CA2432881A1 - Composite siding - Google Patents
Composite siding Download PDFInfo
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- CA2432881A1 CA2432881A1 CA 2432881 CA2432881A CA2432881A1 CA 2432881 A1 CA2432881 A1 CA 2432881A1 CA 2432881 CA2432881 CA 2432881 CA 2432881 A CA2432881 A CA 2432881A CA 2432881 A1 CA2432881 A1 CA 2432881A1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
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- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
A composite siding comprising a binder and a wood-based filler. The composite siding is preferably produced by a pultrusion process and exhibits great dimensional stability, aging resistance to damage characteristics while maintaining high product stiffness and strength.
Description
COMPOSITE SIDING
FIELD OF THE INVENTION
The present invention relates to composite siding and more particularly to composite siding comprising wood fiber in a polymeric binder.
I3ACI~GROUND OF THE INVENTION
Composite products comprising a binding agent such as a polymer or other extrudable plastic into which is incorporated a filler have been produced by both an extrusion and a pultrusion process. An example of existing extrusion processes are described in U.S. Patent No. 5,169;589 to Francoeur et al., U.S. Patent No.
5,204,045 to Courval et al. and U.S. Patent No. 5,169,57 to Courval. The pultrusion process is known in the art and comprises the extrusion of the composite material through a die while simultaneously pulling the thus extruded material in its longitudinal direction to provide polymer and filler orientation to a desired degree. An example of an existing pultrusion process is disclosed in PCT Application '~10 01/45915A1, published June 28, 2001. Pultrusion processes have been used to make a variety of different materials;
however, none have been employed to produce a composite siding composed of a binding agent and wood fiber that meets the high standards ofthe building industry.
SUMMAR'1' OF THE INVENTION
The present invention therefore provides a composite siding comprising a binder and a wood filler. Preferably, the wood filler comprises wood flour or sawdust. The wood siding has superior conventional characteristics, for example stability, weather aging, combustibility characteristics, and resistance to damage in use set forth in Table 1 below while maintaining high product stiffness and product strength.
_2_ BRIEF DESCRIPTION OF THE D V"JINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understooe~ by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIGURE 1 is a perspective view of a piece of composite siding having the characteristics set forth herein.
DETAILED DESCRIPTION OF THE PREFE D EMBODIMENT
The composite siding of the present invention comprise a binding agent and a filler that is extruded and preferably lengthened using a pultrusion process.
The filler and binding agent are placed in a feeder, which in turn feeds a predetermined volume of filler and binding agent into a melt extruder. The fyller and the binding agent are mixed in the melt extruder to form a feed stock as is well known to those of ordinary skill in the art.
As shown in Figure 1, the feedstock then passes to an extruder and is extruded through a die 14 to produce a product 10 of composite material. i>Vlaile being extruded, the composite material is grasped by a mechanical clamp 16 or other pulling means and pulled in the longitudinal direction of extrusion. This orients the polymeric and wood fiber to produce a composite wood-like siding prodhct.
The filler can be a natural fiber such as wood and agricultural fibers such as hemp, flax, straw or wheat; a synthetic fiber such as nylon, polyethylene terephthalate, glass or polypropylene fiber with a polyethylene matrix. The filler can also be a mineral based filler such as slate, talc, vermiculite, mica or nanoclay. Combinations of fillers may also be used. In a presently preferred embodiment, the filler is a wood fiber in the form of sawdust wood flour, wood particles or pulp. All types of bleached or unbleached pulp produced by any of the conventional pulping processes may be employed. In addition, the pulp may be cross-linked or otherwise bleached in ways known in the art.
The most preferred wood fiber is wood flour, processed by grinding planer shavings, chips and sawdust, having a mesh in the range of 10 to 300, and more preferably in the range 10 to 150. In the presently preferred embodiment filler has a mesh size of 60.
The binding agent is a polymer or other suitable extrudable polymer, such as polypropylene, polyethylene, polyvinyl chloride or other known extrudable polymer. It may be virgin or recycled polymer. The binding agent may form approximately 40% to 80% by weight of feedstock 20, and more preferably from 60% to 80% by weight.
