ROLLER NOSE EXTRUDER WITH DIE PLATE FOR EXTRUSION OF MULTIPLE

MATERIAL PRODUCT

FIELD OF THE INVENTION

[0001.] The present invention relates generally to method of forming a product that is made of two or more materials. More particularly, the present application involves a roller nose extruder that has a die that features multiple channels for receiving multiple materials pushed through the extruder to result in a product that is made of multiple materials.

BACKGROUND

[0002.] Extrusion is a method of manufacture in which an elastomeric material is formed into either a final or intermittent shape. The elastomeric material that is shaped may be any type of material capable of being pressed and formed from one shape into another by pressure and, in some instances, heat. The elastomeric material may be synthetic or natural rubber, a combination of both synthetic and natural rubber, synthetic resin, or a combination of rubber and synthetic resin. Tire components are a type of product formed of an elastomeric material through the use of an extrusion process.

[0003.] One type of extrusion process makes use of a roller nose extruder. Here, the elastomeric material is first located within an extrusion barrel into which a helical screw is located. Rotation of the helical screw applies pressure to the elastomeric mass and forces it out of the extrusion barrel. The pushed elastomeric material may then be directed into a transition pressure chamber of an extrusion die head. In the transition pressure chamber the elastomeric material may be compressed or expanded, and the transition pressure chamber can be variously arranged. The elastomeric material may then be transferred between a die and a roller in which the die is shaped and sized to cause the elastomeric material to assume a likewise desired shape and size. The elastomeric material is located against and drawn by the roller across the die, and the roller functions to pull the elastomeric material some distance downstream to a subsequent processing stage if desired.

[0004.] Although capable of forming a product of a desired shape and size, extrusion through the use of a roller nose extruder is limited in that only a single type of material can be formed by the die and roller combination after extrusion. In order to form products of different types of material, a process known as coextrusion can be employed. Coextrusion involves the use of two different helical screws to push two different types of elastomeric materials through their own extrusion barrel. These two different streams of material are moved into engagement with one another in a preformer. After exiting the preformer, the different materials are combined by a flat plate die. Although the process of coextrusion is capable of producing product that has different types of materials, the process is expensive and is reserved for applications involving high output. As such, there remains room for variation and improvement within the art.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005.] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended Figs, in which:

[0006.] Fig. 1 is a perspective view of a roller nose extrusion system with a screw and gearbox assembly not shown.

[0007.] Fig. 2 is a perspective view of the roller nose extrusion system of Fig. 1 with a vault and a die holder removed.

[0008.] Fig. 3 is a schematic view of a roller nose extrusion system. [0009.] Fig. 4 is a perspective view of a die.

[0010.] Fig. 5 is an exploded perspective view of the die of Fig. 4.

[0011.] Fig. 6 is a perspective view of the die with the second plate transparent to show internal features of the die.

[0012.] Fig. 7 is a bottom view of the die.

[0013.] Fig. 8 is a cross-sectional view taken along line 8-8 of Fig. 7.

[0014.] Fig. 9 is a cross-sectional view of a die engaging the roller and extruding first and second extruded components.

[0015.] Fig. 10 is a perspective view of first and second extruded components formed by the die of Fig. 9.

[0016.] Fig. 11 is a cross-sectional view of the die engaging the roller and extruding first and second extruded components.

[0017.] Fig. 12 is a perspective view of first and second extruded components formed by the die of Fig. 11.

[0018.] Fig. 13 is a front view of a product that has a second extruded component with a varying thickness along its width.

[0019.] Fig. 14 is a perspective view of an extrusion system with a second extrusion barrel.

[0020.] Fig. 15 is a perspective view of the extrusion system of Fig. 13 with the second extrusion barrel in communication with the die.

[0021.] Fig. 16 is a perspective view of an extrusion system in accordance with another exemplary embodiment.

[0022.] Fig. 17 is a perspective view of a product in which the second extruded component is placed on top of the upper surface of the first extruded component. [0023.] Fig. 18 is a perspective view of a product in which the second extruded component is placed into a recess of the first extruded component.

