MXPA99000774A - Alveolar thermoplastic polymer and profile and fiber of mad - Google Patents

Abstract

Advanced structural components comprising an alveolar thermoplastic material that can be used in virtually any application where wood components are used are described. Such structural components may comprise dimensioned wood, sized wood cuttings, posts, beams or formed structural elements. An advanced profile composite structural component comprises an outer cover layer with an interior comprising a honeycomb thermoplastic that can be used in the assembly of windowing units adapted for commercial residential structures. Preferably, the structural component of the profile can be used in an optional window assembly. The profile element is adapted for ease of construction of the window units, can be easily installed in a rough opening to structural elements and can be trimmed and adjusted on site. The profile is structurally strong, thermally stable, resistant to shrinkage and will accept and retain the insertion of fasteners such as staples, nails and screws permanently with substantial retention and little or no damage to the units. The profile structural components have strength that allow the manufacture of a structurally firm window unit from two or more alveolar profile elements or other conventional elements

Description

ALVEOLAR THERMOPLASTIC POLYMER AND PROFILE AND WOODEN FIBER ELEMENT FIELD OF THE INVENTION The invention is concerned with the materials used in the manufacture of structural elements or ornament elements used in building materials and windowing units installed in residential and architectural architecture. commercial. More particularly, the invention concerns a profile or improved structural element that can be used as a direct replacement for wood and metal components that have superior properties for windowing, structural or construction purposes. The structural elements of the invention may comprise wood replacements and dimensioned structural components with complex functional shapes such as wood and door crosspieces, jambs, uprights, thresholds, skylights or frames, slideways, hinders and frames and trim elements. miscellaneous In addition, the invention is concerned with the structural components used in the manufacture of windowing units such as windows and doors for commercial and residential architecture. The structural components are made from an extruded composite polymer honeycomb material. The structural components of the invention can form high strength joints in the construction assembly. REF: 29245 The materials can be easily installed, adjusted, wedged and decorated with fasteners and conventional techniques. The components have thermal and mechanical properties that make them durable and still easy to manufacture and install.

BACKGROUND OF THE INVENTION Conventional industrial, commercial and residential architecture commonly involves the use of structural and non-structural components in the assembly of useful units. Such components are often made of concrete, stone, wood, glass or metal. These materials are well known and well understood in their field of application for construction purposes. The wood has been brushed into shaped structural components such as sawn timber, wood trimmings or trim, post and beam and has also been used to form structural components that can be assembled with glass to form door and window units. Wood, sawn timber, trimmings or trimmings, post, beam and assembled units comprising wood have obvious utility and are well suited for many uses in residential or commercial facilities. However, wood used in these applications, under certain circumstances, may have problems. The wood can deteriorate due to the effect of fungi and the attack of insects. In addition, wood elements also suffer from cost problems related to the availability of wood suitable for construction purposes and require substantial maintenance comprising paint or dyeing. Metal components, usually aluminum or steel, are also frequently used in industrial, commercial and residential construction. Metal components can suffer from oxidation or corrosion problems and require their own construction skills and particular maintenance regime. Polymeric vinyl materials have also been used in the formation of structural elements and to form profiles in the assembly of windows and doors. Such vinyl materials typically comprise a greater proportion of a vinyl polymer and a variety of additive materials are employed. Rigid and flexible filled and unfilled thermoplastic materials (filled with additive materials such as fiber, inorganic components, dyes, etc.) have been extruded or injection molded to a variety of structural materials and sealants. A thermoplastic polyvinyl chloride has been combined with wooden elements in the manufacture of PERMASHIELD® windows manufactured by Andersen Corporation many years ago. This vinyl coating or coating technology is described in U.S. Pat. Nos. 2I. , 926,729 and 3,432,885, issued to Zaninni. The technology disclosed in these patents involves the extrusion or injection molding of a thin polyvinyl chloride coating or shell formed loosely around a formed wood structural element. Polyvinyl chloride thermoplastic materials have also been combined with wood products to make extrusion materials. Initial efforts resulted in a material that can be directly extruded to form an element having a modulus of typically around 500,000 or less. Such elements have also failed to have adequate compressive strength, coefficient of thermal expansion, coefficient of elasticity, fastener retention or other useful properties, required for use in many construction applications. More recently, U.S. Patent Nos. 5,486,553, 5,539,027, 5,406,768, 5,497,594, 5,441,801 and 5,518,677 assigned to 7Andersen Corporation, disclose the use of a thermoplastic such as polyvinyl chloride and wood fiber for the purpose of manufacturing a high strength composite material. the technology of FIBREX® brand materials. Such compounds are useful in the manufacture of a structural element such as a hollow profile that can be used in the manufacture of windows and doors. These materials have a high module 56,240 Kg / cm2 (800,000 pounds / inch2 or more) and can be easily manufactured, assembled and installed. These unique high strength materials have had substantial success with respect to their use in the manufacture of windows and doors. The PERMASHIELD® brand technology and the technology of FIBREX® brand materials have substantial utility and have met with substantial success in a variety of applications. Additional extensions of thermoplastic polymer technology are useful for other applications. There is a need to obtain materials that have improved properties.

