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An apparatus and method for continuously forming composites comprising filler materials and thermoactive materials, particularly waste cellulosic materials and waste thermoplastics, are described. One embodiment of the apparatus includes either a batchwise or continuous mixer, such as a cyclone, for

An apparatus and method for continuously forming composites comprising filler materials and thermoactive materials, particularly waste cellulosic materials and waste thermoplastics, are described. One embodiment of the apparatus includes either a batchwise or continuous mixer, such as a cyclone, for forming mixtures comprising filler and thermoactive material. The mixtures are conveyed to a continuous consolidation apparatus. Alternatively, the mixtures may be densified in a densifying apparatus before entering the consolidation apparatus. The consolidation apparatus includes a hot-gas distribution system having plural paired gas cells, such as rollers or hoods, for applying hot air to the charge. A first cell of each pair applies gas to the mixture. The second cell of each pair operates at a pressure less than that of the first cell, thereby creating a pressure differential across the charge. Certain embodiments of the apparatus include at least one set of baffles positioned adjacent a cell, at least one shroud positioned about a cell, or at least one set of baffles positioned adjacent a first cell and at least one shroud positioned about a second cell. The baffles and shrouds are used to eliminate or substantially reduce the amount of gas that is vented to the surrounding atmosphere. The method comprises continuously consolidating the mixtures by applying a hot, dry noncondensable gas to the mixture. Besides the filler material and the thermoactive material the mixture may further include materials selected from the group consisting of biocides, fungicides, fire retardants, conductive materials, pigments, water retardants, wax-like materials, coupling agents, crosslinking agents, and combinations thereof.

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1. An apparatus for continuous formation of composites comprising a mixture of filler and thermoactive materials, the apparatus comprising a mixer for forming the mixture of filler and thermoactive material and providing a continuous charge of the mixture to a conveyor, which conveys the continuous

