Composite Building Materials and Methods of Manufacture

A composite building material includes carpet waste having carpet fibers and adhesive, and an inorganic filler that includes fly ash. The composite building material may be produced by providing the carpet waste, mixing the carpet waste with the inorganic filler to produce a homogeneous blend, and forming the homogeneous blend into the composite building material. The composite building material may optionally include a base polymer, slack wax, and/or calcium carbonate.

Carpet Waste Composite

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material. 127-. (canceled)28. A composite building material comprising:a first layer comprising a first carpet waste, a first binding agent, and an inorganic filler in addition to any filler present in the first carpet waste; anda second layer disposed on the first layer, the second layer comprising a second carpet waste, a second binding agent, and a colorant.29. The composite building material of claim 28 , wherein at least one of the first carpet waste and the second carpet waste comprises a processed carpet waste comprising a reduced amount of inorganic filler relative to an amount present within an unprocessed carpet waste.30. The composite building material of claim 28 , wherein the first binding agent and the second binding agent are each selected from the group consisting of methylenediphenyldiisocyanate (MDI) claim 28 , urea formaldehyde (UF) claim 28 , melamine urea formaldehyde (MUF) claim 28 , and phenol formaldehyde (PF).31. The composite building material of claim 28 , wherein at least one of the first binding agent and the second binding agent comprises methylenediphenyldiisocyanate (MDI) and water.32. The composite building material of claim 28 , wherein the first layer further comprises natural fibers.33. The composite building material of claim 28 , further comprising at least one of a patterned surface claim 28 , a cover layer claim 28 , and a sanded surface.34. The composite building material of claim 33 , wherein the patterned surface comprises at least one of a molded surface claim 33 ...

CARPET WASTE COMPOSITE

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material. 127-. (canceled)28. A composite building material , comprising:a first layer comprising a carpet waste, a first binding agent, and an inorganic filler in addition to any filler present in the carpet waste; anda second layer disposed on the first layer and comprising natural fibers and a second binding agent.29. The composite building material of claim 28 , wherein the first binding agent comprises methylenediphenyldiisocyanate (MDI).30. The composite building material of claim 28 , wherein the first binding agent comprises a product of a reaction involving methylenediphenyldiisocyanate (MDI).31. The composite building material of claim 28 , wherein the second binding agent comprises phenol formaldehyde (PF).32. The composite building material of claim 28 , wherein the second binding agent comprises a product of a reaction involving phenol formaldehyde (PF).33. The composite building material of claim 28 , wherein the carpet waste comprises carpet fibers having a length from about 0.25 inches to about 1.0 inch.34. The composite building material of claim 28 , wherein the carpet waste comprises carpet fibers having a length of about 1.0 inch.35. The composite building material of claim 28 , further comprising at least one of a patterned surface claim 28 , a cover layer claim 28 , or a sanded surface.36. The composite building material of claim 35 , wherein the patterned surface comprises at least one of a molded surface claim 35 , an embossed surface claim 35 , a colored surface claim 35 , or a wood ...

WOOD-PLASTIC COMPOSITES UTILIZING IONOMER CAPSTOCKS AND METHODS OF MANUFACTURE

An extruded composite adapted for use as a building material includes a core having a base polymer and a natural fiber in a substantially homogeneous mixture and an ionomer capstock. To improve adherence of the ionomer to a base polymer, the ionomer can be mixed with a similar or substantially similar base polymer prior to coextrusion with the core. Additionally, various additives may be mixed with the capstock material to improve visual aesthetics of the product and performance of the building material, especially over time. 131-. (canceled)32. A coextruded composite adapted for use as a building material , the coextruded composite comprising:a core comprising a base polymer and a natural fiber in a substantially homogeneous mixture; anda capstock consisting essentially of an ionomer, a capstock polymer different from the ionomer, and at least one additive selected from the group consisting of colorants, adhesion promoters, antistatic additives, UV stabilizers, antioxidants, biocides, fire retardants, lubricants, flame retardants, mold inhibitors, compatiblizers, and coupling agents, in a substantially homogeneous mixture,wherein the capstock polymer is present in the capstock in an amount from 72.5% to 99%, by weight.33. The coextruded composite of claim 32 , wherein the base polymer and the capstock polymer each is selected from the group consisting of polypropylene claim 32 , polyethylene claim 32 , and combinations thereof.34. The coextruded composite of claim 33 , wherein the polyethylene is selected from the group consisting of HDPE claim 33 , MDPE claim 33 , LDPE claim 33 , LLDPE claim 33 , and combinations thereof.35. The coextruded composite of claim 32 , wherein the base polymer comprises a first polymer and the capstock polymer comprises the first polymer.36. The coextruded composite of claim 32 , wherein the core is characterized by an absence of ionomer.37. The coextruded composite of claim 32 , wherein the core comprises 1% to 100% base polymer claim ...

