Starch-plastic composite resins and profiles made by extrusion
First Claim
Patent Images
1. A manufactured product for use as a wood substitute, comprising:
- from 20-80% by weight starch;
from 0.5-4% by weight of a compatibilizer; and
from 20-78% by weight of a synthetic resin.
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Accused Products
Abstract
Composite materials containing non-plasticized, non-gelatinized starch, a compatibilizer and a synthetic resin, such as polyethylene and/or polypropylene, may be used to make wood replacement products for use as construction materials.
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Citations
47 Claims
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1. A manufactured product for use as a wood substitute, comprising:
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from 20-80% by weight starch;
from 0.5-4% by weight of a compatibilizer; and
from 20-78% by weight of a synthetic resin. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method of making a substitute wood product, the method comprising the steps of:
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combining ingredients including;
from 20-80% by weight starch, from 0.5-4% by weight of a compatibilizer, from 20-78% by weight of a synthetic resin, and from 0-15% by weight fibers;
processing the ingredients to achieve a melt temperature of the synthetic resin; and
extrusion shaping the substitute wood product. - View Dependent Claims (11)
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12. A manufactured product for use as a wood substitute, comprising:
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from 20-80% by weight granular starch;
from 20-78% by weight of a synthetic resin;
from 0.5-4% by weight of a compatibilizer;
from 0-15% by weight of a fiber;
from 0.5-4% by weight of a lubricant, said lubricant containing no metal ions;
from 0-2% by weight of a foaming agent;
from 0-1% by weight of a colorant;
from 0-5% by weight talc;
from 0-2% by weight of an antimicrobial agent; and
from 0-0.3% by weight of a UV stabilizer. - View Dependent Claims (13, 14, 15, 16, 17)
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18. A method of making a substitute wood product, the method comprising the steps of:
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combining ingredients including;
from 20-80% by weight predried starch, from 20-78% by weight of a synthetic resin, from 0.5-4% by weight of a compatibilizer, said compatibilizer having a melt index of 2-150, from 0-15% by weight fiber, from 0.5-4% by weight of a lubricant, said lubricant containing no metal ions, from 0-2% by weight of a foaming agent, from 0-1% by weight of a colorant, from 0-5% by weight talc, from 0-2% by weight of an antimicrobial agent, and from 0-0.3% by weight of a UV stabilizer;
processing the ingredients to achieve a melt temperature of 260-400°
F.; and
extrusion shaping the substitute wood product. - View Dependent Claims (19, 20)
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21. A manufactured product for use as a wood substitute, comprising:
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from 20-80% by weight granular starch;
from 20-78% by weight of a synthetic resin;
from 0.5-4% by weight of a compatibilizer; and
from 0-15% by weight of a fiber. - View Dependent Claims (22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33)
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34. A method of making a substitute wood product, the method comprising the steps of:
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combining ingredients including;
from 20-80% by weight predried starch, from 20-78% by weight of a synthetic resin, from 0.5-4% by weight of a compatibilizer, said compatibilizer having a melt index of 2-150, and from 0-15% by weight of a fiber;
processing the ingredients to achieve a melt temperature of 260-400°
F.; and
extrusion shaping the substitute wood product. - View Dependent Claims (35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47)
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Specification