Method of texturing synthetic material extrusions
A method of texturing a synthetic material, such as polyvinyl chloride (PVC), to resemble a natural material is provided. The method can include texturing a PVC profile after extrusion in order to achieve a surface roughness of about 70 to about 300 micro inches roughness average. The method can include producing a line pattern surface roughness to make the textured PVC resemble a wood finish, particularly when the method includes applying a paint or stain to the textured PVC. The method can include producing a radial pattern surface roughness to make the textured PVC resemble a brushed metal finish. The method of the present invention can be applied to existing PVC elements, such as extruded elements, either at the manufacturing level or at the consumer level. A kit can also be provided including a texturing means, a paint or stain, and instructions.
1. A method of finishing a synthetic material extrusion (SME), the method comprising steps of:
texturing the SME to obtain a marked SME having a plurality of scores thereon, the marked SME having a roughness average (Ra) of about 70 micro-inches to about 300 micro-inches, the texturing including sanding the SME or brushing the SME;
polishing the marked SME to remove at least one of whiskers and burrs from the marked extrusion, the at least one of whiskers and burrs having been formed by sanding the SME or brushing the SME;
staining the marked SME to obtain a stained marked SME having a stained wood finish; and
applying a protective coating to the stained marked SME.
2. The method of claim 1 wherein:
the SME is obtained by an extrusion process; and
texturing the SME is performed after the extrusion process, subsequent a cooling phase of the SME.
3. The method of claim 2 wherein the extrusion process is performed on an extrusion line and texturing the SME is performed with the SME on the extrusion line.
4. The method of claim 2 wherein the extrusion process is performed on an extrusion line and texturing the SME is performed with the SME off the extrusion line.
5. The method of claim 1 wherein a portion of the plurality of scores are substantially parallel to each other.
6. The method of claim 1 wherein the plurality of scores form a radial pattern, a circular pattern, a cross-hatched pattern, an isotropic pattern, or a wood pattern.
7. The method of claim 1 wherein sanding the SME includes rubbing sandpaper against the SME.
8. The method of claim 7 wherein the sandpaper has a Coated Abrasive Manufacturers Institute (CAMI) grit designation of about 40 to about 180.
9. The method of claim 1 wherein the SME is composed of polyvinyl chloride, cellular polyvinyl chloride, acrylonitrile butadiene styrene, Geloy™, acrylic or acrylonitrile styrene acrylate.
10. The method of claim 1 wherein the SME is a hollow SME.
11. The method of claim 1 wherein the SME includes at least one of a U-shaped profile, a T-shaped profile, or an L-shaped profile.
12. A method of finishing a synthetic material construction element (SMCE), the method comprising steps of:
texturing the SMCE to obtain a marked SMCE having a plurality of scores thereon, the marked SMCE having a roughness average (Ra) of about 70 micro-inches to about 300 micro-inches, the texturing including sanding the SMCE or brushing the SMCE;
polishing the marked SMCE to remove at least one of whiskers and burrs from the marked SMCE, the at least one of whiskers and burrs having been formed by sanding the SME or brushing the SME;
staining the marked SMCE to obtain a stained marked SMCE having a stained wood finish; and
applying a protective coating to the stained marked SMCE.
13. The method of claim 12 wherein:
the SMCE is obtained by an extrusion process; and
texturing the SMCE is performed after the extrusion process, subsequent a cooling phase of the SMCE.
14. The method of claim 12 wherein the extrusion process is performed on an extrusion line and texturing the SMCE is performed with the SMCE on the extrusion line.
15. The method of claim 13 wherein the extrusion process is performed on an extrusion line and texturing the SMCE is performed with the SMCE off the extrusion line.
16. The method of claim 12 wherein the SMCE is an element formed by compression molding, injection molding or thermoforming.