Brief Description of the Invention It has been found that a superior structural honeycomb material can be used to form an element that can be used as a replacement for the elements of stone, wood, glass and metal. The element comprises a thermoplastic foam and comprises an alveolar composite consisting of a thermoplastic polymer and a wood fiber. Wood fiber can be derived either from softwoods or evergreen trees or plants or from hardwoods commonly known as perishable broadleaf trees. Soft woods are generally preferred for the manufacture of fibers because the resulting fibers are longer, contain higher percentages of lignin and lower percentages of hemicellulose than hardwoods. The additional composition of the fiber can be derived from a variety of secondary sources or fiber regeneration which include bamboo, rice, sugar cane and recycled fibers from newspapers, boxes, computer prints, etc. A preferred source of wood fiber of this invention comprises the product of wood fiber or by-product of sawing or soft brushing woods. A quality fiber can be made by brushing and a brushing byproduct commonly known as wood sawdust or brushing residue can be used. A wide variety of thermoplastic polymers or resins can be used in the honeycomb composite materials of the invention. For the purpose of this application, a useful resin is a general term covering a thermoplastic that may or may not contain an additional filler or reinforcing material, other than wood fiber, which has mechanical, chemical and thermal properties, suitable for use as structural components, machine components and components of the chemical processing equipment. Resins useful in the invention have been found to include polymeric condensation materials and polymeric vinyl materials. The alveolar material can provide improved thermal and physical properties. A wide variety of polymeric vinyl materials can be used in the composite materials that can be used in the composite materials of the invention. Useful vinyl polymers are polymers made by homopolymerization, copolymerization or terpolymerization methods. Polymeric condensation resins can also be used in the composite materials of the invention. The improved properties in the alveolar composite include shrinkage and improved COTE resistance, compression resistance and fastener retention. Such material exhibits properties that make the structural element ideal for industrial, commercial and domestic construction applications. The materials have acceptable thermal properties in which they include minimum coefficient of thermal expansion, minimum shrinkage and minimum thermal distortion. In addition, the materials can be easily manufactured, assembled to a useful structure and can be easily installed. For the purpose of this patent application, the term "extrusion mass" indicates the material processed by an extruder which results in a honeycomb plastic plastic fiber composite. The extrusion dough may comprise a mixture of powder, discrete thermoplastic wood fibers in flakes or pellets and a separate blowing agent, each component blended together to form a final extrusion dough. Alternatively, the extrusion dough may comprise a preformed pellet comprising thermoplastic, wood fiber and pre-formed blowing agent and a pre-extrudate in a pellet composition. Alternatively, the extrusion dough may comprise a chip of thermoplastic wood fiber, mixed or dry blended with a blowing agent. Alternatively, the extrusion mass may comprise the thermoplastic with the blowing agent dissolved or dispersed in the thermoplastic in the form of a pellet which is then mixed with a separate wood fiber phase. In other words, the extrusion dough may comprise the thermoplastic, the wood fiber or the blowing agent in any useful form of an extrudable mass.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is an elevated side view of a typical side window retainer used for testing the physical properties discussed in the specification. Figure 2 is a direct side view of a typical window or threshold stop as used for properties of physical properties discussed in the specification. Figure 3 is an isometric view of the end of a typical gauze box used for physical property testing, discussed in the specification. These structures in Figures 1-3 are useful as components of windowing units.