The balance of the feedstock comprises the filler.
Additives to improve material properties or to enhance the production process may also be added, for example, lubricants, Ultra Violet radiation stabilizers, and anti-bacterials.
All of the components, i.e., filler, binding agent and additives may be combined prior to extrusion by compounding into pellet form or by pre-mixing.
The pultrusion process is the preferred method for producing the siding of the present invention, although conventional extnasion processes may be employed:
The pultrusion process produces a highly oriented polymer profile. The resultant composite material, produced by this process, generally has a higher tensile and flexural strength and modules than the extrudate. In the presently preferred embodiment an oriented product of composite material, formed with a wood-fiber concentrate filler may be produced in standard widths of 2 inches, 3 inches or 6 inches (5.08cm, 7.62cm or 15.24cm), or for that matter any other desired width producible by the pultrusion process.
FIGURE 1 illustrates the oriented product 10 of composite material. Produced in the manner outlined above, the composite material may have striations 12 of filler, formed in a dispersion pattern with a wood-grain appearance. The resultant oriented product resembles soft wood siding and can be used in residential and commercial applications as such. Appropriate attaching means, such as a tongue and groove, or snap lock, can be incorporated in the die or subsequently tooled in to the oriented material to create a product that can be attached in overlapping relation like conventional siding.
Surface treatment can also be applied to the oriented product for increasing the surface properties of the product, for example adding a protective coating, such as polyurethane, to protect the surface layer from scratching. Other coatings may be employed, for example, to enhance the paintability of the siding. Embossing means can be used to add texture or smoothness to the product surfaces.
By varying parameters of the pultrusion process, such as temperature, the pressure and die contours, properties of composite product can be changed. The properties of composite material can also be changed by varying amounts of the filler, and by changing the composition of the filler(s). These variations in processing parameters will affect the physical properties of.composite product, such as colour, texture, electrical conductivity, and fire retardancy, and the other desired properties set forth below.
The oriented product of composite material can be manipulated in order to meet a manufacturer's specifications with regards to the final commercial application. Oriented product can be cut and shaped during the pultrusion process. In the presently preferred embodiment, composite material is extruded as oriented product of varying specifications, however it can also be extruded as a sheet for use in commercial applications other than siding.
Extrusion rates for the composite material will vary depending on various factors such as the particular binders and fillers selected, the degree of reduction, and the cross-sectional area of the extruded strip or column. Extrusion rates are however rather slow and rates on the order of six inches per minute (6 in./min.) to three feet per minute (3 ft./min) are not atypical.
As stated above, the composite material may also be drawn through a die, or simultaneously pushed (extruded) and drawn through a die by conventional pultrusion processes. One manner of drawing the composite material through a die is to initially commence by extrusion, as discussed above. Once an end of the oriented product begins to emerge from the die, the end may be grasped, such as by a mechanical clamp and pulled. The pulling may be done with no further extrusion force being applied to yield an oriented end product 10. Pulling rates of up to 14 ft./min. (fourteen feet per minute) have been achieved. Pulling rates of 20 ft./min. (twenty feet per minute) are entirely feasible.
The properties of the oriented end product produced by drawing have properties that are different from those produced by extrusion alone. By way of example, a starting billet formed by combining a wood fiber-plastic concentrate containing 30% by weight wood particles of about 60 mesh size and 70~/° by weight virgin polypropylene. This combination yields a composition having a specific gravity of 0.51 that is much lower than expected without the introduction of air voids. The volume ratio of wood, polypropylene and air in the composition is 11 %, 40% and 49%, respectively.
The resulting combination was heated and extruded to form the billet.
The billet is of rectangular cross-section measuring about one inch by five inches.
The billet is heated in an oven to about 150°C (i.e., close to but below, the melting point of polypropylene which is about 160°C) and is transferred to a pressure chamber and initially forced through a die. The extruded material is then grasped using the clamp and drawn at a rate of about four feet per minute. Once it is entirely drawn through the die 38, it is allowed to cool into the oriented end product. The draw ratio (i.e., the initial cross-sectional area divided by the final cross-sectional area) is about 8.
