Patent ID: 6752941
Filing Date: 2004-06-22
Classification: B29C,B29K,B29L,B44C,B44F

Abstract:
A method of producing a plank product having a controllable and realistic wood-grain appearance, the plank product with at least one accent color, the method comprising the steps of:a) introducing into an extruder a powdered or pelletized base material and accent color pellets, said base material containing less than about 75% by weight wood flour, and having a vicat softening temperature, said accent color pellets (i) having a higher vicat softening temperature than said base material, and (ii) comprising a styrene polymer having a high vicat softening temperature and a melt flow index of greater than or equal to 1.0 gram per 10 minutes, and at least one additional resin having a substantially lower vicat softening temperature than the styrene polymer; and b) extruding said base material and said accent color pellets through an extrusion die to form a plank under processing temperatures whereby the accent color pellets cause delayed introduction and controlled dispersion of the accent color into the plank material.