Improved variegated composites and related methods of manufacture

Abstract

Abstract of the Disclosure Embodiments of the invention include a composite. The composite includes a crystalline polymer, a plurality of wood fibers blended with the crystalline polymer, an outer surface, and an amorphous polymer visible on the outer surface. The amorphous polymer has a first color and the blend of the crystalline polymer and the plurality of wood fibers has a second color different from the first color. The invention also includes a method of manufacturing the wood-plastic composites such that one polymer is shifted in the composite relative to the other polymer.

1.  A composite, comprising: 
     a first polymer; 
     a plurality of wood fibers dispersed in the first polymer; 
     an outer surface; and 
     a second polymer adapted to not blend substantially with the first polymer; 
     wherein the first polymer and the second polymer form a pattern on the outer surface of the composite. 
   
   
       2.  The composite of  claim 1 , wherein the first polymer further comprises at least one of polypropylene and polyethylene. 
   
   
       3.  The composite of  claim 1 , wherein the second polymer further comprises at least one of a polymethylmethacrylate, an alphamethylstyrene acrylonitrile, and a polycarbonate. 
   
   
       4.  The composite of  claim 1 , wherein the outer surface includes streaks of the second polymer. 
   
   
       5.  The composite of  claim 1 , wherein the first polymer has a melting temperature that is substantially the same as a melting temperature of the second polymer. 
   
   
       6.  The composite of  claim 1 , wherein the outer surface is variegated. 
   
   
       7.  The composite of  claim 1 , wherein a first portion of the outer surface has a first color and a second portion of the outer surface has a second color. 
   
   
       8.  The composite of  claim 1 , further comprising a third polymer configured to resist blending with the first polymer; 
     wherein the composite is manufactured such that the third polymer is deliberately visible on the outer surface, 
     wherein the third polymer has a third color different from the first polymer and the second polymer. 
   
   
       9.  The composite of  claim 1 , wherein the composite is at least one of a building material, a decking material, a railing component, and a decking board. 
   
   
       10.  The composite of  claim 1 , further comprising a colorant blended with one of the first polymer and the second polymer. 
   
   
       11.  A method of manufacturing a wood-plastic composite, comprising: 
     providing a first polymer; 
     providing a plurality of wood fibers; 
     providing a second polymer not substantially soluble in the first polymer; 
     melting the first polymer; 
     blending the first polymer and the plurality of wood fibers to form a blend; 
     adding the second polymer in an unmelted state to the blend to form a feed; and 
     forming a profile body from the feed, the profile body further comprising a pattern formed by the first polymer and the second polymer. 
   
   
       12.  The method of  claim 11 , further comprising forming streaks of the second polymer on the outer surface. 
   
   
       13.  The method of  claim 11 , further comprising forming streaks of the first polymer on the outer surface. 
   
   
       14.  The method of  claim 11 , further comprising shifting the second polymer towards the outer surface. 
   
   
       15.  The method of  claim 11 , further comprising variegating the outer surface. 
   
   
       16.  The method of  claim 11 , further comprising providing at least one of a single screw extruder and a double screw extruder, 
     wherein the step of extruding includes extruding the feed via the at least one of the single-screw extruder and the double screw extruder. 
   
   
       17.  The method of  claim 11 , wherein the step of mixing includes forming a first color from the second polymer and forming the second color from a blend of the first polymer and the plurality of wood fibers. 
   
   
       18.  The method of  claim 11 , further comprising providing a third polymer not substantially soluble in the first polymer; 
     adding the third polymer in an unmelted state to the blend to form the feed, 
     wherein the pattern is formed by the first polymer, the second polymer, and the third polymer. 
   
   
       19.  The method of  claim 11 , further comprising providing a core, 
     wherein the step of forming the profile body includes forming the profile body around at least a portion of the core. 
   
   
       20.  The method of  claim 11 , further comprising providing a colorant; and 
     blending the colorant with one of the first polymer and the second polymer. 
   
   
       21.  The composite of  claim 1 , wherein the first polymer has a first color and the second polymer has a second color. 
   
   
       22.  The composite of  claim 1 , wherein the second polymer is not substantially soluble in the first polymer. 
   
   
       23.  The method of  claim 11 , wherein the first polymer has a first color and the second polymer has a second color. 
   
   
       24.  The method of  claim 11 , wherein the second polymer is not substantially soluble in the first polymer. 
   
   
       25.  A composite, comprising: 
     a first polymer comprising polyethylene; 
     a plurality of wood fibers dispersed in the first polymer; 
     an outer surface; and 
     a second polymer comprising polyethylene; 
     wherein the first polymer and the second polymer form a pattern on the outer surface of the composite. 
   
   
       26.  The composite of  claim 25 , wherein the plurality of wood fibers comprise about 38% of the composite by weight. 
   
   
       27.  The composite of  claim 25 , wherein the plurality of wood fibers are configured to pass through a size 30 mesh or smaller sieve. 
   