The oriented end product bears a remarkable similarity both in Look and in feel to wood. The oriented end product is diminished in density by about half compared to the starting billet. The density of the oriented end product as about 0.510 g/cc (grams per cubic centimeter) compared to a density of about 0.80 g/cc for the starting billet.
The oriented end product can be shaped as if it were wood and in planing and sawing behaves very much like wood, producing shavings remarkably like wood shavings and sawdust remarkably like wood sawdust. The oriented end product receives both nails and screws much like wood but without splitting.
In testing, the oriented end product is found to have a density and flexural strength not unlike wood and a modulus of elasticity equal to that of low density w~od or t/3 that of grade 2 lumber. Typical desired properties are set forth in the Table bel~w.
_6_ Range of Values (for patent CharacteristicMeasure Test Standardapplication) Target Linear expansionTemperature: 1/32" to 1/16"3/64' to 1/16"
ASTM in 8 ft in 8 ft along the D696 (0.07%) for length, for length 3/8 in 3/8"
Moisture: material material (40F
ASTM to D103'7, SectionsThermal coef 125F temperature 107- of 110 expansion change) (TCOE) _ tic 10-6 to TCOE = 6x 9x 10-6 10'6 to In/In/F 8X 10-6 111/In/F
Linear expansionTemperature: 0.005" to 1/64" in 8 ASTM 0.015" in width, for 8' along the D1037 Sec in width or 3/8" material width 107-110 3/8"
Maintains for samples material prep dimensional Moisture:
stability ASTM
(40F to 125F) D1037, Sections (20% 107-RH to 90% 110 RH) Thickness Temperature: 0.005" to less than swell ASTM 0.015" for 3% for 3/8"
D1037 Sec 318' materialmaterial for samples prep Moisture:
ASTM
D1037, Seceions Sag between NIA 0.005" to Less than supports 0.35" in 0.0035"' ~ 24"
span between (24" stud studs c.c.
spacing) _7_ Range of Values (for patent CharacteristicMeasure Test Standard application)Target Freeze-thaw ICBO AC 174 / 70% to 100%85-95% of cycling ~ ~f (structural ASTM Std D6662 unconditionedunconditioned value value degradation (50%relative (50%relative due to hygrothermal ANSI Standard 135, humidity;humidity; 70F.) 70F.) cycling) Section 4.2 Weatherability~ I % to 15% max 1-5% max residual of substrate residual swell swell (Physical change due to hygrothennal cycling) Withstands WeatherabilityANSI Standard 135, No No checking, Weather of checking, erosion, erosion, and Aging primed substrateSec 4.2 flaking, fiber flaking, fiber raising. raising.
(low maintenance,(Physical Adhesion: I/16" to Adhesion: I/16' change due to does not fade to hygrothermal3116' of coating 1 /8" of coating over time, holds cycling) picked-up picked-up paint well) Permeability ASTh~l Standard E96 0.2 0.2 to 0.4 of - OS perms. perms substrate Water absorptionANSI Standard 135 3% to 5-10% by weight - 15% by weight 24 hrs AST1VI Standard D1037 Sec 163,164 Thickness ANSI Standard 135 2% to ~ Less than swell due 8% 3%
to H2O absorptionASTNI Standard -24 hrs D 1037 Sec 163,164 Surface H20 ASTIR Standard 4-300 g/1005-10 g100 in2 in2 absorption 0473, Sec 82-87 - Cobb ring ~ ~ -_$_ Range of ~la)ues (for patent Characteristic Measure Test Standard application) Target Non combustible Ignition temperature: ASTM D1929 400 - 800°F Greater than 550°F
Lowest air temperature that will cause self ignition Resistant to Damage Flardness: Resistance AST1VI D143/ASTM 200 - 1200 lbs 300-500 lbs in Use to indentations and D1037, section 68-73 wear ANSI 135 Load req'd to press a 0.44" dia. ball to a depth of 0.222 in Impact: Index of ASTM Standard 5-10 in 7-9 in resistance to impact. D1037 Sec 91-95 Failure is reached ANSI Standard 135 when a visible fracture occurs at the bottom surface of the specimen.
