WO2018170582A1

WO2018170582A1 - Process for the preparation of a composite material

Info

Publication number: WO2018170582A1
Application number: PCT/CA2018/050239
Authority: WO
Inventors: Richard Gerhard Jones
Original assignee: Teal Cedar Products Ltd.
Priority date: 2017-03-21
Filing date: 2018-03-01
Publication date: 2018-09-27

Abstract

The present document describes a process for the preparation of a wood-plastic composite material comprising linear low density plastic, high density plastic, calcium carbonate, wood flour and a coupling agent. The present document also describes compositions and products, such as, for example, shingles, made using the composition obtained from the process.

Description

Title: PROCESS FOR THE PREPARATION OF A COMPOSITE MATERIAL

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority of US provisional patent application No. 62/474, 104 filed on March 21 , 2017 the specification of which is hereby incorporated by reference in its entirety.

BACKGROUND

(a) Field

[0002] The subject matter disclosed generally relates to a process for the preparation of a wood-plastic composite material, and wood-plastic composite material produced therefrom. More specifically, the subject matter disclosed relates to a process for the preparation of a wood-plastic composite material comprising linear low density plastic, high density plastic; calcium carbonate, wood flour; and a coupling agent, and comprising about 0.5% or less moisture content, and at least about 92% fiber encapsulation level.

(b) Related Prior Art

[0003] Natural wood material used in building can be damaged by water, sunlight, or other elements. Therefore, much research has been performed to develop wood-plastic composite material in order to eliminate the problems associated with natural wood. In previous wood-plastic composite material, granular or pelletized wood fiber and synthetic resin are mixed in a predetermined mixing ratio. Other wood-plastic composite materials include stone materials with synthetic resin, which are mixed in a predetermined mixing ratio. Wood-plastic composite material integrates the wood and advantages of plastic as a whole, has the advantages of light weight, high strength, low cost and environmental protection, the obvious advantage of efficiency, and cost on the dual advantages of high performance. Wood-plastic composite materials are increasingly replacing the other traditional material. Although wood-plastic composite materials have advantages in the practical application, however, because of the polarity of the wood fibers and non-polar plastic, compatibility is poor, and the material causes defects that decrease its performance. The current technology used to produce a wood-plastic pellets or profiles, is inadequate to meet compound moisture and fiber encapsulation requirements. If possible, 0% internal moisture is desired and 0.5% external moisture is desired, with a 92% desired minimum fiber encapsulation in the compounded pellet or profiles. Current wood-plastic composite pelletizing equipment is limited to 1 .5% internal and/or external moisture, and a 75% to 80% fiber encapsulation in the pellet. These moisture limitations are created by the use of cooling water with the pelletizer, used to convey the pellets from the die head. It is also limited by efficiency of the vacuum venting systems on the extruder barrel.

[0004] Poor fiber encapsulation increases the ambient moisture rehydration. Any increase in moisture stabilization within profiled shingles creates warpage and structure deformation. The rehydration should be gradual and extend over a 30 day period. Higher moisture content can also degrade the polymer, changing viscosity & creating some brittleness within the structure.

[0005] Therefore, there is a need for further improvements to improve the performance of wood-plastic materials, such as heat insulating performance, sound insulation performance, lightness and costs of fabrication, and the like.

[0006] There is also a need to further improve the performance of wood- plastic materials by reducing the internal moisture and/or external moisture.

[0007] There is also a need to further improve the performance of wood- plastic materials by increases in moisture stabilization within to obtain gradual rehydration over an extended period.

SUMMARY

[0008] According to an embodiment, there is provided a process for the preparation of a wood-plastic composite material comprising the step of:

1 ) preparing a hot melt uniformly blended mix comprising a) between about 10% to about 15% w/w linear low density plastic; b) between about 30% to about 40% w/w high density plastic;

c) between about 10% to about 25% w/w calcium carbonate;

d) between about 25% to about 65% w/w wood flour; and e) between about 1 % to about 4% of a coupling agent, wherein the linear low density plastic and the high density plastic are melted and intermixed with the calcium carbonate, wood flour and coupling agent at a speed sufficient to generate a temperature between about 180° and 190°C, and for a time sufficient to obtain the hot melt uniformly blended mix, wherein the hot melt uniformly blended mix comprises about 0.5% or less moisture content, and at least about 92% fiber encapsulation level.

[0009] The speed sufficient provides a Froude number of from about 300 to about 1295.

[0010] The process may further comprise step 2):

2) forming a thick sheet from the hot melt uniformly blended mix, wherein the thick sheet is cooled from a first temperature of about 180°C to about 190°C a second temperature of about 135°C to about 145°C.

[0011] The process may further comprise step 3) :

3) thermoform and shape the thick sheet in a thermoforming mold to obtain a thermoformed and shaped product therefrom.

[0012] The process may further comprise step 1 ') after step 1 ):

1 ') discharging the hot melt uniformly blended mix in a hot melt extruder in a temperature- and humidity-controlled environment.

[0013] The discharging may be by gravity.

[0014] The temperature- and humidity-controlled environment may be an enclosure.

[0015] The discharging may be to the feed throat of a hot melt extruder. [0016] The process may further comprise step 0) before step 1 :

0) preparing the wood flour from a dried and pulverized sawdust.

[0017] The dried and pulverized sawdust may be prepared from sawdust having a particle size between about 0.3175 cm to about 2,2225 cm.

[0018] The sawdust may have a moisture content from about 25% to about 75%.

[0019] The sawdust may be dried in a sawdust dryer, to obtain a dried sawdust having a moisture content of about 12 to about 15%.

[0020] The dried and pulverized sawdust or the dried sawdust may be pulverized in a sawdust pulverizer to produce the wood flour.

[0021] The dried and pulverized sawdust may be obtained from a step of pulverizing and drying the sawdust in a kinetic disintegration dryer-pulverizer comprising a suspended chain to pulverize the sawdust.

[0022] The suspended chain may comprises a series of link of about 1 .27 cm.

[0023] The suspended chain may be about 15.24 cm long.

[0024] The suspended chain may be made from steel.

[0025] The dried and pulverized sawdust may be obtained from a combined sawdust dryer and pulverizer.

[0026] The dried and pulverized sawdust may be treated with an internal classifier to produce the the wood flour.

[0027] The wood flour may be hemlock wood flour, cedar wood flour or combinations thereof.

[0028] The process wood flour may have a particle size of between about 250 and about 425 microns (60 to 40 mesh). [0029] The wood flour may have a moisture content of about 7% to about 10%.

[0030] The calcium carbonate may have a particle size of between about 1 and about 5 microns.

[0031] The calcium carbonate (CaC03) mineral may be calcite, aragonite, limestone, or a combination thereof.

[0032] The linear low density plastic may be linear low density polyethylene.

[0033] The high density plastic may be a polyvinylchloride (PVC), a polyethylene (HDPE), a terephthalate (PET), a polytetrafluoroethylene (PTFE), a polystyrene (PS), a polyvinylidine chloride.

[0034] The high density plastic may be high density polyethylene.

[0035] The linear low density plastic or the high density plastic may be recycled plastic.

[0036] The coupling agent may be a maleic anhydride-grafted resin.

[0037] The coupling agent may be at about 1 % to about 3% w/w of the composition.

[0038] The process may further comprise a light stabilizer.

[0039] The light stabilizer may be a UV absorber, a UV quencher, a hindered amine light stabilizer (HALS), or combinations thereof.

[0040] The composite material may comprise from about 2% to about 5 % w/w of the light stabilizer.

[0041] The process may further comprise a flame retardant.

[0042] The flame retardant may be mineral wool, gypsum, perlite, calcium silicate (Ca2Si04), aluminium hydroxide (AIOH), magnesium hydroxide (Mg(OH)2), zinc borate, huntite, hydromagnesite, red phosphorus, chlorendic acid derivatives, chlorinated paraffins, decabromodiphenyl ether, decabromodiphenyl ethane, polymeric brominated compounds such as brominated polystyrenes, brominated epoxy oligomers, tetrabromophthalic anyhydride, tetrabromobisphenol A, hexabromocyclododecane, antimony trioxide, triphenyl phosphate, resorcinol bis(diphenylphosphate), bisphenol A diphenyl phosphate, and tricresyl phosphate (TCP), dimethyl methylphosphonate, aluminum diethyl phosphinate, tris(2,3-dibromopropyl) phosphate, tris(1 ,3-dichloro-2- propyl)phosphate, and tetrekis(2-chlorethyl)dichloroisopentyldiphosphate, and combinations thereof.

