GB2407793A - Fascia board with a foamed core and an unfoamed skin - Google Patents

Fascia board with a foamed core and an unfoamed skin Download PDF

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Publication number
GB2407793A
GB2407793A GB0326063A GB0326063A GB2407793A GB 2407793 A GB2407793 A GB 2407793A GB 0326063 A GB0326063 A GB 0326063A GB 0326063 A GB0326063 A GB 0326063A GB 2407793 A GB2407793 A GB 2407793A
Authority
GB
United Kingdom
Prior art keywords
board
core
plastics material
roofing
forming
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB0326063A
Other versions
GB2407793A8 (en
GB0326063D0 (en
Inventor
Andrew Jarrett
Ian Crisp
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Celuform Ltd
CDW Products Ltd
Original Assignee
Celuform Ltd
CDW Products Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Celuform Ltd, CDW Products Ltd filed Critical Celuform Ltd
Priority to GB0326063A priority Critical patent/GB2407793A/en
Publication of GB0326063D0 publication Critical patent/GB0326063D0/en
Publication of GB2407793A publication Critical patent/GB2407793A/en
Publication of GB2407793A8 publication Critical patent/GB2407793A8/en
Withdrawn legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
    • E04D13/15—Trimming strips; Edge strips; Fascias; Expansion joints for roofs
    • E04D13/158—Trimming strips; Edge strips; Fascias; Expansion joints for roofs covering the overhang at the eave side, e.g. soffits, or the verge of saddle roofs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/305—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets
    • B29C48/307—Extrusion nozzles or dies having a wide opening, e.g. for forming sheets specially adapted for bringing together components, e.g. melts within the die
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/06—PVC, i.e. polyvinylchloride
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B29K2105/043—Skinned foam

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)

Abstract

The present invention provides a method and a die for forming a roofing fascia board of plastics material and comprises a foamed plastics core and un-foamed plastics skin. The board is formed by co-extruding a first foamed plastics material forming the core of the board and a second un-foamed plastics material that is delivered onto the opposing major faces of the core of the board by means of a delivery channel 5 that branches 6 and 7 to pass around the core (3a,3b figure 5) of the board. The delivery channel branches are shaped to enhance the flow of the second plastics material to the opposing face of the core of the board to provide a substantially even delivery of the second plastics material to both faces of the board. The branching channels have a cross section that narrows in both width and depth as the channels run adjacent the opposing face of the core. Also included is a roofing fasica board with an unfoamed skin and a foam core.