Nail-head pull- ANSI Standard 135 150-400 lbs 180 lbs through and ASTM Standard D1037 Sec 54-60 Lateral nail resistance ANSI Standard 13S 1 SO - 300 lbs . 150 - 300 lbs (along strong and ASTM Standard direction) D1037 Sec 54-60 Can be carried in 16' Product stiffness, EI ASTM Standard 9150-68,5001bs-15500-36900 Ibs-length as a plank D1037, Sec I 1 in2/ft of width in2/ft of width Capable of resisting ladder and wind loads with minimal ~ residual deflection Range of 'Values (for patent Characteristic lvleasure Tc,st Standard application) Target Can be carried in 16' Product bending ASTM Standard 49-190 ft-lbs/ft of 80-165 ft-Ibs/ft of length as a plank strength, M I71037 Sec 155-1 S8 width width without breaking ANSI Standard 135 Capable of resisting ladder and wind loads without breaking The measuring and testing methods used to evaluate the products of the present Invention are set forth under the column labeled '°Test Standard." All standards are conventional ASTM or AI~lSI standards.
While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
FIELD OF THE INVENTION
The present invention relates to composite siding and more particularly to composite siding comprising wood fiber in a polymeric binder.
I3ACI~GROUND OF THE INVENTION
Composite products comprising a binding agent such as a polymer or other extrudable plastic into which is incorporated a filler have been produced by both an extrusion and a pultrusion process. An example of existing extrusion processes are described in U.S. Patent No. 5,169;589 to Francoeur et al., U.S. Patent No.
5,204,045 to Courval et al. and U.S. Patent No. 5,169,57 to Courval. The pultrusion process is known in the art and comprises the extrusion of the composite material through a die while simultaneously pulling the thus extruded material in its longitudinal direction to provide polymer and filler orientation to a desired degree. An example of an existing pultrusion process is disclosed in PCT Application '~10 01/45915A1, published June 28, 2001. Pultrusion processes have been used to make a variety of different materials;
however, none have been employed to produce a composite siding composed of a binding agent and wood fiber that meets the high standards ofthe building industry.
SUMMAR'1' OF THE INVENTION
The present invention therefore provides a composite siding comprising a binder and a wood filler. Preferably, the wood filler comprises wood flour or sawdust. The wood siding has superior conventional characteristics, for example stability, weather aging, combustibility characteristics, and resistance to damage in use set forth in Table 1 below while maintaining high product stiffness and product strength.
_2_ BRIEF DESCRIPTION OF THE D V"JINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understooe~ by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIGURE 1 is a perspective view of a piece of composite siding having the characteristics set forth herein.
DETAILED DESCRIPTION OF THE PREFE D EMBODIMENT
The composite siding of the present invention comprise a binding agent and a filler that is extruded and preferably lengthened using a pultrusion process.
The filler and binding agent are placed in a feeder, which in turn feeds a predetermined volume of filler and binding agent into a melt extruder. The fyller and the binding agent are mixed in the melt extruder to form a feed stock as is well known to those of ordinary skill in the art.
As shown in Figure 1, the feedstock then passes to an extruder and is extruded through a die 14 to produce a product 10 of composite material. i>Vlaile being extruded, the composite material is grasped by a mechanical clamp 16 or other pulling means and pulled in the longitudinal direction of extrusion. This orients the polymeric and wood fiber to produce a composite wood-like siding prodhct.
The filler can be a natural fiber such as wood and agricultural fibers such as hemp, flax, straw or wheat; a synthetic fiber such as nylon, polyethylene terephthalate, glass or polypropylene fiber with a polyethylene matrix. The filler can also be a mineral based filler such as slate, talc, vermiculite, mica or nanoclay. Combinations of fillers may also be used. In a presently preferred embodiment, the filler is a wood fiber in the form of sawdust wood flour, wood particles or pulp. All types of bleached or unbleached pulp produced by any of the conventional pulping processes may be employed. In addition, the pulp may be cross-linked or otherwise bleached in ways known in the art.
The most preferred wood fiber is wood flour, processed by grinding planer shavings, chips and sawdust, having a mesh in the range of 10 to 300, and more preferably in the range 10 to 150. In the presently preferred embodiment filler has a mesh size of 60.