[0043] The process may further comprise a colorant.

[0044] The process may further comprise an antimicrobial agent.

[0045] The antimicrobial agent may be zinc borate hydrate.

[0046] The hot melt uniformly blended mix may be prepared in an ultrahigh-speed thermo-kinetic mixer.

[0047] According to another embodiment, there is provided a wood-plastic composite material prepared by the process of the present invention, and having about 0.5% or less moisture content, and at least about 92% fiber encapsulation level.

[0048] According to another embodiment, there is provided a wood-plastic composite material comprising: a) between about 12% to about 15% w/w linear low density plastic; b) between about 30% to about 38% w/w high density plastic;

c) between about 0% to about 40% w/w calcium carbonate;

d) between about 20% to about 50% w/w wood flour; and e) a coupling agent,

comprising about 0.5% or less moisture content, and at least about 92% fiber encapsulation level. [0049] The wood flour may be hemlock wood flour, cedar wood flour or combinations thereof.

[0050] The wood flour may have a particle size of between about 250 and about 425 microns (60 to 40 mesh).

[0051] The calcium carbonate may have a particle size of between about 3 and about 10 microns, or about 4 to about 5 microns.

[0052] The calcium carbonate (CaC03) mineral may be calcite, aragonite, limestone, or a combination thereof.

[0053] The linear low density plastic may be linear low density polyethylene, linear low density polypropylene, or a combination thereof.

[0054] The high density plastic may be a polyvinylchloride (PVC), a polyethylene (HDPE), a terephthalate (PET), a polytetrafluoroethylene (PTFE), a polystyrene (PS), a polyvinylidine chloride.

[0055] The high density plastic may be high density polyethylene, high density polypropylene, or a combination thereof.

[0056] The linear low density plastic or the high density plastic may be recycled plastic.

[0057] The coupling agent may be a maleic anhydride-grafted resin.

[0058] The coupling agent may be at about 1 % to about 4% w/w of the composition.

[0059] The composite material may further comprise a light stabilizer.

[0060] The light stabilizer may be a UV absorber, a UV quencher, a hindered amine light stabilizer (HALS), or combinations thereof.

[0061] The composite material may comprise from about 2% to about 5 % w/w of the light stabilizer.

[0062] The composite material may further comprise a flame retardant. [0063] The flame retardant may be mineral wool, gypsum, perlite, calcium silicate (Ca2Si04), aluminium hydroxide (AIOH), magnesium hydroxide (Mg(OH)2), zinc borate, huntite, hydromagnesite, red phosphorus, chlorendic acid derivatives, chlorinated paraffins, decabromodiphenyl ether, decabromodiphenyl ethane, polymeric brominated compounds such as brominated polystyrenes, brominated epoxy oligomers, tetrabromophthalic anyhydride, tetrabromobisphenol A, hexabromocyclododecane, antimony trioxide, triphenyl phosphate, resorcinol bis(diphenylphosphate), bisphenol A diphenyl phosphate, and tricresyl phosphate (TCP), dimethyl methylphosphonate, aluminum diethyl phosphinate, tris(2,3-dibromopropyl) phosphate, tris(1 ,3-dichloro-2- propyl)phosphate, and tetrekis(2-chlorethyl)dichloroisopentyldiphosphate, and combinations thereof.

[0064] The composite material may further comprise a colorant.

[0065] The composite material may further comprise an antimicrobial agent.

[0066] The antimicrobial agent may be zinc borate hydrate.

[0067] According to another embodiment, there is provided an item of manufacture prepared from the composite material of the present invention.

[0068] The item of manufacture may be a shingle.

[0069] The following terms are defined below.

[0070] The term "Froude number" is intended to mean a dimensionless number defined as the ratio of the flow inertia to the external field (the latter in many applications simply due to gravity). The Froude number is based on the speed-length ratio which is defined as: where uo is a characteristic flow velocity, go is in general a characteristic external field, and h is a characteristic length.

[0071] In this disclosure, the word "comprising" is used in a non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article "a" does not exclude the possibility that more than one of the elements is present, unless the context clearly requires that there be one and only one of the elements. In this disclosure the recitation of numerical ranges by endpoints includes all numbers subsumed within that range including all whole numbers, all integers and all fractional intermediates (e.g., 1 to 5 includes 1 , 1 .5, 2, 2.75, 3, 3.80, 4, and 5 etc.).

[0072] In this disclosure the singular forms "a", "an", and "the" include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a composition containing "a compound" includes a mixture of two or more compounds.

[0073] In this disclosure term "or" is generally employed in its sense including "and/or" unless the content clearly dictates otherwise. In this disclosure, unless otherwise indicated, all numbers expressing quantities or ingredients, measurement of properties and so forth used in the specification and claims are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary or necessary in light of the context, the numerical parameters set forth in the disclosure are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings of the present disclosure and in light of the inaccuracies of measurement and quantification. Without limiting the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, their numerical values set forth in the specific examples are understood broadly only to the extent that this is consistent with the validity of the disclosure and the distinction of the subject matter disclosed and claimed from the prior art.

[0074] In this disclosure the term "additive" means any additions to a mixture which are present in relatively low quantities, but whose presence is desired by a user for other reasons. In embodiment zinc borate is used as an additive, in other embodiments a coloring agent is used as an additive. By way of example and not limitation, an additive may be used to prevent or reduce bacterial, algal or moss growth or to prevent degradation, or to color or change the appearance of the material, or to help the material cure. In embodiments an additive may be a coupling agent.

[0075] In this disclosure the term "Mesh" means U.S. filter mesh sizes and the mesh size represents the number of openings per square inch. It will be understood that in particular embodiments the particle sizes for individual components may be larger or smaller than those presented for the illustrative embodiments.

[0076] The term "wood flour" means and includes any form of fragmented wood material and is intended to mean finely ground wood material will be in the range of 40 to 60 mesh and consequently have a particle size of about 250 microns to 425 microns.

[0077] In this disclosure the term "rock" or "mineral", "rock dust" means and includes all suitable forms of calcium carbonate. It will be understood by those skilled in the art that in embodiments the rock may be relatively soft or otherwise easy to fragment, grind or reduce to powder. In embodiments the rock may be relatively porous. In particular embodiments the rock is or comprises limestone or similar materials. In embodiments the limestone powder may be waste from other processes. [0078] In this disclosure the term "melting" refers to heating a plastic component or mixture of components comprising plastic, so that the plastic adopts a substantially liquid consistency so that the plastic and other components can be substantially homogeneously intermixed forming a molten mass. In embodiments melting may occur at any suitable temperature and in embodiments occurs at between about 180°C and about 190°C. Where the plastic used is or comprises polypropylene, a suitable temperature is about 180°C, but in embodiments temperatures of about 180°C, 181 °C, 182°C, 183°C, 184°C, 185°C, 186°C, 187°C, 188°C, 189°C, 190°C, or from about 180 to about 190°C, or from about 181 to about 190°C, 182 to about 190°C, 183 to about 190°C, 184 to about 190°C, 185 to about 190°C, 186 to about 190°C, 187 to about 190°C, 188 to about 190°C, 189 to about 190°C, or from about 180 to about 189°C, or from about 181 to about 189°C, 182 to about 189°C, 183 to about 189°C, 184 to about 189°C, 185 to about 189°C, 186 to about 189°C, 187 to about 189°C, 188 to about 189°C, or from about 180 to about 188°C, or from about 181 to about 188°C, 182 to about 188°C, 183 to about 188°C, 184 to about 188°C, 185 to about 188°C, 186 to about 188°C, 187 to about 188°C, or from about 180 to about 187°C, or from about 181 to about 187°C, 182 to about 187°C, 183 to about 187°C, 184 to about 187°C, 185 to about 187°C, 186 to about 187°C, or from about 180 to about 186°C, or from about 181 to about 186°C, 182 to about 186°C, 183 to about 186°C, 184 to about 186°C, 185 to about 186°C, or from about 180 to about 185°C, or from about 181 to about 185°C, 182 to about 185°C, 183 to about 185°C, 184 to about 185°C, or from about 180 to about 184°C, or from about 181 to about 184°C, 182 to about 184°C, 183 to about 184°C, or from about 180 to about 183°C, or from about 181 to about 183°C, 182 to about 183°C, or from about 180 to about 182°C, or from about 181 to about 182°C, or from about 180 to about 181 °C will be suitable. Those skilled in the art will readily select a suitable melting temperature to take account of the properties of the particular plastic used and of the mixture of components.

