Apparatus and method for continuous formation of composites having filler and thermoactive materials, and products made by the method

Abstract

A method for forming a product from cellulosic material and thermoactive material is described. A mat is formed from a mixture having a predetermined amount of cellulosic material and a predetermined amount of thermoplastic material. The mat is then consolidated and pressed to a predetermined final product thickness. At least a portion of a surface of the mat or product is then surface modified. Consolidating the mixture may include forming a first face layer, forming a core layer on the first face layer, and forming a second face layer on the core layer. Forming the core layer may include depositing mixtures of wood flakes and plastic flakes according to mixture flake size in successive layers such that the core layer has larger flakes adjacent the first face layer and adjacent the second face layer, and smaller flakes in a middle portion of the core layer. The method also can include fusing a sheet of plastic material to at least one surface of the mat, and surface modifying the plastic material. Grafting chemicals can be applied to surface modified mats, plastic material or products. A composite product also is described. One embodiment of the product comprises a first portion having a first core formed from a mixture comprising a cellulosic material and a thermoplastic material, and at least one face layer attached to the first core. The product also comprises a second portion bonded to the first portion. The second portion comprises a second core formed from a mixture comprising a cellulosic material and a thermoplastic material, and at least one face layer attached to the second core.

1 - 60 . (canceled)  
   
   
       61 . A method for forming a multilayer product, comprising: 
 forming a first face layer comprising a mixture of cellulosic material and plastic material;    forming a second face layer separately from the first face layer;    forming a core separately from the first and second face layers;    placing the core on the first face layer;    placing the second face layer on a top surface of the core; and    consolidating the multilayer product by the application of heat and pressure.    
   
   
       62 . A method for forming a composite product, comprising: 
 providing a mixture comprising thermoplastic material and cellulosic material;    forming a mat from the mixture; and    subjecting at least a portion of the mat to a first flow of hot, dry non-condensable gas.    
   
   
       63 - 145 . (canceled)  
   
   
       146 . An apparatus for sorting cellulosic and thermoplastic flakes of different sizes used in forming a composite product, comprising: 
 a frame positioned above a receiving surface;    a plurality of axles coupled to the frame, each of the axles rotatably supporting a plurality of spaced apart sprockets, the axles being driven to rotate the sprockets in a movement direction; and    a plurality of zones arranged in the movement direction, each zone being defined by a spacing between adjacent axles within the respective zone, the spacings defining openings through which correspondingly sized flakes can pass,    wherein flakes dispensed onto the frame in a first zone are moved in the movement direction through successive zones by rotation of the sprockets with flakes passing through the openings and being deposited on the receiving surfaces in accordance with the sizes of the flakes.    
   
   
       147 . The apparatus of  claim 146 , wherein the openings in the respective zones increase in size from the first zone through each successive zone in the movement direction.  
   
   
       148 . The apparatuGoughs of  claim 146 , wherein the receiving surface is a moving surface moving in a process direction.  
   
   
       149 . The apparatus of  claim 148 , wherein the process direction of the moving surface is opposite the movement direction of the flakes.  
   
   
       150 . The apparatus of  claim 146 , further comprising a dispenser positioned adjacent one end of the frame to dispense the flakes onto the first zone.  
   
   
       151 . The apparatus of  claim 146 , wherein the frame is inclined relative to horizontal.  
   
   
       152 . An apparatus for sorting cellulosic and thermoplastic flakes of different sizes used in forming a composite product, comprising: 
 a first sorting device, having a first frame positioned above a receiving surface, a plurality of axles coupled to the frame, each of the axles rotatably supporting a plurality of spaced apart sprockets, the axles being driven to rotate the sprockets in a first movement direction, and a plurality of zones arranged in the first movement direction, each zone being defined by a spacing between adjacent axles within the respective zone, the spacings defining openings through which correspondingly sized flakes can pass;    a second sorting device positioned adjacent the first forming device, the second sorting device having a second frame positioned above the receiving surface, a plurality of axles coupled to the frame, each of the axles rotatably supporting a plurality of spaced apart sprockets, the axles being driven to rotate the sprockets in a second movement direction, and a plurality of zones arranged in the second movement direction, each zone being defined by a spacing between adjacent axles within the respective zone, the spacings defining openings through which correspondingly sized flakes can pass,    wherein flakes dispensed onto the first and second frames in respective first zones are moved in respective first and second movement directions through successive zones by rotation of the sprockets with flakes passing through the openings and being deposited on the receiving surface in accordance with the sizes of the flakes.