Method for extruding plastic with accent color pattern
First Claim
1. A method of producing a plastic extrudate with a base color and at least one accent color, comprising the steps of:
- a) introducing into an extruder a base color producing material and an accent color producing material, said base color producing material comprising powder sized material, said accent color producing material comprising pellets which (i) are larger than the powder sized material of said base color material, (ii) have a higher deflection temperature than said base color material; and
(iii) wherein said base color producing material comprises polyvinylchloride and wherein said accent color producing material comprises a material selected from the group consisting of acrylics, polycarbonates and mixtures thereof;
b) extruding said base color producing material and said accent color producing material through an extrusion die to form the plastic extrudate under processing temperatures whereby the accent color carrying pellets cause delayed introduction and restricted dispersion of the accent color into the plastic extrudate;
c) introducing into said extrusion die a substrate producing material, and co-extruding said substrate producing material with said base color producing material and said accent color producing material.
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Accused Products
Abstract
A new and useful process for producing a plastic article (e.g., vinyl siding) with an accent color pattern incorporated therein, and a specially formed accent color pellet which is useful in such a process. The process contemplates extruding a plastic product from a base compound formed of powder sized particles and specially formed accent color pellets. The accent color pellets are alloyed masses of resins and pigment which are larger than the powder particles of the base compound, and have a higher deflection temperature than the base compound. The alloyed pellets are designed with controlled heat deflection characteristics. During the extrusion process, the accent color pellets begin to soften and disperse later than the base compound, and cause restricted dispersion of the accent color into the base compound, thereby producing accent color streaks in the resulting extrudate. The process is particularly suited for producing a simulated woodgrain or streaking effect in plastic. (e.g., vinyl) siding.
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Citations
18 Claims
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1. A method of producing a plastic extrudate with a base color and at least one accent color, comprising the steps of:
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a) introducing into an extruder a base color producing material and an accent color producing material, said base color producing material comprising powder sized material, said accent color producing material comprising pellets which (i) are larger than the powder sized material of said base color material, (ii) have a higher deflection temperature than said base color material; and
(iii) wherein said base color producing material comprises polyvinylchloride and wherein said accent color producing material comprises a material selected from the group consisting of acrylics, polycarbonates and mixtures thereof;b) extruding said base color producing material and said accent color producing material through an extrusion die to form the plastic extrudate under processing temperatures whereby the accent color carrying pellets cause delayed introduction and restricted dispersion of the accent color into the plastic extrudate; c) introducing into said extrusion die a substrate producing material, and co-extruding said substrate producing material with said base color producing material and said accent color producing material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 18)
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10. A method of producing an extruded product having a base color and at least one accent color, comprising the steps of:
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(a) forming a base compound comprising powder sized particles adapted to be extruded to produce an extrudate having said base color, (b) providing accent color pellets having a deflection temperature 30-60% higher than the deflection temperature of the base compound, said accent color pellets having a lower surface area per unit weight than the powder sized particles of the base compound, (c) providing a substrate-producing material, (d) introducing said substrate-producing material, said base compound, and said accent color pellets into an extrusion die, and (e) co-extruding said base compound, said accent color pellets, and said substrate-producing material into an extrudate with a desired product shape, said accent color pellets causing delayed introduction and restricted dispersion of accent color into the extrudate; wherein said base compound comprises polyvinylchloride and wherein said accent color pellets are formed from a material selected from the group consisting of acrylics, polycarbonates and mixtures thereof. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17)
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Specification