US 12,311,580 B2
Composite lumber comprising curable polymer and renewable natural materials and method for making the same
Chauncey E. Chambers, Chesterland, OH (US)
Filed by Chauncey E. Chambers, Chesterland, OH (US)
Filed on Jun. 26, 2024, as Appl. No. 18/755,047.
Claims priority of provisional application 63/527,193, filed on Jul. 17, 2023.
Prior Publication US 2025/0026043 A1, Jan. 23, 2025
Int. Cl. B29B 7/80 (2006.01); B29B 7/00 (2006.01); B29C 39/00 (2006.01); B29C 39/38 (2006.01); B29C 48/00 (2019.01); B29K 63/00 (2006.01); B29K 75/00 (2006.01); B29K 105/16 (2006.01); B29K 511/00 (2006.01); B29L 31/10 (2006.01)
CPC B29B 7/80 (2013.01) [B29B 7/005 (2013.01); B29C 39/003 (2013.01); B29C 39/38 (2013.01); B29C 48/022 (2019.02); B29K 2063/00 (2013.01); B29K 2075/00 (2013.01); B29K 2105/16 (2013.01); B29K 2511/00 (2013.01); B29L 2031/10 (2013.01)] 15 Claims
OG exemplary drawing
 
1. A method of forming composite lumber or other building material including natural materials, comprising the steps of:
obtaining one or more natural materials from a renewable plant-based and/or tree-based source;
separating the one or more natural materials into at least two different size groups;
preheating a polymer to a temperature above 25° C.;
preheating the one or more natural materials to a temperature above 25° C.;
blending a smallest size group of the preheated natural materials with the preheated polymer to create a first heated composite mixture;
blending the first heated composite mixture with at least one larger size group of the preheated natural materials to form a second heated composite mixture;
blending a curative with the second heated composite mixture to form a heated curable composite mixture; and
molding and curing the heated curable composite mixture to produce a piece of composite lumber or other building material, and
wherein the polymer comprises one or more of polyurethane and epoxy and the polymer is present in an amount that ranges from greater than 60 parts by weight based and less than 90 parts by weight.