Abstract: A method is disclosed for manufacturing connectable or non-connectable elongate porous plastic profiles 12 from substantially continuous randomised extruded plastic strands made of recycled thermoplastics. Current manufacturing processes can manufacture similar products, comprising short partially melted plastic particles melded together forming planks. These planks, however, are inherently friable, easily broken and not readily connectable. These shortcomings are caused by the manufacturing method used, being friction plate agglomeration. This invention utilises an extrusion process, which produces substantially endless random strands of thermoplastic 13 which drop and are welded together to form a porous mass, which is then compressed into boards or planks by pulling the mass through a forming tool 6 and 7. The profile can be adjusted to form edge recesses allowing the planks to be fitted together, for instance to form area coverings, or they can simply be laid end to end to form drainage channels.

Abstract: A method is disclosed for manufacturing connectable or non-connectable elongate porous plastic profiles 12 from substantially continuous randomised extruded plastic strands made of recycled thermoplastics. Current manufacturing processes can manufacture similar products, comprising short partially melted plastic particles melded together forming planks. These planks, however, are inherently friable, easily broken and not readily connectable. These shortcomings are caused by the manufacturing method used, being friction plate agglomeration. This invention utilises an extrusion process, which produces substantially endless random strands of thermoplastic 13 which drop and are welded together to form a porous mass, which is then compressed into boards or planks by pulling the mass through a forming tool 6 and 7. The profile can be adjusted to form edge recesses allowing the planks to be fitted together, for instance to form area coverings, or they can simply be laid end to end to form drainage channels.