Apparatus and method for co-extruding multi color plastics

An apparatus for producing a multi layer plastic extrudant;

• the apparatus comprising:
• a first extruder configured to extrude a first plastic extrudant;
• a second extruder configured to extrude a second plastic extrudant, the second plastic extrudant being at least partially transparent;
• a third extruder configured to extrude a third plastic extrudant;
• a mixer coupled to the second extruder and the third extruder and configured to produce a mixture of the second plastic extrudant and the third plastic extrudant, the mixture including a non-linear pattern;
• and
• a co-extrusion block comprising a first channel and a second channel, wherein the first channel is coupled to the first extruder to receive the first plastic extrudant to produce a first layer and wherein the second channel is coupled to the mixer to receive the mixture of the second plastic extrudant and the third plastic extrudant to produce a second layer, the second layer containing the non-linear pattern wherein the third plastic extrudant of the mixture is visible within the second layer due to the second plastic extrudant of the mixture being at least partially transparent.

The apparatus of 9, wherein the mixer comprises:

• a housing having a first end and a second end and an interior region, the first end configured to receive the second plastic extrudant and the third plastic extrudant and the second end configured to expel the mixture of the two extrudants through a plurality of outlets;
• a shaft having a first end and a second end, the first end located proximate to the first end of the housing and the second end located proximate to the second end of the housing, the shaft being rotatable relative to the housing about an axis;
• at least one projection coupled to the shaft and rotatable with the shaft, the at least one projection configured to orient the mixture of the two extrudants relative to the plurality of outlets in the second end of the housing;
• and
• a thrust bearing configured to couple the second end of the shaft to the second end of the housing to permit expulsion of the mixture in a non-linear pattern as the mixture is oriented relative to the plurality of outlets.

A method for producing a plastic sheet, comprising the steps of:

• extruding a first plastic extrudant to produce a first layer;
• extruding a second plastic extrudant having an appearance, the appearance being at least partially transparent and including a first color;
• extruding a third plastic extrudant having another appearance, the other appearance including a second color;
• mixing the second plastic extrudant and the third plastic extrudant to produce a mixture, the mixture including a non-linear pattern;
• and
• applying the mixture of the second and third plastic extrudant to the first layer to produce a second layer wherein the third plastic extrudant of the mixture is visible within the second layer due to the appearance of the second plastic extrudant of the mixture.

A method for producing a plastic sheet, comprising the steps of:

• extruding a first plastic extrudant having a first appearance, the first appearance being at least partially transparent and including a first color;
• extruding a second plastic extrudant having a second appearance, the second appearance including a second color;
• mixing the first plastic extrudant and the second plastic extrudant to produce a mixture having a non-linear pattern;
• and
• producing a sheet from the mixture, the second plastic extrudant being visible within the sheet due to the appearance of the first plastic extrudant.

An apparatus for producing a plastic extrudant;

• the apparatus comprising:
• a first extruder configured to extrude a first plastic extrudant;
• a second extruder configured to extrude a second plastic extrudant, the second plastic extrudant being at least partially transparent;
• a mixer coupled to the first extruder and the second extruder and configured to produce a mixture of the first plastic extrudant and the second plastic extrudant, the mixture including a non-linear pattern;
• and
• a die coupled to the mixer to receive the mixture of the first plastic extrudant and the second plastic extrudant to produce a layer, the layer containing the non-linear pattern wherein the first plastic extrudant of the mixture is visible within the layer due to the second plastic extrudant of the mixture being at least partially transparent.

The apparatus of 32, wherein the mixer comprises:

• a housing having a first end and a second end and an interior region, the first end configured to receive the first plastic extrudant and the second plastic extrudant and the second end configured to expel the mixture of the two extrudants through a plurality of outlets;
• a shaft having a first end and a second end, the first end located proximate to the first end of the housing and the second end located proximate to the second end of the housing, the shaft being rotatable relative to the housing about an axis;
• at least one projection coupled to the shaft and rotatable with the shaft, the at least one projection configured to orient the mixture of the two extrudants relative to the plurality of outlets in the second end of the housing;
• and
• a thrust bearing configured to couple the second end of the shaft to the second end of the housing to permit expulsion of the mixture in a non-linear pattern as the mixture is oriented relative to the plurality of outlets.