Abstract: A system and method for manufacturing composite material components having substantially uniform properties comprising means to control the metering of constituent composite material components during manufacture. The resulting composite material components may, for example, be used in the construction of decking systems, railing, porches, fences, stairs, or other similar or suitable applications that may benefit from aesthetically pleasing appearances.

Abstract: The present invention relates generally to an integrated belt machine. More particularly, the present invention is directed to an integrated belt puller and 3D forming machine for continuously forming 3D products from plastic materials.

Abstract: The present invention is a siding panel and a method of making the siding panel. The siding panel comprises a planar portion extending the longitudinal length of the siding panel. The planar portion comprises a first edge and a second edge. The width from the first edge to the second edge is at least about 4.0 inches. The planar portion has a surface variance of less than about 0.05 inches relative to an imaginary straight line connecting the first edge and the second edge, and the radius curvature between the first edge and the second edge is at least about 85 inches.

Abstract: The apparatus and method of the present invention is directed to an improved composite fence and, more particularly, to a composite fence made of cellulosic fillers and/or inorganic fillers. An alternative embodiment of the present invention is directed to a fence in which a substrate is embedded in a plastic composite. One example of a component of the present invention is comprised of a substrate sheet that is embedded in a plastic composite. Another example of a component of the present invention is a perforated substrate that is embedded in a plastic composite.

Abstract: Simulated stone, masonry and brick textured products such as siding panels are obtained when specially selected materials are properly admixed and formed via molding techniques. For instance, exemplary methods of manufacturing embodiments of panels, wall structures, and other products that may have contoured and textured surfaces and may simulate the appearances of conventional building or construction materials including, but not limited to, stone, bricks, masonry, concrete, stucco, wood, other conventional building materials, and combinations of any of these materials are disclosed. Such products are manufactured from suitable molds according to a prescribed process methodology using synthetic polymeric materials in addition to other materials such as coloring and texturing materials. Prerequisite surface textures may be produced that effectively simulate actual stone, masonry and brick panels.

Abstract: The present invention is a vinyl siding panel and a method of making the vinyl siding panel. The vinyl siding panel comprises a planar portion extending the longitudinal length of the vinyl siding panel. The planar portion comprises a first edge and a second edge. The width from the first edge to the second edge is at least about 4.0 inches. The planar portion has a surface variance of less than about 0.05 inches relative to an imaginary straight line connecting the first edge and the second edge, and the radius curvature between the first edge and the second edge is at least about 85 inches.

Abstract: A component such as a siding panel comprised of a PVC/wood flour composite. Another embodiment is a component such as a siding panel that is made from a PVC/CPE/wood flour composite. The cellulosic composite may be extruded through a die and then bent into the shape of the component. Optionally, a reinforcement backer (e.g., an expanded polystyrene foam panel) may be adhered to the cellulosic composite siding.

Abstract: The present invention relates generally to an integrated belt machine. More particularly, the present invention is directed to an integrated belt puller and 3D forming machine for continuously forming 3D products from plastic materials.

Abstract: The present invention relates to a system and a method for cooling extruded and molded materials. The present invention is especially useful to thoroughly cool an extrudate by directing a cooling fluid toward a surface of the extrudate (e.g., an interior surface that defines a hollow portion of an extrudate). Hollows may be created in order to reduce material, weight, and/or processing time. A cooling fluid is diverted toward the surface of the extrudate so as to cool the material and assist in solidification. A baffle may serve to divert the cooling fluid in the desired direction. In another example, the extrudate may be partially or totally immersed in a liquid cryogenic fluid. Increases in production line throughput may result by rapidly cooling the molded material. In addition, the more efficient cooling may be achieved with a lesser amount of the cooling fluid, and the velocity and temperature of the cooling fluid may be reduced.

Abstract: The present invention is a method of assembling fence sections using a banding machine to band an assembled fence section together so that the fence section does not fall apart as it is transferred to the site where it will be used. The fence section may be assembled at the beginning of an assembly line. The fence section may then move along the line toward the banding machine. The fence section is then banded and moved through the banding machine to be placed into a box.

Abstract: A lineal for framing openings in buildings that may provide a finished appearance to the opening being framed. The lineal may be comprised of a nailing hem and an overhang. The lineal may additionally comprise a channel portion. The lineal with a channel portion may be manufactured as a one-piece or two-piece unit. The two-piece unit may have a portion that slides onto or snaps into the channel portion. The lineal may have insulation applied to its underside.

