System and method for making extruded, composite material

Abstract

Systems and methods for making a material composition are disclosed. The method includes mixing a thermoset polymer, a petroleum distillate, a release agent, and a catalyst to form an admixture. A cellulosic material is mixed with the admixture to form a generally homogenous furnish. The system includes a mixing chamber, a feeding chamber, and a die. The die includes a pressing chamber, which has a volume formed by first and second platens. The platens are in facing opposition to one another and have a length extending continuously from an entrance to an exit of the die. The platens have a plurality of orifices and heating elements disposed along the length. The platens are disposed in first and second positions. The first position forms a first volume and the second position forms a second volume.

1 . An apparatus for forming a continuous cellulosic-based composite material comprising:
 a mixing chamber comprising a volume and at least one entrance and an exit;   a feeding chamber comprising a volume, an entrance, and an exit, the entrance of the feeding chamber being in fluid communication with the exit of the mixing chamber; and   a die comprising an entrance, an exit, a piston, a ram, and a pressing chamber, the entrance of the die being in fluid communication with the exit of the feeding chamber, the pressing chamber having a volume formed by first and second platens, the first and second platens being disposed in facing opposition to one another and having a length extending continuously from at least the entrance of the die to the exit of the die, the first and second platens having a plurality of orifices and heating elements disposed along the length, the first and second platens being disposed in first and second positions, the first position forming a first volume and the second position forming a second volume.   
     
     
         2 . The apparatus according to  claim 1 , wherein the reciprocating ram displaces a predetermined amount of a workpiece through the volume of the pressing chamber at a continuous rate. 
     
     
         3 . The apparatus according to  claim 2 , wherein the continuous rate is approximately 990 pounds per hour. 
     
     
         4 . The apparatus according to  claim 3 , wherein the entrance of the die comprises an input chute. 
     
     
         5 . The apparatus according to  claim 4 , wherein the workpiece is introduced into the volume of the pressing chamber through an input chute. 
     
     
         6 . The apparatus according to  claim 1 , wherein a distance between the first and second platens in the first position is a first distance. 
     
     
         7 . The apparatus according to  claim 6 , wherein a distance between the first and second platens in the second position is a second distance. 
     
     
         8 . The apparatus according to  claim 7 , wherein the second distance is greater than the first distance. 
     
     
         9 . The apparatus according to  claim 1 , wherein ends of the first and second platens in the first position are proximate the entrance of the die. 
     
     
         10 . The apparatus according to  claim 1 , wherein ends of the first and second platens in the second position are proximate the exit of the die. 
     
     
         11 . The apparatus according to  claim 1 , wherein a spacer is disposed between the first and second platens. 
     
     
         12 . The apparatus according to  claim 1 , wherein the spacer has a first end and a second end, the first end proximate the entrance of the die and the second end proximate the exit of the die, the first end of the spacer having a first thickness and the second end of the spacer having a second thickness. 
     
     
         13 . The apparatus according to  claim 12 , wherein the second thickness is greater than the first thickness. 
     
     
         14 . The apparatus according to  claim 1 , wherein the first volume is greater than the second volume. 
     
     
         15 . The apparatus according to  claim 1 , wherein the piston is disposed proximate the entrance of the die and opposite the exit of the die. 
     
     
         16 . The apparatus according to  claim 5 , wherein the piston is positioned substantially perpendicular to the input chute. 
     
     
         17 . The apparatus according to  claim 16 , wherein the ram is coupled to the piston. 
     
     
         18 . The apparatus according to  claim 17 , wherein the ram comprises a face, the face contacting the workpiece. 
     
     
         19 . The apparatus according to  claim 18 , wherein the face comprises a serrated edge. 
     
     
         20 . The apparatus according to  claim 18 , wherein the face comprises a flat edge. 
     
     
         21 . The apparatus according to  claim 3 , wherein the piston exerts a force on the workpiece substantially planar to the length of the first and second platens. 
     
     
         22 . The apparatus according to  claim 21 , wherein the force of the piston displaces the workpiece toward the exit of the die at the continuous rate. 
     
     
         23 . The apparatus according to  claim 2 , wherein the first and second platens compress the workpiece to a substantially uniform density. 
     
     
         24 . The apparatus according to  claim 23 , wherein the density is in a range between approximately 27 and approximately 36 pounds per cubic foot. 
     
     
         25 . The apparatus according to  claim 1 , wherein the first and second platens each have a thickness, wherein the plurality of orifices are formed through the thickness of the first and second platens. 
     
     
         26 . The apparatus according to  claim 1 , further comprising:
 a hopper comprising a volume, an entrance, an exit, and a screw feeder disposed proximate the exit of the hopper, the exit of the hopper being in fluid communication with one of the entrances of the mixing chamber; and   a resin injector comprising at least one tank and a regulating valve, the regulating valve being in fluid communication with another one of the entrances of the mixing chamber.   
     
     
         27 . The apparatus according to  claim 26 , wherein the hopper further comprises a screen having a plurality of orifices, the orifices each having a diameter. 
     
     
         28 . The apparatus according to  claim 27 , wherein the diameter is in a range between approximately one-eighth of an inch and approximately three-eighths of an inch. 
     
     
         29 . The apparatus according to  claim 27  further comprising:
 a cyclone having an entrance, an exit, and a middle portion, the middle portion being disposed between the entrance and the exit of the cyclone and including at least one magnet, the exit of the cyclone being in fluid communication with the entrance of the hopper, wherein cellulosic material is directed from the entrance of the cyclone to the exit of the cyclone passing through the middle portion, whereby the at least one magnet removes ferrous material from the cellulosic material.