Description

Improvements to Fascia Boards
Field of the Invention
The present invention concerns improvements in or relating to manufacture of boards that are formed as plastics foam extrusions co-extruded with an unfoamed plastics skin, such as are used for fascia boards, barge boards/weather boards and other decorative/weatherproofing purposes.
Backaround to the Invention
Traditionally the fascia boards, barge boards and other cladding used around the roofs of buildings have been of wood that is painted or otherwise treated to optimise the preservation of the wood for an adequate working life and give an attractive appearance. Inherently, however, the wood does become progressively weather beaten and rotten. Accordingly, more and more of late, extruded plastics cladding systems have gained favour for cladding roof ends and edges. These extruded plastics fascia boards and the like may be of a PVC foam core co-extruded with a skin of unfoamed PVC on one face to enhance strength and integrity and give an attractive external appearance to the board.
In practice it has proven manageable to co-extrude a skin for one face of the fascia board but not feasible to co-extrude skins for both major faces of the fascia board. A key problem with seeking to do this is that the surface area to be covered by the unfoamed liquid PVC is generally too great when covering a large fascia board on both sides and the liquid PVC cannot be relied upon to evenly cover both faces. In consequence, double-skinning of fascia boards and the like by providing a skin on both front and back faces has either not been attempted or, if at all, only attempted on smaller components.
A general objective of the present invention is to enable double-skinning of large co- extruded plastics boards such as fascia boards or the like, i.e. providing a skin on both front and back faces of the board, without undermining the uniformity and integrity of the skin formed on the respective faces of the board.
e e eve sa soe. e e ë ..ë e e e eve e- * - e Summarv of the Invention According to a first aspect of the present invention there is provided a method for forming a roofing fascia board or other correspondingly large expanse board of plastics material with a foamed plastics core and un-foamed plastics skin, wherein the board is formed by co-extruding a first foamed plastics material forming the core of the board and a second un-foamed plastics material that is delivered onto the opposing major faces of the core of the board by means of a delivery channel that branches to pass around the core of the board and the delivery channel branches are shaped to enhance the flow of the second plastics material to the opposing face of the core of the board to provide a substantially even delivery of the second plastics material to both faces of the board.
Unlike the conventional single (front only)-skinned board manufacturing process, where the delivery channel for the second material is of a uniform cross-section, in the present invention the delivery channel branches are of a cross-section that varies longitudinally of the channel.
In the preferred embodiment both the width and depth of the channel branches are lesser as they run adjacent the opposing face of the core of the board. Indeed, the channel branches suitably deepen as the channel branches diverge to pass around the core and then become progressively shallower as they run along the opposing face of the core of the board converging toward each other. Furthermore, in the preferred embodiment the channel branches also become progressively narrower as they run along the opposing face of the core of the board converging toward each other. Preferably the channel branches converge toward the core of the board as they run along the opposing face of the core of the board converging toward each other.
In the conventional co-extrusion mould the first foamed plastics material forming the core is extruded through a narrow slot in the mould, the perimeter of the slot being angular, defining a sharp edge/ 90 degree transition from the bore of the slot to the major face of the mould or a staged transition with a 45 degree canted interface between the bore of the slot and the major face of the mould. In a further improvement of the present invention, the perimeter of the slot through which the a' a ' a q 3 me core is extruded is not angular, but chamfered/ convex curved whereby the un foamed liquid plastics material is applied smoothly and evenly to the core.
According to a second aspect of the present invention there is provided a roofing fascia board or other correspondingly large expanse board of plastics material with a foamed plastics core and un-foamed plastics skin, wherein the skin covers both major faces of the board and suitably is formed by the method of the first aspect of the invention.
According to a third aspect of the present invention there is provided a die for forming a roofing fascia board or other correspondingly large expanse board of plastics material with a foamed plastics core and un-foamed plastics skin by co- extruding a first foamed plastics material forming the core of the board and a second un-foamed plastics material, the die having a passage through which the foamed plastics material passes defining the core of the board and a delivery channel that branches to pass around the passage for the core of the board and the delivery channel branches are shaped to enhance the flow of the second plastics material to the opposing face of the core of the board to provide a substantially even delivery of the second plastics material to both faces of the board.
