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US 11,712,831 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.
Claims12
An extruded board, comprising:
- a first lightened portion of an extruded board surface formed with a uniformly colored foamed resin, the first lightened portion including a first plurality of void spaces formed using the uniformly colored foamed resin;
- and
- a first streak portion of the extruded board surface formed with the uniformly colored foamed resin, the first streak portion including a second plurality of void spaces, a first longitudinally extending portion extending longitudinally along the extruded board, a second longitudinally extending portion extending longitudinally along the extruded board, and a first laterally extending arch shaped portion connecting the first longitudinally extending portion and the second longitudinally extending portion, wherein
- the first and second longitudinally extending portions are on opposite sides of the first lightened portion,
- the first plurality of void spaces have a first average size,
- the second plurality of void spaces have a second average size, and
- the first average size is larger than the second average size.
4 more elements
An extruded board, comprising:
- a first lightened portion of an extruded board surface formed with a uniformly colored foamed resin, the first lightened portion including a first plurality of void spaces formed using the uniformly colored foamed resin;
- a first streak portion of the extruded board surface formed with the uniformly colored foamed resin, the first streak portion including a second plurality of void spaces, a first longitudinally extending portion extending longitudinally along the extruded board, a second longitudinally extending portion extending longitudinally along the extruded board, and a first laterally extending arch shaped portion connecting the first longitudinally extending portion and the second longitudinally extending portion, wherein the first lightened portion appears to be visually lighter than the first streak portion;
- and
- a second lightened portion of the extruded board surface formed with the uniformly colored foamed resin, the second lightened portion including a third plurality of void spaces, a third longitudinally extending portion extending longitudinally along the extruded board, a fourth longitudinally extending portion extending longitudinally along the extruded board, and a second laterally extending arch shaped portion connecting the third longitudinally extending portion and the fourth longitudinally extending portion, wherein the first streak portion is located between the first lightened portion and the second lightened portion,
- wherein:
- the first longitudinally extending portion forms a first shape along the extruded board surface;
- the second longitudinally extending portion forms a second shape along the extruded board surface;
- the first shape is different from the second shape;
- and
- a plurality of the first plurality of first void spaces are partially closed by respective flaps formed by the uniformly colored foamed resin.
7 more elements
An extruded board, comprising:
- a first lightened portion of an extruded board surface formed with a uniformly colored foamed resin, the first lightened portion including a first plurality of void spaces;
- and
- a first streak portion of the extruded board surface formed with the uniformly colored foamed resin, the first streak portion including a second plurality of void spaces, a first longitudinally extending portion extending longitudinally along the extruded board, a second longitudinally extending portion extending longitudinally along the extruded board, and a first laterally extending arch shaped portion connecting the first longitudinally extending portion and the second longitudinally extending portion, wherein the first lightened portion appears to be visually lighter than the first streak portion, wherein a plurality of the first plurality of first void spaces are partially closed by respective flaps formed by the uniformly colored foamed resin.
Dependencies are inferred from the claim text.