Cellulosic composite component
View Patent ↗A component such as a siding panel comprised of a PVC/wood flour composite. Another embodiment is a component such as a siding panel that is made from a PVC/CPE/wood flour composite. The cellulosic composite may be extruded through a die and then bent into the shape of the component. Optionally, a reinforcement backer (e.g., an expanded polystyrene foam panel) may be adhered to the cellulosic composite siding.
1. A siding panel made from a composite material, said composite material comprising:
cellulosic filler in an amount of about 15 to about 35% by weight of said composite material;
PVC resin in an amount of about 20 to about 70% by weight of said composite material; and
chlorinated polyethylene in an amount not exceeding about 40% by weight of said composite material.
2. The siding panel of claim 1 wherein the thickness of said siding panel is between about 0.050 and about 0.075 inch.
3. The siding panel of claim 1 wherein said cellulosic filler is at least about 40 mesh wood flour.
4. The siding panel of claim 1 wherein said cellulosic filler is in an amount of about 20 to about 30% by weight of said composite material.
5. The siding panel of claim 4 wherein said cellulosic filler is in an amount of about 25% by weight of said composite material.
6. The siding panel of claim 1 wherein said PVC resin is in an amount of about 30 to about 60% by weight of said composite material.
7. The siding panel of claim 6 wherein said PVC resin is in an amount of about 40 to about 50% by weight of said composite material.
8. The siding panel of claim 2 wherein said stabilizer is in an amount of about 1 to about 3% by weight of said composite material.
9. The siding panel of claim 2 wherein said lubricant is in an amount of about 2.5 to about 5% by weight of said composite material.
10. The siding panel of claim 2 wherein said process aid is in an amount of about 1 to about 3% by weight of said composite material.
11. The siding panel of claim 1 wherein said chlorinated polyethylene is in an amount of about 5 to about 30% by weight of said composite material.
12. The siding panel of claim 11 wherein said chlorinated polyethylene is in an amount of about 10 to about 20% by weight of said composite material.
13. The siding panel of claim 1 wherein said composite material further comprises inorganic filler in an amount up to about 15% by weight of said composite material.
14. The siding panel of claim 13 wherein said inorganic filler is in an amount of about 2 to about 10% by weight of said composite material.
15. The siding panel of claim 1 further comprising a reinforcement backer secured to said composite material.
16. The siding panel of claim 15 wherein said reinforcement backer is comprised of extruded or expanded polystyrene foam.
17. The siding panel of claim 15 wherein said reinforcement backer is secured to said composite material by an adhesive selected from the group consisting of neoprene, urethanes, and pressure sensitive hot melt adhesives.
18. A component made from a composite material, said composite material comprising:
cellulosic filler in an amount of about 20 to about 30% by weight of said composite material;
PVC resin in an amount of about 30 to about 60% by weight of said composite material;
chlorinated polyethylene in an amount of about 5 to about 30% by weight of said composite material; and
inorganic filler in an amount not exceeding about 15% by weight of said composite material.
19. The component of claim 18 wherein said PVC resin is in an amount of about 40 to about 50% by weight of said composite material.
20. The component of claim 18 wherein said chlorinated polyethylene is in an amount of about 10 to about 20% by weight of said composite material.
21. The component of claim 18 wherein said inorganic filler is in an amount of about 2 to about 10% by weight of said composite material.
22. The component of claim 18 wherein said component is selected from the group consisting of siding panels, siding accessories, interior and exterior decorative house moldings, picture frames, furniture components, deck components, deck railings, window moldings, window components, window lineals, door components, roof components, fence components, fence posts, fence rails, and floor components.
23. The component of claim 18 wherein said component is made by a process selected from the group consisting of extrusion, compression molding, and injection molding.
24. A component made from a composite material, said composite material comprising:
cellulosic filler in an amount of about 20 to about 30% by weight of said composite material; and
an alloy in an amount of about 70 to about 80% by weight of said composite material, said alloy comprising PVC and chlorinated polyethylene;
wherein said chlorinated polyethylene is in an amount of about 5 to about 30% by weight of said composite material.
25. The component of claim 24 wherein said chlorinated polyethylene is in an amount of about 10 to about 20% by weight of said composite material.
26. The component of claim 24 further comprising a reinforcement backer secured to said composite material.
27. The component of claim 24 wherein said component is selected from the group consisting of siding panels, siding accessories, interior and exterior decorative house moldings, picture frames, furniture components, deck components, deck railings, window moldings, window components, window lineals, door components, roof components, fence components, fence posts, fence rails, and floor components.
28. The component of claim 26 wherein said component is made by a process selected from the group consisting of extrusion, compression molding, and injection molding.
29. The siding panel of claim 1 wherein said composite material further comprises:
stabilizer in an amount of about 0.5 to about 4% by weight of said composite material;
lubricant in an amount of about 1 to about 8% by weight of said composite material; and
process aid in an amount of about 0.5 to about 5% by weight of said composite material.
30. The component of claim 18 wherein said composite material further comprises:
stabilizer in an amount of about 1 to about 3% by weight of said composite material;
lubricant in an amount of about 2.5 to about 5% by weight of said composite material; and
process aid in an amount of about 1 to about 3% by weight of said composite material.
31. A component made from a composite material, said composite material comprising:
cellulosic filler in an amount of about 15 to about 35% by weight of said composite material; and
an alloy in an amount of about 65 to about 85% by weight of said composite material, said alloy comprising PVC and chlorinated polyethylene;
wherein said chlorinated polyethylene is in an amount of about 5 to about 40% by weight of said composite material.
32. The component of claim 31 wherein said chlorinated polyethylene is in an amount of about 5 to about 30% by weight of said composite material.
33. The component of claim 32 wherein said chlorinated polyethylene is in an amount of about 10 to about 20% by weight of said composite material.
34. The component of claim 31 further comprising a reinforcement backer secured to said composite material.
35. The component of claim 31 wherein said component is a siding panel.
36. The component of claim 31 wherein the thickness of said component is between about 0.050 and about 0.075 inch.
37. The component of claim 31 wherein said cellulosic filler is in an amount of about 20 to about 30% by weight of said composite material.
38. The component of claim 31 wherein said PVC is in an amount of about 20 to about 70% by weight of said composite material.
39. The component of claim 38 wherein said PVC is in an amount of about 30 to about 60% by weight of said composite material.
40. The component of claim 39 wherein said PVC is in an amount of about 40 to about 50% by weight of said composite material.