DETAILED DESCRIPTION OF THE INVENTION Wood Fiber The primary source for the wood fiber of this invention comprises the product or by-product of wood fiber from the grinding, sawing or brushing of wood materials, preferably soft woods. A quality fiber can be made by brushing and a brushing byproduct commonly known as saw dust or brushing residue can be used. Such a wood fiber has a regular reproducible shape and aspect ratio. Fibers based on a random selection of about 100 fibers are commonly at least 0.05, preferably 0.1 mm in length, approximately 0.02 to 1 mm thick and commonly have an aspect ratio of at least 1.5. Preferably, the fibers are 0.1 to 5 mm in length with an aspect ratio between 2 and 7, preferably 2.5 to 6. The preferred fiber for use in this invention consists of the fibers derived from common processes in the manufacture of windows and doors. Wood elements are commonly cut or sawed to size in a direction transverse to the grain to form appropriate lengths and widths of wood materials. The by-product of such sawing operations is a substantial amount of sawdust powder. In shaping a regular shaped piece of wood into a useful brushed shape, wood is commonly passed through machines that selectively separate the wood from the piece to leave the shape useful. Such brushing operations produce substantial amounts of sawdust powder or by-products of brushing residues. Finally, when the formed materials are cut to size and angular joints, flat or butt joints, overlap joints, box and spigot joints are fabricated from the pre-formed wood elements a substantial waste cut is produced. Such large trimming pieces are commonly cut and machined to convert the larger objects to the wood fiber having the dimensions that approximate the dimensions of the sawdust powder or brushing residues. The wood fiber sources of the invention can be combined independently of the particle size and used to make the compound. The fiber stream can be pre-dimensioned to a preferred range or can be sized after mixing. In addition, the fiber may be pre-packed before use in the manufacture of the composite. Such a sawdust powder material may contain substantial proportions of byproducts of the compatible waste stream. Such byproducts include waste polyvinyl chloride or other thermoplastic or polymeric materials that have been used as a coating, coating or sheathing on wood elements; recycled structural elements, made from thermoplastic or composite materials; polymeric coating materials; adhesive components in the form of thermal-function adhesives, solvent-based adhesives, powdered adhesives, etc .; paints that include water-based paints, alkyd paints, epoxy paints, etc .; condoms, antifungal agents, antibacterial agents, insecticides, etc., and other waste streams common in the manufacture of wooden doors and windows. The total content of the waste stream of the wood fiber materials is commonly less than 25 weight percent (% by weight) of the input of total wood fiber to the composite product. From the recycling of total wasteapproximately 10% by weight of that may consist of a thermoplastic. Commonly, intentional recycling ranges from about 1 to about 25% by weight, preferably about 2% to about 20% by weight, more commonly from about 3 to about 15% of the contaminants based on the serine powder. Moisture control is an important element of manufacturing an extruded or formed linear composite formed tablet. Moisture may interfere with, or change the constancy of the compound and the alveolar product. Depending on the equipment used and the processing conditions, control of the water content of the material can be important in the formation of a successful structural element substantially free of substantial changes in density, internal voids or surface defects. The concentration of water present in the sawdust during the formation of the chip or foaming or foaming of the linear extrudate when heated can be vaporized instantaneously from the surface of the newly extruded structural element and can proceed as a result of rapid volatilization, forming a deep steam bubble into the extruded element that can pass from the interior through the hot thermoplastic extrudate to leave a substantial defect. In a similar manner, surface water can form bubbles and leave cracks, bubbles or other surface defects in the extruded member. In addition, designer resins that are sensitive to moisture should be avoided. The water may react with some condensation polymers to result in an increased melt flow index (MI) (MI as measured by ASTM 1238) and a reduced molecular weight (Mn or M "). Trees, when cut, depending on relative humidity and season may contain 30 to 300% by weight of water based on fiber content. After the cut in fruit and the finished one to a dimensioned wood, the wood of the station can have a content of water of 20 to 30% in weight based on the content of fiber. Dried wood oven-dried, cut to length may have a water content usually in the range of 8 to 12%, commonly 8 to 10% by weight based on the fiber. Some wood source, such as poplar, may have an increased moisture content, while some hardwoods may have a reduced water content. Due to the variation in the water content of the wood fiber source and the sensitivity of the extruded product to the control of the water content at a level of less than 8% by weight of the pellet based on the pellet, the weight is important. For structural elements extruded in a non-ventilated extrusion process, the pellet should be as dry as possible and have a water content of between 0.01 and 5%, preferably less than 1.5% by weight. When ventilated equipment is used in the manufacture of the extruded linear element, a water content of less than 8% by weight can be tolerated if the processing conditions are such that the ventilated extrusion equipment can dry the thermoplastic material before the final formation of the structural element in the extrusion head.

Thermoplastic Polymers, Homopolymers, Copolymers and Polymer Combinations A wide variety of thermoplastic polymers or resins can be used in the inventive alveolar composite materials. For the purpose of this application, a useful resin is a general term covering a thermoplastic that may or may not contain a filler or reinforcing material that has mechanical, chemical and thermal properties appropriate for use as structural components, machine components and components of chemical processing equipment. Resins useful in the invention have been found to include polymeric condensation materials and polymeric vinyl materials. Included are vinyl and condensation polymer resins and alloys thereof, such as acrylonitrile-butadiene-styrene (ABS), polyacetyl resins, polyacrylic resins, fluorocarbon resins, nylon, phenoxy resins, polybutylene resins, polyarylether such as polyphenylether, polyphenylsulfide materials, polycarbonate materials, chlorinated polyether resins, polyether sulfone resins, polyphenylene oxide resins, polysulfone resins, polyimide resins, thermoplastic urethane elastomers and many other resin materials. Vinyl polymers are commonly manufactured by the polymerization of monomers having an ethylenically unsaturated olefinic group. Polymer condensation resins are commonly prepared by a condensation polymerization reaction which is commonly considered a stepwise chemical reaction in which two or more molecules combined, often but not necessarily accompanied by the separation of water or some other simple substance typically volatile. If a polymer is formed, the process is called polycondensation.

