The invention relates to a multiple-layer composite board of discrete materials and plastic. The multiple-layer composite board of discrete materials and plastic is formed by providing independently stratified plastic layers and discrete material layers, which are pressed in melting state of the alternate plastic layers and discrete material layers and cooled. Due to this stratification, centralized plastic layers constitute high load capacity and discrete material layers pressed with pressure lower than normal extrusion process constitute low density for the multiple-layer composite board of discrete materials and plastic.

A reusable, fiber containing pulp product is described that is highly suited for use in the manufacture of paper products. The reusable, fiber containing pulp product provides a mixture of fibers and small, dense polymer/particle fragments. The polymer/particle fragments within the reusable, fiber containing pulp product have a size range and density that facilitates efficient removal of the polymer/particle fragments using pressure screens.

A reusable, fiber containing pulp product is described that is highly suited for use in the manufacture of paper products. The reusable, fiber containing pulp product provides a mixture of fibers and small, dense polymer/particle fragments. The polymer/particle fragments within the reusable, fiber containing pulp product have a size range and density that facilitates efficient removal of the polymer/particle fragments using pressure screens.

An efficient method and apparatus for making a compressed structural fiberboard from agricultural fibrous matter. The method and apparatus provides a conveyor having variable drives for carrying the agricultural fibrous matter; a hopper having variable drives for conditioning and delivering the agricultural fibrous matter to an extruder; the extruder having a cyclic ram with linear actuators and a floating plate to drive the cyclic ram between an extended position, wherein the agricultural fibrous matter is compacted into the compressed structural fiberboard, and a retracted position, wherein the agricultural fibrous matter is delivered to the extruder; synthetic oil heaters for heating the compressed structural fiberboard; a heat sink track cooler for cooling the compressed structural fiberboard; and a water jet cutting system for cutting the compressed structural fiberboard into individual boards.

An efficient method and apparatus for making a compressed structural fiberboard from agricultural fibrous matter. The method and apparatus provides a conveyor having variable drives for carrying the agricultural fibrous matter; a hopper having variable drives for conditioning and delivering the agricultural fibrous matter to an extruder; the extruder having a cyclic ram with linear actuators and a floating plate to drive the cyclic ram between an extended position, wherein the agricultural fibrous matter is compacted into the compressed structural fiberboard, and a retracted position, wherein the agricultural fibrous matter is delivered to the extruder; synthetic oil heaters for heating the compressed structural fiberboard; a heat sink track cooler for cooling the compressed structural fiberboard; and a water jet cutting system for cutting the compressed structural fiberboard into individual boards.

Structures for use in forming products having a wood grain appearance include, for example, a plurality of extruded layers having different colors/shades spirally wound about a longitudinal axis to an outer surface to define the structure. The plurality of extruded layers include varying thicknesses along a spiral length of the plurality of layers and/or portions of the plurality of extruded layers encircling the longitudinal axis include portions disposed at different distances from the longitudinal axis. In some embodiments, the spirally winding includes forming a cylindrical structure, and pressing the cylindrical structure into a cuboid structure having a square or rectangular cross-section across the longitudinal axis and at least a portion of the plurality of extruded layers defining a square or rectangle pattern across the longitudinal axis. Longitudinal portions may be cut from the structures to form the products having a wood grain appearance.

Structures for use in forming products having a wood grain appearance include, for example, a plurality of extruded layers having different colors/shades spirally wound about a longitudinal axis to an outer surface to define the structure. The plurality of extruded layers include varying thicknesses along a spiral length of the plurality of layers and/or portions of the plurality of extruded layers encircling the longitudinal axis include portions disposed at different distances from the longitudinal axis. In some embodiments, the spirally winding includes forming a cylindrical structure, and pressing the cylindrical structure into a cuboid structure having a square or rectangular cross-section across the longitudinal axis and at least a portion of the plurality of extruded layers defining a square or rectangle pattern across the longitudinal axis. Longitudinal portions may be cut from the structures to form the products having a wood grain appearance.

Embodiments herein relate to a composite material including about 10 to 80 wt. % of a polymer phase, the polymer phase comprising a thermoplastic polymer with a density of less than about 1.9 g-m.sup.3; and about 20 to 90 wt. % of a dispersed mixed particulate phase, the dispersed mixed particulate phase comprising a mixed particulate and about 0.005 to 8 wt. % of a coating of at least one interfacial modifier. The mixed particulate including a portion of a reinforcing fiber and a portion of a particle. The composite material having a Young's modulus of greater than 700 MPa. In various embodiments, structural building components made from the composite are included as well as additive manufacturing components made from the composite. Other embodiments are also included herein.

Embodiments herein relate to a composite material including about 10 to 80 wt. % of a polymer phase, the polymer phase comprising a thermoplastic polymer with a density of less than about 1.9 g-m.sup.3; and about 20 to 90 wt. % of a dispersed mixed particulate phase, the dispersed mixed particulate phase comprising a mixed particulate and about 0.005 to 8 wt. % of a coating of at least one interfacial modifier. The mixed particulate including a portion of a reinforcing fiber and a portion of a particle. The composite material having a Young's modulus of greater than 700 MPa. In various embodiments, structural building components made from the composite are included as well as additive manufacturing components made from the composite. Other embodiments are also included herein.

A plank has a first portion with at least three layers. The first layer is of a plant material, and has an inner surface that includes a nonwoven fabric or a fiberglass mesh. The second layer is of an adhesive paper material that includes a macromolecular glue where the macromolecular glue is 50-55% melamine, 35-40% plasticizer, and 3-5% formaldehyde. The third layer is one of bamboo, wood, or paper. The plank has a second portion, which may be of a plastic composite base material or a magnesium oxide composite base material. When the second portion is of a plastic composite material, the first portion is fused to the second portion by cold pressing or a polyurethane reactive adhesive. When the second material is of a magnesium oxide composite base material, the first portion is thermally pressed to the second portion by cold pressing, hot pressing or a polyurethane reactive adhesive.