Claims
- 1. A composite comprising:
a fiber having a lumen with voids; a suspension drawn into the lumen to beneficiate the fiber; and a polymeric material imbedded with the fiber; whereby the natural voids of the lumen are preserved by the suspension causing the fiber to maintain natural density and strength characteristics.
- 2. The composite of claim 1 wherein the suspension includes a chemical blowing agent.
- 3. The composite of claim 2 wherein the chemical blowing agent is exothermic.
- 4. The composite of claim 3 wherein the chemical blowing agent is azodicarbonamide.
- 5. The composite of claim 3 wherein the chemical blowing agent is a hydrazine derivative.
- 6. The composite of claim 1 wherein the suspension includes a carrier.
- 7. The composite of claim 6 wherein the carrier is a film-forming thermoplastic selected from the group of acrylics, epoxies, phenolics, melamines and vinyls.
- 8. The composite of claim 6 wherein the carrier is a film-forming thermosetting polymer.
- 9. The composite of claim 1 wherein the suspension includes a catalyst.
- 10. The composite of claim 9 wherein the catalyst is selected from the group of calcium carbonate, and compounds of cadmium, zinc, barium, calcium, strontium, magnesium, lead, tin or silicon.
- 11. The composite of claim 1 wherein approximately 1-10 parts of the suspension are mixed with approximately 100 parts of the fiber.
- 12. The composite of claim 1 wherein the fiber is a bast fiber.
- 13. The composite of claim 12 wherein the fiber is flax.
- 14. The composite of claim 12 wherein the fiber is hemp.
- 15. The composite of claim 12 wherein the fiber is jute.
- 16. The composite of claim 12 wherein the fiber is coir.
- 17. The composite of claim 12 wherein the fiber is kenaf.
- 18. The composite of claim 12 wherein the fiber is ramie.
- 19. The composite of claim 1 wherein the fiber is a wood fiber.
- 20. The composite of claim 1 wherein the fiber is a wheat fiber.
- 21. The composite of claim 1 wherein the fiber is a straw fiber.
- 22. The composite of claim 1 wherein the fiber is a lingo-cellulosic fiber.
- 23. The composite of claim 1 comprising approximately 25% to 99% of the polymeric material.
- 24. The composite of claim 23 wherein the polymeric material is a polyvinyl chloride foam.
- 25. The composite of claim 23 wherein the polymeric material is a polyolefin.
- 26. The composite of claim 25 wherein the polymeric material is polyethylene.
- 27. The composite of claim 23 wherein the polymeric material is polypropylene.
- 28. The composite of claim 23 wherein the polymeric material is a cellulosic.
- 29. The composite of claim 23 wherein the polymeric material is a vinyl.
- 30. The composite of claim 23 wherein the polymeric material is an acrylic.
- 31. The composite of claim 23 wherein the polymeric material is a urethane.
- 32. The composite of claim 23 wherein the polymeric material is a styrenic.
- 33. The composite of claim 1 further comprising at least one additive that is adsorbed onto a surface of the fiber.
- 34. The composite of claim 33 wherein the least one additive that is a coloring agent.
- 35. The composite of claim 33 wherein the least one additive that is a stabilizer.
- 36. The composite of claim 33 wherein the least one additive that is an antioxidant.
- 37. The composite of claim 33 wherein the least one additive that is a filler.
- 38. The composite of claim 33 wherein the least one additive that is an extender.
- 39. The composite of claim 33 wherein the least one additive that is a wetting agent.
- 40. The composite of claim 33 wherein the least one additive that is a bonding agent.
- 41. The composite of claim 33 wherein the least one additive that is an impact modifier.
- 42. The composite of claim 1 wherein the composite is formed into a composite structural member.
- 43. The composite of claim 42 wherein the composite structural member is a decking board.
- 44. The composite of claim 42 wherein the composite structural member is an exterior trim profile.
- 45. The composite of claim 42 wherein the composite structural member is a railing.
- 46. The composite of claim 42 wherein the composite structural member is a gazebo component.
- 47. The composite of claim 42 wherein the composite structural member is a cladding member.
- 48. The composite of claim 42 wherein the composite structural member is a molding.
- 49. The composite of claim 42 wherein the composite structural member is a door jam.
- 50. The composite of claim 42 wherein the composite structural member is a siding member.
- 51. The composite of claim 42 wherein the composite structural member is a window profile.
- 52. The composite of claim 42 wherein the composite structural member is formed by extruding the composite.
- 53. The composite of claim 52 wherein the composite structural member is further formed be thermoforming.
- 54. The composite of claim 42 wherein the composite structural member is formed by injection molding.
- 55. A method for making a beneficiated fiber comprising:
mixing a suspension with a fiber to form a homogeneous mixture; drawing the suspension into a lumen of the fiber by a capillary action to beneficiate the fiber; and cooling the beneficiated fiber.
- 56. The method of claim 55 further comprising fluffing the beneficiated fiber.
- 57. The method of claim 55 wherein the fiber is a bast fiber.
- 58. The method of claim 55 wherein the suspension includes a carrier, a chemical blowing agent and a catalyst.