[0024.] Fig. 19 is a perspective view of a product in which the second extruded component is shaped by the die to have a desired cross-sectional size and shape.

[0025.] Fig. 20 is an exploded perspective view of a die with a pair of inlets.

[0026.] Fig. 21 is a close up view of the die of Fig. 20.

[0027.] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the invention.

DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS

[0028.] Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a third embodiment. It is intended that the present invention include these and other modifications and variations.

[0029.] It is to be understood that the ranges mentioned herein include all ranges located within the prescribed range. As such, all ranges mentioned herein include all sub-ranges included in the mentioned ranges. For instance, a range from 100-200 also includes ranges from 110-150, 170- 190, and 153-162. Further, all limits mentioned herein include all other limits included in the mentioned limits. For instance, a limit of up to 7 also includes a limit of up to 5, up to 3, and up to 4.5.

[0030.] The present invention provides for an extrusion system 10 that utilizes a die 22 capable of producing a product 66 that includes both a first extruded component 12 and a second extruded component 14. The die 22 may be part of a roller nose extrusion system 10 and can be made of two die plates 38 and 40, and a pair of channels 24 and 26 may extend through the die 22 for transport of the first and second extruded components 12, 14. The die 22 configuration allows for the pair of extruded components 12, 14 to be formed together to eliminate the need for subsequent formation and assembly of these two components.

[0031.] With reference to Fig. 1, an extrusion system 10 is illustrated that can be utilized by an operator 50 through a control panel or other input/output instructional device. The extrusion system 10 may include a roller nose extruder. In this regard, a product 66 may be pressed or otherwise transported into a vault 62 and then subsequently moved into a die 22. The die 22 can be held in place by a die holder 64 that is stationary with respect to the vault 62. A roller 20 rotates about its central axis and rotates relative to the die 22, die holder 64, and vault 62. The die 22 can have a passageway therethrough for the transport of the product 66, and the configuration of the die 22 will shape and size the product 66 as desired. The product 66 is pushed through the die 22 by the rotating roller 20 and/or a combination of the rotating roller 20 and other pressure forces upstream from the die 22. Product 66 on the roller 20 is rotated away from the die 22 and then onto a secondary roller 58 and then to a downstream stage for subsequent processing.

[0032.] Fig. 2 shows the extrusion system 10 with the die holder 64 and the vault 62 removed. The product 66 engages both the outer surface of the rotating roller 20 and the die 22 as it is moved through the die 22. Portions of the die 22 are transparent in order to show internal features of the die 22 such as a first channel 24 and a second channel 26. There are four strips of product 66 extruded from the die 22. However, the die 22 can be configured in a variety of manners so that any number of strips of product 66 can be extruded as desired. For example, from 1-4, from 5-10, from 11-20, or up to 40 strips of product 66 can be extruded from the die 22 in accordance with various exemplary embodiments. The shape of the die 22 can be varied so that all of the strips of product 66 have different sizes and shapes, or so that some of the strips are identical while other strips of the product 66 are different in shape and/or size.

[0033.] Fig. 3 shows the extrusion system 10 as having a pair of extrusion barrels 16, 18 into which a first extruded component 12 and a second extruded component 14 are located. The extruded components 12, 14 may be different from one another in that they are not the same types of material. In some instances, the first extruded component 12 is rubber of a particular composition, while the second extruded component 14 is rubber of a different composition. A first extrusion screw 34 may be located within the first extrusion barrel 16, and rotation of the first extrusion screw 34 may cause the first extruded component 12 to be pushed out of the first extrusion barrel 16. The first extruded component 12 can move from the first extrusion barrel 16 into a vault 62 that is in communication with the first extrusion barrel 16. The transition pressure chamber or vault 62 is shaped in a manner that can constrict the flow of the first extruded component 12 and cause its shape to change into a desired form. The vault 62 may expand or contract so that the flow of the first extruded component 12 is altered as desired upon being transported therein. The vault 62 may function to split the flow of the first extruded component 12 up into two or more different streams of first extruded component 12. The vault 62 is open to the roller 20 in that the first extruded component 12 engages the roller 20 when the first extruded component 12 is in the vault 62. The vault 62 may be a single component, or more than one component and thus more than one flow path in certain embodiments. The extrusion system 10 may be arranged so that a vault 62 is not present and so that the first extruded component 12 flows from the first extrusion barrel 16 directly to the die 22. Although shown as having a portion of the vault 62 on the bottom proximate to the first extrusion barrel 16 arranged so as to isolate the roller 20 from the first extruded component 12, the vault 62 may be arranged in other embodiments so that no portion of the vault 62 isolates the first extruded component 12 from the roller 20. In this regard, the first extruded component 12 exits the first extrusion barrel 16 and immediately engages the roller 20 without transitioning through a portion of the vault 62 that isolates the first extruded component 12 from the roller 20.