Brief Descrintion of the Drawing A preferred embodiment of the present invention will now be more particularly described, by way of example, with reference to the accompanying drawings, wherein: Figure 1 is a perspective view of the internal face of a first half of a die suitable for co-extruding a core of foamed PVC and a skin of un-foamed PVC; Figure 2 is a perspective view of the internal face of the mating second half of the die; Figure 3 is a detailed view of the right hand end of the die half of Figure 2; Figure 4 is a sectional view of the first die half taken along the line X-X in Figure 2; and ce.
ce.e es. a a a a a a a Figure 5 is a sectional view of the first die half taken along the line Y-Y in Figure 2.
Description of the Preferred Embodiments
As shown in Figures 1 to 5 the die for co-extrusion of a roofing fascia board having a skin of unfoamed PVC surrounding a core of foamed PVC has mating first and second die halves 1, 2 each of which has a central elongate slot 3a, 3b through which the foamed PVC core is extruded. Elongate slot 3a, 3b defines a channel for extrusion of a foamed PVC core that is a flat board with a respective groove along each lateral edge as defined by respective ridges 4, 4' in that part of the die 1, 2.
With the two die halves 1, 2 mated to each other the foam PVC core (E shown in ghost line in Figure 5) passes through the channel defined by the slot 3a of the first half 1 and through the channel defined by the slot 3b defined by the second half 2 forming the core of the board. At the same time a skin of unfoamed liquid PVC is applied to the major faces of the board core E. This unfoamed liquid PVC is supplied to the major faces of the board as it is being formed by means of a delivery channel arrangement that is in a plane that is perpendicular to the axis/plane of the board and loops around the elongate slot 3a, 3b.
The channel arrangement is branched. A first main portion 5 of the unfoamed liquid PVC delivery channel enters the die block 1, 2 from the centre of one long edge of the die block 1, 2 and as it approaches toward the elongate slot 3a, 3b it branches into respective first and second branching channels 6, 7 which respectively loop around opposing lateral edges of the elongate slot 3a, 3b. The initial/ proximal length of the branch channels 6, 7 diverge and the terminal/ distal lengths of the branch channels 6,7 converge toward each other to a point substantially central of the elongate slot 3a, 3b substantially opposite the main entry channel 5.
The profile of the unfoamed liquid PVC delivery channel 5 is suitably broadly elliptical, which is to say that each half of the channel 5 defined by respective half of the die 1, 2 is a relatively shallow but broad arcuate channel half and when the two die halves 1, 2 are mated together define a relatively broad but shallow elliptical cross section tubular channel. When the channel 5 branches into separate branch channels 6, 7 the cross sectional profile of those branch channels 6, 7 suitably becomes progressively greater in cross sectional area as the branches 6, 7 diverge, ece : : : : : . : suitably by deepening of those respective channels as they extend away from the main channel 5 (compare sections X-X and Y-Y shown in Figure 4 and Figure 5, respectively). The purpose of this is to facilitate flow of the liquid unfoamed PVC such that a substantial proportion of the liquid PVC flows around the lateral ends of the slot 3 through which the foamed core passes and is delivered to the opposing face of the slot 3a, 3b to be deposited on the opposing face of the core E. Some of the unfoamed liquid PVC will rise from the initial/ proximal lengths of the branching channels 6, 7 over the plateau part 10 of the die that surrounds the slot 3a, 3b and some of the unfoamed liquid PVC will pass further along the respective branching channels 6, 7 before rising up over the plateau 10 and seeping toward the slot 3a, 3b.
The purpose of the configuration of the branching delivery channels to have a varying cross sectional area along their length is to ensure uniform delivery of the unfoamed liquid PVC to each of the first and second major faces of the board core E as it is formed. Accordingly, not only is the initial length of each of the branching channels 6, 7 progressively deeper but also as those branching channels 6, 7 loop around the opposing lateral ends of the slot 3a, 3b they then begin to become shallower and also narrower as they then converge towards each other toward the centre of the slot 3a, 3b. Furthermore, as can be seen from Figures 1 and 2, that portion of the respective branch channels 6, 7 that converges not only marks a convergence of the respective branching channels 6, 7 towards each other but also marks a convergence towards the slot 3a, 3b. The narrowing of the converging branch channels 6, 7 and the convergent onto the slot 3a, 3b ensures that the liquid PVC that reaches this distal end of the respective branching channels 6, 7 is progressively facilitated in rising up over the plateau 10 to reach the slot 3a, 3b and be delivered onto the opposing face of the core E as it is formed.
A further feature of the die is that the perimeter 30 of the slot 3a, 3b is not merely a right angled edge or provided with a canted face for the liquid PVC to pass over to come into contact with the nascent core of the board. Instead, the perimeter 30 of the slot 3a, 3b is chamfered, having a smoothly convex curving form which has been found to substantially enhance the application of the unfoamed liquid PVC onto the foamed PVC core E.

