Process for preparing siding
An in-line process for forming pre-finished siding manufactured from cellular poly vinyl chloride comprising embossing, milling, parting, punching, and coating the poly vinyl chloride such that the resulting siding is suited for use in an environment exposed to a wide range of fluctuating temperatures and moisture. The process accommodates the natural expansion and contraction of cellular poly vinyl chloride by producing a novel milled clapboard configuration that, when used as siding, can be installed to create a historically correct clapboard installation.
1. A method for forming cellular poly vinyl chloride clapboard siding, comprising:
profiling a cellular poly vinyl chloride board in a moulder to yield a two-up back-to-back configuration, wherein the profiling comprises:
milling a first end and a second end of a cellular poly vinyl chloride board to form a profiled end, a radius, and a lower assembly groove on each of the first and second ends;
milling a first and a second face of the cellular poly vinyl chloride board to qualify a thickness of the board; and
milling a first saw groove and a first upper assembly groove on the first face and a second saw groove and a second upper assembly groove on the second face;
sawing the profiled cellular poly vinyl chloride board at the first and second saw grooves to yield at least two cellular poly vinyl chloride clapboards; and
coating the cellular poly vinyl chloride clapboards with a polyurethane based coating.
2. The method of claim 1 , wherein the cellular poly vinyl chloride clapboard moves through the moulder at a speed of about 100 feet per minute.
3. The method of claim 2 , wherein milling the first and second ends comprises applying a first cutter to the first end of the cellular poly vinyl chloride board and a second cutter to the second end of the cellular poly vinyl chloride board, and moving the cutters in relation to the board at a speed of about 8,000 revolutions per minute.
4. The method of claim 3 , wherein milling the first and second ends further comprises qualifying a width of the cellular poly vinyl chloride board by the first and second cutters.
5. The method of claim 3 , wherein each of the first and second lower assembly grooves are milled to have a throat opening of about 0.080 inch.
6. The method of claim 3 , wherein milling the board to qualify the thickness of the board comprises applying a third cutter to the first face and a fourth cutter to the second face, and moving the third and fourth cutters in relation to the board at a speed of about 8,000 revolutions per minute.
7. The method of claim 6 , wherein the board is milled such that the qualified thickness of the cellular poly vinyl chloride board is about 0.500 inch.
8. The method of claim 6 , wherein milling the board to form the first and second saw grooves and the first and second upper assembly grooves comprises applying a first milling head to the first face and a second milling head to the second face, and moving the first and second milling heads in relation to the cellular poly vinyl chloride board at a speed of about 12,000 revolutions per minute.
9. The method of claim 8 , wherein each of the first and second upper assembly grooves is milled to form a throat opening of about 0.080 inch.
10. The method of claim 1 , wherein the profiling further comprises dissipating static that occurs during the milling steps.
11. The method of claim 10 , wherein dissipating static comprises electrically connecting any component contacting the cellular poly vinyl chloride board in the milling operations to earth ground via a copper wire network.
12. The method of claim 1 , wherein sawing comprises passing a band saw blade through the poly vinyl chloride board at the saw grooves wherein the poly vinyl chloride is fed to the band saw blade at a feed speed of about 60 meters per second.
13. The method of claim 1 , wherein coating comprises uniformly spraying the polyurethane based coating on the cellular poly vinyl chloride clapboards.
14. The method of claim 1 , wherein the cellular poly vinyl chloride clapboards are coated with about a 4 millimeter thick coating of the polyurethane based coating.
15. The method of claim 1 , further comprising drying the coated cellular poly vinyl chloride clapboards, wherein drying comprises exposing the clapboards to about 10 minutes of flash-off time at ambient temperature, to about 20 minutes of cure time at approximately 125 degrees Fahrenheit, and to about 10 minutes of cool down.
16. The method of claim 1 , further comprising punching a plurality of nailing slots into the poly vinyl chloride clapboards via a slotting machine, wherein the clapboards are fed into a slotting machine at a speed of about 200 feet per minute.
17. The method of claim 1 , further comprising feeding the cellular poly vinyl chloride clapboards into a cleaning and de-ionizing module at a rate of about 200 feet per minute, wherein the module dissipates static charge built up on the cellular poly vinyl chloride clapboards, and brushes and vacuums the cellular poly vinyl chloride clapboards.
18. A method for forming cellular poly vinyl chloride clapboard siding comprising:
feeding a cellular poly vinyl chloride sheet into a gang rip saw at a speed of about 20 feet per minute;
cutting the cellular poly vinyl chloride sheet into a plurality of cellular poly vinyl chloride boards;
conveying each of the cellular poly vinyl chloride boards into a moulder at a speed of about 100 feet per minute;
milling each of the cellular poly vinyl chloride boards;
conveying each of the cellular poly vinyl chloride boards to a band type sawing machine at a speed of about 100 feet per minute;
parting each cellular poly vinyl chloride board with a band type sawing machine to form individual cellular poly vinyl chloride clapboards;
feeding the cellular poly vinyl chloride clapboards to a paint application booth at a speed of about 200 feet per minute;
coating the cellular poly vinyl chloride clapboards with a polyurethane based coating;
drying the coated cellular poly vinyl chloride clapboards, wherein drying comprises exposing the coated cellular poly vinyl chloride clapboards to about 10 minutes of flash-off time at ambient temperature, to about 20 minutes of cure time at approximately 125 degrees Fahrenheit, and to about 10 minutes of cool down.
19. The method of claim 18 , wherein milling comprises forming a two-up back-to-back cellular poly vinyl chloride board configuration, and wherein the milling creates a first lower assembly groove on a first face of the cellular poly vinyl chloride board, a second lower assembly groove on a second face of the cellular poly vinyl chloride board, a first upper assembly groove on the first face of the cellular poly vinyl chloride board, and a second upper assembly groove on the second face of the cellular poly vinyl chloride board, wherein the first and second lower assembly grooves and the first and second upper assembly grooves all comprise a throat opening of about 0.080 inch.