The binding agent is a polymer or other suitable extrudable polymer, such as polypropylene, polyethylene, polyvinyl chloride or other known extrudable polymer. It may be virgin or recycled polymer. The binding agent may form approximately 40% to 80% by weight of feedstock 20, and more preferably from 60% to 80% by weight.
The balance of the feedstock comprises the filler.
Additives to improve material properties or to enhance the production process may also be added, for example, lubricants, Ultra Violet radiation stabilizers, and anti-bacterials.
All of the components, i.e., filler, binding agent and additives may be combined prior to extrusion by compounding into pellet form or by pre-mixing.
The pultrusion process is the preferred method for producing the siding of the present invention, although conventional extnasion processes may be employed:
The pultrusion process produces a highly oriented polymer profile. The resultant composite material, produced by this process, generally has a higher tensile and flexural strength and modules than the extrudate. In the presently preferred embodiment an oriented product of composite material, formed with a wood-fiber concentrate filler may be produced in standard widths of 2 inches, 3 inches or 6 inches (5.08cm, 7.62cm or 15.24cm), or for that matter any other desired width producible by the pultrusion process.
FIGURE 1 illustrates the oriented product 10 of composite material. Produced in the manner outlined above, the composite material may have striations 12 of filler, formed in a dispersion pattern with a wood-grain appearance. The resultant oriented product resembles soft wood siding and can be used in residential and commercial applications as such. Appropriate attaching means, such as a tongue and groove, or snap lock, can be incorporated in the die or subsequently tooled in to the oriented material to create a product that can be attached in overlapping relation like conventional siding.
Surface treatment can also be applied to the oriented product for increasing the surface properties of the product, for example adding a protective coating, such as polyurethane, to protect the surface layer from scratching. Other coatings may be employed, for example, to enhance the paintability of the siding. Embossing means can be used to add texture or smoothness to the product surfaces.
By varying parameters of the pultrusion process, such as temperature, the pressure and die contours, properties of composite product can be changed. The properties of composite material can also be changed by varying amounts of the filler, and by changing the composition of the filler(s). These variations in processing parameters will affect the physical properties of.composite product, such as colour, texture, electrical conductivity, and fire retardancy, and the other desired properties set forth below.
The oriented product of composite material can be manipulated in order to meet a manufacturer's specifications with regards to the final commercial application. Oriented product can be cut and shaped during the pultrusion process. In the presently preferred embodiment, composite material is extruded as oriented product of varying specifications, however it can also be extruded as a sheet for use in commercial applications other than siding.
Extrusion rates for the composite material will vary depending on various factors such as the particular binders and fillers selected, the degree of reduction, and the cross-sectional area of the extruded strip or column. Extrusion rates are however rather slow and rates on the order of six inches per minute (6 in./min.) to three feet per minute (3 ft./min) are not atypical.
As stated above, the composite material may also be drawn through a die, or simultaneously pushed (extruded) and drawn through a die by conventional pultrusion processes. One manner of drawing the composite material through a die is to initially commence by extrusion, as discussed above. Once an end of the oriented product begins to emerge from the die, the end may be grasped, such as by a mechanical clamp and pulled. The pulling may be done with no further extrusion force being applied to yield an oriented end product 10. Pulling rates of up to 14 ft./min. (fourteen feet per minute) have been achieved. Pulling rates of 20 ft./min. (twenty feet per minute) are entirely feasible.
The properties of the oriented end product produced by drawing have properties that are different from those produced by extrusion alone. By way of example, a starting billet formed by combining a wood fiber-plastic concentrate containing 30% by weight wood particles of about 60 mesh size and 70~/° by weight virgin polypropylene. This combination yields a composition having a specific gravity of 0.51 that is much lower than expected without the introduction of air voids. The volume ratio of wood, polypropylene and air in the composition is 11 %, 40% and 49%, respectively.
The resulting combination was heated and extruded to form the billet.
The billet is of rectangular cross-section measuring about one inch by five inches.
The billet is heated in an oven to about 150°C (i.e., close to but below, the melting point of polypropylene which is about 160°C) and is transferred to a pressure chamber and initially forced through a die. The extruded material is then grasped using the clamp and drawn at a rate of about four feet per minute. Once it is entirely drawn through the die 38, it is allowed to cool into the oriented end product. The draw ratio (i.e., the initial cross-sectional area divided by the final cross-sectional area) is about 8.
The oriented end product bears a remarkable similarity both in Look and in feel to wood. The oriented end product is diminished in density by about half compared to the starting billet. The density of the oriented end product as about 0.510 g/cc (grams per cubic centimeter) compared to a density of about 0.80 g/cc for the starting billet.
The oriented end product can be shaped as if it were wood and in planing and sawing behaves very much like wood, producing shavings remarkably like wood shavings and sawdust remarkably like wood sawdust. The oriented end product receives both nails and screws much like wood but without splitting.
In testing, the oriented end product is found to have a density and flexural strength not unlike wood and a modulus of elasticity equal to that of low density w~od or t/3 that of grade 2 lumber. Typical desired properties are set forth in the Table bel~w.
_6_ Range of Values (for patent CharacteristicMeasure Test Standardapplication) Target Linear expansionTemperature: 1/32" to 1/16"3/64' to 1/16"
ASTM in 8 ft in 8 ft along the D696 (0.07%) for length, for length 3/8 in 3/8"
Moisture: material material (40F
ASTM to D103'7, SectionsThermal coef 125F temperature 107- of 110 expansion change) (TCOE) _ tic 10-6 to TCOE = 6x 9x 10-6 10'6 to In/In/F 8X 10-6 111/In/F
Linear expansionTemperature: 0.005" to 1/64" in 8 ASTM 0.015" in width, for 8' along the D1037 Sec in width or 3/8" material width 107-110 3/8"
Maintains for samples material prep dimensional Moisture:
stability ASTM
(40F to 125F) D1037, Sections (20% 107-RH to 90% 110 RH) Thickness Temperature: 0.005" to less than swell ASTM 0.015" for 3% for 3/8"
D1037 Sec 318' materialmaterial for samples prep Moisture:
ASTM
D1037, Seceions Sag between NIA 0.005" to Less than supports 0.35" in 0.0035"' ~ 24"
span between (24" stud studs c.c.
spacing) _7_ Range of Values (for patent CharacteristicMeasure Test Standard application)Target Freeze-thaw ICBO AC 174 / 70% to 100%85-95% of cycling ~ ~f (structural ASTM Std D6662 unconditionedunconditioned value value degradation (50%relative (50%relative due to hygrothermal ANSI Standard 135, humidity;humidity; 70F.) 70F.) cycling) Section 4.2 Weatherability~ I % to 15% max 1-5% max residual of substrate residual swell swell (Physical change due to hygrothennal cycling) Withstands WeatherabilityANSI Standard 135, No No checking, Weather of checking, erosion, erosion, and Aging primed substrateSec 4.2 flaking, fiber flaking, fiber raising. raising.
(low maintenance,(Physical Adhesion: I/16" to Adhesion: I/16' change due to does not fade to hygrothermal3116' of coating 1 /8" of coating over time, holds cycling) picked-up picked-up paint well) Permeability ASTh~l Standard E96 0.2 0.2 to 0.4 of - OS perms. perms substrate Water absorptionANSI Standard 135 3% to 5-10% by weight - 15% by weight 24 hrs AST1VI Standard D1037 Sec 163,164 Thickness ANSI Standard 135 2% to ~ Less than swell due 8% 3%
to H2O absorptionASTNI Standard -24 hrs D 1037 Sec 163,164 Surface H20 ASTIR Standard 4-300 g/1005-10 g100 in2 in2 absorption 0473, Sec 82-87 - Cobb ring ~ ~ -_$_ Range of ~la)ues (for patent Characteristic Measure Test Standard application) Target Non combustible Ignition temperature: ASTM D1929 400 - 800°F Greater than 550°F
Lowest air temperature that will cause self ignition Resistant to Damage Flardness: Resistance AST1VI D143/ASTM 200 - 1200 lbs 300-500 lbs in Use to indentations and D1037, section 68-73 wear ANSI 135 Load req'd to press a 0.44" dia. ball to a depth of 0.222 in Impact: Index of ASTM Standard 5-10 in 7-9 in resistance to impact. D1037 Sec 91-95 Failure is reached ANSI Standard 135 when a visible fracture occurs at the bottom surface of the specimen.