Vinyl Polymers A wide variety of polymeric vinyl materials can be used in the composite materials that can be used in the composite materials of the invention. Useful vinyl polymers are polymers made by homopolymerization, copolymerization or terpolymerization methods. Homopolymers include polyolefins, such as polyethylene, polypropylene, poly-1-butene, etc., polyvinylchloride, polymethacrylate, polymethylmethacrylate. Also useful are copolymers of alpha olefins with second monomers such as ethylene-propylene copolymers, ethylene-exylene copolymers, ethylene-methacrylate copolymers, ethylene-methacrylate copolymers. etc. While styrene homopolymers are not preferred, copolymer materials made by the polymerization of styrene with the second vinyl monomer are useful. However, a preferred class of thermoplastics include styrenic copolymers. The term styrenic copolymer indicates that the styrene is copolymerized with a second vinyl monomer which results in a vinyl polymer. Such materials contain at least 5 mol percent styrene and the remainder consists of one or more other vinyl monomers. An important class of these materials are styrene acrylonitrile (SAN) polymers. SAN polymers are disordered amorphous linear copolymers produced by the copolymerization of styrene acrylonitrile and optionally other monomers. Emulsion, suspension and continuous mass polymerization techniques have been used. SAN copolymers have excellent transparency, thermal properties, good chemical resistance and hardness. These polymers are also characterized by their rigidity, dimensional stability and load carrying capacity. SANs modified by olefin (OSA polymeric materials) and acrylonitrile styrene acrylics (polymeric materials ASA) are known. These materials are somewhat softer than unmodified SANs and are ductile, opaque, two-phase terpolymers that have a surprisingly improved weatherability. ASA resins are disordered amorphous terpolymers produced either by bulk copolymerization or by graft copolymerization. In mass copolymerization, an acrylic monomer of styrene and acrylonitrile are combined to form a heteric terpolymer. In an alternative preparation technique, styrene-acrylonitrile oligomers and monomers can be grafted to a fundamental chain of acrylic elastomer. Such materials are characterized as weather resistant and ultraviolet resistant products that provide excellent property retention accommodation of color stability and property stability with outdoor exposure. These materials can also be combined with a variety of other polymers including polyvinyl chloride, polycarbonate, polymethyl methacrylate and others. An important class of styrene copolymers include the acrylonitrile-butadiene-styrene monomers. These resins are a very versatile family of designer thermoplastics produced by the copolymerization of the three monomers. Each monomer provides an important property to the final terpolymer material. The final material has excellent thermal resistance, thermal resistance and surface hardness combined with processability, rigidity and strength. The polymers are also hard and impact resistant. The styrene copolymer resin family has a melt flow index ranging from about 0.5 to 25, preferably from about 0.5 to 20. An important class of designer resins that can be used in the compounds of the invention include acrylic resins. Acrylics comprise a wide array of polymers and copolymers in which the main monomeric constituents are an acrylate or ester methacrylate. These resins are often provided in the form of a hard, clear sheet or pellets. Acrylic monomers polymerized by free radical processing initiated by normally peroxides, azo compounds or radiant energy. Commercial polymer formulations are frequently provided in a variety of additives are modifiers used during polymerization that provide a specific set of properties for certain applications. Pills made for resin grade applications are commonly processed either in bulk or bulk (continuous solution polymerization) followed by extrusion or tabletting or continuously by polymerization in an extruder in which the unconverted monomer is separated under reduced pressure and recovered for its recycling. Acrylic plastics are commonly made by the use of methyl acrylate, methyl methacrylate, higher alkyl acrylates and other copolymerizable vinyl monomers. Preferred acrylic resin materials useful in the compounds of the invention have a melt flow index of about 0.5 to 50, preferably about 1 to 30 g / 10 minutes. Polymer blends or polymeric alloys may be useful in the manufacture of the bar or linear extruded product of the invention. Such alloys normally comprise two miscible polymers blended together to form a uniform composition. Scientific and commercial progress in the area of polymer blends has led to the discovery that important improvements in physical properties can be made, not by the development of a new polymeric material, but by the formation of mixtures or alloys of miscible polymers. An equilibrium polymer alloy comprises a mixture of two amorphous polymers that exit as a single phase from intimately mixed segments of the two macro molecular components. Miscible amorphous polymers form glasses in sufficient cooling and a homogenous or miscible polymer mixture exhibits a single composition dependent on the glass transition temperature (Tg). The immiscible or non-alloyed polymer mixture typically exhibits two or more vitreous transition temperatures associated with the immiscible polymer phases. In the simplest cases. The properties of polymer alloys reflect a weighted average of properties in the composition possessed by the components. In general, however, the dependence of the properties on the composition varies in a complex way with a particular property, the nature of the components (glass or crystalline, rubberized or semi-crystalline), the thermodynamic state of the mixture and its mechanical state if the molecules and phases are oriented. The primary requirement for the substantially thermoplastic design resin material is that it retains sufficient thermoplastic properties to allow melt blending or mixing with the wood fiber, which allows the formation of linear extruded pellets and allows the material of the composition or pellet is extruded or injection molded in a thermoplastic process that forms the rigid structural element. Design resins and resin alloys are available from a variety of manufacturers including B.F. Goodrich, G.E., Dow, and Dupont.

