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US 10,486,354 B2Granted
Extruded board with realistic appearance
AssigneePoly-Wood, LLC
InventorsDouglas Rassi, Jason Carrington, Kevin Nobes
Life of this patent
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Abstract
In one embodiment, a method of forming an extruded board includes mixing a resin and a foaming agent, melting the mixed resin and foaming agent to form a uniformly colored extrudate, differentially expanding voids formed from the foaming agent within the uniformly colored extrudate by passing the uniformly colored extrudate through a breaker plate, forming a board with the differentially expanded voids and uniformly colored extrudate, and forming lightened portions on an outermost surface of the formed board.
Claims14
A method of forming an extruded board, comprising:
- mixing a resin and a foaming agent;
- melting the mixed resin and foaming agent to form a uniformly colored twisting extrudate with a screw portion of an extruder;
- controlling the temperature of the uniformly colored twisting extrudate at an end of the screw portion to a temperature which allows for foaming of the foaming agent;
- contacting a breaker plate with the uniformly colored twisting extrudate at the temperature which allows for foaming of the foaming agent;
- linearizing the uniformly colored twisting extrudate with the breaker plate;
- differentially expanding voids formed from the foaming agent within the uniformly colored extrudate as the uniformly colored twisting extrudate is linearized with the breaker plate;
- forming a board with the differentially expanded voids and uniformly colored extrudate;
- and
- forming lightened portions on an outermost surface of the formed board.
6 more elements
Dependencies are inferred from the claim text.