Abstract:
A polymer board with a cut edge is automatically advanced through a stationary, non-spinning sealing element that contacts and compresses the cut edge and provides a sealed and smooth surface to the cut edge.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of priority of U.S. provisional application No. 62/220,281, filed Sep. 18, 2015, which is incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    Many of the cellular polyvinyl chloride (PVC) trim board manufacturers have used heated, rolling wheels to seal the edge of their trim boards, such as disclosed by U.S. Pat. No. 8,333,582 and published application US 2013/0099416 (both incorporated herein by reference). While such earlier process was an improvement from the un-sealed, open cell structure from the prior vintage of trim boards, the sealed edges from this process did not fully seal the surface, and did not provide an edge that was materially similar to the extruded top and bottom surface of the trim boards. The standard test to estimate how well the edge was sealed was “the pencil test”. This included drawing a line with a graphite lead pencil and then attempting to erase the line with the pencil&#39;s eraser. Any open cell structure would capture graphite in the cells which could not be removed with the eraser and indicate that the surface was not fully sealed. 
       SUMMARY 
       [0003]    To answer the deficiencies of prior sealing systems and methods, the present invention creates a sealed surface where all visible traces of graphite can be erased away. In addition, a more precise test of measuring the gloss level of the sealed edge versus the top and bottom of the trim board demonstrates that the sealed edge with this new technology more accurately approximates the extruded surface of the top and bottom of the trim board. 
         [0004]    The present invention includes a system and method of sealing open cell structure resulting from cutting foamed polymer sheets into individual boards. Embodiments of the invention include multiple stationary sealing elements that can be operated from ambient temperature to elevated temperatures (wherein one or more pairs may apply heat). The edges of the board are routed or milled to ensure a flat, squared surface. The edges are then passed between stationary elements that apply pressure, creating friction as the board slides along the sealing elements. Some or all of the elements may be heated to cause softening, or melting of the outer most layer of material. Subsequent elements may operate at lower temperatures and higher pressures that freeze and cold work the outer layer of material. The resulting surface is a sealed, slightly textured surface similar to the uncut, extruded top and bottom surface of the board. 
         [0005]    In embodiments of the invention, extruded PVC boards that have been cut along their length (and therefore have rough side edges) have the sides sealed by pulling the boards through a system that applies hot pressure from stationary bars abutting the rough sides of each PVC board. Specifically, most PVC trim board is manufactured by extruding 48″ wide foamed PVC sheets which are then ripped (cut) into traditional wood trim widths, i.e., 1×4, 1×6, 1×8, etc. Where the boards are cut, the cut surface results in an exposed open cell surface, whereas the top and bottom surface which is not cut has a nice, smooth extruded skin. Most trim board manufacturers have now implemented “edge sealing” to somewhat melt and seal the cut edges to eliminate, or reduce the exposure of the open cell surface. For example, U.S. Pat. No. 8,333,582 and pending application published as US 2013/0099416 disclose using heated, rotating and motor-driven rollers to transport the material through the machine and melt and create a skin on the exposed surface. 
         [0006]    By contrast, embodiments of the present invention include a system where the cut PVC boards are (1) pulled with a pulling machine (on unheated guide rollers) through stationary metal elements (ambient or heated) and friction, pressure and heat create a skin on the rough, exposed surface and (2) further pulled through a stationary spool (or other corner shaping element) that, while the new skin on the sides is still hot, presses the corners of the sides of the board into a desirable rounded corner shape (since it was found that simply creating the skin with hot elements led to the excess hot PVC moving to the corners and creating undesirable sharp corners). 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    In order to facilitate a fuller understanding of the exemplary embodiments, reference is now made to the appended drawings. These drawings should not be construed as limiting, but are intended to be exemplary only. 
           [0008]      FIG. 1  illustrates a perspective view of a board with stationary side sealing units applying heat and a puller roller pulling the board, according to one embodiment of the invention. 
           [0009]      FIG. 2  illustrates a perspective view of a board with multiple pairs of stationary side sealing units and multiple puller rollers pulling the board, according to one embodiment of the invention. 
           [0010]      FIG. 3  illustrates a perspective view of a pair of angled corner shaping units pushing the warm corners of a board being pulled by puller roller after the board&#39;s exit from between a pair of stationary side sealing units in one embodiment of the invention. 
           [0011]      FIG. 4  illustrates a perspective view of two pairs of angled corner shaping units pushing the warm corners of a board being pulled by puller roller after the board&#39;s exit from between a pair of stationary side sealing units in one embodiment of the invention. 
           [0012]      FIG. 5  illustrates a spool-shaped corner shaping unit as an alternative to angled rod units as shown in  FIGS. 3 and 4  in one embodiment of the invention. 
           [0013]      FIG. 6  illustrates a perspective view of a side edge sealing system with multiple pairs of stationary side sealing units and multiple puller rollers and also including a pair of corner shaping spools, according to one embodiment of the invention. 
           [0014]      FIG. 7  illustrates a perspective view of a pair of sealing elements connected to dovetail guide blocks in one embodiment of the invention, 