Carpet waste composite

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material.

Carpet waste composite

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material.

Carpet waste composite

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material.

Wood-Plastic Composites Using Recycled Carpet Waste and Systems and Methods of Manufacturing

An extruded composite utilized as a building material includes a base polymer, unseparated processed recycled carpet waste, and a filler material, which may be a wood filler or other natural fiber. The recycled carpet waste may be used to decrease the amount of both base polymer and wood filler to achieve an equivalent product at lower cost. The extruded composite may also utilize chemical foaming agents to reduce density. Both foamed and non-foamed composites may be capstocked.

Carpet Waste Composite

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material.

CARPET WASTE COMPOSITE

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material.

Wood-plastic composites utilizing ionomer capstocks and methods of manufacture

An extruded composite adapted for use as a building material includes a core having a base polymer and a natural fiber in a substantially homogeneous mixture and an ionomer capstock. To improve adherence of the ionomer to a base polymer, the ionomer can be mixed with a similar or substantially similar base polymer prior to coextrusion with the core. Additionally, various additives may be mixed with the capstock material to improve visual aesthetics of the product and performance of the building material, especially over time.

Plastic Composites Using Recycled Carpet Waste and Systems and Methods of Recycling Carpet Waste

An extruded composite utilized as a building material includes a base polymer, unseparated processed recycled carpet waste, and a filler material, which may be a wood filler or other natural fiber. Carpet waste may be separated into components that may be utilized in a variety of plastics applications, including extruded composites utilized as building materials. Separation may include shaving face fiber from bound fiber secured in a backing fiber and/or may include separating fiber pile and backing fibers from carpet adhesive to remove inorganic materials such as calcium carbonate.

Foil or film laminated enhanced natural fiber/polymer composite

A natural fiber/polymer composite product that includes a core (preferably with a textured surface) and a film or pigment surface layer applied to that textured core surface. The core comprises at least one natural fiber and at least one polymer intimately admixed together to form a composite.

Carpet waste composite

A composite material produced from carpet waste and a binding agent, in intimate association, which material includes 25% and 99% carpet waste and between 1 and 25% binding agent. A method for manufacturing the composite material is also disclosed.

Carpet waste composite

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material.

Carpet waste composite

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material.

Multi-color fiber-plastic composites and systems and methods for their fabrication

This invention relates to methods and systems for forming composite extrudates including at least a base polymer, a plurality of fibers dispersed in the base polymer, and one or more colorants forming a visible, multi-color pattern, e.g., mimicking the appearance of natural wood.

Carpet waste composite

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material.

Carpet waste composite

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material.

