System and method for making extruded, composite material
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.