Method of manufacturing composite board

• US 7,022,756 B2
• Filed: 04/09/2003
• Issued: 04/04/2006
• Est. Priority Date: 04/09/2003
• Status: Expired due to Fees

• Current Assignee: Masco Retail Cabinet Group LLC (Cabinetworks Group Michigan LLC)
• Original Assignee: Mills Pride LP (Masco Corporation)
• Inventors: Singer, Larry
• Primary Examiner(s): SZEKELY, PETER A
• Application Number:
  US10/410,979
• Publication Number:
  US 20040202857A1
• Time in Patent Office: 1,091 Days
• Field of Search: 524 13- 14
• US Class Current: 524/14
• CPC Class Codes: B27N 3/00 Manufacture of substantially flat articles, e.g. boards, from particles or fibres
• CPC Class Codes: B27N 3/002 characterised by the type of binder compositions of macromolecular compounds C08L
• CPC Class Codes: B27N 3/007 and at least partly composed of recycled material
• CPC Class Codes: B27N 3/28 characterised by using extrusion presses
• CPC Class Codes: B29C 70/58 comprising fillers only , e.g. particles, powder, beads, flakes, spheres B29C70/025 takes precedence, agglomerating hollow spheres to produce synthetic foam B29C70/66; compounding ingredients per se C08K
• CPC Class Codes: B29K 2711/14 Wood, e.g. woodboard or fibreboard
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: Y10T 428/253 Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/31989 Of wood

Abstract

A composite board is made from waste medium density fiber (MDF) board or waste particle board that includes solid urea formaldehyde. The waste board is chopped and milled into particles having a size between 20 mesh and 150 mesh, creating a waste flour. After removing moisture from the waste flour, the dried waste flour is mixed with a thermoplastic to bind and encapsulate the waste flour. Internal lubricants are added to improve the flow characteristics of the blended material, and external lubricants are added to present sticking of the mixture to an extruder or mold. Mineral fillers are added to improve the flexural modules of the composite board, and a plasticizer can be added to improve the physical properties or mechanical characteristics of the mixture. An ultraviolet absorber, a biocide, and a pigment can also be added. The blended material is extruded or molded into a desired shape. When cooled, the thermoplastic hardens to form a solid composite board.

Claims

1. A composite material comprising:

a plurality of particles, each, particle of said plurality of particles including both wood and solid urea formaldehyde;

a mineral filler mixed with said plurality of particles; and

a thermoplastic bonding agent that bonds said plurality of particles to form a composite material.

2. The composite material as recited in claim 1 wherein the composite material includes approximately 50–

70% of said plurality of particles, approximately 30–

50% of said bonding agent, approximately 1–

3% of a first lubricant and a second lubricant, approximately 3–

12% of a mineral filler, and approximately 0.05–

3% of a plasticizer.

3. The composite material as recited in claim 1 wherein said wood is virgin wood.

4. The composite material as recited in claim 1 wherein said plurality of particles includes 8–

15% of said solid urea formaldehyde by weight.

5. The composite material as recited in claim 1 wherein said plurality of particles have a size from approximately 150 mesh and 20 mesh.

6. The composite material as recited in claim 1 wherein said bonding agent is one of high density polyethylene, low density polyethylene, polypropylene, polyvinyl chloride, impact co-polymer polypropylene, or styrene acrylonitril.

7. The composite material as recited in claim 1 further including a first lubricant and a second lubricant mixed with said plurality of particles.

8. The composite material as recited in claim 7 wherein said first lubricant is zinc stearate and said second lubricant is ethylene bis-steramide.

9. The composite material as recited in claim 1 wherein said mineral filler is one of magnesium silicate, calcium carbonate, or aluminum tri-hydrate.

10. The composite material as recited in claim 1 further including a plasticizer mixed with said plurality of particles.

11. The composite material as recited in claim 1 including at least one of an ultraviolet absorber, a biocide, or a pigment mixed with said plurality of particles.

12. A panel formed from the composite material of claim 1.

20. The composite material as incited in claim 12 wherein the panel includes a coating.

21. The composite material as recited in claim 20 wherein the coating includes a material of a group consisting of polyvinyl chloride, melamine, meal, foil, impregnated paper, polyester, veneer, or combination thereof.

22. The compose material as recited in claim 12 wherein said panel is from a consumer recycle stream.

23. The composite material as recited in claim 22 wherein said panel is from a consumer recycle stream consisting of cabinets, molding, deck boards, storage units, desks, or combinations thereof.

13. A composite material comprising:

a plurality of particles including both wood and solid urea formaldehyde;

a thermoplastic bonding agent that bonds said plurality of particles;

a first lubricant and a second lubricant mixed with said plurality of particles;

a mineral filler mixed with said plurality of particles; and

a plasticizer mixed with said plurality of particles.

14. The composite method as recited in claim 13 wherein said wood is virgin wood.

15. The composite material as recited in claim 13 wherein said bonding agent is one of high density polyethylene, low density polyethylene, polypropylene, polyvinyl chloride, impact co-polymer polypropylene, or styrene acrylonitril.

16. The composite material as recited in claim 13 wherein said first lubricant is zinc stearate and said second lubricant is ethylene bis-steramide.

17. The composite material as recited in claim 13 wherein said mineral filler is one of magnesium silicate, calcium carbonate, or aluminum tri-hydrate.

18. The composite material as recited in claim 13 further at least one of an ultraviolet absorber, a biocide, or a pigment mixed with said plurality of particles.

19. The composite material as recited in claim 13 wherein the composite material includes approximately 50–

70% of said plurality of particles, approximately 30–

50% of said bonding agent, approximately 1–

3% of said first lubricant and said second lubricant, approximately 3–

12% of said mineral filler, and approximately 0.05–

3% of said plasticizer.

24. A composite material comprising:

a plurality of particles formed from a chopped composite wood panel, wherein the chopped composite wood panel comprises at least wood, solid urea formaldehyde and a veneer; and

a thermoplastic bonding agent that bonds said plurality of particles to form a composite material.

25. A composite material comprising:

a mixture of wood particles and solid urea formaldehyde particles;

a mineral filler mixed with said mixture; and

a thermoplastic bonding agent that bonds said wood particles, said solid urea formaldehyde particles, and said mineral filler together to form a composite material.