Resins of the condensation polymer Resins of the condensation polymer that can be used in the materials of the compound of the invention include polyamides, polyamide-imide polymers, polyarylsulphones, polycarbonate, polybutylene terephthalate, polybutylene naphthalate, polyetherimides, polyethersulfones, terephthalate polyethylene, thermoplastic polyimides, polyphenylether blends, polyphenylene sulfide, polysulfones, thermoplastic polyurethanes and others. Preferred condensation design resins include polycarbonate materials, polyphenyloxide materials, and polyester materials including polyethylene terephthalate, polybutylene terephthalate, polybutylene naphthalate, and polybutylene naphthalate materials. Polycarbonate design resins are high performance amorphous thermoplastics that have high impact strength, clarity, thermal resistance and dimensional stability. Polycarbonates are generally classified as a polyester or carbonic acid with organic hydroxy compounds. The most common polycarbonates are based on phenol A as a hydroxy compound copolymerized with carbonic acid. Frequently, materials are made by the reaction of a bisphenol A with phosgene (COCÍ?). The polycarbonates can be made with phthalate monomers introduced into the polymerization extruder to improve properties such as thermal resistance, additional trifunctional materials, they can also be used to increase the strength of the melt or extrusion blow molded materials. Polycarbonates can often be used as a versatile mixing material as a component with other commercial polymers in the manufacture of alloys. The polycarbonates can be combined with polyethylene terephthalate acrylonitrile-butadiene-styrene resins, maleic anhydride styrene resins and others. Other preferred alloys comprise a copolymer of styrene and a polycarbonate. The preferred melt for polycarbonate materials should have rates between 0.5 and 7, preferably between 1 and 5 g / 10 minutes. A variety of polymeric polyester condensation materials including polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polybutylene naphthalate, may be useful in the thermoplastic resin-fiber composite composites of the invention. Polyethylene terephthalate and polybutylene terephthalate are high performance polymeric condensation materials. Such polymers are frequently prepared by a copolymerization between a diol (ethylene glycol, 1,4-butanediol) with dimethyl terephthalate or 2,6-dicarboxynaphthalene. In the polymerization of the material, the polymerization mixture is heated to a high temperature to result in the transesterification reaction that liberates methanol and results in the formation of the design plastic. Similarly, the materials of polyethylene naphthalate and polybutylene naphthalate can be made by copolymerization as mentioned above when using as a source of acid, a naphthalenedicarboxylic acid. Naphthalene thermoplastics have a higher T and higher stability at high temperature compared to terephthalate materials. However, all of these polyester materials are useful in the composite structural materials of the invention. Such materials have a preferred molecular weight characterized by melt flow properties. Useful polyester materials have a viscosity at 265 ° C of about 500-2000 centipoise (cp), preferably about 800-1300 cp. Polyphenylene oxide materials are design thermoplastics that are useful at temperature ranges as high as 330 ° C. Polyphenylene oxide has excellent mechanical properties, dimensional stability and dielectric characteristics. Commonly, phenylene oxides are manufactured and sold as alloys or polymer blends when combined with other polymers or fiber. The polyphenylene oxide typically comprises a homopolymer of 2,6-dimethyl-1-phenol. The polymer commonly known as poly (oxy- (2,6-dimethyl-1,4-phenylene)). Polyphenylene is frequently used as an alloy or mixture with a polyamide, normally 6-6 nylon, alloys with high impact polystyrene or styrene and others. A preferred melt melt index for the polyphenylene oxide material useful in the invention normally ranges from about 1 to 20, preferably about 5 to 10 g / 10 minutes. The melt viscosity is approximately 1000 to 265 ° C.