Claims (10)

1. A method for forming a roofing fascia board or other correspondingly large expanse board of plastics material with a foamed plastics core and un-foamed plastics skin, wherein the board is formed by co-extruding a first foamed plastics material forming the core of the board and a second un-foamed plastics material that is delivered onto the opposing major faces of the core of the board by means of a delivery channel that branches to pass around the core of the board and the delivery channel branches are shaped to enhance the flow of the second plastics material to the opposing face of the core of the board to provide a substantially even delivery of the second plastics material to both faces of the board.
2. A method for forming a roofing fascia board or the like as claimed in Claim 1, wherein the delivery channel branches are of a cross-section that varies longitudinally of the channel.
3. A method for forming a roofing fascia board or the like as claimed in Claim 2, wherein both the width and depth of the channel branches are lesser as they run adjacent the opposing face of the core of the board.
4. A method for forming a roofing fascia board or the like as claimed in Claim 3, wherein the channel branches deepen as the channel branches diverge to pass around the core and then become progressively shallower as they run along the opposing face of the core of the board converging toward each other.
5. A method for forming a roofing fascia board or the like as claimed in Claim 3 or 4, wherein the channel branches also become progressively narrower as they run along the opposing face of the core of the board converging toward each other'
6. A method for forming a roofing fascia board or the like as claimed in any of Claims 3, 4 or 5, wherein the channel branches converge toward the core of the board as they run along the opposing face of the core of the board converging toward each other.
7. A method for forming a roofing fascia board or the like as claimed any preceding claim, wherein the perimeter of the slot through which the core is extruded is not angular, but chamfered/ convex curved whereby the unfoamed liquid plastics material is applied smoothly and evenly to the core.
8. A roofing fascia board or other correspondingly large expanse board of plastics material with a foamed plastics core and un-foamed plastics skin, wherein the skin covers both major faces of the board.
9. A roofing fascia board or the like as claimed in Claim 8, having been formed by the method of any of Claims 1 to 7.
10. A die for forming a roofing fascia board or other correspondingly large expanse board of plastics material with a foamed plastics core and un-foamed plastics skin by co-extruding a first foamed plastics material forming the core of the board and a second un-foamed plastics material, the die having a passage through which the foamed plastics material passes defining the core of the board and a delivery channel that branches to pass around the passage for the core of the board and the delivery channel branches are shaped to enhance the flow of the second plastics material to the opposing face of the core of the board to provide a substantially even delivery of the second plastics material to both faces of the board
GB0326063A 2003-11-07 2003-11-07 Fascia board with a foamed core and an unfoamed skin Withdrawn GB2407793A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB0326063A GB2407793A (en) 2003-11-07 2003-11-07 Fascia board with a foamed core and an unfoamed skin

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0326063A GB2407793A (en) 2003-11-07 2003-11-07 Fascia board with a foamed core and an unfoamed skin

Publications (3)

Publication Number Publication Date
GB0326063D0 GB0326063D0 (en) 2003-12-10
GB2407793A true GB2407793A (en) 2005-05-11
GB2407793A8 GB2407793A8 (en) 2005-07-12

Family

ID=29726169

Family Applications (1)

Application Number Title Priority Date Filing Date
GB0326063A Withdrawn GB2407793A (en) 2003-11-07 2003-11-07 Fascia board with a foamed core and an unfoamed skin

Country Status (1)

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GB (1) GB2407793A (en)

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3438448A1 (en) * 1984-10-19 1986-04-24 Gebrüder Kömmerling Kunststoffwerke GmbH, 6780 Pirmasens Plastics profile bar and process and crosshead die for the production thereof

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3438448A1 (en) * 1984-10-19 1986-04-24 Gebrüder Kömmerling Kunststoffwerke GmbH, 6780 Pirmasens Plastics profile bar and process and crosshead die for the production thereof

Also Published As

Publication number Publication date
GB2407793A8 (en) 2005-07-12
GB0326063D0 (en) 2003-12-10

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WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)