Filing Information

Inventor(s)	David J. Stucky · Randall Elinski ·
Assignee(s)	CertainTeed Corporation ·  View assignee updates
Attorney/Agent(s)	Oblon, Spivak, McClelland, Maier & Neustadt, P.C. ·
Primary Examiner	Blaine Copenheaver ·
Assistant Examiner	Leanna Roche′ ·
Application Number	US9055098
Filing date	04/03/1998
Issue date	02/05/2002
Predicted expiration date	04/03/2018
U.S. Classifications	428/317.9  · 521/920  · 521/145  · 524/35  · 428/318.8  ·
International Classifications	--
Kind Code	B1
International Classifications	4283179 · 4283188 · 521145 · 521920 · 524 35 ·

Patent Family

Abstract

Foamed polymer-fiber composites, building materials and methods of making such building materials are provided by this invention. The composites include about 35-75 wt. % of a polymeric resin, about 25-65 wt. % fiber and have a specific gravity of less than about 1.25 g/cc. The low density is provided by the introduction of a blowing agent or gas into a molten precursor of the composite during thermo forming, such as in an extrusion operation.

Independent Claims | See all claims (21)

1. 1. A foamed polymer composite building material, comprising about 35-73 wt. % polyvinyl chloride (PVC) resin; about 27-65 wt. % fiber, and a specific gravity of about 1.07 g/cc or less, said composite building material including at least 1% porosity by volume of solids and being formed from a molten precursor comprising from about 1.0 parts to about 1.5 parts of a gaseous medium or blowing agent per hundred parts of PVC resin; wherein said building material is capable of having a screw fastener countersunk therein without predrilling.
2. 15. A foamed polymer-wood composite, formed from a molten mixture comprising: about 35-73 wt. % PVC resin, about 27-65 wt. % wood fiber, and from about 1.0 parts to about 1.5 parts of a gaseous medium or blowing agent per hundred parts of PVC resin, said molten mixture forming a polymer-wood composite having a specific gravity of about 1.07 g/cc or less, and a flexural modulus of about 100,000-450,000 psi; wherein said polymer-wood composite is capable of having a screw fastener countersunk therein without predrilling.
3. 19. A foamed polymer wood composite building material having a generally board-shaped cross-section, formed from a molten precursor comprising: about 45-60 wt. % of a polyvinyl-chloride resin, about 27-65 wt. % wood flour, about 0.1-15 wt. % acrylic modifier; and about 1.0 parts to about 1.5 parts of a chemical blowing agent per hundred parts of polyvinyl chloride resin; said building material having a specific gravity of about 1.07 g/cc or less and being capable of having a screw fastener countersunk therein without predrilling; said building material also comprising a flexural modulus of about 100,000-450,000 psi.