US20170312970A1 - Extrusion-coated structural members having extruded profile members - Google Patents
Extrusion-coated structural members having extruded profile members Download PDFInfo
- Publication number
- US20170312970A1 US20170312970A1 US15/655,148 US201715655148A US2017312970A1 US 20170312970 A1 US20170312970 A1 US 20170312970A1 US 201715655148 A US201715655148 A US 201715655148A US 2017312970 A1 US2017312970 A1 US 2017312970A1
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- United States
- Prior art keywords
- structural
- extrusion
- coated
- substrate
- recess
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B5/00—Joining sheets or plates, e.g. panels, to one another or to strips or bars parallel to them
- F16B5/0004—Joining sheets, plates or panels in abutting relationship
- F16B5/0008—Joining sheets, plates or panels in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edge
- F16B5/0012—Joining sheets, plates or panels in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edge a tongue on the edge of one sheet, plate or panel co-operating with a groove in the edge of another sheet, plate or panel
- F16B5/0016—Joining sheets, plates or panels in abutting relationship by moving the sheets, plates or panels substantially in their own plane, perpendicular to the abutting edge a tongue on the edge of one sheet, plate or panel co-operating with a groove in the edge of another sheet, plate or panel with snap action
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B7/00—Connections of rods or tubes, e.g. of non-circular section, mutually, including resilient connections
- F16B7/04—Clamping or clipping connections
- F16B7/044—Clamping or clipping connections for rods or tubes being in angled relationship
- F16B7/0446—Clamping or clipping connections for rods or tubes being in angled relationship for tubes using the innerside thereof
- F16B7/0473—Clamping or clipping connections for rods or tubes being in angled relationship for tubes using the innerside thereof with hook-like parts gripping, e.g. by expanding, behind the flanges of a profile
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49616—Structural member making
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/23—Sheet including cover or casing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24521—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness with component conforming to contour of nonplanar surface
Definitions
- Another embodiment of the present invention concerns a method of making an extrusion-coated structural system, the method comprising extrusion coating a coating material onto at least a portion of a substrate to form an extrusion-coated structural member, wherein the extrusion coating forms at least one extruded profile member extending outwardly from the substrate for a maximum distance that is at least two times greater than the average thickness of the coating material coated onto the substrate proximate the extruded profile member.
- FIG. 26 is a side perspective view of the extrusion-coated structural system depicted in FIG. 25 , with the panels arranged in an assembled configuration;
- FIG. 34 is side perspective view of the extrusion-coated structural system depicted in FIG. 33 ;
- FIG. 42 is side perspective view of yet another embodiment of an extrusion-coated structural system comprising a bridging member, arranged in a flat configuration;
- FIG. 55 is a side perspective view of the extrusion-coated structural system shown in FIG. 54 , arranged in an a folded configuration;
- FIG. 65 a is a side view of the flush configuration used to strength test a substrate as described in Example 3;
- the coating material applied via extrusion coating may comprise at least one thermosetting and/or thermoplastic resin, optionally in combination with additional components.
- suitable coating materials and types of substrates suitable for use in the extrusion-coated structural systems of the present invention will be discussed in detail shortly.
- only one of substrates 112 a or 112 b may include a reinforced region 113 .
- Each of reinforced regions 113 a,b include one or a plurality of structural recesses 118 extending inwardly from at least one surface 120 a , 120 b of substrates 114 a,b .
- Structural recesses 118 may be coated with a coating material having a thickness greater than the coating material coated onto substrate 114 a,b proximate recesses 118 and/or may be further configured according to one or more embodiments described previously with respect to FIGS. 1-3 .
- recess attachment surface 224 may include at least one intervening material layer.
- Extrusion-coated structural system 250 further comprises four hardware members, shown as screws 266 a - d , each comprising a hardware protrusion 268 a - d , shown in FIG. 7 as being threaded hardware protrusions. As shown in FIG. 7 , each of hardware protrusions 268 a - d of hardware members 266 a - d are configured for insertion into respective recess inlets 257 a,b and 259 a,b ( 259 a not shown) via structural recess 262 a - b of substrate 254 c .
- the extrusion-coated structural member 512 comprises a structural recess 518 collectively defined by substrates 514 a,b .
- Structural recess 518 is an elongated recess at least partially coated with coating material 516 .
- Structural recess 518 presents a recess attachment surface 524 configured to at least partially support at least a portion of hardware member 520 , shown as a shelf support pin in FIGS. 15 and 16 , when hardware member 520 is inserted into structural recess 518 .
- the broad portion 526 of hardware member 520 can be configured for receipt into the broad section 528 of structural recess 518
- the narrow portion 530 of hardware member 520 may be configured for receipt into a narrow section 532 of structural recess 518 .
- substrates 1112 and 1114 can define a gap 1130 there between.
- opposing surfaces 1132 , 1134 of substrates 1112 , 1114 shown in FIGS. 42-44 are not parallel, but instead are angularly aligned with one another at an alignment angle, shown as ⁇ in FIG. 42 , measured from surface 1132 of substrate 1112 to surface 1134 of substrate 1114 .
- an extrusion-coated structural system 1350 is shown as comprising a plurality of substrates 1352 , 1354 , and 1356 and a coating material 1358 extrusion coated onto at least a portion of substrates 1352 , 1354 , 1356 .