[0079] In this disclosure the term "moisture content" refers to the weight of moisture on a wet (or total weight) basis, as per the formulas:

in which:

Mn = moisture content (%) of material n Ww = wet weight of the sample, and Wd = weight of the sample after drying.

[0080] In this disclosure the terms "fiber encapsulation" or "fiber encapsulation level" refers to the plastic component covering of the wood particles in the wood/plastic composite (WPC), and the degree (or level) to which this covering is achieved by the plastic component. A lesser degree of fiber encapsulation results in a greater exposure of the wood fiber to sources of moisture. Exposure to moisture for prolonged periods results in debonding of the wood/polymer interface caused by the intrusion of moisture. Therefore, a lower degree of fiber encapsulation / a lower fiber encapsulation level is associated with poor wood-fiber interfaces with the polymer material, while a higher degree of fiber encapsulation / a higher fiber encapsulation level is associated with better wood-fiber interfaces with the polymer material. According to the present invention, a fiber encapsulation level of at least 92% is desired. Therefore, the fiber encapsulation level may be of at least 92, 93, 94, 95, 96, 97, 98, 99, or 100%, or from about 92% to about 100%, or from about 93% to about 100%, or from about 94% to about 100%, or from about 95% to about 100%, or from about 96% to about 100%, or from about 97% to about 100%, or from about 98% to about 100%, or from about 99% to about 100%, or from about 92% to about 99%, or from about 93% to about 99%, or from about 94% to about 99%, or from about 95% to about 99%, or from about 96% to about 99%, or from about 97% to about 99%, or from about 98% to about 99%, or from about 92% to about 98%, or from about 93% to about 98%, or from about 94% to about 98%, or from about 95% to about 98%, or from about 96% to about 98%, or from about 97% to about 98%, or from about 92% to about 97%, or from about 93% to about 97%, or from about 94% to about 97%, or from about 95% to about 97%, or from about 96% to about 97%, or from about 92% to about 96%, or from about 93% to about 96%, or from about 94% to about 96%, or from about 95% to about 96%, or from about 92% to about 95%, or from about 93% to about 95%, or from about 94% to about 95%, or from about 92% to about 94%, or from about 93% to about 94%, or from about 92% to about 93% fiber encapsulation level.

[0081] In this disclosure the terms "ultrahigh-speed thermo-kinetic mixer" or "thermokinetic compounder" are to be used interchangeably, and is a device that produces uniformly blended, fully dispersed and, in most cases, fluxed compound that can be immediately processed by a simple shaping device The device performs the mixing, dispersing, heating and fluxing so only downstream shaping of the compound is required. The material processed in the device forms a turbulent centrifugal annular layer of increasing density along the inner wall of the mixing/compounding cylinder. Specially designed mixing elements provide for an extremely high acceleration of the feedstock. Interaction with the braking effect of friction at the walls of the mixing/compounding chamber results in large differences in particle velocity within the annular layer and intensive mixing turbulences. Uniform disintegration and blending of the constituents are thereby achieved in a matter of seconds. The friction generated by the high differences in velocity within the annular product layers can be used precisely for breaking up agglomerates, drying and melting of polymer mixes.

[0082] Features and advantages of the subject matter hereof will become more apparent in light of the following detailed description of selected embodiments, as illustrated in the accompanying figures. As will be realized, the subject matter disclosed and claimed is capable of modifications in various respects, all without departing from the scope of the claims. Accordingly, the drawings and the description are to be regarded as illustrative in nature, and not as restrictive and the full scope of the subject matter is set forth in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0083] Further features and advantages of the present disclosure will become apparent from the following detailed description, taken in combination with the appended drawings, in which:

[0084] Fig. 1 illustrates a method according to an embodiment of the present invention.

[0085] Fig. 2 illustrates a method according to an embodiment of the present invention.

[0086] Fig. 3 illustrates a method according to an embodiment of the present invention.

[0087] Fig. 4 illustrates a method according to an embodiment of the present invention.

[0088] Fig. 5 illustrates a kinetic disintegration mixer and process of using the same, according to an embodiment of the present invention.

[0089] It will be noted that throughout the appended drawings, like features are identified by like reference numerals.

DETAILED DESCRIPTION

[0090] According to an embodiment hot melt mixing technology using an ultrahigh-speed thermo-kinetic mixer/com pounder is used to produce a fully dispersed, fully fluxed, uniformly blended compound with a maximum of 0.5 % moisture content, and at least 92% fiber encapsulation level.

[0091] Poor Fiber Encapsulation levels increase the ambient moisture rehydration times. This faster re-hydration time within the material creates internal stresses, warpage and deformation of the finished products formed from the composite material. The ideal re-hydration period should be over a 30 day period.

[0092] Higher internal moisture levels (above 0.5%) within the wood/plastic composite (WPC) compound also degrades the polymer, changing viscosity levels and creating a more brittle structure. The process of the present invention eliminates both the single pass and multiple pass WPC extrusion techniques currently used to produce pellets or profiles. It also eliminates all internal and external lubricants required to maximize throughput and surface finish on the extruded profiles.

[0093] Now referring to Fig. 1 , in embodiments there is disclosed a process (100) for the preparation of a wood-plastic composite material comprising the step (102) of:

1 ) preparing a hot melt uniformly blended mix comprising

a) between about 10% to about 15% w/w linear low density plastic; b) between about 30% to about 40% w/w high density plastic;

c) between about 10% to about 25% w/w calcium carbonate;

d) between about 25% to about 65% w/w wood flour; and e) between about 1 % to about 3% of a coupling agent, wherein the linear low density plastic and the high density plastic are melted and intermixed with the calcium carbonate, wood flour and coupling agent at a speed sufficient to generate a temperature between about 180°C and about 190°C, and for a time sufficient to obtain the hot melt uniformly blended mix, wherein the hot melt uniformly blended mix comprises about 0.5% or less moisture content, and at least about 92% fiber encapsulation level. In embodiments, the horizontally positioned central rotating shaft of the thermo-kinetic mixer has several staggered (variably positioned) mixing elements attached to a shaft. The mixing does not require an external heat source, and captures the heat from the mixing and centrifugal force in the thermo-kinetic mixer. The unrestricted impingement of the mix of ingredients being blended against the interior chamber walls, induced by high tip speeds, effects the thermos-kinetic heating of the compound batch. This high material turbulence creates a rapid temperature increase, resulting in a very short mixing cycle time of 60 seconds. This mixing cycle time includes a material fill time of 15 seconds, a compounding time of 40 seconds and a fully blended compound discharge time of 5 seconds. This based upon a 6.35 kg (14 lbs) batch size. With a 30% wood fiber loading, optimum results are obtained with a rotor tip speed of 36 m/sec. Increasing the wood fiber level to 65%, requires a rotor tip speed of 42 m/sec. A pre-programmed microprocessor controls the mixing cycle time, melt temperature (e.g. 190°C) and tip speed, to ensure consistent batches. In embodiments, the speed sufficient to mix all the ingredients of the composition of the present invention generate a temperature between about 180°C and about 190°C provides a Froude number of about 300 to about 1295, or about 400 to about 1295, or about 500 to about 1295, or about 600 to about 1295, or about 700 to about 1295, or about 800 to about 1295, or about 900 to about 1295, or about 1000 to about 1295, or about 1 100 to about 1295, or about 1200 to about 1295. That is, the mixing of the ingredients provides the Froude number. Newtons or shear strength measures are typically based on laminar flow situation, do not describe accurately the process of the present invention, while the thermos-kinetic mixing concept used in the present invention creates extensive turbulence flow, never laminar flow. The change of material conditions from initial powdery to a molten mass of various viscosities, depending on the specific condition of the process cycle also greatly influences the process conditions. For these reasons, the Froude number is a more adequate value to describe the process condition required to obtain product of the present invention.

[0094] In embodiments, the process 100 of the present invention further comprises step 2 (104), of forming a thick sheet from the hot melt uniformly blended mix, wherein the thick sheet is cooled from a first temperature of about 180°C to about 190°C to a second temperature of about 135 to about 145°C. First temperatures about 190°C results in fiber degradation while below 180°C, increases compound moisture levels about 0.5%.

[0095] In embodiments, the process 100 of the present invention further comprises step 3 (106), after step 2, of thermoforming and shaping the thick sheet in a thermoforming mold to obtain a thermoformed and shaped product therefrom.

