Patent ID: 7972546

Claim:
A method for producing a composite comprising a construction element having a length, a substantially non-hollow cross section perpendicular to the length, an outer weatherable layer, an intermediate layer and an inner layer, the method comprising the steps of: providing, in extrudable form, (1) a first composition comprising a first weatherable polymeric material, (2) a second composition comprising a second polymeric material, and (3) a third composition comprising a third polymeric material, introducing each of the compositions into a different extrusion pathway of a single extruder/feedblock/pipehead assembly adapted to be fed by three co-extruders, wherein the extrusion pathways of the first, second and third polymeric materials are arranged such that, in cross section, the third polymeric material is circumscribed by the second polymeric material, and the second polymeric material is circumscribed by the first polymeric material; extruding the compositions to produce an annular form, wherein the extruder/feedblock/pipehead assembly is arranged to produce said annular form through a convergent flow pathway; introducing the annular form into a forming/shaper die having a desired cross sectional shape; to produce a reshaped form wherein the annular form is collapsed about a central hollow to form a substantially non-hollow, layered form, and cutting the reshaped form into a desired length, wherein the composite thus formed comprises a rigid construction element having said length, a substantially non-hollow cross-section perpendicular to the length, an outer weatherable layer, an intermediate layer and an inner layer.