Foaming Foamed or foamed thermoplastics are usually manufactured by dispersing or expanding a gas phase through a liquid polymer phase to create a foam comprising a polymeric component and a gas component included in a closed or open structure. The preservation of the resulting alveolar state is important to maintain the desired structural properties. The most common process involves an expansion of alveolar thermoplastic materials. The expansion process commonly involves three stages. First, small discontinuities or cells with created in a fluid or plastic phase. These discontinuities are grown to the desired volume to produce a cellular structure. Then, the cellular structure is stabilized by physical (cooling) or chemical (crosslinking) means to form the resulting cellular or polymeric cellular structure. Virtually all thermoplastic foams are blown with inert gas foaming agents or chemical blowing agents that decompose. Such agents commonly foam when using inert gases such as nitrogen or carbon dioxide, hydrocarbons containing 3 to 5 carbon atoms, chlorinated hydrocarbons and chlorofluorocarbons such as CFC-11, CFC-12, CFC-113, CFC-114. Chemical blowing agents operate by decomposing at elevated temperatures to an inert gas. The physical blowing agents operate by dissolving or dispersing in the plastic or molten polymer phase and pressure is released, evaporating to the gaseous state to create the growth of the cellular structure. In the application of this invention, the preferred blowing agents are conventional diazo blowing agents, which upon decomposition produce nitrogen, an effective inert blowing agent that creates a cellular structure throughout the polymeric composite / wood fiber. More specifically, blowing agents that can be used in the process of the invention include chemical blowing agents such as organic or inorganic bicarbonates or oxylates, azo-chemicals, hydrozides and amine nitrates. Low-boiling liquids that can produce gas by vaporization in areas of lower pressure include carbon dioxide, aliphatic hydrocarbons such as propane, butane, pentane and isomers thereof. Chlorinated and fluorinated hydrocarbons such as methylene chloride, dichloro-difluoromethane and monochlorotrifluoromethane are useful. The blowing agent is usually mixed with the thermoplastic materials in well-known processes. In general, chemical blowing agents are mixed with thermoplastic pellets or powders before the introduction of the mixed material into an inlet of the extruder. The physical blowing agents can be dosed to the molten polymer in the extruder for intimate mixing prior to foaming to a lower pressure zone. Such blowing procedures are a well known process comprised by those of ordinary skill in the art. Careful control of the blowing agent addition and extrusion temperature is necessary to ensure that the foaming is present at the correct time and place and the blowing agent is not wasted.

Examples Formulation of the PVC compound - honeycomb fiber All tests of the PVC composite of honeycomb fibers have been accomplished by using material produced as follows: • 34 kg (75 pounds) per hour of feed rate of composite pellets of PVC standard wood fibers (see US Patents Nos. 5,486,553, 5,539,027, 5,406,768, 5,497,594, 5,441,801 and 5,518,677, by information of the pellet). • Co-feeding approximately 13.5 grams per minute of Reedy International AP-40 blowing agent (agent of azide that generates nitrogen gas (N2)) 0.810 Kg per hour (1.786 pounds / hour), 2.38%. • Co-feeding approximately 36.1 grams per minute of modifying acrylic K-415 Paraloid from Rohm & Haas (2,166 Kg / hour (4,776 lbs / hour), 6.37%).

Operating conditions of the extruder The materials used and the operating conditions of the extruder representative for the manufacture of the PVC composite / honeycomb fiber are shown in the following table. Resting results of the alveolar composite: Experiment 'Siinn l taanpaa Density (g / cc) Fine (50 mesh) Standard Flat Chips 60/40 * 0.87 0.82 0.84 70/30 na 0.77 na • "-" Compound standard tablet = 1.4 g / cc 80/20 0.71 0 71 0.74 Pine = 0.4 g / cc COE (xl05 cm cm F) Fine (50 meshes) Standard Flat chips 60/40 1.74 70/30 ** PVC = 4.0 xlO 5 cm / cm ° C 80/20 2.57 2.81 standard bar compound = 1 2 FLEXION MODULE (psi) Fine (50 mesh) Standard Flat shavings 60/40 333,155 na 394,775 70/30 na 227,643 na ** PVC = 410,000 psi 80/20 147,663 132,611 170,608 Standard pill compound = 1,000,000 psi Nail insertion (pounds) Fine (50 mesh) Standard Flat shavings 60/40 129 na 149 ** No penetration to standard compound 70/30 na 118 na tablet before the nail is double 80/20 84 77 129 Oak: light penetration before it is double 1 weight / weight ratio of PVC to wood fiber 38 Coefficient of Linear Thermal Expansion Several polymers were tested for linear thermal expansion (ASTM No. D 696-9181). Each polymer was extruded as a grinding box for this test. The results of these tests are summarized in the table: The alveolar wood fiber composite is more thermally stable than the non-foamed wood fiber PVC composite and is more thermally stable than PVC. Both of these materials have larger coefficients of thermal expansion than the honeycomb material. The advantage of a reduced coefficient of thermal expansion is a window that will fit in a window opening and outdoors in a more reliable manner.

Frame bending test A bending test using a 40.6 cm (sixteen inch) spacing was carried out to determine the lateral strength of several polymers by using INSTRON force / displacement data set with three test points. The tests were carried out on samples of 40.6 cm (16 inches) long with cross section dimensions of 1.75 cm x 5.78 cm (0.688 x 2.078 inches). A standard force was applied to the midpoint and increased until a displacement of 0.63 cm (0.25 inches) was obtained. This force and a calculated Young's Modulus was recorded for each test. The table below gives the load in pounds / force (pounds) and Young's modulus for each sample material with a predetermined deflection of 0.63 cm (0.25 inches) (ASTM test No. D-1037 96a).

