oil reservoir (not
shown) and a stand-alone hot oil heater (not shown). A feed line
454 transports the hot oil to the heating elements 450 and a return
line 456 transports cooled oil to the pump 452 for re-heating and
subsequent recirculation.
[0058] In an embodiment shown in FIG. 1, the piston 430 is disposed
proximate the input chute 410 and opposite the output channel 420.
The piston 430 is positioned substantially perpendicular to the
input chute 410. Preferably, the piston 430 is powered by a
hydraulic oil pump 432. Alternatively, the piston 430 can be
powered by any other suitable means, such as pneumatic or motorized
means and exerts a force in the volume 442 of the pressing chamber
440 in a generally planar direction from the input chute 410 toward
the output channel 420. The force of the piston 430 is preferably
in a range between approximately 1000 pounds per square inch (psi)
and 2500 psi. The force of the piston 430 displaces the furnish
toward the output channel 420. Preferably, the piston 430 cycles 15
times per minute.
[0059] Referring now to FIG. 4A, a detail of an embodiment of the
piston 430 is shown. The piston 430 is connected to a ram 460.
Preferably, the piston 430 is connected to the ram 460 by a clevis
432. Alternatively, any other suitable connecting means can be
provided.
[0060] Referring now to FIG. 4B, a side view of the ram 460 is
shown. In the embodiment shown in FIG. 4B, the ram 460 is
approximately 32 inches by approximately 34 inches. Alternatively,
other suitable dimensions can be used. The ram includes an end 462
and a serrated face 464. Preferably, the serrated face 464 is
approximately 1.1 inches by approximately 34 inches. Alternatively,
any other suitable dimensions can be used. Disposed between the end
462 and the serrated face 464 is a body 466. The body 466 includes
a plurality of wear strips 468. In one embodiment, several wear
strips 468 are disposed proximate the serrated face 464. Several
other wear strips 468 are disposed perpendicular to the end 462 and
the serrated face 464. The wear strips can be attached to the face
by a plurality of fasteners (not shown). Preferably, the serrated
face 464 forms a jagged surface. Alternatively, the serrated face
464 can be a generally smooth surface.
[0061] Referring now to FIG. 4C, another side view of the ram 460
is shown. In an embodiment shown in FIG. 4C, the end 462 is formed
of two plates 463. The two plates 463 are joined to the body 466.
The two plates 463 can be joined to the body 466 by welding or by
fastening. Alternatively, the two plates 463 can be formed
integrally with the body 466. The thickness of the end 462 is
preferably two-and-one-half inches. The thickness of the body is
approximately 1.1 inches. A plurality of bushings 465 are formed or
drilled through the entire thickness of the end 462. Preferably, an
inner diameter of the bushings 465 is one-and-three-quarters inch
and an outer diameter of the bushings 465 is two-and-one quarter
inches. Alternatively, any other suitable diameters can be
provided. The plurality of bushings 465 provides a means of
attachment for the clevis 432 to couple the piston 430 and the ram
460. Thus, the force of the piston 430 is transferred to the ram
460.
[0062] The ram 460 displaces the furnish in the pressing chamber
400. The pressing chamber is formed by the first platen 470, the
second platen 480, and the platen spacer 490. The movement of the
furnish through the pressing chamber compresses the furnish to a
predetermined density. Preferably, the density of the furnish is in
a range between 27 and 36 pcf. Preferably, the ram 460 displaces
the furnish through the die at a rate of 990 pounds per hour.
Alternatively, any other suitable rate can be used.
[0063] An embodiment of the apparatus also includes a hopper 500
and a resin injector 600. The hopper 500 includes a volume 510, an
entrance 520, an exit 530, and a screw feeder 540. The volume 510
of the hopper 500 is formed by a plurality of hopper walls 550 and
holds the cellulosic material. The screw feeder 540 is disposed
proximate the exit 530 of the hopper 500. The exit 530 of the
hopper 500 is in fluid communication with the first entrance 220 of
the mixing chamber 200. The screw feeder 540 continuously
introduces the cellulosic material from the exit 530 of the hopper
500 to the first entrance 220 of the mixing chamber 200 at a rate
in a range between approximately 800 and approximately 1300 pounds
per hour. Alternatively, a faster or slower rate can be used.
[0064] An embodiment of the hopper 500 also includes a screen (not
shown) disposed in an upper portion of the hopper 500 between the
entrance 520 of the hopper and the screw feeder 540. Thus, the
screen separates the entrance 520 of the hopper 500 and the exit
530 of the hopper. Most preferably, the screen is
one-eighth-of-an-inch thick. Preferably, the screen is
three-eighths-of-an-inch thick. Alternatively, any other suitable
thickness can be used for the screen. A plurality of orifices (not
shown) is disposed in the screen. Most preferably, a diameter of
each of the orifices is one-eighth-of-an-inch, also known as U.S.
mesh #6. Preferably, the diameter of each of the orifices is
three-eighths-of-an-inch. Alternatively, any suitable diameter can
be provided. Thus, the screen prevents cellulosic material having a
diameter greater than or equal to the screen orifice diameter from
passing through the exit 530 of the hopper 500.
