RECYCLED-PLASTIC WOOD-CHIPPING COMPOSITE SHEATHING PANEL

PANNEAU DE REVETEMENT COMPOSITE BOIS-PLASTIQUE ET DE COPEAUX RECYCLE

English Abstract

The invention is a waterproof, wood-plastic composite sheathing panel intended
for
construction purposes. The panel consists of thin wood chippings constituting
between 15%
and 60% of the total mass; shredded recycled polyethylene and polypropylene
resins
constituting between 40% and 85% of the total mass; and additives including
colorants and
inhibitors of ultraviolet light, excessive heat, or fire, constituting between
1% and 10% of the
total mass. The panel may be produced by separate homogenization of specific
components, which are then added to a mold in three distinct layers. The top
and bottom
layers consist exclusively of shredded polymer resins and additives, with a
central layer
consisting of wood chippings, shredded polymer resins, and or additives. Once
all
components are assembled within the mold, it is heated via induction methods
to a
temperature not less than 160 degrees celsius and not exceeding 200 degrees
celsius, and
is then formed into a uniform panel using compression molding methods.
Date Recue/Date Received 2021-08-05

Claims

The embodiments of the invention in which an exclusive property or privilege
is
claimed are defined as follows:
1. A waterproof, multi-layer composite wood-plastic sheathing panel,
characterized by:
a. A proportion of wood chippings, and a proportion of recycled thermoplastic
polymer resins; and
b. A layer of wood chippings suspended within two layers of recycled
thermoplastic polymer resin.
2. A composite sheathing panel, as claimed in Claim 1, consisting of a
composition in
which the thermoplastic polymer resin is a combination of recycled
polyethylene(PE)
or polypropylene(PP).
3. A composite sheathing panel, as claimed in Claim 1 or Claim 2, consisting
of a
composition in which the wood chips are1/4" thick or thinner.
4. A composite sheathing panel, as claimed in any one of Claims 1 to 3,
consisting of a
composition additionally comprising a non-organic additive.
5. A composite sheathing panel, as claimed in Claim 4, consisting of a
composition in
which the non-organic additive is aluminum trihydrate, iron oxide, carbon
black or any
related carbon additives, titanium dioxide, zinc oxide, calcium carbonate,
glass fibers,
or any combination thereof in proportions of 1% to 10% of the mass of the
composition.
6. A composite sheathing panel, as claimed in any one of Claims 1 to 5,
consisting of a
composition in which the recycled thermoplastic polymer resin represents from
40%
to 85% of the mass of the composition.
7. A composite sheathing panel, as claimed in any one of Claims 1 to 6,
consisting of a
composition in which the wood chippings represent from 15% to 60% of the mass
of
the composition.
Date Recue/Date Received 2021-08-05

Description

Recycled-Plastic Wood-Chipping Composite Sheathing Panel
Field of the invention:
This invention relates to composite panels comprising plastic polymers and
wood,
and a process for their production.
Prior Art:
Prior Art sheathing panels are manufactured from a composite mixture of
thermosetting plastic resin, generally constituting less than 10% of total
mass, and a wood
component of various shapes and sizes, generally constituting greater than 90%
of the total
mass. Representations of such products may include oriented strand boards,
disclosed in
the American patent 14/955,726, or plywood panels, disclosed in the Japanese
patent
1-344050.
Sheathing panels are manufactured primarily from wood, the fibers of which
provide
strength to the panels. The wood pieces are layered, generally oriented with
the grain of the
wood laying alternately to the grain of the wood of the layers above and
below. A
thermosetting plastic resin acts to bind the wood pieces together. It should
be noted that the
resin often does not provide significant water resistance for the panel,
resulting in their
difficulty of use for exterior applications. This wood and resin mixture is
then pressed under
intense heat and pressure to produce a dense and rigid panel, which is then
cut to size.
Wood-resin panels are certified for structural use purposes in Canada through
the
CSA standard 0325. Wood-resin panels are also certified for use as structural
building
materials around the world through the adoption of various regulations, for
example, the
DOC PS2-92 Wood-Based Structural Use Panels code in the United States of
America.
Summary of the Invention:
An object of the present invention is to provide a wood-plastic sheathing
panel
composed of chipped wood and recycled thermoplastic polymer resins, in place
of the
thermosetting polymer resin used in most sheathing material.
Another object of the present invention is to provide a wood-plastic sheathing
panel
designed for resistance to water and harsh environments, including rain and
snow, by use of
component layering techniques.
Yet another object of the present invention is to provide a material of
comparable
structural properties in comparison to other sheathing panels.
Yet another object of the present invention is to provide resistance to fires
and
ultraviolet light.
The present invention comprises a wood and plastic composite material produced
in
the style of a sheathing panel. The panel consists of thin wood chippings,
shredded recycled
polyethylene and polypropylene resins, and inorganic additives including
colorants and
inhibitors of ultraviolet light, excessive heat, or fire. The panel is
composed of three distinct
Date Recue/Date Received 2021-08-05