CARPET WASTE COMPOSITE

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material. 127-. (canceled)28. A composite building material , comprising: a processed carpet waste comprising a reduced amount of inorganic filler relative to an amount present within an unprocessed carpet waste; and', 'a first binding agent in intimate association with the processed carpet waste; and, 'a first layer comprisinga second layer disposed on the first layer and comprising natural fibers and a second binding agent.29. The composite building material of claim 28 , wherein the first binding agent comprises at least one of methylenediphenyldiisocyanate (MDI) or a product of a reaction involving methylenediphenyldiisocyanate (MDI).30. The composite building material of claim 28 , wherein the second binding agent comprises at least one of phenol formaldehyde (PF) or a product of a reaction involving phenol formaldehyde (PF).31. The composite building material of claim 28 , wherein the carpet waste comprises carpet fibers having a length from about 0.25 inches to about 1.0 inch.32. The composite building material of claim 28 , wherein the carpet waste comprises carpet fibers having a length of about 1.0 inch.33. The composite building material of claim 28 , further comprising at least one of a patterned surface claim 28 , a cover layer claim 28 , or a sanded surface.34. The composite building material of claim 35 , wherein the patterned surface comprises at least one of a molded surface claim 35 , an embossed surface claim 35 , a colored surface claim 35 , or a wood grain pattern.35. The composite ...

Wood-plastic composites utilizing ionomer capstocks and methods of manufacture

An extruded composite adapted for use as a building material includes a core having a base polymer and a natural fiber in a substantially homogeneous mixture and an ionomer capstock. To improve adherence of the ionomer to a base polymer, the ionomer can be mixed with a similar or substantially similar base polymer prior to coextrusion with the core. Additionally, various additives may be mixed with the capstock material to improve visual aesthetics of the product and performance of the building material, especially over time.

Wood-Plastic Composites Utilizing Ionomer Capstocks and Methods of Manufacture

An extruded composite adapted for use as a building material includes a core having a base polymer and a natural fiber in a substantially homogeneous mixture and an ionomer capstock. To improve adherence of the ionomer to a base polymer, the ionomer can be mixed with a similar or substantially similar base polymer prior to coextrusion with the core. Additionally, various additives may be mixed with the capstock material to improve visual aesthetics of the product and performance of the building material, especially over time.

Carpet waste composite

A composite material produced from carpet waste and a binding agent, in intimate association, which material includes 25% and 99% carpet waste and between 1 and 25% binding agent. A method for manufacturing the composite material is also disclosed.

Baluster connector

Composites Utilizing Polymeric Capstocks and Methods of Manufacture

An extruded composite adapted for use as a building material includes a core having a base polymer and a filler material in a substantially homogeneous mixture and a polymeric capstock modified with an elastomer and/or a plastomer. To improve adherence of the polymeric capstock to the base polymer, the capstock can include a capstock polymer that is similar or substantially similar the base polymer. Additionally, various additives may be mixed with the capstock material to improve visual aesthetics of the product and performance of the building material, especially over time.

CARPET WASTE COMPOSITE

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material. 127-. (canceled)28. A composite board comprising:a substantially homogeneous mixture comprising a carpet waste, an inorganic filler in addition to any filler present in the carpet waste, and a binding agent; anda cover layer disposed on at least a portion of the substantially homogeneous mixture, the cover layer comprising a patterned surface.29. The composite board of claim 28 , wherein the carpet waste comprises at least one of nylon claim 28 , polyester claim 28 , and polypropylene.30. The composite board of claim 28 , wherein the carpet waste comprises polyester.31. The composite board of claim 28 , wherein the binding agent comprises at least one of methylenediphenyldiisocyanate (MDI) claim 28 , urea formaldehyde (UF) claim 28 , melamine urea formaldehyde (MUF) claim 28 , and phenol formaldehyde (PF).32. The composite board of claim 28 , wherein the binding agent comprises methylenedipheyldiisocyanate (MDI) claim 28 , and wherein MDI is present in the mixture in an amount from about 2% to about 20% by weight.33. The composite board of claim 28 , wherein the mixture further comprises an additive selected from the group consisting of a colorant claim 28 , a fire retardant claim 28 , a fiberglass claim 28 , a mold inhibitor claim 28 , and combinations thereof.34. The composite board of claim 28 , wherein the mixture further comprises natural fibers selected from the group consisting of wood chips claim 28 , wood flour claim 28 , wood flakes claim 28 , sawdust claim 28 , flax claim 28 , jute ...

Carpet waste composite

A composite material produced from carpet waste and a binding agent, in intimate association, which material includes 25% and 99% carpet waste and between 1 and 25% binding agent. A method for manufacturing the composite material is also disclosed.

