Fiber reinforced cellular pvc

Abstract

The present invention relates to exterior siding, trim and rigid architectural assemblies for buildings.

What is claimed is: 
     
         1 . A composition comprising cellular PVC reinforced with at least one continuous fiber oriented in a first direction within the cellular PVC material, wherein the at least one continuous fiber is bonded to the cellular PVC, and wherein the at least one continuous fiber provides resistance to temperature-induced expansion and contraction along the direction of the at least one fiber. 
     
     
         2 . The cellular PVC material of  claim 1 , wherein the at least one continuous fiber is coated with an agent that bonds the fibers to the cellular PVC. 
     
     
         3 . The cellular PVC material of  claim 1 , wherein the at least one continuous fiber is selected from the group consisting of co-mingled silicate based fiber and thermoplastic fiber, non-comingled silicate based fibers, non-comingled carbon based fibers and non-comingled polyamide based fibers. 
     
     
         4 . The cellular PVC material of  claim 3 , wherein the at least one continuous fiber is a silicate based fiber. 
     
     
         5 . The cellular PVC material of  claim 4 , wherein the silicate based fiber is a glass fiber. 
     
     
         6 . The cellular PVC material of  claim 3 , wherein the at least one continuous fiber is a co-mingled silicate based fiber and thermoplastic fiber. 
     
     
         7 . The cellular PVC material of  claim 6 , wherein the silicate based fiber is a glass fiber. 
     
     
         8 . The cellular PVC material of  claim 2 , wherein the agent that bonds the at least one continuous fiber to the cellular PVC is polybutylene terephthalate. 
     
     
         9 . The cellular PVC material of  claim 1 , wherein the first direction is aligned with the direction at which the cellular PVC material is extruded. 
     
     
         10 . A method to produce a composition comprising cellular PVC reinforced with at least one continuous fiber oriented in a first direction within the cellular PVC material, wherein the at least one continuous fiber is bonded to the cellular PVC, and wherein the at least one continuous fiber provides resistance to temperature-induced expansion and contraction along the direction of the at least one fiber comprising the steps of:
 a. providing a starting mixture comprising PVC powder or pellets and a blowing agent;   b. heating the starting mixture;   c. extruding the starting mixture through a form;   d. combining the extrudate with at least one continuous fiber coated with an agent that bonds the fibers to the cellular PVC;   e. passing the extrudate combined with the at least one continuous fiber in to a calibration chamber, allowing the combined extrudate to form cellular PVC reinforced with at least one continuous fiber oriented in a first direction within the cellular PVC material, and allowing the cellular PVC reinforced with at least one continuous fiber oriented in a first direction within the cellular PVC material to reach its final desired dimensions as defined by the calibration chamber dimensions; and   f. cooling the cellular PVC reinforced with at least one continuous fiber oriented in a first direction within the cellular PVC material, and cutting the cellular PVC to the desired length.   
     
     
         11 . The method of  claim 10 , wherein the at least one continuous fiber is coated with an agent that bonds the fibers to the cellular PVC. 
     
     
         12 . The method of  claim 10 , wherein the at least one continuous fiber is selected from the group consisting of co-mingled silicate based fiber and thermoplastic fiber, non-comingled silicate based fibers, non-comingled carbon based fibers and non-comingled polyamide based fibers. 
     
     
         13 . The method of  claim 12 , wherein the at least one continuous fiber is a silicate based fiber. 
     
     
         14 . The method of  claim 13 , wherein the silicate based fiber is a glass fiber. 
     
     
         15 . The cellular PVC material of  claim 12 , wherein the at least one continuous fiber is a co-mingled silicate based fiber and thermoplastic fiber. 
     
     
         16 . The cellular PVC material of  claim 15 , wherein the silicate based fiber is a glass fiber. 
     
     
         17 . The method of  claim 11 , wherein the agent that bonds the at least one continuous fiber to the cellular PVC is polybutylene terephthalate. 
     
     
         18 . The method of  claim 10 , wherein the first direction is aligned with the direction of extrusion of the cellular PVC material. 
     
     
         19 . The method of  claim 10 , wherein the at least one continuous fiber coated with an agent that bonds the fibers to the cellular PVC is pre heated prior to addition to the extrudate.