           [0015]      FIG. 8  illustrates a perspective view of sealing elements and dovetail guide blocks provided on each side of a machine in one embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0016]    The following description is intended to convey a thorough understanding of the embodiments by providing a number of specific embodiments and details involving a method and apparatus for manufacturing a decorated extruded profile. It is understood, however, that the invention is not limited to these specific embodiments and details, which are exemplary only. It is further understood that one possessing ordinary skill in the art, in light of known devices, systems and methods, would appreciate the use of the invention for its intended purposes and benefits in any number of alternative embodiments. 
         [0017]    Generally speaking, the various exemplary embodiments described herein relate to devices, systems and methods for sealing the edges of cut/ripped cellular polyvinyl chloride (PVC) boards  50 . It will be appreciated that embodiments of the invention may be applicable to boards that comprise other polymer and plastic materials beyond cellular PVC. 
         [0018]    The resultant articles may be useful in, for example, deck systems, fence systems, building products, floor coverings, or components thereof, such as planks, slats, rails, posts, flooring, siding, roofing materials, and the like. In addition, the articles may have many of the desirable properties of natural wood products, and may be sturdy, lightweight, and have excellent weatherability properties. 
         [0019]    As shown in  FIG. 1 , the present invention seeks to answer the need of extruded cellular PVC boards  50  that are cut and have rough edges for such edges (left and right side surfaces)  55  to be made smooth and approximate the look and gloss of the extruded top and bottom surfaces. In embodiments, as shown in  FIGS. 2 and 3 , the PVC boards  50  are pulled by a pulling machine  130  and advanced in line through puller rollers  120  for interaction with sealing head devices  100  having sealing units  105  that preferably have a smooth, rounded and/or cylindrical shape. In some embodiments a system of the invention further includes corner shaping devices  150  as shown in  FIGS. 3-6 . 
         [0020]    In other embodiments it will be appreciated that push-machines, combinations of push and pull machines, conveyor systems and other board advancement techniques may be implemented to advance boards in an automated production line. It is preferable that boards be advanced in embodiments of the present in invention in a range of 20 fpm (feet per minute) to 200 fpm, and more preferably from 60 fpm to 200 fpm. 
         [0021]    In various embodiments, pairs of sealing units  105  positioned across from one another at opposite edges  55  of the board  50  may preferably be heated to achieve desired results. Such heating may preferably range from about 115° F. to about 500° F. Different head devices  100  (which provide pairs of sealing units  105 ) may also be provided at different temperatures depending on variables such as the speed of advancement of the boards, the pressure (compression distance), desired results and other parameters. Preferably where a board  50  in the production line is fed above 60 fpm, such as tests conducted at 70 fpm, better edge sealing resulted where a first two pairs of sealing units were hotter (e.g. 475-500° F.) than a last two pairs of sealing units (e.g 120-160° F.). It will be appreciated that in alternative embodiments, the rough board edges  55  might be heated by blowers or other heating elements to desirable temperatures and then passed through unheated stationary sealing units  105  whereby compression is applied to achieve sealing without a sealing unit necessarily providing the heat to the edges  55 . 
         [0022]    In some embodiments of the invention it was determined that sealing units  105  created sharp corners that could be viewed as undesirable in various applications for a PVC board  50 . To provide more rounded corners to a board edge  55  sealed by the present invention, corner shaping elements  150  such as shown in  FIGS. 3-6  are implemented. While such shaping elements  150  are preferably not necessary to be heated as the corner shaper  150  pushes the warm corners after leaving one or more pairs of heated sealing elements  105 , in some embodiments the corner shapers  150  might be heated to provide a desired effect. 
         [0023]    Referring to  FIGS. 5 and 6 , in one embodiment the corner shapers  150  may be spool-shaped units  151  so that the curvature of the unit  151  provides desirable interaction at the corners of sealed edges  55  of a board  50  of the invention. Preferably the spools  151  are free floating and are not heated, and can move up and down to “soften” the sharp corners. The spools  151  are preferably stationary and do not spin, but apply drag or friction between the surface of the spool  151  and the corner of the board  50 . 
         [0024]    In alternative embodiments, such as shown in  FIGS. 3 and 4 , a corner shaping element  150  has a small, stationary metal bar/rod that is about 45 degrees to each corner to eliminate a sharp edge from forming at the corners of the board edges  55  during the sealing process. The corner shaping element  150  with angled bar provides similar corner shaping functions as the spool  151 , but the angled bar/rod will contact the corner of every thickness board (½″, ⅝″, ¾″ and 1″) at the same angle whereas the radius of the spool  151  causes boards  50  of different thicknesses to contact the spool  151  at different points and hence the angle of the contact surface for the spool  151  is not constant from one thickness to another. 
         [0025]    In alternative embodiments of the invention shown in  FIGS. 7 and 8 , a sturdier sealing system is utilized with the components of the invention to provide improved performance of edge sealing, including good results at faster foot-per-minute run rates with less pressure between sealing elements. More sealing head elements  100  can also be provided in a more rigid machine. Specifically the size of the machine frame, and the mechanisms holding the sealing units  105  were made physically larger, and with thicker metal, so there is much less bending or flexing of the structure of the machine. It was found that the more rigid machine and the additional sealing head elements  100  allowed using less pressure and run at higher rates and achieve good quality sealed edges  55  that were only achieved with lower run rates on an alternative and less sturdy development machine. With the more rigid machine and five pairs of sealing head elements  100 , the following conditions in “Table A,” with the pairs of sealing elements numbered in order encountered by the board edges  55 , below permitted run rates of 120-160 fpm with little noticeable difference in surface finish as the run rate is increased: 
         [0000]    
       