RAILING SYSTEM AND COUPLING ELEMENT AND METHODS OF ASSEMBLY

A connector for attaching a hollow baluster to a hollow rail in an extruded railing system includes two sections. A plug portion is adapted to be received in an end of the hollow baluster. A projection is adapted to be received in an aperture formed through a wall of the hollow rail. The projection may include a resilient tab configured to engage an interior surface of the hollow rail when received therein. In one embodiment, the plug portion and projection have axes that are not collinear and form an included angle. An outer taper of the plug portion allows for installation in stairway railing systems having ramp angles that deviate from the nominal.

Carpet Waste Composite

A composite material is produced from carpet waste and a binding agent, in intimate association, and may also include wood fiber or chips and/or other additives. A method of manufacturing a composite material includes shredding carpet waste, coating the carpet waste with a binding agent, and subjecting the shredded, coated carpet waste to elevated heat and pressure. As an additional step, the composite material may be actively cooled to prevent deformation of the material.

Systems and Methods for Generating Surface Patterns on Composite Building Materials

Systems and methods are described for generating surface patterns on composite building materials. An example method includes: providing a base polymer; providing a natural fiber; mixing and heating the base polymer and the natural fiber to produce a base mixture including a substantially homogeneous melt blend; extruding the blend through a die to form an extruded profile; and dispensing a pigment from a micro-extruder onto a surface of the extruded profile to form a colored surface pattern. 1. A method of manufacturing an extruded composite building material , the method comprising the steps of:providing a base polymer;providing a natural fiber;mixing and heating the base polymer and the natural fiber to produce a base mixture comprising a substantially homogeneous melt blend;extruding the blend through a die to form an extruded profile; anddispensing a pigment from a micro-extruder onto a surface of the extruded profile to form a colored surface pattern.2. The method of claim 1 , wherein the micro-extruded pigment is dispensed onto the surface when the extruded profile is in a molten state.3. The method of claim 1 , wherein dispensing the pigment comprises moving the micro-extruder relative to the extruded profile.4. The method of claim 1 , wherein dispensing the pigment comprises varying a flowrate of the pigment from the micro-extruder.5. The method of claim 1 , wherein the colored surface pattern comprises a line having a directional component perpendicular to an extruded length of the extruded profile.6. The method of claim 1 , further comprising:providing an image of a desired colored surface pattern; andreproducing the desired colored surface pattern on the extruded profile, using the pigment.7. The method of claim 1 , wherein the pigment comprises a blend of a colorant and a carrier polymer.8. The method of claim 7 , wherein the carrier polymer and the base polymer comprise the same polymer.9. The method of claim 8 , wherein the same polymer is selected ...

Composites utilizing polymeric capstocks and methods of manufacture

An extruded composite adapted for use as a building material includes a core having a base polymer and a filler material in a substantially homogeneous mixture and a polymeric capstock modified with an elastomer and/or a plastomer. To improve adherence of the polymeric capstock to the base polymer, the capstock can include a capstock polymer that is similar or substantially similar the base polymer. Additionally, various additives may be mixed with the capstock material to improve visual aesthetics of the product and performance of the building material, especially over time.

Wood-plastic composites using recycled carpet waste and methods of manufacturing

Plastic composites using recycled carpet waste and systems and methods of recycling carpet waste

An extruded composite utilized as a building material includes a base polymer, unseparated processed recycled carpet waste, and a filler material, which may be a wood filler or other natural fiber. Carpet waste may be separated into components that may be utilized in a variety of plastics applications, including extruded composites utilized as building materials. Separation may include shaving face fiber (402) from bound fiber (406) secured in a backing fiber (408) and/or may include separating fiber pile and backing fibers from carpet adhesive (410) to remove inorganic materials such as calcium carbonate.

Composite building materials and methods of manufacture

A composite building material includes carpet waste having carpet fibers and adhesive, and an inorganic filler that includes fly ash. The composite building material may be produced by providing the carpet waste, mixing the carpet waste with the inorganic filler to produce a homogeneous blend, and forming the homogeneous blend into the composite building material. The composite building material may optionally include a base polymer, slack wax, and/or calcium carbonate.