Abstract: The present invention relates to a system and a method for cooling extruded and molded materials. The present invention is especially useful to thoroughly cool an extrudate by directing a cooling fluid toward a surface of the extrudate (e.g., an interior surface that defines a hollow portion of an extrudate). Hollows may be created in order to reduce material, weight, and/or processing time. A cooling fluid is diverted toward the surface of the extrudate so as to cool the material and assist in solidification. A baffle may serve to divert the cooling fluid in the desired direction. In another example, the extrudate may be partially or totally immersed in a liquid cryogenic fluid. Increases in production line throughput may result by rapidly cooling the molded material. In addition, the more efficient cooling may be achieved with a lesser amount of the cooling fluid, and the velocity and temperature of the cooling fluid may be reduced.

Abstract: The present invention relates to a system and a method for cooling extruded and molded materials. The present invention is especially useful to thoroughly cool an extrudate by directing a cooling fluid toward a surface of the extrudate (e.g., an interior surface that defines a hollow portion of an extrudate). Hollows may be created in order to reduce material, weight, and/or processing time. A cooling fluid is diverted toward the surface of the extrudate so as to cool the material and assist in solidification. A baffle may serve to divert the cooling fluid in the desired direction. In another example, the extrudate may be partially or totally immersed in a liquid cryogenic fluid. Increases in production line throughput may result by rapidly cooling the molded material. In addition, the more efficient cooling may be achieved with a lesser amount of the cooling fluid, and the velocity and temperature of the cooling fluid may be reduced.

Abstract: A system and method for directing a fluid through a die. A transfer device for a fluid (e.g., a cooling fluid or a material) may extend through an interior of the die. The transfer device may be situated such that undesired heat transfer with other portions of the die is limited.

Abstract: An extrusion process is described for the extrusion of a synthetic wood material. The process includes a significantly higher compression ratio through which the extruded product must pass. The higher compression ratio results in significantly improved product qualities.

Abstract: The present invention is a component such as a siding panel that may be comprised of various formulations of cellulosic/polymer composite materials. One embodiment of the present invention is a siding panel that is comprised of a cellulosic/PVC composite material. This composite material may include at least one cellulosic filler in the amount of about 30% to about 60% by weight and a PVC material in the amount of about 40% to about 70% by weight. The PVC material may include about 1 to about 10 parts stabilizer(s) per 100 parts of the PVC resin, about 2 to about 12 parts lubricant(s) per 100 parts of the PVC resin, and about 0.5 to about 8 parts process aid(s) per 100 parts of the PVC resin. Another embodiment of the present invention is a siding panel that may be comprised of a cellulosic/polypropylene composite material.

Abstract: A multilayer synthetic wood component comprised of a layer of a first synthetic wood composition that is secured to a layer of a second synthetic wood composition. As a result, the present invention may provide a component that utilizes the beneficial characteristics of each of the compositions. For instance, the component can have an improved combination of appearance, strength, durability, weight, weatherability, and other characteristics. Moreover, the present invention enables the ingredients of each layer to be tailored to the particular application. Consequently, certain ingredients can be conserved, thereby reducing the cost and/or the weight of the component.

Abstract: The present invention is a fence assembly comprising fence segments and connectors. Each fence segment may be secured to another fence segment by a connector. The present invention may use in-line connectors, living hinge connectors, male/female hinged connectors, and/or end caps. The connectors may be adapted to fit into the hollow channel rails by a friction fit, press fit, adhesion, or any other suitable connecting means.

Abstract: A trim piece for use with siding. The trim piece includes a proximal end portion that is adapted to engage a support structure such as a clip. A cover piece extends from the proximal end portion. When used as top course molding, the cover piece may cover the nailing hem of an underlying piece of siding. A distal end portion of the cover piece may be comprised of a flexible plastic material in order to account for the slop of the siding.

Abstract: The present invention is a component having a synthetic wood layer that is secured to a foamed polymer layer. The foamed polymer layer is comprised of a polymer selected from the group consisting of high density polyethylene, polypropylene, polyvinyl chloride, low density polyethylene, chlorinated polyvinyl chloride, acrylonitrile butadiene styrene, ethyl-vinyl acetate, and polystyrene. The component can be used for a variety of different purposes such as fencing, furniture, cabinets, storage devices, lawn edging, flower boxes, flooring, roofing, wall covering, building siding, basement flooring, basement wall covering, interior and exterior decorative house moldings, crown moldings, chair rails, picture frames, porch decks, deck railings, window moldings, window components, door components, door moldings, various other lawn and garden uses, various other below grade uses, and various other indoor and outdoor uses.