[0034.] The extrusion system 10 may also include a second extrusion barrel 18 that houses a second extruded component 14. The second extruded component 14 is not the same type of material as the first extruded component 12. A second extrusion screw 36 rotates in order to force the second extruded component 14 out of the second extrusion barrel 18. The second extrusion barrel 18 is isolated from the first extrusion barrel 16 so that their contents are not transferred into one another. The first and second extrusion screws 34, 36 may be helical in some embodiments so that their rotation causes the described movement of the first and second extruded components 14, 16. In other arrangements, the first and second extrusion screws 34, 36 need not be used and any mechanism capable of pushing or removing the first and second extruded components 14, 16 from the first and second extrusion barrels 16, 18 can be employed. For example, a plunger arrangement, a gravity feed arrangement, a paddle wheel arrangement, or meshing gears in the form of a gear pump can be used to push the first and second extruded components 14, 16 through the extrusion system 10.

[0035.] The second extruded component 14 from the second extrusion barrel 18 is pushed out of the second extrusion barrel 18 and flows into the die 22. The first extruded component 12 is transferred from the vault 62 into the die 22. The first extruded component 12 also engages the roller 20 as it moves through the die 22. The die 22 may or may not engage the roller 20. The die 22 functions to size and shape the first extruded component 14 and it emerges from the die 22 in the desired form. The second extruded component 14 may or may not be shaped by the die 22. The second extruded component 14 is located on top of the first extruded component 12 so that the second extruded component 14 does not engage the roller 20. However, it is to be understood that other embodiments are possible in which the second extruded component 14 does in fact engage the roller 20 either within the die 22 or upon exiting the die 22.

[0036.] The combined stream of first and second extruded component 12, 14 makes up the product 66 that exits the die 22 and engages the roller 20. As the roller 20 rotates, the product 66 moves in the direction of reference number 68 and off of the roller 20. The product 66 can be subsequently processed downstream or may be considered finished at this point upon the desired output from the extrusion system 10. An additional roller 58 may be present at this point in the process downstream from the first described roller 20 in the machine direction 68. The product 66 may engage the roller 58, and in this instance the second extruded component 14 may engage the second roller 58. The first extruded component 12 may also engage the second roller 58, or the second extruded component 14 may exclusively engage the second roller 58. The second roller 58 is distinguished from the first roller 20 in that the first roller 20 is the first one to engage the product 66, and in that the first roller 20 is upstream from the second roller 58, and in that the first roller 20 may engage the die 22 in some instances while the second roller 58 is always free from engagement with the die 22. After engaging the roller 58, the product 66 may be further moved and directed to a subsequent processing station downstream or may be considered finished and removed from the process. The roller 58 may or may not be a driven roller.

[0037.] The extrusion system 10 may be arranged so that a preformer is not required and is not present in the extrusion system 10. The product 66 that is extruded may be produced in small bands and the extrusion system 10 and its individual components may be classified as a micro extruder. The extrusion system 10 extrudes through the die 22 on a roller nose extruder line and results in multiple extruded components 12, 14 being formed on the product 66 instead of just a single extruded component incorporated into the product 66. The extrusion system 10 is not a co- extrusion process, but is instead an extrusion system 10 that utilizes a roller nose extruder line that receives a second extruded component 14 directly into the die 22 without first being pre-formed and wherein the second extruded component may not engage the roller 20. However, the extrusion system 10 could in some embodiments be adapted for use inside of a co-extrusion line. For example, the extrusion system 10 could be used to add bands of product 66 to the bottom of a tread that is formed in a co-extrusion line.