   
       28.  The composite of  claim 25 , wherein the second polymer includes a polycarbonate. 
   
   
       29.  The composite of  claim 25 , wherein at least one of the first polymer and the second polymer has a melting temperature of about 132°. 
   
   
       30.  The composite of  claim 25 , wherein at least one of the first polymer and the second polymer comprise between about 53% and about 55% of the composite by weight. 
   
   
       31.  The composite of  claim 25 , wherein the second polymer comprise about 2% of the composite by weight. 
   
   
       32.  A composite, comprising: 
     a first polymer comprising polyethylene; 
     a plurality of wood fibers dispersed in the first polymer; 
     an outer surface; and 
     a second polymer comprising polypropylene; 
     wherein the first polymer and the second polymer form a pattern on the outer surface of the composite. 
   
   
       33.  The composite of  claim 32 , wherein the plurality of wood fibers comprise about 38% of the composite by weight. 
   
   
       34.  The composite of  claim 32 , wherein the plurality of wood fibers are configured to pass through a size 30 mesh or smaller sieve. 
   
   
       35.  The composite of  claim 32 , wherein the polypropylene is one of a polypropylene homo polymer and a polypropylene co-polymer. 
   
   
       36.  The composite of  claim 32 , wherein at least one of the first polymer and the second polymer has a melting temperature of about 132°. 
   
   
       37.  The composite of  claim 32 , wherein at least one of the first polymer and the second polymer comprise between about 53% and about 55% of the composite by weight. 
   
   
       38.  The composite of  claim 32 , wherein the second polymer comprises about 2% of the composite by weight. 
   
   
       39.  The composite of  claim 1 , wherein the second polymer further comprises at least one of polypropylene and polyethylene. 
   
   
       40.  The composite of  claim 1 , wherein both the first polymer and the second polymer each further comprise at least one of polypropylene and polyethylene. 
   
   
       41.  A method of manufacturing a wood-plastic composite, comprising: 
     providing a first polymer; 
     providing a plurality of wood fibers; 
     providing a second polymer; 
     mixing the first polymer, the plurality of wood fibers, and the second polymer to form a feed; and 
     forming a profile body from the feed, the profile body further comprising a pattern formed by the first polymer and the second polymer. 
   
   
       42.  The method of  claim 41 , further comprising forming streaks of the second polymer on the outer surface. 
   
   
       43.  The method of  claim 41 , further comprising forming streaks of the first polymer on the outer surface. 
   
   
       44.  The method of  claim 41 , further comprising shifting the second polymer towards the outer surface. 
   
   
       45.  The method of  claim 41 , further comprising variegating the outer surface. 
   
   
       46.  The method of  claim 41 , further comprising providing at least one of a single screw extruder and a double screw extruder, 
     wherein the step of extruding includes extruding the feed via the at least one of the single-screw extruder and the double screw extruder. 
   
   
       47.  The method of  claim 41 , wherein the step of mixing includes forming a first color from the second polymer and forming the second color from a blend of the first polymer and the plurality of wood fibers. 
   
   
       48.  The method of  claim 41 , further comprising providing a third polymer not substantially soluble in the first polymer; 
     adding the third polymer in an unmelted state to the feed, 
     wherein the pattern is formed by the first polymer, the second polymer, and the third polymer. 
   
   
       49.  The method of  claim 41 , further comprising providing a core, 
     wherein the step of forming the profile body includes forming the profile body around at least a portion of the core. 
   
   
       50.  The method of  claim 41 , further comprising providing a colorant; and 
     blending the colorant with one of the first polymer and the second polymer. 
   
   
       51.  The method of  claim 41 , further comprising mixing the first polymer and the plurality of wood fibers and then adding the second polymer. 
   
   
       52.  The method of  claim 41 , further comprising mixing the first polymer and the second polymer and then adding the plurality of wood fibers. 
   
   
       53.  The method of  claim 41 , further comprising mixing the second polymer and the plurality of wood fibers and then adding the first polymer. 
   
   
       54.  The method of  claim 41 , further comprising blending the first polymer and the plurality of wood fibers and then adding the second polymer. 
   
   
       55.  The method of  claim 41 , further comprising blending the second polymer and the plurality of wood fibers and then adding the first polymer. 
   
   
       56.  The composite of  claim 25 , wherein the polyethylene is at least one of a high density polyethylene and a low density polyethylene. 
   
   
       57.  The composite of  claim 32 , wherein the polyethylene is at least one of a high density polyethylene and a low density polyethylene. 
   
   
       58.  The composite of  claim 25 , wherein the pattern is a natural, wood-like pattern. 
   
   
       59.  The composite of  claim 32 , wherein the pattern is a natural, wood-like pattern. 
   
   
       60.  The composite of  claim 25 , wherein the pattern is a splotchy pattern. 
   
   
       61.  The composite of  claim 32 , wherein the pattern is a splotchy pattern.