Extruded board with realistic appearance

1. A method of forming an extruded board, comprising:

mixing a resin and a foaming agent;

melting the mixed resin and foaming agent to form a uniformly colored twisting extrudate with a screw portion of an extruder;

controlling the temperature of the uniformly colored twisting extrudate at an end of the screw portion to a temperature which allows for foaming of the foaming agent;

contacting a breaker plate with the uniformly colored twisting extrudate at the temperature which allows for foaming of the foaming agent;

linearizing the uniformly colored twisting extrudate with the breaker plate;

differentially expanding voids formed from the foaming agent within the uniformly colored extrudate as the uniformly colored twisting extrudate is linearized with the breaker plate;

forming a board with the differentially expanded voids and uniformly colored extrudate; and

forming lightened portions on an outermost surface of the formed board.

2. The method of claim 1 , wherein differentially expanding the voids comprises:

forming at least one first longitudinally extending area of first void spaces; and

forming at least one second longitudinally extending area of second void spaces, wherein the first void spaces are on average larger than the second void spaces.

3. The method of claim 2 , wherein at least a portion of the at least one first longitudinally extending area is immediately alongside at least a portion of the at least one second longitudinally extending area.

4. The method of claim 1 , wherein forming the lightened portions comprises:

removing a portion of an outer surface of the formed board;

creating a plurality of open void spaces by removing the portion of the outer surface; and

at least partially closing each of the plurality of open void spaces.

5. The method of claim 4 , wherein forming the lightened portions comprises:

planing the formed board.

6. The method of claim 5 , wherein forming the lightened portions further comprises:

buffing an exposed outer surface of the formed board.

7. The method of claim 4 , wherein mixing a resin and a foaming agent comprises:

providing waste material, the waste material having a first color; and

mixing the waste material with a virgin resin portion, wherein the uniformly colored extrudate has a second color and the second color is the same color as the first color.

8. The method of claim 1 , wherein mixing a resin and a foaming agent comprises:

providing waste material, the waste material having a first color; and

mixing the waste material with a virgin resin portion, wherein the uniformly colored extrudate has a second color and the second color is the same color as the first color.

9. The method of claim 8 , wherein differentially expanding voids comprises:

forcing the uniformly colored extrudate through a plurality of concentrically positioned orifices in the breaker plate.

10. The method of claim 9 , wherein differentially expanding voids further comprises:

forcing the uniformly colored extrudate through a plurality of concentrically positioned elongated orifices in the breaker plate.

11. The method of claim 8 , further comprising;

exposing the outermost surface of the formed board by removing an outer surface layer of between about 0.20 inches and 0.060 inches of the formed board.

12. The method of claim 11 , further comprising:

forming a clear sealer layer on the outermost surface of the formed board.

13. The method of claim 1 , wherein forming the board comprises:

moving the linearized extrudate through an extrusion die.

14. The method of claim 13 wherein the extrusion die is a die with a single dog-bone shaped opening.