[0096] Now referring to Fig. 2, according to some embodiments, the process 200 of the present invention may also comprise step 1 ') (204) , after step 1 ) (202), of discharging the hot melt uniformly blended mix to a hot melt extruder through a temperature- and humidity-controlled environment, such as an enclosure, following step 2) (206) of forming a thick sheet from the hot melt uniformly blended mix, wherein the thick sheet is cooled from a first temperature of about 180°C to about 190°C a second temperature of about 135 to about 145°C, and step 3) (208) of thermoforming and shaping the thick sheet in a thermoforming mold to obtain a thermoformed and shaped product therefrom.

[0097] In embodiments, "melting" refers to heating a plastic component or mixture of components comprising plastic, so that the plastic adopts a substantially liquid consistency so that the plastic and other components can be substantially homogeneously intermixed forming a molten mass. In embodiments melting may occur at the temperatures disclosed above. Those skilled in the art will readily select a suitable melting temperature to take account of the properties of the particular plastic used and of the mixture of components.

[0098] In embodiments heating/melting/mixing occur for any suitable time, depending on batch size. In particular embodiments, a very short mixing cycle time of 60 seconds may be used. This mixing cycle time includes a material fill time of 15 seconds, a compounding time of 40 seconds and a fully blended compound discharge time of 5 seconds. In alternative embodiments, any suitable combination of temperature, mixing method and time, will be adopted to suit particular purposes. The ability of creating and controlling a rapid temperature rise from intense shearing allows transfers of mechanical energy to heat. This ensures a completely blended material within the chamber, operating at atmospheric pressure, continuously venting all volatiles and moisture. This time frame remains consistent for each compound batch, the only variable is tip speed, which is preprogrammed to the desired fiber level in formulation.

[0099] In embodiment, the melting step occurs in a closed vessel. Conventional WPC extrusion compounding or pelletizing introduces the wood fiber at mid-point of the extruder screw, not at the feed throat. All other materials process through the feed throat, reaching their desired melt temperature, then the wood fiber is introduced. This processing design is necessary to minimize fiber processing time and to prevent fiber degradation. This however, also limits fiber encapsulation levels and moisture levels. In the present invention, the melting / blending step occurs within a closed vessel and each batch of particle receives the identical amount of mixing work and thermal exposure. All materials within the blend, including additives and fibers, are processed simultaneously at a pre-determined shear rate, achieving optimum encapsulation and moisture levels. In some embodiments oxygen may be excluded and in other embodiments, oxygen may not be excluded. Those skilled in the art will readily identify suitable models and procedures.

[00100] Now referring to Fig. 3, in embodiments, step 2) of forming the thick sheet from the hot melt uniformly blended mix involves cooling the mixture of plastic on a conveyor, such as the sheet die cooling roll system (310). In embodiments the composite material is actively cooled using cooled air or other suitable means, all of which will be readily identified and implemented by those skilled in the art. [00101] In embodiments, there is disclosed a method for making shingles, the method comprising forming and shaping the composite material according to embodiments.

[00102] In embodiments, the term "plastic" means any suitable plastic. In particular embodiments plastic includes low density and high density plastics, and include, as preferred embodiments polyethylene or polypropylene of high and low densities. In embodiments plastic may be recycled. In embodiments, the low density plastic is linear low density plastic. In embodiments plastic is provided in the form of pellets or shredded or otherwise comminuted plastic. According to some embodiments the plastic comprises other components. In embodiments, the plastic may be polyvinylchloride (PVC), polyethylene terephthalate (PET), polytetrafluoroethylene (PTFE), polystyrene, poyvinylidine chloride (Saran), linear low density polyethylene, low density polyethylene, high density polyethylene (HDPE, LDPE and LLDPE), or combinations thereof.

[00103] In particular embodiment, the high density plastic may be a 4-6 melt range injection or extrusion grade natural resin in pellet or re-grind form. Resin will require a processing range between 180-190°C.

[00104] In particular embodiments, the low density plastic or the linear low density plastic may be a 5-7 melt range injection or extrusion grade natural virgin resin.

[00105] The process of the present invention may comprise between about 10% to about 15% w/w, or from about 1 1 % to about 15% w/w, or from about 12% to about 15% w/w, or from about 13% to about 15% w/w, or from about 14% to about 14%, or from about 10% to about 14% w/w, or from about 1 1 % to about 14%, or from about 12% to about 14%, or from about 13% to about 14%, or from about 10% to about 13% w/w, or from about 1 1 % to about 13%, or from about 12% to about 13%, or from about 10% to about 12% w/w, or from about 1 1 % to about 12%, or from about 10% to about 1 1 % w/w low density plastic. [00106] The process of the present invention may comprise between about 30% to about 40% w/w, 30% to about 39% w/w, 30% to about 38% w/w, or from about 30% to about 37% w/w, or from about 30% to about 36% w/w, or from about 30% to about 35% w/w, or from about 30% to about 34% w/w, or from about 30% to about 33% w/w, or from about 30% to about 32% w/w, or from about 30% to about 31 % w/w, or about 31 % to about 40% w/w, or about 31 % to about 39% w/w, or about 31 % to about 38% w/w, or from about 31 % to about 37% w/w, or from about 31 % to about 36% w/w, or from about 31 % to about 35% w/w, or from about 31 % to about 34% w/w, or from about 31 % to about 33% w/w, or from about 31 % to about 32% w/w, or about 32% to about 40% w/w, or about 32% to about 39% w/w, or about 32% to about 38% w/w, or from about 32% to about 37% w/w, or from about 32% to about 36% w/w, or from about 32% to about 35% w/w, or from about 32% to about 34% w/w, or from about 32% to about 33% w/w, or about 33% to about 40% w/w, or about 33% to about 39% w/w, or about 33% to about 38% w/w, or from about 33% to about 37% w/w, or from about 33% to about 36% w/w, or from about 33% to about 35% w/w, or from about 33% to about 34% w/w, or about 34% to about 40% w/w, or about 34% to about 39% w/w, or about 34% to about 38% w/w, or from about 34% to about 37% w/w, or from about 34% to about 36% w/w, or from about 34% to about 35% w/w, or about 35% to about 40% w/w, or about 35% to about 39% w/w, or about 35% to about 38% w/w, or from about 35% to about 37% w/w, or from about 35% to about 36% w/w, or about 36% to about 40% w/w, or about 36% to about 39% w/w, or about 36% to about 38% w/w, or from about 36% to about 37% w/w, or about 37% to about 40% w/w, or about 37% to about 39% w/w, or about 37% to about 38% w/w, or about 38% to about 40% w/w, or about 38% to about 39% w/w, or about 39% to about 40% w/w or about 30, 31 , 32, 33, 34, 35, 36, 37, 38, 39, 40% w/w high density plastic.

[00107] In embodiments, the term "calcium carbonate" is dust from any suitable forms of calcium carbonate. It will be understood by those skilled in the art that in embodiments the rock may be relatively soft or otherwise easy to fragment, grind or reduce to powder. In embodiments the rock may be relatively porous. In particular embodiments the calcium carbonate is or comprises limestone or similar materials. In particular embodiments, the calcium carbonate (CaC03) mineral is calcite, aragonite, limestone or a combination thereof. In particular embodiments, the calcium carbonate (CaC03) mineral is limestone. In embodiments the limestone powder may be waste from other processes.

[00108] In particular embodiment, the calcium carbonate or rock powder, or calcium carbonate has a water content of about 1 % to about 5%, or about 1 % to about 4%, or about 1 % to about 3%, or about 1 % to about 3%, or about 2% to about 5%, or about 2% to about 4%, or about 2% to about 3%, or about 3% to about 5%, or about 3% to about 4%, or about 4% to about 5%. In embodiments the rock is limestone.