- 59. The method of claim 58 wherein approximately 1-10 parts of the suspension are mixed with approximately 100 parts of the fiber.
- 60. The method of claim 55 further comprising adsorbing an additive selected from the group of coloring agents, stabilizers, antioxidants, fillers, extenders, wetting agents, bonding agents and impact modifiers onto a surface of the fiber.
- 61. The method of claim 60 wherein the additives are adsorbed onto the surface of the fiber by mixing at a temperature of approximately 350-500 degrees Fahrenheit.
- 62. The method of claim 55 wherein the suspension in drawn into the lumen of the fiber by a continuous kneader/mixer
- 63. The method of claim 62 wherein the kneader/mixer is at a temperature of approximately 200-350 degrees Fahrenheit.
- 64. The method of claim 55 further comprising mixing the beneficiated fiber with a melted polymeric material forming a composite.
- 65. The method of claim 64 further comprising extruding the beneficiated fiber and the polymeric material to form a composite structural member.
- 66. The method of claim 65 further comprising extruding the beneficiated fiber into a sheet.
- 67. The method of claim 66 further comprising thermoforming the sheet.
- 68. The method of claim 64 further comprising the step of injection molding the beneficiated fiber and polymeric material to form a composite structural member.
- 69. A beneficiated fiber comprising:
a fiber having a lumen with voids; and a suspension drawn into the lumen to beneficiate the fiber; whereby the natural voids of the lumen are preserved by the suspension causing the fiber to maintain natural density and strength characteristics.
- 70. The beneficiated fiber of claim 69 wherein the suspension includes a chemical blowing agent, a carrier, and a catalyst.
- 71. The beneficiated fiber of claim 70 wherein approximately 1-10 parts of the suspension are mixed with approximately 100 parts of the fiber.
- 72. The beneficiated fiber of claim 70 wherein the chemical blowing agent is exothermic.
- 73. The beneficiated fiber of claim 71 wherein the chemical blowing agent is azodicarbonamide.
- 74. The beneficiated fiber of claim 71 wherein the chemical blowing agent is a hydrazine derivative.
- 75. The beneficiated fiber of claim 70 wherein the carrier is a film-forming thermoplastic selected from the group of acrylics, epoxies, phenolics, melamines and vinyls.
- 76. The beneficiated fiber of claim 70 wherein the carrier is a film-forming thermosetting polymer.
- 77. The beneficiated fiber of claim 70 wherein the catalyst is selected from the group of calcium carbonate, and compounds of cadmium, zinc, barium, calcium, strontium, magnesium, lead, tin or silicon.
- 78. The beneficiated fiber of claim 69 wherein the fiber is a bast fiber.
- 79. The beneficiated fiber of claim 78 wherein the fiber is flax.
- 80. The beneficiated fiber of claim 78 wherein the fiber is hemp.
- 81. The beneficiated fiber of claim 78 wherein the fiber is jute.
- 82. The beneficiated fiber of claim 78 wherein the fiber is coir.
- 83. The beneficiated fiber of claim 78 wherein the fiber is kenaf.
- 84. The beneficiated fiber of claim 78 wherein the fiber is ramie.
- 85. The beneficiated fiber of claim 69 wherein the fiber is a wood fiber.
- 86. The beneficiated fiber of claim 69 wherein the fiber is a wheat fiber.
- 87. The beneficiated fiber of claim 69 wherein the fiber is a straw fiber.
- 88. The beneficiated fiber of claim 69 wherein the fiber is a lingo-cellulosic fiber.
- 89. The beneficiated fiber of claim 69 further comprising at least one additive that is adsorbed onto a surface of the fiber.
- 90. The beneficiated fiber of claim 89 wherein the least one additive that is a coloring agent.
- 91. The beneficiated fiber of claim 89 wherein the least one additive that is a stabilizer.
- 92. The beneficiated fiber of claim 89 wherein the least one additive that is an antioxidant.
- 93. The beneficiated fiber of claim 89 wherein the least one additive that is a filler.
- 94. The beneficiated fiber of claim 89 wherein the least one additive that is an extender.
- 95. The beneficiated fiber of claim 89 wherein the least one additive that is a wetting agent.
- 96. The beneficiated fiber of claim 89 wherein the least one additive that is a bonding agent.
- 97. The beneficiated fiber of claim 89 wherein the least one additive that is an impact modifier.
- 98. The beneficiated fiber of claim 89 wherein the additive is adsorbed onto the surface of the fiber by mixing.
- 99. The beneficiated fiber of claim 90 wherein the additive is adsorbed onto the surface of the fiber by mixing at a temperature of approximately 350-500 degrees Fahrenheit.
- 100. The beneficiated fiber of claim 69 wherein the fiber is beneficiated at a temperature of approximately 200-350 degrees Fahrenheit.
Parent Case Info
[0001] This application is a continuation-in-part of application Ser. No. 10/269,051, filed Oct. 10, 2002.
Continuation in Parts (1)
|
Number |
Date |
Country |
Parent |
10269051 |
Oct 2002 |
US |
Child |
10684117 |
Oct 2003 |
US |