[0038.] Figs. 4 and 5 illustrate a die 22 that can be used in accordance with one exemplary embodiment. The die 22 is made up of a first die plate 38 and a second die plate 40 that engage one another and are held into engagement with one another during execution of the extrusion process. The plates 38, 40 may be provided with interlocking components to effect this connection, or the die holder 64 may be arranged to allow for the plates 38 and 40 to be connected to one another. The first die plate 38 and the second die plate 40 are designed to be removable from one another so that they can be taken apart and internal features can be cleaned. In some embodiments, the second die plate 40 can be removed and substituted with a different die plate 40 so that a different sized, shaped, and/or configured product 66 can be produced as desired. Although described as having a pair of die plates 38 and 40, it is to be understood that the die 22 may be a single, unitary component in other arrangements. Still further, the die 22 may be made of any number of die plates besides two in yet other exemplary embodiments.

[0039.] The first extruded component 12 enters the back of the die 22 and flows to the front of the die 22 in a longitudinal direction 28 of the die. The die 22 has a width that extends in a transverse direction 32 of the die 22. The die 22 also has a vertical direction 30 that extends generally in the direction towards and away from the roller 20 when the die 22 is assembled with the roller 20 during extrusion. The die 22 includes a series of first channels 24 located on a terminal end of the die 22 in the vertical direction 30. All of the first channels 24 may exit the die 22 at the bottom in the vertical direction 30 so that all of them directly face the roller 20 and so that none of them are spaced from the roller 20 in the vertical direction 30. It is to be understood that the first channels 24 can exit the die 22 in any direction or in multiple directions from the same die 22. For example the first channels can exit the die 22 in both the longitudinal direction 28 and the vertical direction 30, only in the vertical direction 30, only in the longitudinal direction 28, both in the longitudinal direction 28 and in the transverse direction 32 or both in the vertical direction 30 and transverse direction 32. The first channels 24 are spaced along the width of the die 22 in the transverse direction 32. Although six first channels 24 are illustrated, any number are possible in other embodiments of the die 22. The ends of the die 22 in the transverse direction 32 may be configured to engage the die holder 64 so that the die 22 can be retained next to the roller 20 during extrusion. The die 22 can include an inlet 60, or multiple inlets 60, on its front face in the longitudinal direction 28 that receives the second extruded component 14 during the extrusion process. The inlet may be spaced from the top and bottom of the die 22 in the vertical direction 30.

[0040.] Fig. 5 shows the second die plate 40 removed from the first die plate 38. A second channel 36 is defined in the first die plate 38 and is in communication with the inlet 60 so that the second extruded component 14 inserted through the inlet 60 flows into the second channel 36. The second die plate 40 may function to cover the second channel 36. The second channel 36 may be defined by both the second die plate 40 and the first die plate 38, and their removability allows the second channel 36 to be cleaned of the second extruded component 14 from time to time as maintenance of the die 22 requires. The second die pate 40 may also include cut out portions that define a portion of the first channels 24. The first channels 24 may thus be defined by both the first and second die plates 38 and 40.

[0041.] Fig. 6 shows the first die plate 38 assembled onto the second die plate 40, but the first die plate 38 as being transparent in order to observe features of the first and second channels 24 and 26. The embodiment of Fig. 6 differs slightly from that immediately discussed with respect to Figs. 4 and 5 in that only four first channels 24 are present, but otherwise includes the same features. The inlet 60 extends in the longitudinal direction 28 and is in communication with the second channel 26 that extends from the inlet 60 in the transverse direction 32. The second channel 26 is in communication with each one of the first channels 24 and extends in both the transverse direction 32 and the vertical direction 30 to engage the first channels 24. The second extruded component 14 upon being injected into the inlet 60 may follow the path of the second channel 26 until it exits from the second channel 26 at the various first channels 24. The first extruded component 12 flows through the first channel 24 and does not flow through any portion of the second channel 26. The second extruded component 14 exiting the second channel 26 engages the first extruded component 12 in the first channel 24. The second extruded component 14 may thus be placed onto an upper surface of the first extruded component 12 and this combined product 66 may exit the die 22.