[00109] According to an embodiment, the process of the present invention comprises between about 10% to about 25% w/w, or about 1 1 % to about 25% w/w, about 12% to about 25% w/w, about 13% to about 25% w/w, about 14% to about 25% w/w, about 15% to about 25% w/w, about 16% to about 25% w/w, about 17% to about 25% w/w, about 18% to about 25% w/w, about 19% to about 25% w/w, about 20% to about 25% w/w, about 21 % to about 25% w/w, about 22% to about 25% w/w, about 23% to about 25% w/w, about 24% to about 25% w/w, or about 10% to about 24% w/w, or about 1 1 % to about 24% w/w, about 12% to about 24% w/w, about 13% to about 24% w/w, about 14% to about 24% w/w, about 15% to about 24% w/w, about 16% to about 24% w/w, about 17% to about 24% w/w, about 18% to about 24% w/w, about 19% to about 24% w/w, about 20% to about 24% w/w, about 21 % to about 24% w/w, about 22% to about 24% w/w, about 23% to about 24% w/w, or about 10% to about 23% w/w, or about 1 1 % to about 23% w/w, about 12% to about 23% w/w, about 13% to about 23% w/w, about 14% to about 23% w/w, about 15% to about 23% w/w, about 16% to about 23% w/w, about 17% to about 23% w/w, about 18% to about 23% w/w, about 19% to about 23% w/w, about 20% to about 23% w/w, about 21 % to about 23% w/w, about 22% to about 23% w/w, or about 10% to about 22% w/w, or about 1 1 % to about 22% w/w, about 12% to about 22% w/w, about 13% to about 22% w/w, about 14% to about 22% w/w, about 15% to about 22% w/w, about 16% to about 22% w/w, about 17% to about 22% w/w, about 18% to about 22% w/w, about 19% to about 22% w/w, about 20% to about 22% w/w, about 21 % to about 22% w/w, or about 10% to about 21 % w/w, or about 1 1 % to about 21 % w/w, about 12% to about 21 % w/w, about 13% to about 21 % w/w, about 14% to about 21 % w/w, about 15% to about 21 % w/w, about 16% to about 21 % w/w, about 17% to about 21 % w/w, about 18% to about 21 % w/w, about 19% to about 21 % w/w, about 20% to about 21 % w/w, or about 10% to about 20% w/w, or about 1 1 % to about 20% w/w, about 12% to about 20% w/w, about 13% to about 20% w/w, about 14% to about 20% w/w, about 15% to about 20% w/w, about 16% to about 20% w/w, about 17% to about 20% w/w, about 18% to about 20% w/w, about 19% to about 20% w/w, or about 10% to about 19% w/w, or about 1 1 % to about 19% w/w, about 12% to about 19% w/w, about 13% to about 19% w/w, about 14% to about 19% w/w, about 15% to about 19% w/w, about 16% to about 19% w/w, about 17% to about 19% w/w, about 18% to about 19% w/w, or about 10% to about 18% w/w, or about 1 1 % to about 18% w/w, about 12% to about 18% w/w, about 13% to about 18% w/w, about 14% to about 18% w/w, about 15% to about 18% w/w, about 16% to about 18% w/w, about 17% to about 18% w/w, or about 10% to about 17% w/w, or about 1 1 % to about 17% w/w, about 12% to about 17% w/w, about 13% to about 17% w/w, about 14% to about 17% w/w, about 15% to about 17% w/w, about 16% to about 17% w/w, or about 10% to about 16% w/w, or about 1 1 % to about 16% w/w, about 12% to about 16% w/w, about 13% to about 16% w/w, about 14% to about 16% w/w, about 15% to about 16% w/w, or about 10% to about 15% w/w, or about 1 1 % to about 15% w/w, about 12% to about 15% w/w, about 13% to about 15% w/w, about 14% to about 15% w/w, or about 10% to about 14% w/w, or about 1 1 % to about 14% w/w, about 12% to about 14% w/w, about 13% to about 14% w/w, or about 10% to about 13% w/w, or about 1 1 % to about 13% w/w, about 12% to about 13% w/w, or about 10% to about 12% w/w, or about 1 1 % to about 12% w/w, or about 10% to about 1 1 % w/w, or about 10, 1 1 , 12, 13, 14, 15, 16, 17, 18, 19, 20, 21 , 22, 23, 24, 25% w/w calcium carbonate.

[00110] In embodiments, the calcium carbonate may have a particle size of between about 1 to about 5 microns, or about 1 to about 4 microns, or about 1 to about 3 microns, or about 1 to about 2 microns, or about 2 to about 5 microns, or from about 2 to about 4 microns, or from about 2 to about 3 microns, or from about 3 to about 5 microns, or from about 3 to about 4 microns, or from about 4 to about 5 microns, or about 2, 3, 4, 5, microns.

[00111] In embodiments, the calcium carbonate may have a melt range of 3 to about 5 melt flow index (MFI), or about 4 to about 5 MFI, or about 3 to about 4 MFI, or about 3, 4, 5 MFI.

[00112] In embodiments, the calcium carbonate may have a density of between about 1 .65 to about 1 .7 g/cm³, or from about 1.65 to about 1 .69 g/cm³, or from about 1 .65 to about 1.68 g/cm³, or from about 1 .65 to about 1 .67 g/cm³, or from about 1 .65 to about 1 .66 g/cm³, or about 1 .66 to about 1.7 g/cm³, or from about 1 .66 to about 1 .69 g/cm³, or from about 1 .66 to about 1.68 g/cm³, or from about 1 .66 to about 1 .67 g/cm³, or about 1 .67 to about 1 .7 g/cm³, or from about 1 .67 to about 1 .69 g/cm³, or from about 1 .67 to about 1 .68 g/cm³, or about 1 .68 to about 1.7 g/cm³, or from about 1 .68 to about 1 .69 g/cm³, or about 1 .69 to about 1 .7 g/cm³, or about 1 .65, 1 .66, 1 .67, 1 .68, 1 .69, or 1 .7 g/cm³.

[00113] In embodiments particle size may be relatively homogeneous or may be heterogeneous within the parameters specified.

[00114] In another embodiment, the process of the present invention comprises wood flour. In this disclosure the term "wood flour" means and includes any form of fragmented wood material. In particular embodiments, wood flour comprises bark material. In particular embodiments the wood material is hemlock or is cedar, or combination thereof. In a preferred embodiment, the wood material is hemlock. In particular embodiments the sawdust is dried or substantially dried before use. In embodiments, sawdust particles with a moisture range between about 25% to 60% moisture content are pre-dried, for example in an indirect rotary dryer, to reduce the moisture range to 12-15% moisture content. Next, the sawdust having a 12-15% moisture content is then pulverized to produce a wood flour. The frictional heat generated during this step further reduces the moisture range to about 7-10% moisture content. Introduction of the wood flour into the thermos-kinetic mixer as described above achieves a final moisture content that is 0.5% or less. Also see example 1 below. According to another embodiment, the wood flour used in the present invention may be prepared from untreated sawdust having for example a particle size range between about 0.3175 cm to about 2,2225 cm (about 1/8" to about 7/8"), or about 0.635 cm to about 2,2225 cm, or about 0.9525 cm to about 2,2225 cm, or about 1 ,27 cm to about 2,2225 cm, or about 1 ,5875 cm to about 2,2225 cm, or about 1 ,905 cm to about 2,2225 cm, or about 0.3175 cm to about 1 ,905 cm, or about 0.635 cm to about 1 ,905cm, or about 0.9525 cm to about 1 ,905 cm, or about 1 ,27 cm to about 1 ,905 cm, or about 1 ,5875 cm to about 1 ,905 cm, or or about 0.3175 cm to about 1 ,5875 cm, or about 0.635 cm to about 1 ,5875 cm, or about 0.9525 cm to about 1 ,5875 cm, or about 1 ,27 cm to about 1 ,5875 cm, or about 0.3175 cm to about 1 ,27 cm, or about 0.635 cm to about 1 ,27 cm, or about 0.9525 cm to about 1 ,27 cm, or about 0.3175 cm to about 0.9525 cm, or about 0.635 cm to about 0.9525 cm, or about 0.3175 cm to about 0.635 cm. The moisture content of the untreated sawdust may be between 25-75%. This wide range of moisture and particles sizes is limiting in achieving a consistent wood flour when using conventional drying and pulverizing equipment.