Multi-color fiber-plastic composites and systems and methods for their fabrication

This invention relates to methods and systems for forming composite extrudates including at least a base polymer, a plurality of fibers dispersed in the base polymer, and one or more colorants forming a visible, multi-color pattern, e.g., mimicking the appearance of natural wood.

Wood-plastic composites using recycled carpet waste and systems and methods of manufacturing

An extruded composite utilized as a building material includes a base polymer, unseparated processed recycled carpet waste, and a filler material, which may be a wood filler or other natural fiber. The recycled carpet waste may be used to decrease the amount of both base polymer and wood filler to achieve an equivalent product at lower cost. The extruded composite may also utilize chemical foaming agents to reduce density. Both foamed and non- foamed composites may be capstocked.

Wood-plastic composites utilizing ionomer capstocks and methods of manufacture

Foil or film laminated enhanced natural fiber/polymer composite

A natural fiber/polymer composite product that includes a core (preferably with a textured surface) and a film or pigment surface layer applied to that textured core surface. The core comprises at least one natural fiber and at least one polymer intimately admixed together to form a composite.

Carpet waste composite

Plastic composites using recycled carpet waste and systems and methods of recycling carpet waste

An extruded composite utilized as a building material includes a base polymer, unseparated processed recycled carpet waste, and a filler material, which may be a wood filler or other natural fiber. Carpet waste may be separated into components that may be utilized in a variety of plastics applications, including extruded composites utilized as building materials. Separation may include shaving face fiber (402) from bound fiber (406) secured in a backing fiber (408) and/or may include separating fiber pile and backing fibers from carpet adhesive (410) to remove inorganic materials such as calcium carbonate.

Composites utilizing polymeric capstocks and methods of manufacture

An extruded composite adapted for use as a building material includes a core having a base polymer and a filler material in a substantially homogeneous mixture and a polymeric capstock modified with an elastomer and/or a plastomer. To improve adherence of the polymeric capstock to the base polymer, the capstock can include a capstock polymer that is similar or substantially similar the base polymer. Additionally, various additives may be mixed with the capstock material to improve visual aesthetics of the product and performance of the building material, especially over time.

Carpet waste composite

A composite material produced from carpet waste and a binding agent, in intimate association, which material includes 25% and 99% carpet waste and between 1 and 25% binding agent. A method for manufacturing the composite material is also disclosed.

Carpet waste composite

A composite material produced from carpet waste and a binding agent, in intimate association, which material includes 25% and 99% carpet waste and between 1 and 25% binding agent. A method for manufacturing the composite material is also disclosed.

Foil or film laminated enhanced natural fiber/polymer composite

A natural fiber/polymer composite product that includes a core (preferably with a textured surface) and a film or pigment surface layer applied to that textured core surface. The core comprises at least one natural fiber and at least one polymer intimately admixed together to form a composite.

Composite building materials and methods of manufacture

An example composite building material includes one or more layers of polymeric fibers, binding agent, and optional fillers, and at least one surface layer of resin-impregnated paper or a fiberglass film disposed above and/or below the one or more layers. The one or more layers can include a core layer with longer polymeric fibers and top and bottom layers with shorter polymeric fibers. A method of manufacturing the composite building material includes forming the one or more layers, applying the at least one surface layer above and/or below the one or more layers, and heating and pressing the combined layers.

Composite building materials and methods of manufacture

An example composite building material includes one or more layers of polymeric and/or glass fibers, binding agent, and optional fillers. At least one surface layer of resin-impregnated paper or a fiberglass film can be disposed above and/or below the one or more layers. The one or more layers can include a core layer (e.g., with longer polymeric fibers) and a top layer (e.g., with shorter polymeric fibers). An example method of manufacturing the composite building material includes forming the one or more layers, applying the at least one surface layer above and/or below the one or more layers, and heating and pressing the combined layers.