Nail-head pull- ANSI Standard 135 150-400 lbs 180 lbs through and ASTM Standard D1037 Sec 54-60 Lateral nail resistance ANSI Standard 13S 1 SO - 300 lbs . 150 - 300 lbs (along strong and ASTM Standard direction) D1037 Sec 54-60 Can be carried in 16' Product stiffness, EI ASTM Standard 9150-68,5001bs-15500-36900 Ibs-length as a plank D1037, Sec I 1 in2/ft of width in2/ft of width Capable of resisting ladder and wind loads with minimal ~ residual deflection Range of 'Values (for patent Characteristic lvleasure Tc,st Standard application) Target Can be carried in 16' Product bending ASTM Standard 49-190 ft-lbs/ft of 80-165 ft-Ibs/ft of length as a plank strength, M I71037 Sec 155-1 S8 width width without breaking ANSI Standard 135 Capable of resisting ladder and wind loads without breaking The measuring and testing methods used to evaluate the products of the present Invention are set forth under the column labeled '°Test Standard." All standards are conventional ASTM or AI~lSI standards.
While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
Claims (35)
1. A composite siding comprising a binder and the wood filler having a thermal coefficient of expansion along the length of 2×10 -6 to 9×10 -6 in./in./°F.
2. The product of Claim 1, wherein said coefficient of expansion along the length is 6×10 -6 to 8×10 -6 in./in./°F.
3. The product of Claim 1, having a linear expansion along the width thereof of 0.005 to 0.015 in. for a product having an 8 in. width in 3/8 in. material.
4. The product of Claim 3, wherein said linear expansion along said width is about 1/64 in.
5. The product of Claim 1, wherein said product has a thickness swell of from 0.005 in. to 0.015 in. for a 3/8 in. material.
6. The product of Claim 5, wherein said thickness swell is less than 3% of the thickness of 3/8 in. material.
7. The product of Claim 1, wherein the sag between the supports ranges from 0.005 in. to 0.035 in. in a 24 in. span between studs.
8. The product of Claim 7, wherein said sag between supports is less than 0.035 in.
9. The product of Claim 1, wherein the structural degradation due to hygrothermal cycling results in performance from 70% to 100% of the unconditioned (50% relative humidity, 70°F) values.
10. The product of Claim 9, wherein said structural degradation is from 85%
to 90% of the unconditioned (50% relative humidity, 70°F) value.
to 90% of the unconditioned (50% relative humidity, 70°F) value.
11. The product of Claim 1, wherein the physical change because of hygrothermal cycling is from 1% to 15% of the maximum residual swell.
12. The product of Claim 11, wherein said physical change is from 1% to 5%
of the maximum residual swell.
of the maximum residual swell.
13. The product of Claim 1, wherein the physical change due to hygrothermal cycling results in little or no checking, erosion, flaking, fiber raising and wherein the adhesion is 1/16 to 3/16 in. of coating being picked up.