[0065] The resin injector 600 includes a plurality of tanks 610
holding the admixture. The tanks 610 include a thermoset polymer
tank 612, a release agent tank 614, a petroleum distillate tank
616, and a catalyst tank 618. Preferably a capacity of the
thermoset tank 612 is 3,000 gallons, a capacity of the release
agent tank 614 is 250 gallons, a capacity of the petroleum
distillate tank 616 is 1,000 gallons, and a capacity of the
catalyst tank is 250 gallons. Alternatively, any suitable number,
capacities, and configurations of tanks can be provided.
[0066] The resin injector 600 also includes a resin valve 630. The
resin valve 630 is in fluid communication with and can be disposed
proximate the second entrance 230 of the mixing chamber 200. The
resin valve 630 regulates the flow of the admixture from the tanks
610 into the mixing chamber 200. Preferably, the admixture enters
the mixing chamber 200 at a rate in a range between 0.15 and 0.35
gallons per minute. Alternatively, the admixture can enter the
mixing chamber 200 at any other suitable rate. The admixture is
sprayed onto the cellulosic material in the volume 210 of the
mixing chamber 200. Preferably, prior to entering the mixing
chamber 200, the thermoset resin, the release agent, and the
petroleum distillate are mixed in a mixing tank 620 forming a
blend. Alternatively, the thermoset resin, release agent, and
petroleum distillate can be mixed together after being introduced
into the mixing chamber 200.
[0067] A plurality of tank lines 622 provide pathways from the
plurality of tanks 610 to the mixing tank 620. Most preferably, the
thermoset polymer flows from tank 612 through tank line 622 to the
mixing tank 620 at a rate of 131 pounds per hour. Most preferably,
the release agent flows from tank 614 through tank line 622 to the
mixing tank 620 at a rate in a range between one and ten pounds per
hour. In one embodiment, the release agent flow rate can be 3.5
pounds per hour. Most preferably, the petroleum distillate flows
from tank 616 through tank line 622 at a rate of 16 pounds per
hour. Most preferably, the release agent flows from the tank 618
through tank line 622 at a rate of 4 pounds per hour.
Alternatively, any other suitable flow rates can be used.
Preferably, the blend flows from the mixing tank 620 and is
combined with the catalyst from the catalyst tank 618 in a resin
valve feed line 624 and forms the admixture. Alternatively, the
catalyst can be added directly to the mixing chamber 200 through a
separate injection port (not shown).
[0068] The embodiment shown also includes a cyclone 700. The
cyclone 700 includes an entrance 710, an exit 720, and a middle
portion 730. The middle portion 730 is disposed between the
entrance 710 and the exit 720 of the cyclone 700. The middle
portion 730 includes at least one magnet (not shown). The exit 720
of the cyclone 700 is in fluid communication with the entrance 520
of the hopper 500. Preferably, cellulosic material is introduced
into the apparatus 100 through the entrance 710 of the cyclone 700.
As the cellulosic material is directed from the entrance 710
through the middle portion 730 and to the exit 720 of the cyclone
700, the magnet removes ferrous material that is present in the
cellulosic material. The process of making the cellulosic-based
composite material will next be described.
[0069] FIG. 5 shows a flowchart of a process of using the apparatus
shown in FIG. 1 and described above. As indicated by blocks 805 and
810 in FIG. 5, the method of making a material composition shown
preferably includes mixing a thermoset polymer, petroleum
distillate, and a release agent, and with combining a catalyst to
form an admixture 815. Alternatively, the catalyst can be combined
with the cellulosic material directly. As indicated by block 820,
the admixture 815 mixes with a cellulosic material 816 in the
mixing chamber 200 to form a generally homogenous furnish 825. Most
preferably, the thermoset is present in the furnish in an amount of
6 to 10 percent by weight. Preferably, the thermoset polymer is a
melamine urea formaldehyde resin. A thermoset polymer is a polymer
that does not melt when heated after initial hardening, in contrast
to a thermoplastic polymer. Alternatively, any other suitable
thermoset can be used. In one embodiment, the chiller 250 maintains
the admixture and the cellulosic material at a temperature of 65
degrees F. In one embodiment, the petroleum distillate is
preferably an emulsified wax. Alternatively, the petroleum
distillate can be any other suitable emulsified wax. Most
preferably, the release agent is a modified fatty oil commercially
available from E.U.P. Wurtz GmbH & Co. (product No. PAT-2660).
In one embodiment, the release agent is preferably a modified fatty
oil. Release agents are also known as separators, parting agents,
or parting compounds. Other release agents that can be used are
emulsified waxes, montan waxes, and zinc sterates. Common release
agents include soft liquids, such as soap, petroleum jelly, or thin
oils. Alternatively, the release agent can be any other suitable
lubricant commonly used in extrusion of wood and plastics. In one
embodiment, the catalyst is ammonium chloride. Alternatively, the
catalyst can be any other suitable catalyst, such as ammonium
sulphate or aluminum sulphate.