[0042.] Fig. 7 is a bottom view of the die 22 that shows the four first channels 24 as being defined on the lower vertical surface of the die 22. The first channels 24 extend completely from one terminal side of the die 22 to an opposite terminal side of the die 22 in the longitudinal direction 28. The first channels 24 are linear in that they do not extend to the left or right in the transverse direction 32. The second channel 26 is defined by the first die plate 38 and the second die plate 40. The second channel 26 is shown as having exits into the first channels 24 at locations spaced from the terminal end of the die 22 in the longitudinal direction 28. The first extruded component 12 moves in the direction of travel 44 upon exiting the die 22. The second extruded component 14 moves in the direction of travel 48 upon exiting the die 22. The directions of travel 44 and 48 are parallel to one another and are the same as one another as they are in the same direction upon exiting.

[0043.] Fig. 8 is a cross-sectional view taken along line 8-8 of Fig. 7 and shows the shape of the first channels 24. The first channels 24 are shown as being triangular in shape and all being roughly of the same size and shape as one another. The second channels 26 are not shown in Fig. 8, but may be positioned so as to cause the second extruded component 14 to engage the first extruded component 12 at different locations. However, in other arrangements the product 66 being produced is the same when all of the strips of the product 66 are compared to one another.

[0044.] Fig. 9 is a cross sectional view of the die 22 arranged adjacent the roller 20. The die 22 engages the roller 20 during the extrusion process. The first extruded component 12 is located in the first channel 24 and engages both the second die plate 40 and the roller 20 so as to be located between these two components. The first channel 24 is not completely triangular in shape but has a profile that has an enlargement at the top of the triangle in the vertical direction 30. The enlargement is not present in the first die plate 38, but is present in the second die plate 40. The enlargement receives the second extruded component 14 as it leaves the second channel 26 and enters the first channel 24. The second extruded component 18 thus flows through the second channel 26 and then into the first channel 24 before exiting the die 22. Fig. 10 shows the product 66 produced upon being extruded from the die 22 described in Fig. 9. A layer of the second extruded component 14 is placed on top of the first extruded component 12. The amount of the second extruded component 14 is less than that of the first extruded component 12 by cross-sectional area of the product 66. The width 46 of the second extruded component 14 is less than the width 42 of the first extruded component 12. However, other arrangements are possible in which the width 46 of the second extruded component 14 is greater than the width 42 of the first extruded component 12. In yet other arrangements the widths 42 and 46 are the same as one another. Further, although shown as being applied to only one section of the cross-sectional profile of the first extruded component 12, other arrangements of extrusion are possible in which separate areas of the first extruded component 12 are applied with the second extruded component 14. [0045.] The second extruded component 14 can be applied to the first extruded component 12 evenly in that a single layer with the same thickness is applied. In this regard, the thickness of the second extruded component 14 may be the same along its entire width 46. The geometry and thus thickness of the first extruded component 12 may be varied along its width 42 and this thickness may be greater than the thickness of the second extruded component 14.

[0046.] Fig. 11 shows a different arrangement of the die 22 than the one illustrated and described with respect to Fig. 9. The die 22 in Fig. 11 includes first channels 66 that have a blocking plate 70 located therein in all four of the first channels 66. The first extruded component 12 flowing through the first channels 24 engage the blocking plates 70 and this causes the first extruded component 12 to assume a shape that is triangular in cross-section but with a depression at the upper section of the triangle in the vertical direction 30 of the die 22. The blocking plate 70 causes a depression in the first extruded component 12 to be formed that is filled by the second extruded component 14 as it exits the second channel 26. The second extruded component 14 flows into the first channel 24 and engages the first extruded component 12 to form the product 66. The resulting product 66 is triangular in cross-sectional shape.