[00115] Therefore, in order to resolve these variables and according to another embodiment, a combination dryer and pulverizer unit based upon a kinetic disintegration process similar to that described above allows the combination of size reduction and moisture removal within a single operation. The kinetic disintegration process equipment (dryer and pulverizer) requires no external heat source and captures the heat of comminution combined with centrifugal forces to expedite moisture extraction. According to this embodiment, the internal baffle plates and impact plates of the kinetic disintegration mixer were replaced with customized suspended chains on the main vertical drive shaft. The original internal baffle/impact plates were unable to provide wood flour having the required moisture and particle size ranges. The original internal baffle/impact plates provided high levels of fine particles (fines) between 100-200 mesh size (i.e. between 149 to 74 microns) caused by the large flat plate surface area. Replacing the plates with circular bar did reduce fines, but did not provide satisfactory moisture levels. Therefore, according to an embodiment, a series of steel chains prove able to provide acceptable wood flour. Such chains comprise for example links of about 1 .27 cm (0.5 in) and are about 15.24 cm (6 in) long. Suitable material include any steel or metal that offers high resistance to pitting, corrosion, moisture and low spark resistance. For example, grade 80 alloy steel is suitable. According to an embodiment, the use of these suspended chains resulted in a decrease from 25-30% fines to about 5% fines, within the desired moisture range. High rotational tip speeds generated air flow velocities between about 1219,2 m/min to about 1371 ,6 m/min (4000-4500 ft/min), or about 1249,68 m/min to about 1371 ,6 m/min, or about 1280, 16 m/min to about 1371 ,6 m/min, or about 1310,64 m/min to about 1371 ,6 m/min, or about 1341 , 12 m/min to about 1371 ,6 m/min, or about 1219,2 m/min to about 1341 , 12 m/min, or about 1249,68 m/min to about 1341 , 12 m/min, or about 1280, 16 m/min to about 1341 , 12 m/min, or about 1310,64 m/min to about 1341 , 12 m/min, or about 1219,2 m/min to about 1310,64 m/min, or about 1249,68 m/min to about 1310,64 m/min, or about 1280, 16 m/min to about 1310,64 m/min, or about 1219,2 m/min to about 1280, 16 m/min, or about 1249,68 m/min to about 1280, 16 m/min, or about 1219,2 m/min to about 1249,68 m/min. The untreated sawdust is accelerated within the chamber, colliding with the rotating chains. Kinetic energy is released through this impact, pulverizing the untreated sawdust and releasing heat to dry the wood fibers (wood flour) thus pulverized. An internal classifier controls particle size, allowing the in-spec particles of wood flour (see below) to exit the chamber to the final classification/packaging area. The obtained wood flour will have a moisture content of about 7 to about 10%, or from about 8 to about 10%, or from about 9 to about 10%, 7 to about 9%, or from about 8 to about 9%, or from about 7 to about 8%, or about 7, 8, 9, or 10%.

[00116] Now referring to Fig. 5, there is shown a kinetic disintegration mixer and process according to the present invention, with dryer-pulverizer (600), comprising inlet (601 ) for receiving wood chips, drive shaft (602), outlet (603) for discharge of steam. Attached to drive shaft (602) are a number of suspended chains (604) having a series of chain links as described above. The dryer- pulverizer (600) also comprises internal screening (605) for retention of oversized fiber or wood chips. Upon activation, the wood chips are pulverized and the resulting flour dried, as described above. The resulting flour is then transferred to a final wood flour screening (650), where the on spec fiber is collected through outlet (606) and transferred to thermokinetic mixer (607) and oversized fibers or fines are rejected through outlets (608 and 609), respectively.

[00117] In particular embodiments particles of wood flour will be in the range of 40 to 60 mesh and consequently have a particle size of about 250 microns to 425 microns. It will be understood that in alternative embodiments the particles are less than about 425, 400, 375, 350, 325, 300, 275, 250 microns in size. In alternative embodiment, the particles are from about 250 to about 425 microns, or about 250 to about 400 microns, or about 250 to about 375 microns, or about 250 to about 350 microns, or about 250 to about 300 microns, or about 250 to about 275 microns, or about 275 to about 425 microns, or about 275 to about 400 microns, or about 275 to about 375 microns, or about 275 to about 350 microns, or about 275 to about 300 microns, or about 300 to about 425 microns, or about 300 to about 400 microns, or about 300 to about 375 microns, or about 300 to about 350 microns, or about 325 to about 425 microns, or about 325 to about 400 microns, or about 325 to about 375 microns, or about 325 to about 350 microns, or about 350 to about 425 microns, or about 350 to about 400 microns, or about 350 to about 375 microns, or about 375 to about 425 microns, or about 375 to about 400 microns, or about 400 to about 425 microns.

[00118] In embodiments, the process of the present invention comprises between about 25% to about 65% w/w, about 25% to about 60% w/w, about 25% to about 55% w/w, about 25% to about 50% w/w, or from about 25% to about 45% w/w, or from about 25% to about 40% w/w, or from about 25% to about 35% w/w, or from about 25% to about 30% w/w, about 30% to about 65% w/w, about 30% to about 60% w/w, about 30% to about 55% w/w, about 30% to about 50% w/w, or from about 30% to about 45% w/w, or from about 30% to about 40% w/w, or from about 30% to about 35% w/w, about 35% to about 65% w/w, about 35% to about 60% w/w, about 35% to about 55% w/w, about 35% to about 50% w/w, or from about 35% to about 45% w/w, or from about 35% to about 40% w/w, about 40% to about 65% w/w, about 40% to about 60% w/w, about 40% to about 55% w/w, about 40% to about 50% w/w, or from about 40% to about 45% w/w, about 45% to about 65% w/w, about 45% to about 60% w/w, about 45% to about 55% w/w, about 45% to about 50% w/w, about 50% to about 65% w/w, about 50% to about 60% w/w, about 50% to about 55% w/w, about 55% to about 65% w/w, about 55% to about 60% w/w, about 60% to about 65% w/w wood flour.

[00119] In embodiments, the process of the present invention may further comprise a coupling agent. Coupling agents are chemical substance capable of reacting with both the reinforcement and the resin matrix of a composite material. It may also bond inorganic fillers or fibers to organic resins to form or promote a stronger bond at the interface. The coupling agent may be applied from a solution or gas phase to the reinforcement, added to the resin, or both. The coupling agent acts as interface between resin and glass fiber (or filler materials) to form a chemical bridge between the two. Most commonly used are organotrialkoxysilanes, titanates, zirconates and organic acid-chromium chloride coordination complexes. According to an embodiment, the coupling agent may be a maleic anhydride grafted resin. Fusabond 790™ demonstrated good results. The coupling agent may be present in the composite material at about 1 to about 4% w/w, or about 1 to about 3% w/w, or about 1 to about 2% w/w, or about 2 to about 4% w/w, or about 2 to about 3% w/w, or about 3 to about 4% w/w, or about 1 , 2, 3, or 4%.

[00120] In embodiments, the process of the present invention may further comprise a light stabilizer. Light stabilizers are used directly or by combinations to prevent the various effects such as oxidation, chain scission and uncontrolled recombinations and cross-linking reactions that are caused by photo-oxidation of polymers (i.e. the plastics found in the present invention). Polymers are considered to get weathered due to the direct or indirect impact of heat and ultraviolet light. The effectiveness of the stabilizers against weathering depends on solubility, the ability to stabilize in different polymer matrix, the distribution in matrix, evaporation loss during processing and use. In particular embodiments, light stabilizer is a UV absorber, a UV quencher, a hindered amine light stabilizer (HALS), or combination thereof. According to an embodiment, the light stabilizer and a HALS such as for example CESA-LIGHT #7132™.

[00121] In embodiments, the process of the present invention comprises from about 2% to about 5 % w/w, or from about 2% to about 4%, or from about 2% to about 3%, or from about 3% to about 5%, or from about 3% to about 4%, or from about 4% to about 5%, or about 2, 3, 4, or 5% of light stabilizer.

[00122] In embodiments, the process of the present invention may further comprise a flame retardant. Flame retardants are compounds added to manufactured materials, such as plastics and textiles, and surface finishes and coatings that inhibit, suppress, or delay the production of flames to prevent the spread of fire. They may be mixed with the base material (additive flame retardants) or chemically bonded to it (reactive flame retardants). Mineral flame retardants are typically additive while organohalogen and organophosphorus compounds can be either reactive or additive.

[00123] In particular embodiments, the flame retardant is chosen from mineral wool, gypsum, perlite, calcium silicate (Ca2Si04), aluminium hydroxide (AIOH), magnesium hydroxide (Mg(OH)2), zinc borate, huntite, hydromagnesite, red phosphorus, chlorendic acid derivatives, chlorinated paraffins, decabromodiphenyl ether, decabromodiphenyl ethane, polymeric brominated compounds such as brominated polystyrenes, brominated epoxy oligomers, tetrabromophthalic anyhydride, tetrabromobisphenol A, hexabromocyclododecane, antimony trioxide, triphenyl phosphate, resorcinol bis(diphenylphosphate), bisphenol A diphenyl phosphate, and tricresyl phosphate (TCP), dimethyl methylphosphonate, aluminum diethyl phosphinate, tris(2,3- dibromopropyl) phosphate, tris(1 ,3-dichloro-2-propyl)phosphate, and tetrekis(2- chlorethyl)dichloroisopentyldiphosphate, and combinations thereof.

