Abstract: A composite article includes a matrix having first and second opposing surfaces defining a transverse dimension and a filler material embedded in the matrix. The filler material presents a density gradient in the transverse dimension wherein a minimum filler density is at the first surface. In one embodiment, the composite article is a non-laminated article defining first and second regions wherein the first region encompasses the first surface. The first region has a filler-to-matrix ratio that varies along the transverse dimension, the filler-to-matrix ratio being at a minimum at the first surface. The first region can include one or more additives. A method for forming a composite article includes injecting first and second compositions into a die head at different points so as to produce a partially mixed composition that is discharged from the die head. The second composition contains less filler material than the first composition.

Abstract: A method for forming a composite article includes injecting first and second compositions into a die head at different points so as to produce a partially mixed composition that is discharged from the die head. The second composition contains less filler material than the first composition.

Abstract: A novel planking system utilizing an inventive groove design is provided. The novel groove is defined by two opposing side walls and a groove end wall. The groove side walls present two generally opposed tongue-engaging projections that automatically provide a uniform space between planks during installation, and accommodate expansion of the planks after installation by breaking away when force is exerted on the projections by an adjacent plank. The present invention is also concerned with a combination of planks having an inventive tongue-and-groove configuration, as well as inventive methods of assembling planks to accommodate the expansion and contraction of the assembled planks after installation.

Abstract: A novel planking system utilizing an inventive groove design is provided. The novel groove is defined by two opposing side walls and a groove end wall. The groove side walls present two generally opposed tongue-engaging projections that automatically provide a uniform space between planks during installation, and accommodate expansion of the planks after installation by breaking away when force is exerted on the projections by an adjacent plank. The present invention is also concerned with a combination of planks having an inventive tongue-and-groove configuration, as well as inventive methods of assembling planks to accommodate the expansion and contraction of the assembled planks after installation.

Abstract: A method for forming a composite article includes injecting first and second compositions into a die head at different points so as to produce a partially mixed composition that is discharged from the die head. The second composition contains less filler material than the first composition.

Abstract: A deck system employing a plurality of substantially hidden fasteners to couple the floor boards of the deck to the joists. Each hidden fastener is rigidly coupled to a respective joist and positioned between a pair of adjacent floorboards. Each fastener forms a mating relationship with specially configured sides of the boards to thereby rigidly couple the boards to the joists.

Abstract: A composite article includes a matrix having first and second opposing surfaces defining a transverse dimension and a filler material embedded in the matrix. The filler material presents a density gradient in the transverse dimension wherein a minimum filler density is at the first surface. In one embodiment, the composite article is a non-laminated article defining first and second regions wherein the first region encompasses the first surface. The first region has a filler-to-matrix ratio that varies along the transverse dimension, the filler-to-matrix ratio being at a minimum at the first surface. The first region can include one or more additives. A method for forming a composite article includes injecting first and second compositions into a die head at different points so as to produce a partially mixed composition that is discharged from the die head. The second composition contains less filler material than the first composition.

Abstract: A deck system employing a plurality of substantially hidden fasteners to couple the floor boards of the deck to the joists. Each hidden fastener is rigidly coupled to a respective joist and positioned between a pair of adjacent floorboards. Each fastener forms a mating relationship with specially configured sides of the boards to thereby rigidly couple the boards to the joists.

Abstract: A deck system employing a plurality of specially configured floor boards which can be coupled to the joists of the deck via a plurality of substantially hidden fasteners. Each board includes similarly configured opposite sides that define a longitudinal groove therein. Each hidden fastener is rigidly coupled to a respective joist and positioned between a pair of adjacent floor boards. Each fastener forms a mating relationship with the sides of the boards to thereby rigidly couple the boards to the joists.

Abstract: New wood-synthetic resin composite products and methods of forming these products are provided. The products comprise a cellulosic or fibrous material and polypropylene (preferably reactor flake polypropylene). The products are formed by passing ingredients including the fibrous material and polypropylene through an extruder (preferably a twin screw extruder) at temperatures of from about 150-260° C. The extruded composite products have physical properties very similar to those of natural wood, including high tensile strengths, high compressive strengths, and high densities.