[0047.] Fig. 12 shows the product 66 formed by the die 22 arrangement of Fig. 11. The product 66 includes the first extruded component 12 that is triangular in cross-section but with a depression near the top of the triangle. The depression is filled in by the second extruded component 14 so that the resulting cross-sectional shape of the product 66 is triangular. The upper surface of the product 66 is thus planar without the appearance of the second extruded component 14 laying onto the upper surface of a planar first extruded component 12, but instead onto a depression in the upper surface of the first extruded component 12. The thickness and width 46 of the second extruded component 14 are both smaller than the thickness and width 42 of the first extruded component 12. [0048.] The second extruded component 14 has been described as having a flat profile shape upon being extruded onto the first extruded component 12. However, other cross- sectional shapes of the second extruded component 14 are possible in which the thickness of the second extruded component 14 is varied along its width 46 as desired. With reference to Fig. 13, a product 66 is shown in which volume is added to portions of the second extruded component 14 along its width 46 such that the second extruded component 14 has areas of differing thickness. This added thickness may be applied in order to cover a wire or wire edges that could be incorporated into the product 66. The change in thickness across the width 46 can be achieved by the shape of the first or second die plates 38, 40 that cause the first and second channels 24, 26 to be shaped in a particular fashion so that the resulting extruded profile of the second extruded component 14 is executed in a desired thickness that varies across its width 46.

[0049.] The second extruded component 14 may be delivered to the die 22 in an arrangement as illustrated with reference to Figs. 14 and 15. A framework 52 may be constructed proximate to the roller 20 and die 22 and may be stationary with respect to the die 22 when the roller 20 rotates and the extrusion system 10 functions to create the product 66. A pivot arm 54 can be pivotally attached to the framework 52. The second extrusion barrel 18 is attached to the pivot arm 54. Fig. 14 shows the pivot arm 54 and the second extrusion barrel 18 moved out of position so that the second extrusion barrel 18 does not engage the die 22. In this position, the die 22 may be accessed and the second die plate 40 removed and replaced. Further, other components of the extrusion system 10 may be accessed when the second extrusion barrel 18 is positioned away from the die 22.

[0050.] When the extrusion of product 66 is desired, the pivot arm 54 can be pivoted with respect to the framework 52 and the second extrusion barrel 18 can be moved into engagement with the die 22. The second extruded component 14 may be dispensed from the second extrusion barrel 18 and into the engaged die 22. The second extrusion barrel 18 may itself be pivotally mounted to the pivot arm 54 so that it can pivot thereto. In other embodiments, the second extrusion barrel 18 is rigidly mounted onto the pivot arm 54. Although shown as employing a pivot arm 54 arrangement, other arrangements of mounting the second extrusion barrel 18 to the die 22 are possible. Fig. 1 shows the second extrusion barrel 18 mounted onto a sliding mechanism 56 that is in turn mounted onto the framework 52. The sliding mechanism 56 can slide relative to the framework 52 and thus may slide relative to the die 22. The second extrusion barrel 18 may move into and out of engagement with the die 22. Still additional types of mounting the second extrusion barrel 18 to the die 22 exist. For instance, the die 22 may be permanently attached to the second extrusion barrel 18 so that the inlet 60 is permanently attached to the second extrusion barrel 18, and so that the second extrusion barrel 18 does not pivot, slide, or otherwise move relative to the die 22. In yet other embodiments the second extrusion barrel 18 does not move, but a line from the second extrusion barrel 18 to the inlet 60 can be removed and attached in order to place these components into communication with one another.