[00124] In embodiments, the flame retardant is present in the composite material of the present invention at about 1 to about 3% w/w, or from about 1 to about 2% w/w, or from about 2 to about 3% w/w, or about 1 , 2, 3% w/w.

[00125] In embodiments, the process of the present invention may further comprise an antimicrobial agent. The antimicrobial agent may be incorporated into the composition of the composite material of the present invention, or may be coated on finished product embodiments made from the composite material of the present invention. Suitable antimicrobial agents include Zinc 2 -pyridinethiol-1 -oxide, N-butyl-1 , 2-benzisothiazolin-3-one, zinc hydrates such as 2 ΖηΟ·Β2θ3·3.5Η2θ (Borogard® GB™) or any other suitable compound known in the art and combinations thereof. [00126] In embodiments, the antimicrobial agent is present in the composite material of the present invention at about 1 to about 4% w/w, or from about 1 to about 3% w/w, or from about 1 to about 2% w/w, or from about 2 to about 4% w/w, or from about 2 to about 3% w/w, or from about 3 to about 4% w/w, or about 1 , 2, 3, 4% w/w.

[00127] In embodiments, the process of the present invention may further comprise a colorant, to provide the finished product embodiments made from the composite material of the present invention with an appealing color. The colorant may be incorporated into the composition of the composite material of the present invention, or may be coated on finished product embodiments. Suitable colorants include but are not limited to dyes, pigments, biological pigments, inks, paint, colored chemicals, and combinations thereof.

[00128] In embodiments, the colorant is present in the composite material of the present invention at about 1 to about 3% w/w, or from about 1 to about 2% w/w, or from about 2 to about 3% w/w, or about 1 , 2, 3% w/w.

[00129] According to another embodiment, there is provided a wood-plastic composite material prepared by the process of the present invention, and having about 0.5% or less moisture content, and at least about 92% fiber encapsulation level.

[00130] In this disclosure the relative amounts of ingredients of the composite material are described in terms of ratios. In embodiments ratios may be weightweight, volume:volume or weight:volume. Suitable measurements will be understood and adopted by those skilled in the art in light of the materials to be quantified. In particular embodiments ratios are expressed in terms of weightweight.

[00131] The present invention will be more readily understood by referring to the following examples which are given to illustrate the invention rather than to limit its scope. EXAMPLE 1 WPC PROCESS #1

[00132] Now referring to Fig. 3, the process (300) includes a sawdust feed (302) which feeds wet sawdust into a combination dryer/pulverizer (303/304) to produce a wood flour (305). The wood flour (305) is then fed, along with the other ingredients, including linear low density plastic, high density plastics, calcium carbonate, and optional additives (301 ) into a loss-in-weight metering system (306), which feeds the mixture into an ultrahigh-speed thermo-kinetic mixer (compounder) (307), which produces a fully dispersed, fully fluxed, uniformly blended compound, with under 0.5% moisture and 92% or more fiber encapsulation levels. The WPC compound Hot Melt uniformly blended mix may be discharged into a customized pneumatically operated ram feeder (308) followed by a hot melt extruder to melt pump (309). The ram feeder (308) is enclosed within a temperature and/or humidity controlled chamber.

[00133] The hot melt extruder conveys the hot melt compound from (308) into a melt pump (309) which pumps the WPC compound into profile die (310) (e.g. a sheet die), producing a thick sheet profile at 190°C. A series of water cooled guide/puller chill rolls (310), lowers the sheet temperature to 140°C. The sheet is then fed directly to thermoforming equipment (311 ) and using matched molds, the shingle (e.g. product 312) is formed under pressure.

[00134] This in-line compounding/thermoforming process, will replace the conventional WPC extrusion/pelletizing processes, commonly known.

EXAMPLE 2

WPC PROCESS #2

[00135] Now referring to Fig. 4, the process (400) includes a sawdust feed (402) which feeds untreated sawdust [e.g. sawdust having particle size range between about 0.3175 cm to about 2,2225 cm (about 1/8" to about 7/8")] into a kinetic disintegration dryer-pulverizer having customized suspended chains on the main vertical drive shaft (the kinetic disintegration dryer-pulverizer) (403). The impact of the chains with untreated sawdust releases kinetic energy which pulverizes the sawdust. Heat produced through this impact also dries the wood fibers thus pulverized. An internal classifier (404) controls particle size and an in- spec wood flour (405) is produced/collected. The wood flour (405) is then fed, along with the other ingredients, including linear low density plastic, high density plastics, calcium carbonate, and optional additives (401 ) into a loss-in-weight metering system (406), which feeds the mixture into an ultrahigh-speed thermo- kinetic mixer (compounder) (407), which produces a fully dispersed, fully fluxed, uniformly blended compound, with under 0.5% moisture and 92% or more fiber encapsulation levels. The WPC compound Hot Melt uniformly blended mix may be discharged into a customized pneumatically operated ram feeder (408) followed by a hot melt extruder to melt pump (409). The ram feeder is enclosed within a temperature and/or humidity controlled chamber.

[00136] The hot melt extruder conveys the hot melt compound into a melt pump (409) which pumps the WPC compound into profile die (410) (e.g. a sheet die), producing a thick sheet profile at 190°C. A series of water cooled guide/puller chill rolls (410), lowers the sheet temperature to 140°C. The sheet is then fed directly to thermoforming equipment (411 ) and using matched molds, the shingle (e.g. product 412) is formed under pressure.

[00137] This in-line compounding/thermoforming process, will replace the conventional WPC extrusion/pelletizing processes, commonly known. EXAMPLE 3 FORMULATIONS:

[00138] A single formulation has been developed that will be able to produce both Thermoformed Shingles & Injection Molded Shingles. All materials used for Injection Molding, will be supplied from the Trim Scrap generated during Thermoforming. The scrap will be collected on line & will be conveyed directly to a Grinder, producing WPC regrind material. This material will then be conveyed directly to Injection Molding equipment, providing a 100% material recovery.

Table 1 - Material Formulation:

[00139] The LLDPE resin improves the mechanical properties at both low and high temperatures, associated with roofing ambient conditions. The LLDPE improves environmental stress cracking resistance, critical during the nailing installation of Shingles. Without the LLDPE resin, all sample shingles failed during the nailing test.

[00140] While preferred embodiments have been described above and illustrated in the accompanying drawings, it will be evident to those skilled in the art that modifications may be made without departing from this disclosure. Such modifications are considered as possible variants comprised in the scope of the disclosure.

Claims

CLAIMS:

1 . A process for the preparation of a wood-plastic composite material comprising the step of:

1 ) preparing a hot melt uniformly blended mix comprising

c) between about 10% to about 25% w/w calcium carbonate;

d) between about 25% to about 65% w/w wood flour; and e) between about 1 % to about 4% of a coupling agent, wherein said linear low density plastic and said high density plastic are melted and intermixed with said calcium carbonate, wood flour and coupling agent at a speed sufficient to generate a temperature between about 180° and 190°C, and for a time sufficient to obtain said hot melt uniformly blended mix, wherein said hot melt uniformly blended mix comprises about 0.5% or less moisture content, and at least about 92% fiber encapsulation level.

2. The process of claim 1 , wherein said speed sufficient provides a Froude number of from about 300 to about 1295.

3. The process of any one of claims 1 - 2, further comprising step 2):

2) forming a thick sheet from said hot melt uniformly blended mix, wherein said thick sheet is cooled from a first temperature of about 180°C to about 190°C a second temperature of about 135°C to about 145°C.

4. The process of claim 3, further comprising step 3) :

3) thermoform and shape said thick sheet in a thermoforming mold to obtain a thermoformed and shaped product therefrom.

5. The process of any one of claims 1 to 4, further comprising step 1 ') after step 1 ):

1 ') discharging said hot melt uniformly blended mix in a hot melt extruder in a temperature- and humidity-controlled environment.

6. The process of claim 5, wherein said discharging is by gravity.

7. The process of any one of claims 5 - 6, wherein said temperature- and humidity-controlled environment is an enclosure.

8. The process of any one of claims 5 - 7, wherein discharging is to the feed throat of a hot melt extruder.

9. The process of any one of claims 1 to 8, further comprising step 0) before step 1 :

0) preparing said wood flour from a dried and pulverized sawdust.

