Patent ID: 8632868

Claim:
An extrudate with integral foam insulation, comprising: an integral structural extrusion formed of a first thermoplastic resin suitable for use in the fenestration industry; the integral structural extrusion extending in a longitudinal direction; the integral structural extrusion defining at least first and second chambers extending in the longitudinal direction; the first of the chambers being hollow; the second chamber including an integrated foamed insulation formed of a second thermoplastic resin; the integrated insulation substantially filling the second chamber; the integrated foamed insulation being defined by a plurality of strands that define a plurality of longitudinal air pockets that run in the longitudinal direction of the structural extrusion; the first thermoplastic resin and the second thermoplastic resin are compatible and recyclable together; and wherein the structural extrusion and the integrated foamed insulation have been coextruded through an extrusion die such that the structural extrusion is integrally bonded to the integrated foamed insulation in a unity fashion.