1. An apparatus for continuous formation of composites comprising a mixture of filler and thermoactive materials, the apparatus comprising a mixer for forming the mixture of filler and thermoactive material and providing a continuous charge of the mixture to a conveyor, which conveys the continuous charge to a hot-gas distribution system having at least one pair of gas cells positioned along the conveyor for applying hot gas to the charge in a consolidation zone, wherein a first cell of the pair applies hot gas to one side of the charge and wherein a second cell of the pair operates at a pressure less than that of the first cell, thereby creating a pressure differential across the charge, the second cell receiving gas expelled by the first cell, the apparatus further comprising shrouds that substantially surround the pair of gas cells.2. The apparatus according to claim 1 having plural paired gas cells.3. The apparatus according to claim 1 wherein the gas cells are rollers.4. The apparatus according to claim 1 wherein the gas cells are stationary.5. The apparatus according to claim 1 wherein the mixer includes a hot-gas inlet for receiving hot gas from a source for heating the filler material and the thermoactive material.6. The apparatus according to claim 1 wherein the mixer comprises a cyclone mixer.7. The apparatus according to claim 1 and further comprising baffles positioned adjacent the gas cells.8. The apparatus according to claim 2 and further comprising baffles positioned adjacent at least one of the gas cells.9. The apparatus according to claim 1 wherein the hot-gas distribution system comprises multiple pairs of cells, including cells for applying a densifying force to the charge, and wherein the pairs of cells are fluidly interconnected in series with a gas application cell of one pair connected to a suction or evacuation cell of same pair, with the suction or evacuation cell of one pair connected in series to press cell of another pair.10. The apparatus according to claim 2 wherein such apparatus comprising first paired gas cells, a first cell of the pair applying hot gas to a charge and a second cell of the pair operating to receive gas applied to the charge by the first cell of the pair, and at least a second pair of gas cells positioned adjacent the first paired gas cells, where a first cell of the second paired gas cells, positioned adjacent the first cell of the first paired gas cells, receives hot gas applied to the charge by a second cell of the second pair, the gas flowing through the charge and received by the first cell of the second pair, thereby providing pulsed hot gas application to the charge as the charge moves between pairs of cells.11. The apparatus according to claim 1 where the conveyor conveys the continuous charge in a first direction, and gas flows in a direction opposite to the first direction of charge movement through the consolidation zone.12. The apparatus according to claim 1 where the conveyor conveys the continuous charge of the mixture in a first direction, and wherein the gas flows in the first direction of charge movement through the consolidation zone.13. The apparatus according to claim 1 wherein each cell is a drum-type roller.14. The apparatus according to claim 13 wherein the rollers include central stationary gas application or recovery portion.15. The apparatus according to claim 1 and further comprising a surface modifier for surface modifying at least a portion of a surface of the composite.16. The system according to claim 15 where the surface modifier operates by flame oxidation, corona oxidation, e-beam, photoactivation, and combinations thereof.17. An apparatus for the continuous formation of composites comprising a mixture of filler and thermoactive materials, the apparatus comprising:a mixer that forms the mixture of filler and thermoactive material and provides a continuous charge of the mixture to a conveyor for continuously moving a charge through a consolidation zone; and at least a first pair of gas cells positioned on opposite sides of the charge, one cell of the pair for injecting hot gas into the charge, the other cell of the pair for drawing gas through the moving charge, the apparatus further comprising shrouds that substantially surround the gas cells. 18. The apparatus according to claim 17 further comprising multiple pairs of cells.19. The apparatus according to claim 18 wherein the multiple cells are fluidly interconnected.20. The apparatus according to claim 18 wherein the multiple cells are interconnected in series.21. The apparatus according to claim 18 wherein the multiple cells are interconnected in parallel.22. The apparatus according to claim 17 where the conveyor for conveying the continuous charge moves in a first direction, and where the gas flow direction is opposite to charge moving direction.23. The apparatus according to claim 17 where the conveyor for conveying the continuous charge moves in a first direction, and where the gas flow direction is the same as charge moving direction.24. The apparatus according to claim 17 comprising first paired gas cells, a first cell of the pair applying hot gas to the charge and a second cell of the pair operating to receive hot gas applied to the charge by the first cell of the pair, and at least a second pair of gas cells positioned adjacent the first paired gas cells, where a first cell of the second paired gas cells, positioned adjacent the first cell of the first paired gas cells, receives hot gas applied to the charge by a second cell of the second pair, the gas flowing through the charge and received by the first cell of the second pair, thereby providing pulses of hot gas to the moving charge.25. A system for continuously forming a composite that includes thermoactive material and filler material, comprising:a mixer for forming a mixture comprising filler material and thermoactive material; a continuous consolidation apparatus for applying hot-gas to a charge in a consolidation zone, the apparatus comprising plural paired gas cells wherein a first cell of each pair applies gas to one major surface of a charge and wherein a second cell of each pair operates at a pressure less than that of the first cell, thereby creating a pressure differential across the charge, the second cell receiving gas passing through the charge the consolidation apparatus further comprising shrouds that substantially surround at least one pair of the plural paired gas cells; and a first densifying apparatus downstream from the consolidation apparatus for applying a densifying pressure to the charge. 26. The system according to claim 25 and further including a mat-forming apparatus upstream of the consolidation apparatus.27. The system according to claim 25 and further comprising a second densifying apparatus upstream of the consolidation apparatus.28. The system according to claim 25 wherein the densifying apparatus comprises densifying pressure cells for applying a densifying pressure to the charge.29. The system according to claim 25 and further comprising a second densifying apparatus comprising densifying cells downstream of the gas cells.30. The system according to claim 25 wherein the densifying apparatus operates continuously.31. The system according to claim 25 wherein the densifying apparatus operates batchwise.32. The system according to claim 25 wherein the gas cells comprise press cells.33. The system according to claim 25 comprising a press comprising press cells downstream of the gas cells.34. A system for making composites comprising at least one thermoactive material and at least one filler material, the system comprising:a mixer for forming mixtures comprising thermoactive and filler materials; a mat-forming apparatus for forming mats from the mixture; a continuous consolidation apparatus for receiving the mat, the consolidation apparatus having a hot-gas distribution system comprising plural paired rollers wherein a first roller of each pair applies gas to a charge and wherein a second roller of each pair operates at a pressure less than ambient, the consolidation apparatus comprising shrouds that substantially surround at least one pair of the plural paired rollers; and a densifying apparatus for applying a densifying pressure to the charge downstream of the consolidation apparatus.