[0051.] Fig. 16 shows an extrusion system 10 in accordance with another exemplary embodiment. The first extruded component 12 may be introduced into the system 10 by way of an inlet 78. The inlet 78 is in communication with the interior of the first extrusion barrel 16 and the first extruded component 12 flowing through the inlet 78 will go into the interior of the first extrusion barrel 16. A first gear box 74 functions to both mount the first extrusion barrel 16 and provide a rotating movement to the first extrusion screw 34. The opposite end of the first extrusion barrel 16 is mounted to a frame that also holds the die holder 64 that in turn supports the die 22. The roller 20 is likewise mounted to the same frame, and the second extrusion barrel 18 is positioned proximate to the die 22. The second extrusion barrel 18 may be moved into and out of engagement with the die 22 as previously discussed. The product 66 output from the die 22 is transported on the roller 20 to a conveyor belt 72 and moved to a desired location.

[0052.] The process executed by use of the extrusion system 10 can be used to create three different kinds of multiband products 66 as shown in Figs. 17-19. In Fig. 17, the second extruded component 14 is placed onto the upper surface of the first extruded component 12 at two different places in which each portion of the second extruded component 14 has a rectangular cross- sectional shape. The combined widths 46 are less than the width 42. The product 66 in Fig. 18 has a pair of recesses formed in the first extruded component 12 and these recesses are filled with the second extruded component 14 to cause the upper surface of the product 66 to be flush across its entire width. The combined widths 46 are less than the width 42, and the cross-sectional shape of the second extruded component 14 is rectangular. The products 66 formed in Figs. 17 and 18 may be extruded from the bottom of the die 22. A further product 66 is illustrated with reference to Fig. 19 in which the bands formed on top of the first extruded component 12 are profiled in shape so as to have cross- sectional shapes that are not rectangular. The second extruded component 14 is placed onto two different sections of the first extruded component 12 and each section has a different cross- sectional shape one being semi-circular and the other being of different thicknesses. The combined widths 46 are less than the width 42, and the second extruded component 14 is placed onto the upper surface of the first extruded component 12 and is not placed into a recess of the first extruded component 12. The second extruded component 14 may be extruded through the front of the die 22.

[0053.] The die 22 has been described as having a single inlet 60 for the injection of the second extruded component 14. Other embodiments are possible in which multiple inlets are present for the introduction of the second extruded component 14 into the die 22. Figs. 20 and 21 disclose an arrangement of the die 22 in which a pair of inlets 60 and 80 are present for the introduction of the second extruded component 14 into the die 22. The inlets 60, 80 extend through the second die plate 40 into the second channels 26 that include portions that are not in communication with one another. The use of a pair of inlets 60, 80 may allow for the second extruded component 14 to more easily flow through the die 22. The second extruded component 14 from the inlet 60 flows onto the first extruded component 12 flowing through two of the first channels 24, and the second extruded component 14 from the inlet 80 engages the first extruded component 12 moving through two separate first channels 24. The second die plate 40 is shaped so as to engage the second extruded component 14 and form different profile shapes into the second extruded component 14 such as one having angles with varying thicknesses, and another having a semi-circular cross-sectional shape.

[0054.] The extrusion system 10 may be capable of producing the product 66 with both the first extruded component 12 and the second extruded component 14 so that a separate first extruded component 12 and a separate second extruded component 14 do not have to be first formed and then subsequently assembled onto one another. The extrusion system 10 may eliminate the need for pre-manufactured bands of material used on a calendar roll in certain manufacturing processes.

[0055.] Although shown and described as employing two extruded components 12, 14, it is to be understood that a third extruded component can be incorporated into the extrusion system 10 in alternative exemplary embodiments. The third extruded component can be transferred thorugh a third extrusion barrel and may be placed onto the first and/or second extruded component 12/14 when constructing the product 66. Any number of additional extruded components can be incorporated into the product 66 in still further exemplary embodiments. From 4-6, from 7-10, or up to 20 extruded components can be included in the product 66 produced by the extrusion system 10 as described herein.

[0056.] While the present invention has been described in connection with certain preferred embodiments, it is to be understood that the subject matter encompassed by way of the present invention is not to be limited to those specific embodiments. On the contrary, it is intended for the subject matter of the invention to include all alternatives, modifications and equivalents as can be included within the spirit and scope of the following claims.