layers, providing the panel with the methods to realize the present
invention's objects. The
advantages and features of the present invention will become more apparent
upon reading
the description of the embodiment of the innovation.
Brief Description of the Drawing
Figure 1 shows a front view of an embodiment of a bisected sheathing panel,
consisting of three layers, in accordance with the embodiment of the present
invention.
Detailed Description of the Embodiment
The present invention is described in detail with reference to Figure 1.
Layer 1 consists of a mixture of recycled polyethylene and polypropylene resin

shreds combined with a mixture of additives including colorants and inhibitors
of ultraviolet
light, excessive heat, or fire. In one embodiment of the present invention,
Layer 1 will
constitute between 10% and 30% of the total mass of the panel. When the
present invention
is in use, Layer 1 is exposed to the environment. For this reason, Layer 1
consists of only
resins, colorants, and inhibitors to achieve the desired objects of the
present invention,
including resistance to both fire and ultraviolet light, and resistance to
liquids including, but
not limited to, water. The presence of colorants provides Layer 1 with
subjective aesthetic
value.
Layer 2 consists of a mixture of thin wood chippings, recycled polyethylene
and
polypropylene resin shreds, and in some embodiments, may consist of a mixture
of additives
including colorants and inhibitors of ultraviolet light, excessive heat, or
fire. In one
embodiment of the present invention, Layer 2 will constitute between 40% and
80% of the
total mass of the panel. When the present invention is in use, Layer 2 will
provide the
majority of the structural strength of the panel, as that is the purpose of
the layered thin
wood chippings. In the present invention, the wood chippings are held together
by the
polyethylene and polypropylene resin, which is melted during the manufacturing
process..
Layer 3 consists of a mixture of recycled polyethylene and polypropylene resin

shreds combined with a mixture of additives including colorants and inhibitors
of ultraviolet
light, excessive heat, or fire. In one embodiment of the present invention,
Layer 3 will
constitute between 10% and 30% of the total mass of the panel. When the
present invention
is in use, Layer 3 is exposed to the environment. For this reason, Layer 3
consists of only
resins, colorants, and inhibitors to achieve the desired objects of the
present invention,
including resistance to both fire and ultraviolet light, and resistance to
liquids including, but
not limited to, water. The presence of colorants provides Layer 3 with
subjective aesthetic
value.
In one embodiment, the present invention consists of thin wood chippings
constituting between 15% and 60% of the total mass; shredded recycled
polyethylene and
polypropylene resins constituting between 40% and 85% of the total mass; and
additives
including colorants and inhibitors of ultraviolet light, excessive heat, or
fire, constituting
between 1% and 10% of the total mass of the panel.
In all embodiments of the present invention, the panels are manufactured
through the
process of compression molding. The components of the three layers are mixed
Date Recue/Date Received 2021-08-05

independently of each other, and are then added to a flat mold one layer at a
time. The mold
is then heated via induction methods to a temperature not less than 160
degrees celsius and
not exceeding 200 degrees celsius to melt the recycled thermoplastic polymer
resins, and is
then formed into a uniform panel using compression molding methods. The
compression of
the panel is done in a plywood press, providing no less than 200kg/cm2 of
force onto the
mold. This force densely packs the components of the present invention to
produce a panel
in a similar fashion to prior art sheathing panels. Once cooled under
pressure, the panels are
then removed from the molds, and are cut to the desired shape for the
sheathing product,
with the intended use of the present invention being similar to that of the
prior art sheathing
panels.
Date Recue/Date Received 2021-08-05