While the honeycomb material does not have as much strength as wood or unfoamed compound, its properties are sufficient for use in stacking and typical residential building applications.

Retention force test Retention force tests were carried out on a PVC-fiber composite of alveolar wood using an INSTRON Model 5500R with a load cell 454 Kg (1000 pounds) and a transverse speed of 0.508 cm (0.200 inches) per minute. Fasteners were inserted "across", which means insertion through the vinyl cap, made of PVC-fiber wood and outward through the lid on the other side. A screw gun operating at low revolutions per minute with a guide sleeve was used to insert galvanized square head screws No. 8 x 5.1 cm (2 inches) with and without pilot holes. Nails were also tested, using 4D finished nails driven manually with a hammer. In all the tests Ponderosa Pine was used as a control reference.

Ul The properties of the honeycombed composite for retaining a fastener such as a screw or nail, are substantially the same (within the variations of the test as the pine). The result is surprising in view of the alveolar nature of the composite and the solid nature of the pine elements.

Separation Test Separation test is carried out on the PVC-free composite of alveolar wood by using a screw gun that rotates at low revolutions per minute with a guide sleeve for inserting galvanized square head screws No. 8 x 5.1 cm (2 inches) with and without pilot holes. A torque torque wrench was used to determine the torque of separation. Each screw was driven by means of a spacer block and the test block in order to ensure the threaded coupling in the entire sample.

Similar to the retention test, the separation test shows that alveolar composite materials are equivalent to pine elements in structural integrity when combined in a nailed or bolted structure.

Notes: • ASTM D4726 PVC profiles used for windows and doors allow up to 2.2 percent maximum shrinkage - The Test Method is ASTM D1042-60 minutes, @ warming in an air oven at 82 ° C (180 ° F) • Average extrusion run of composite profile of standard pellet is approximately 0.4 percent • Typical average for an extrusion of PVC without compound of approximately 2 percent. The shrinkage values for the PVC / alveolar wood fiber composite of the invention were very low. The shrinkage was smaller than the measurable in a standard one-piece test sample of twenty-five centimeters (ten inches). Standard PVC (without fiber or foam) shrinks approximately 1.8 to 2.2% under standard test conditions. The PVC / standard wood fiber composite shrinks approximately 0.4% under standard test conditions. In the tests, it is found that the coefficient of thermal expansion for alveolar composite materials was greater than the unfoamed compound. It is expected that the shrinkage for the alveolar composite is greater than that for the unfoamed compound. The substantial absence of shrinkage in the alveolar composite was surprising. The above test data and examples of the specification provide a basis for understanding the means and limitations of the invention. However, the invention can have many modalities which do not deviate from the spirit and scope of the invention. The invention is comprised in the appended claims to the present.

It is noted that, in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention. Having described the invention as above, property is claimed as contained in the following:

Claims (38)

