Patent ID: 7556758

Claim:
A method for making a hollow wall base from an extrudable thermoplastic material, said method comprising the steps of: extruding heated back layer material from a first extruder; extruding heated top coat layer from a second extruder; fusing said top coat material onto said base material, forming fluid plastic material; passing said fluid material into a die, the die having multi-functional inserts for forming a profile and spaces in the wall base to provide generally uniform wall thickness, the fluid material passing over the multi-functional insert; applying air under pressure through appropriate passages in said die to temporarily lift and detach a front wall from said fluid material; running cool water onto said front wall to cool said front wall; pulling said wall base into at least one cooling tank, cooling said wall base; using a mechanical puller to pull said wall base out of said at least one cooling tank; passing said wall base into a cutter to cut the wall base into desired lengths; and withdrawing the wall base.