Abstract: Aspects described herein are directed to compositions, systems, and methods of manufacturing a polymer-based construction material comprising polymeric resin, filler such as calcium carbonate (CaCO3), and titanium oxide (TiO2). A surface of the polymer-based construction material may be treated such that the surface energy is increased from the material's inherent value to a predetermined value of at least 40 dynes/cm2. Further, the surface energy of the treated surface may persist within 20% of the predetermined value for at least three days.

Abstract: A method and machine for sealing at least one cut edge of a foam board is disclosed. The foam board has a top surface, a bottom surface and at least one cut edge extending between the top surface and the bottom surface. The cut edge is passed over a heated roller to soften the edge and then passed over a second roller having a temperature that is lower than the temperature of the first roller which seals the edge. The cut edge may be milled to square the edge relative to the top and bottom of the board before the cut edge is passed over the heated roller. Additional pairs of rollers may be provided to seal the top surface and the bottom surface of the foam board.

Abstract: In a system and method for making a capped structure having a variegated cap layer a layer of cap materials is applied to a substrate and pin stripes are applied onto the cap layer through an extrusion die. After these materials exit the extrusion die they are passed through a single opening in a die plate to create a capped structure having a variegated appearance. This capped structure has a smooth surface that enables an embosser to create a consistent embossing pattern on the entire surface.

Abstract: A polymer composite and its method of manufacture using a recycled multilayer material. An example of the recycled multilayer material is comprised of a polyethylene/polyethylene terephthalate/aluminum film that may be extruded with organic filler to obtain desirable performance in wood-substitute products such as deck boards, railing, fencing, pergolas, residential cladding/siding, sheet products, and other applications.

Abstract: A polymer composite and its method of manufacture using a recycled multilayer material. An example of the recycled multilayer material is comprised of a polyethylene/polyethylene terephthalate/aluminum film that may be extruded with organic filler to obtain desirable performance in wood-substitute products such as deck boards, railing, fencing, pergolas, residential cladding/siding, sheet products, and other applications.

Abstract: A rail system that may be comprised of various components such as an upper rail, support rail, bottom rail, squash blocks, balusters, post covers, and ancillary components, such as post skirts and caps. In one exemplary embodiment, the rail system may be designed to accommodate perpendicular and angled installations (e.g., both in the horizontal and vertical planes). Furthermore, in another exemplary embodiment, the rail system may be assembled such that the support hardware is substantially hidden from view after installation.

Abstract: A guard rail system that is assembled from a kit of components that includes bottom rails, top rails and balusters and U-shaped top rail inserts that fit into the underside of the top rails. The tops of the balusters are inserted through the spaced apart holes in the base of the insert. The top rail has a body and a pair of spaced apart legs extending downward from the body. After the system has been assembled the legs engage the uprights of the top rail insert to create a compression fit between the top rail insert and the tops of the balusters.

Abstract: A polymer composite and its method of manufacture using a recycled multilayer material. An example of the recycled multilayer material is comprised of a polyethylene/polyethylene terephthalate/aluminum film or polyethylene/nylon/aluminum film that may be extruded with organic filler to obtain desirable performance in wood-substitute products such as deck boards, railing, fencing, pergolas, residential cladding/siding, sheet products, and other applications.

Abstract: A polymer composite and its method of manufacture using a recycled multilayer material. An example of the recycled multilayer material is comprised of a polyethylene/polyethylene terephthalate/aluminum film that may be extruded with organic filler to obtain desirable performance in wood-substitute products such as deck boards, railing, fencing, pergolas, residential cladding/siding, sheet products, and other applications.