10. The process of claim 9, wherein said dried and pulverized sawdust is prepared from sawdust having a particle size between about 0.3175 cm to about 2,2225 cm.

1 1 . The process of claim 10, wherein said sawdust has a moisture content from about 25% to about 75%.

12. The process of any one of claims 9 to 1 1 , wherein said sawdust is dried in a sawdust dryer, to obtain a dried sawdust having a moisture content of about 12 to about 15%.

13. The process of any one of claims 9 to 12, wherein said dried and pulverized sawdust or said dried sawdust is pulverized in a sawdust pulverizer to produce said wood flour.

14. The process of any one of claims 9 - 10, wherein said dried and pulverized sawdust is obtained from a step of pulverizing and drying said sawdust in a kinetic disintegration dryer-pulverizer comprising a suspended chain to pulverize said sawdust.

15. The process of claim 14, wherein said suspended chain comprises a series of link of about 1 .27 cm.

16. The process of any one of claims 14 - 15, wherein said suspended chain is about 15.24 cm long.

16. The process of any one of claims 14 - 16, wherein said suspended chain is made from steel.

17. The process of any one of claims 9 to 16, wherein said said dried and pulverized sawdust is obtained from a combined sawdust dryer and pulverizer.

18. The process of any one of claims 14 to 17, wherein said dried and pulverized sawdust is treated with an internal classifier to produce said said wood flour.

19. The process of any one of claims 1 to 18, wherein said is wood flour is hemlock wood flour, cedar wood flour or combinations thereof.

20. The process of any one of claims 1 to 19, wherein said wood flour has a particle size of between about 250 and about 425 microns (60 to 40 mesh).

21 . The process of any one of claims 1 to 20, wherein said wood flour has a moisture content of about 7% to about 10%.

22. The process of any one of claims 1 to 21 , wherein said calcium carbonate has a particle size of between about 1 and about 5 microns.

23. The process of any one of claims 1 to 22, wherein said calcium carbonate (CaCOs) mineral is calcite, aragonite, limestone, or a combination thereof.

24. The process of any one of claims 1 to 23, wherein said linear low density plastic is linear low density polyethylene.

25. The process of any one of claims 1 to 24, wherein said high density plastic is a polyvinylchloride (PVC), a polyethylene (HDPE), a terephthalate (PET), a polytetrafluoroethylene (PTFE), a polystyrene (PS), a polyvinylidine chloride.

26. The process of any one of claims 1 to 25, wherein said high density plastic is high density polyethylene.

27. The process of any one of claims 1 to 26, wherein said linear low density plastic or said high density plastic is recycled plastic.

28. The process of any one of claims 1 to 27, wherein said coupling agent is a maleic anhydride-grafted resin.

29. The process of any one of claims 1 to 27, wherein said coupling agent is at about 1 % to about 3% w/w of the composition.

30. The process of any one of claims 1 to 28, further comprising a light stabilizer.

31 . The process of claim 30, wherein said light stabilizer is a UV absorber, a UV quencher, a hindered amine light stabilizer (HALS), or combinations thereof.

32. The process of claim 30, wherein said composite material comprises from about 2% to about 5 % w/w of said light stabilizer.

33. The process of any one of claims 1 to 32, further comprising a flame retardant.

34. The process of claim 33, wherein said flame retardant is mineral wool, gypsum, perlite, calcium silicate (Ca2Si04), aluminium hydroxide (AIOH), magnesium hydroxide (Mg(OH)2), zinc borate, huntite, hydromagnesite, red phosphorus, chlorendic acid derivatives, chlorinated paraffins, decabromodiphenyl ether, decabromodiphenyl ethane, polymeric brominated compounds such as brominated polystyrenes, brominated epoxy oligomers, tetrabromophthalic anyhydride, tetrabromobisphenol A, hexabromocyclododecane, antimony trioxide, triphenyl phosphate, resorcinol bis(diphenylphosphate), bisphenol A diphenyl phosphate, and tricresyl phosphate (TCP), dimethyl methylphosphonate, aluminum diethyl phosphinate, tris(2,3- dibromopropyl) phosphate, tris(1 ,3-dichloro-2-propyl)phosphate, and tetrekis(2- chlorethyl)dichloroisopentyldiphosphate, and combinations thereof.

35. The process of any one of claims 1 to 34, further comprising a colorant.

36. The process of any one of claims 1 to 35, further comprising an antimicrobial agent.

37. The process of claim 36, wherein said antimicrobial agent is zinc borate hydrate.

38. The process of any one of claims 1 to 37, wherein said hot melt uniformly blended mix is prepared in an ultrahigh-speed thermo-kinetic mixer.

39. A wood-plastic composite material prepared by the process according to any one of claims 1 to 38, and having about 0.5% or less moisture content, and at least about 92% fiber encapsulation level.

40. A wood-plastic composite material comprising:

a) between about 12% to about 15% w/w linear low density plastic; b) between about 30% to about 38% w/w high density plastic;

c) between about 0% to about 40% w/w calcium carbonate;

d) between about 20% to about 50% w/w wood flour; and e) a coupling agent,

comprising about 0.5% or less moisture content, and at least about 92% fiber encapsulation level.

41 . The composite material of claim 40, wherein said is wood flour is hemlock wood flour, cedar wood flour or combinations thereof.

42. The composite material of claims 40 and 41 , wherein said wood flour has a particle size of between about 250 and about 425 microns (60 to 40 mesh).

43. The composite material of any one of claims 40 to 42, wherein said calcium carbonate has a particle size of between about 3 and about 10 microns, or about 4 to about 5 microns.

44. The composite material of any one of claims 40 to 43, wherein said calcium carbonate (CaC03) mineral is calcite, aragonite, limestone, or a combination thereof.

45. The composite material of any one of claims 40 to 44, wherein said linear low density plastic is linear low density polyethylene, linear low density polypropylene, or a combination thereof.

46. The composite material of any one of claims 40 to 45, wherein said high density plastic is a polyvinylchloride (PVC), a polyethylene (HDPE), a terephthalate (PET), a polytetrafluoroethylene (PTFE), a polystyrene (PS), a polyvinylidine chloride.

47. The composite material of any one of claims 40 to 46, wherein said high density plastic is high density polyethylene, high density polypropylene, or a combination thereof.

48. The composite material of any one of claims 40 to 47, wherein said linear low density plastic or said high density plastic is recycled plastic.

49. The composite material of any one of claims 40 to 48, wherein said coupling agent is a maleic anhydride-grafted resin.

50. The composite material of any one of claims 40 to 49, wherein said coupling agent is at about 1 % to about 4% w/w of the composition.

51 . The composite material of any one of claims 40 to 50, further comprising a light stabilizer.

52. The composite material of claim 51 , wherein said light stabilizer is a UV absorber, a UV quencher, a hindered amine light stabilizer (HALS), or combinations thereof.

53. The composite material of claim 51 , wherein said composite material comprises from about 2% to about 5 % w/w of said light stabilizer.

54. The composite material of any one of claims 40 to 53, further comprising a flame retardant.

55. The composite material of claim 54, wherein said flame retardant is mineral wool, gypsum, perlite, calcium silicate (Ca2Si04), aluminium hydroxide (AIOH), magnesium hydroxide (Mg(OH)2), zinc borate, huntite, hydromagnesite, red phosphorus, chlorendic acid derivatives, chlorinated paraffins, decabromodiphenyl ether, decabromodiphenyl ethane, polymeric brominated compounds such as brominated polystyrenes, brominated epoxy oligomers, tetrabromophthalic anyhydride, tetrabromobisphenol A, hexabromocyclododecane, antimony trioxide, triphenyl phosphate, resorcinol bis(diphenylphosphate), bisphenol A diphenyl phosphate, and tricresyl phosphate (TCP), dimethyl methylphosphonate, aluminum diethyl phosphinate, tris(2,3- dibromopropyl) phosphate, tris(1 ,3-dichloro-2-propyl)phosphate, and tetrekis(2- chlorethyl)dichloroisopentyldiphosphate, and combinations thereof.

56. The composite material of any one of claims 40 to 55, further comprising a colorant.

57. The composite material of any one of claims 40 to 56, further comprising an antimicrobial agent.

58. The composite material of claim 57, wherein said antimicrobial agent is zinc borate hydrate.

59. An item of manufacture prepared from the composite material of any one of claims 39 to 58.

60. The item of manufacture of claim 59, wherein said item is a shingle.