1. Claims 1. A process for forming an alveolar composite, the composite comprises a vinyl polymer composition and a reinforcing wood fiber, the process is characterized in that it comprises the steps of: (a) introducing an extrusion mass comprising a polymeric composition , a source of wood fiber and an agent capable of foaming the polymeric composition, at a path of the extruder comprising a cylinder or barrel, at least one screw drive, the path additionally comprises a hole for moisture positioned between a first heated zone having a temperature of about 165 to 190 ° C and a second heated zone having a temperature of about 165 to 190 ° C, the extrusion path leads to a mandrel and a forming nozzle or mold comprising a meter calibration; (b) forming an alveolar member from the extrusion mass in the nozzle; and (c) contacting a surface of the solid honeycomb element in the meter with a liquid, forming an element with at least a portion of its surface having a smooth hard character. The method according to claim 1, characterized in that the extrusion mass is cut and heated to a temperature of at least 100 ° C before reaching the moisture vent hole. 3. The method according to claim 2, characterized in that after the ventilation hole of the moisture, the extrusion mass is heated to a temperature higher than its melting point and forms a molten extrusion mass that prevents the escape of the Foaming gases through the ventilation hole of moisture. The method according to claim 3, characterized in that the temperature of the extrusion dough does not exceed the decomposition temperature of the foaming agent until the molten extrusion dough is formed. 5. The method according to claim 4, characterized in that the decomposition temperature is greater than 150 ° C. 6. The method according to claim 1, characterized in that the polymer composition comprises a vinyl polymer comprising vinyl chloride. 7. The method of compliance with the claim 1, characterized in that the trajectory of the extruder comprises means, close to the mandrel, to relieve the pressure of the gas formed in the mold or nozzle. The process according to claim 1, characterized in that the extrusion mass comprises the agent and a thermoplastic pellet comprising the polymer composition intimately mixed with the fiber. The process according to claim 1, characterized in that the extrusion dough comprises an acrylic polymeric agent for stabilizing the foam, the foaming agent and a thermoplastic tablet comprising the polymer composition intimately mixed with the fiber. 10. The process according to claim 1, characterized in that the element is a hollow element. 11. The process according to claim 1, characterized in that the element is a solid element. 12. The process according to claim 1, characterized in that the calibration meter comprises a calibration block. 13. The process according to claim 1, characterized in that the agent comprises a blowing agent that generates nitrogen or a blowing agent that generates carbon dioxide or mixtures thereof. The process according to claim 1, characterized in that the mandrel and the nozzle are maintained at a temperature of approximately 170 to 230 ° C. 15. The process according to claim 1, characterized in that the liquid comprises water. 16. An alveolar composite element characterized in that it comprises a vinyl polymer and a wood fiber in the form of a cellular composite structural element comprising an open cell structure, the element is suitable for use as a replacement for a wooden structural element, the composite element comprises approximately 90 to 50% by weight of vinyl polymer and 10 to 50% by weight of the wood fiber, the open cell structure results from the interaction of the cells with the fiber in the composite, the composite element has a coefficient of thermal expansion of less than approximately 5.4x10"cm / cm ° C (3-10" 3 inches / inch-° F), a shrinkage of less than about 2% of an original dimension and an average fastener retention of at least about 70% of a substantially similar pine element. 17. The composite element according to claim 16, characterized in that it comprises approximately 80 to 60% by weight of the polymer and 20% to 40% by weight of the fiber. 18. The composite element according to claim 16, characterized in that the element is a hollow element. 19. The composite element according to claim 16, characterized in that the element is a solid element. 20. The composite element according to claim 16, characterized in that it has a rectangular cross section with a dimension greater than about 1 centimeter. 21. The composite element according to claim 16, characterized in that it has a square cross section with a smaller dimension, greater than about 1 centimeter. 22. The composite element according to claim 16, characterized in that the element comprises a rectangular plank. 23. The composite element according to claim 16, characterized in that the rectangular board is an element having finished dimensions of at least about 5.08 cm (2 inches) deep and 30.48 cm (12 inches) wide. 24. The composite element according to claim 16, characterized in that the element comprises a residential covering. 25. The composite element according to claim 20, characterized in that the covering element is a fastening reinforcement, a visualizable surface feature and an interlacing notch. 26. The composite element according to claim 21, characterized in that the viewable surface comprises a flat surface. 27. The composite element according to claim 21, characterized in that the visualizable surface comprises a surface with wood grain. 28. The composite element according to claim 16, characterized in that it has a shaped cross section. 29. The composite element according to claim 16, characterized in that it comprises a window or door guide. 30. The composite element according to claim 16, characterized in that it comprises a window threshold. 31. The composite element according to claim 16, characterized in that it comprises an ornament element. 32. The composite element according to claim 27, characterized in that it comprises a window stopper or obstacle. 33. The composite element according to claim 16, characterized in that it comprises a Young's modulus greater than about 1757 Kg / cm2 (250,000 pounds / inches2). 34. The composite element according to claim 16, characterized in that it comprises a coefficient of thermal expansion of 0.18x10"5 cm / cm ° C (0.1-10" 5 inches / inch ° F) and 5.4x10"5 cm / cm ° C (3-10-5 inches / inches- ° F) 35. A structural unit characterized in that it comprises at least two structural elements in accordance with claim 16 attached to a mechanically secured joint. according to claim 16, characterized in that the surface of the element consists of a region comprising a honeycomb surface and a region comprising a hard smooth surface 37. The composite element according to claim 16, characterized in that it has a cover layer. top with a thickness of about 0.025 cm (1 thousandth of an inch) to 0.25 cm (100 thousandths of an inch) 38. The composite element according to claim 16, characterized in that the composition n polymer comprises a vinyl polymer comprising vinyl chloride. SUMMARY OF THE INVENTION [0002] Advanced structural components comprising an alveolar thermoplastic material that can be used in virtually any application where wood components are used are described. Such structural components may comprise dimensioned wood, sized wood cuttings, posts, beams or formed structural elements. An advanced profile composite structural component comprises an outer cover layer with an interior comprising a honeycomb thermoplastic that can be used in the assembly of windowing units adapted for residential and commercial structures. Preferably, the structural component of the profile can be used in a window or door assembly. The profile element is adapted for ease of construction of the window units, can be easily installed in a rough opening to structural elements and can be trimmed and adjusted on site. The profile is structurally strong, thermally stable, resistant to shrinkage and will accept and retain the insertion of fasteners such as staples, nails and screws permanently with substantial retention and little or no damage to the units. The profile structural components have strength that allow the fabrication of a structurally firm window unit from two or more alveolar profile elements or other conventional elements.