14. The product of Claim 1, wherein said adhesion is 1/16 in. to 1/8 in. of coating being picked up.
15. The product of Claim 1, wherein the permeability of the substrate is from 0.2 to 0.8 perms.
16. The product of Claim 15, wherein said permeability is from 0.2 to 0.4 perms.
17. The product of Claim 1, wherein the water absorption in 24 hours is from 3% to 15% by weight.
18. The product of Claim 17, wherein said water absorption in 24 hours is from 5% to 10% by weight.
19. The product of Claim 1, wherein the thickness swell due to water absorption over 24 hours is from 2% to 8%.
20. The product of Claim 19, where said thickness swell is less than about 3%.
21. The product of Claim 1, wherein the surface absorption (Cobb ring) is from 4 to 300 g/100 sq.in.
22. The product of Claim 21, wherein said surface water absorption is from 5 to 10 g/100 sq.in.
23. The product of Claim 1, wherein the ignition temperature ranges from 400° to 800°F.
24. The product of Claim 23, wherein the ignition temperature is greater than 550°F.
25. The product of Claim 1, wherein the hardness ranges from 200 to 1200 lbs.
26. The product of Claim 25, wherein the hardness ranges from 300 to 500 lbs.
27. The product of Claim 1, wherein the index of resistance to impact is 5-in.
28. The product of Claim 27 wherein the resistance to impact is 7-9 in.
29. The product of Claim 1, wherein the nailhead pull through ranges from 150 to 400 lbs.
30. The product of Claim 29, wherein the nailhead pull through is about 170 to 190 lbs.
31. The product of Claim 1, wherein the lateral nail resistance along the strong direction is about 150 to 300 lbs.
32. The product of Claim 1, wherein the product stiffness (EI) ranges from 9150 to 68,500 lbs.-in.2/foot of width.
33. The product of Claim 32, wherein the product stiffness (EI) ranges from 15,500 to 36,900 lbs.-in.2/foot of width.
34. The product of Claim 1, wherein the product bending strength (M) ranges from 49 to 190 foot-lbs./foot of width.
35. The product of Claim 34, wherein the product bending strength ranges from 80 to 165 foot-lbs./foot of width.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US10/187,194 US20040001940A1 (en) | 2002-06-28 | 2002-06-28 | Composite siding |
| US10/187,194 | 2002-06-28 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2432881A1 true CA2432881A1 (en) | 2003-12-28 |
Family
ID=29780014
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2432881 Abandoned CA2432881A1 (en) | 2002-06-28 | 2003-06-20 | Composite siding |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US20040001940A1 (en) |
| CA (1) | CA2432881A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9162369B2 (en) | 2008-10-21 | 2015-10-20 | Andre Verville | Embossed monolayer particleboards and methods of preparation thereof |
Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20070254987A1 (en) * | 2006-04-26 | 2007-11-01 | Associated Materials, Inc. | Siding panel formed of polymer and wood flour |
| ES2683727T3 (en) * | 2007-05-14 | 2018-09-27 | Eovations, Llc | Composition of low density oriented polymer with inert inorganic filler |
| US20080306187A1 (en) * | 2007-06-11 | 2008-12-11 | Festa Daniel E | Siding panel formed of polymer and wood floor |
| LV13891B (en) * | 2007-07-30 | 2009-06-20 | Delicate Eco, Sia | Composites and methods of the articles manufacturing by using based on plastic organic fibers filled composites, by plastic injection molding method |
| US10577442B2 (en) * | 2013-08-08 | 2020-03-03 | Eovations, Llc | Plastics-based manufactured article and processes for forming said article |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3954555A (en) * | 1972-09-29 | 1976-05-04 | National Gypsum Company | Fiber reinforced plastic articles and method of preparation |
| US4005036A (en) * | 1974-04-25 | 1977-01-25 | Owens-Corning Fiberglas Corporation | Frothed molding compositions |
| US5075057A (en) * | 1991-01-08 | 1991-12-24 | Hoedl Herbert K | Manufacture of molded composite products from scrap plastics |
| US5565056A (en) * | 1993-04-23 | 1996-10-15 | Aluminum Company Of America | Plural extruder method for making a composite building panel |
| US6122877A (en) * | 1997-05-30 | 2000-09-26 | Andersen Corporation | Fiber-polymeric composite siding unit and method of manufacture |
| US6881367B1 (en) * | 2000-11-06 | 2005-04-19 | Elk Composite Building Products, Inc. | Composite materials, articles of manufacture produced therefrom, and methods for their manufacture |
-
2002
- 2002-06-28 US US10/187,194 patent/US20040001940A1/en not_active Abandoned
-
2003
- 2003-06-20 CA CA 2432881 patent/CA2432881A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9162369B2 (en) | 2008-10-21 | 2015-10-20 | Andre Verville | Embossed monolayer particleboards and methods of preparation thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| US20040001940A1 (en) | 2004-01-01 |
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| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Discontinued |