Method of making a low density cellular PVC boards with sealed edges
View Patent ↗A method for making ornamental trim for use in construction comprising applying a sealing composition having PVC particles in a flowable medium to a cut edge of a foam board, heating the sealing composition to a temperature at which the flowable medium solvates the PVC particles, and cooling the sealing composition to form a continuous sealing cap on the cut edge. A construction component consisting essentially of a foamed cellular board comprising smooth exterior surfaces separated by a cellular network and cut edges, and sealed caps adhered to the cut edges on the foamed cellular board comprising PVC in a polymer matrix. The board has a density of no more than 0.5 g/cm 3 , and the cut edges on which the sealed caps are adhered are unmelted edges.
1. A method for making ornamental trim for use in construction comprising:
cutting a foam board through its thickness to provide a foam board component having a top surface, a bottom surface, two cut longitudinal side edges, and two cut end edges, where the cut side edges and cut end edges define the outermost perimeter of the foam board component;
applying a sealing composition to cut edges defining the outermost perimeter of the foam board component comprising a cellular network exposed by said cut edges, wherein the sealing composition comprises PVC particles suspended in flowable medium;
heating the sealing composition to a temperature at which the flowable medium solvates the PVC particles; and
cooling the sealing composition to form a continuous sealing cap on the cut edges to which the sealing composition was applied.
2. The method of claim 1 wherein the foam board component is a segment of an extruded board of PVC-based material.
3. The method of claim 1 wherein the flowable medium of the sealing composition is plasticizer constituting between about 35 and about 85 parts per hundred parts PVC particles, by weight.
4. The method of claim 1 wherein the flowable medium of the sealing composition is plasticizer constituting between about 45 and about 75 parts per hundred parts PVC particles, by weight.
5. The method of claim 1 wherein the flowable medium of the sealing composition is plasticizer constituting between about 50 and about 70 parts per hundred parts PVC particles, by weight.
6. The method of claim 1 wherein at least 90 wt % of the PVC particles have a particle size between 0.5 and 10 microns.
7. The method of claim 4 wherein at least 90 wt % of the PVC particles have a particle size between 0.5 and 10 microns.
8. The method of claim 1 wherein the foam board component has a density of no more than 0.5 g/cc.
9. The method of claim 1 wherein the foam board component has a density of between 0.3 and 0.5 g/cm 3 .
10. The method of claim 1 wherein the board has a density of between 0.3 and 0.45 g/cm 3 .
11. The method of claim 1 wherein the board has a density of between 0.3 and 0.4 g/cm 3 .
12. The method of claim 1 wherein:
the foam board component is a segment of an extruded board of PVC-based material;
the flowable medium of the sealing composition is plasticizer constituting between about 35 and about 85 parts per hundred parts PVC particles, by weight;
at least 90 wt % of the PVC particles have a particle size between 0.5 and 10 microns; and
the foam board component has a density of between 0.3 and 0.5 g/cm 3 .
13. The method of claim 1 wherein:
the foam board component is a segment of an extruded board of PVC-based material;
the flowable medium of the sealing composition is plasticizer constituting between about 45 and about 75 parts per hundred parts PVC particles, by weight;
at least 90 wt % of the PVC particles have a particle size between 0.5 and 10 microns; and
the foam board component has a density of between 0.3 and 0.5 g/cm 3 .