[0070] In an embodiment, the cellulosic material most preferably
includes discrete wood particles. Preferably, wood fiber is not
used. Preferably, the cellulosic material can vary significantly in
size, shape, weight, moisture content, and material type.
Alternatively, the cellulosic material can be any other suitable
plant-like material. Preferably, the source of the wood particles
is from waste wood, including waste wood from manufacturing
processes, e.g., manufacturing doors. Alternatively, the wood
particles can be from any other suitable source. Preferably, a
diameter of each of the wood particles is less than
one-eighth-of-an-inch. Alternatively, the diameter of each of the
wood particles can be less than three-eighths-of-an-inch.
[0071] In an embodiment, the cellulosic material preferably is
present in the furnish in the amount of 83 to 93.5 percent by
weight. The petroleum distillate is present in the furnish in the
amount of 0 to 2 percent by weight. The release agent is present in
the furnish in the amount of 0.03 to 0.5 percent by weight. The
catalyst is present in the furnish in the amount of 0.5 to 3
percent by weight. Alternatively, any other suitable amounts for
the above can be used.
[0072] In an embodiment, the input chute 410 of the die introduces
the homogenous furnish 825 into a volume 442 of the die 400 as
indicated by block 830. Preferably, the furnish is introduced into
the die at a predetermined rate. Most preferably, the rate is 990
pounds per hour. In an embodiment, the homogenous furnish, as
indicated by block 840, is heated to a temperature of at least 212
degrees F. Preferably, the heating elements 450 of the die 400 heat
the furnish. Accordingly, the heat provided by the heating elements
vaporizes water present in the furnish. In one embodiment, the
water vapor is released from the homogenous furnish as indicated by
block 850. The structure of the heating elements and the grooves
and orifices allowing the release of the vapor in the platens is
described in detail above. Preferably, any other suitable means for
vapor release can be used.
[0073] In an embodiment, the die 400 compresses the homogenous
furnish to a uniform density in the range between approximately 27
and approximately 36 pcf, as indicated by block 860. Most
preferably, the homogenous furnish is compressed by the platens in
the die 400. Alternatively, compressing the homogenous furnish can
be performed by any other suitable means. In an embodiment, as
indicated by block 870, the force of the piston 430 continuously
displaces the homogenous furnish along the length of the die.
Alternatively, the homogenous furnish can be displaced along the
length of the die by any other suitable means. The composite
material is thus formed continuously.
[0074] The continuously formed composite material can be further
processed after it exits the output channel 420. For example, the
composite material can be sanded, shaped, and cut as desired. The
composite material can be used in a variety of applications,
including those suitable for particleboard. For example, the
composite material can be used in hollow-core or solid-core doors
for lockblocks, rails, stiles, and the like.
[0075] An exemplary embodiment of an application for the
composition described above is shown in FIG. 6. A hollow paneled
door 900 includes a front-facing outer skin 910 with a series of
molded panels 912 and a rear-facing outer skin (not shown).
Preferably, the frontfacing outer skin 910 and the rear-facing
outer skin are adhered together by a top rail 920, a bottom rail
922, a latch stile 930, and a hinge stile 932, all of which are
indicated in dotted line.
[0076] Also shown in dotted line is a lockblock 940. The lockblock
940 is produced by the apparatus and the method described above.
Preferably, the lockblock 940 is adhered to the latch stile 930.
Alternatively, the lockblock 940 can be joined to the latch stile
930 by any other suitable means, such as by using a threaded
fastener. A through hole 950 for seating a latch set (not shown)
extends through the front-facing outer skin 910 and the rear-facing
outer skin and the lockblock 940. The lockblock 940 provides a
surface for adhering the front-facing exterior skin 910 and the
rear-facing exterior skin. The lockblock 940 further provides
reinforcement for the latch set and the door 900. While dimensions
for the lockblock 940 can vary, the preferred dimensions for the
lockblock 940 are three inches by six-and-three-quarters of an inch
by one-and-one-eighth of an inch. Alternatively, the dimensions of
the lockblock can be three inches by sixteen inches by
one-and-one-eighth of an inch.
[0077] Most preferably, the top rail 920, the bottom rail 922, the
latch stile 930, the hinge stile 932, and the lockblock 940 are
made of the disclosed composite material. Most preferably, the
composite material is made in accordance with the disclosed system
and method. Alternatively, any other suitable system and method can
be used to produce the disclosed composite material for use in a
hollow paneled door.
[0078] While the present invention has been disclosed with
reference to certain embodiments, numerous modifications,
alterations, and changes to the described embodiments are possible
without departing from the sphere and scope of the present
invention, as defined in the appended claims. Accordingly, it is
intended that the present invention not be limited to the described
embodiments, but that it has the full scope defined by the language
of the following claims, and equivalents thereof.
* * * * *