Abstract: New wood-synthetic resin composite products and methods of forming these products are provided. The products comprise a cellulosic or fibrous material and polypropylene (preferably reactor flake polypropylene). The products are formed by passing ingredients including the fibrous material and polypropylene through an extruder (preferably a twin screw extruder) at temperatures of from about 150-260° C. The extruded composite products have physical properties very similar to those of natural wood, including high tensile strengths, high compressive strengths, and high densities.

Abstract: New wood-synthetic resin composite products and methods of forming these products are provided. The products comprise a cellulosic or fibrous material and polypropylene (preferably reactor flake polypropylene). The products are formed by passing ingredients including the fibrous material and polypropylene through an extruder (preferably a twin screw extruder) at temperatures of from about 150-260° C. The extruded composite products have physical properties very similar to those of natural wood, including high tensile strengths, high compressive strengths, and high densities.

Abstract: A laminate which is useful as a construction material is disclosed. The laminate has a substrate layer which contains vinyl chloride polymer, a butadiene rubber graft copolymer, and has a superstrate layer which contains vinyl chloride polymer, butylacrylate rubber graft copolymer, and titanium dioxide. The superstrate layer protects the substrate layer from excessive exposure to ultraviolet light, heat and moisture, and thereby protects the substrate layer from weathering during outdoor use of the laminate as a material for siding, gutter systems, downspouts, shutters, window casings, and other exterior outdoor weather exposed building material applications.

Abstract: A laminate which is useful as a construction material is disclosed. The laminate has a substrate layer which contains vinyl chloride polymer, a butadiene rubber graft copolymer, and has a superstrate layer which contains vinyl chloride polymer, butylacrylate rubber graft copolymer, and titanium dioxide. The superstrate layer protects the substrate layer from excessive exposure to ultraviolet light, heat and moisture, and thereby protects the substrate layer from weathering during outdoor use of the laminate as a material for siding, gutter systems, downspouts, shutters, window casings, and other exterior outdoor weather exposed building material applications.

Abstract: Foamable thermoplastic resin compositions are provided having vinyl chloride polymer, a graft copolymer having a superstrate grafted to a substrate wherein the superstrate has alphamethyl styrene, unsaturated nitrile, and unsubstituted styrene therein, and the substrate is a butadiene rubber, a rubber-free copolymer having alkylmethacrylate, vinyl aromatic, and unsaturated nitrile therein, and a chemical blowing agent. The foamable thermoplastic resin composition may be coextruded with a non-foamed thermoplastic resin skin to produce a coextruded rigid foamed structure by a process of coextruding the skin and foamable thermoplastic composition. The composition and process are useful for making coextruded rigid foam structures which are useful in rigid foam applications such as foamed pipe and foamed sheet.

Abstract: Foamable thermoplastic resin compositions are provided having vinyl chloride polymer, a graft copolymer having a superstrate grafted to a substrate wherein the superstrate has alphamethyl styrene, unsaturated nitrile, and unsubstituted styrene therein, and the substrate is a butadiene rubber, a rubber-free copolymer having alkylmethacrylate, vinyl aromatic, and unsaturated nitrile therein, and a chemical blowing agent. The foamable thermoplastic resin composition may be coextruded with a non-foamed thermoplastic resin skin to produce a coextruded rigid foamed structure by a process of coextruding the skin and foamable thermoplastic composition. The composition and process are useful for, making coextruded rigid foam structures which are useful in rigid foam applications such as foamed pipe and foamed sheet.

Abstract: Foamable thermoplastic resin compositions are provided having vinyl chloride polymer, a graft copolymer having a superstrate grafted to a substrate wherein the superstrate has alphamethyl styrene, unsaturated nitrile, and unsubstituted styrene therein, and the substrate is a butadiene rubber, a rubber-free copolymer having alkylmethacrylate, vinyl aromatic, and unsaturated nitrile therein, and a chemical blowing agent. The foamable thermoplastic resin composition may be coextruded with a nonfoamed thermoplastic resin skin to produce a coextruded rigid foamed structure by a process of coextruding the skin and foamable thermoplastic composition. The composition and process are useful for making coextruded rigid foam structures which are useful in rigid foam applications such as foamed pipe and foamed sheet.