         
               
               
               
             
           
               
                 TABLE A 
               
               
                   
               
               
                 SEALING 
                   
                 PRESSURE 
               
               
                 ELEMENT PAIR 
                 TEMPERATURE (° F.) 
                 (INTERFERENCE) 
               
               
                   
               
             
             
               
                 1 
                 475 
                 0.035″ 
               
               
                 2 
                 465 
                 0.035″ 
               
               
                 3 
                 120 
                 0.035″ 
               
               
                 4 
                 120 
                 0.035″ 
               
               
                 5 
                 120 
                 0.035″ 
               
               
                   
               
             
          
         
       
     
         [0026]    It is expected that a sturdy machine with five pairs of sealing elements  100  as described in the foregoing embodiment could be run at 200 ft/min with good sealed edges  55 . 
         [0027]    As further shown in  FIGS. 7 and 8 , in preferred embodiments, sealing head elements  100  are connected to dovetail guide blocks  180  that enable the sealing head elements  100 , and respective sealing units  105 , to be moved forward and backward as a respective guide block  180  is moved within a corresponding guide channel of the machine frame. It will be appreciated that moving a guide block  180  and corresponding sealing head element  100  will increase or decrease the distance between a pair of sealing head elements  100  to provide desired friction and compression for achieving desired sealing results of a board  50  with a particular thickness. It will also be appreciated that one sealing head element  100  of a pair could be provided with a guide block  180  for movement and establishing the distance between a pair of sealing units  105 , or each sealing head element  100  in a pair could each be provided with a corresponding guide block  180 . 
         [0028]    In the preceding specification, various embodiments have been described with reference to the accompanying drawings. It will, however, be evident that various modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the exemplary embodiments as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense.