| abstract |
Cohesive composite material is formed by forming a mixture of a melt of thermoplastic polymer and wood having a weight average particle size of about 0.1-0.5 inches in the X-axis, about 0.2-0.8 inches in the Y-axis, and about 0.5-1.5 inches in the Z-axis; shaping the resultant wood-filled polymer melt into a compressible shape; compressing this shape to establish additional intimate contact and bonding sites between the polymer melt and the wood disposed therein; and cooling the resultant compressed shape to solidify the polymer. The composites can be readily produced from abundant, low-cost recycled raw materials. Excellent cohesiveness is achieved, preliminary processing of the wood to introduce chemical functional groups therein is not required, and the composites can be readily worked by various techniques such as shaping, planing, sawing, surface grinding or polishing, and nailing, to yield highly decorative end products. |