- Structural system 1350 further includes a bridging member 1370 extending between at least a portion of substrate 1352 and 1354 and a bridging member 1372 extending between at least a portion of substrate 1354 and 1356 . As shown in FIGS.
- one of bridging member 1370 may be configured to rotate, move, bend, or flex in a different direction than the other bridging member 1372 , such that one or more of substrates 1352 , 1354 , and 1356 may move in a direction other than the direction in which one or more of the other substrates 1352 , 1354 , and 1356 are configured to move.
- structural systems configured in a similar manner to structural system 1350 may be particularly useful for furniture or cabinetry applications, including, for example, in modular furniture applications. In addition to being simpler to assemble, such structural system may also be simpler and/or less expensive to manufacture and ship than similar conventional items.
- Substrates being extrusion coated in coating system 1512 and suitable for use in the extrusion-coated structural system described herein made of a variety of substrate materials.
- the substrates coated in coating system 1512 can comprise a single material, while, in another embodiment, the substrate can be a composite of two or more different materials.
- suitable materials can be one or more of natural wood, wood composites, plastics including cellularized PVC and other foams, metal, fiberglass-reinforced thermoset or thermoplastic polymers, ceramics, cement, and combinations thereof.
- the coating material can also have a percent yield strain of at least about 1 percent, at least about 2 percent, at least about 5 percent and/or not more than about 8 percent, not more than about 6 percent, as calculated by ASTM D882. This may be, in some cases, lower than conventional coatings, such a paint, which may exhibit a percent yield strain greater than 9 percent.
- the coating material used herein may also have a modulus of at least about 10 MPa, at least about 50 MPa, at least about 100 MPa, at least about 500 MPa, at least about 1000 MPa, at least about 1200 MPa and/or not more than about 2500 MPa, not more than about 2000 MPa, not more than about 1500 MPa, measured according to ASTM D882.
- the thermoplastic resin can have an inherent viscosity (I.V.), measured at 25° C. in 60/40 wt/wt phenol/tetrachloroethane, of at least about 0.50, at least about 0.65, at least about 0.69 dL/g and/or not more than about 1.4, not more than about 1.2, not more than about 1.0, not more than about 0.9, not more than about 0.85 dL/g, or in the range of from about 0.50 to about 1.4 dL/g, about 0.50 to about 1.2 dL/g, about 0.50 to about 1.0 dL/g, about 0.50 to about 0.9 dL/g, about 0.50 to about 0.85 dL/g, about 0.65 to about 1.4 dL/g, about 0.65 to about 1.2 dL/g, about 0.65 to about 1.0 dL/g, about 0.65 to about 0.9 dL/g, about 0.65 to about 0.85 dL/g, about 0.65 to about
- the thermoplastic resin used in the coating material can be selected from the group consisting of polyesters, copolyesters, polycarbonates, polymethyl methacrylate (PMMA), including impact-modified PMMA, poly(acrylonitrile-styrene-acrylate) (ASA), poly(acrylonitrile-butadiene-styrene) (ABS), poly(styrene-acrylonitrile) (SAN), cellulose esters and mixtures thereof.
- PMMA polymethyl methacrylate
- ASA acrylonitrile-styrene-acrylate
- ABS acrylonitrile-butadiene-styrene
- SAN poly(styrene-acrylonitrile)
- the opacity modifier can be present in the coating material in an amount in the range of from about 0.05 to about 20 percent, about 0.05 to about 15 percent, about 0.05 to about 10 percent, about 1 to about 20 percent, about 1 to about 15 percent, about 1 to about 10 percent, about 2 to about 20 percent, about 2 to about 15 percent, about 2 to about 20 percent, based on the total weight of the coating material.
- suitable opacity modifiers include metal oxides and metal salts, such as, for example, zinc oxide (ZnO), mica, white lead, barium sulfate (BaSO 4 ), zinc sulfide (ZnS), antimony oxide and titanium dioxide (TiO 2 ).
- Non-limiting examples of the at least one impact modifier include polymers based on a polyolefin rubbery segment, sometimes also referred to as a rubbery phase, polymers based on a polyether rubbery phase, polymers based on an acrylic rubbery phase and polymers based on a butadiene and/or isoprene rubbery phase.
- the at least one impact modifier is chosen from poly(acrylonitrile butadiene styrene) (ABS) polymers.
- the coating may be applied to at least a portion, or substantially all, of the surface of the substrate such that at least about 50 percent, at least about 65 percent, at least about 75 percent, at least about 85 percent, or at least about 95 percent of the total surface area of substrate is covered with a coating material.
- a coating material may be applied to at least a portion, or substantially all, of the surface of the substrate such that at least about 50 percent, at least about 65 percent, at least about 75 percent, at least about 85 percent, or at least about 95 percent of the total surface area of substrate.
- n is an integer between 3 and 10, inclusive
- the entirety of the outer surface of the substrate may be coated such that all sides of the substrate are completely encapsulated by the coating material.
- the average thickness of the coating material may be in the ranges discussed previously.
- one or both of structural members 1752 and 1762 may have additional protrusions and/or recesses configured to be inserted into one or more other recesses and/or configured to receive one or more other protrusions of the other structural members, not shown in FIGS. 61-63 .
- coating materials 1756 and/or 1766 may be applied to (coated onto) at least about 50 percent, at least about 60 percent, at least about 70 percent, at least about 80 percent, at least about 90 percent, at least about 95 percent, or at least about 99 percent of the total surface area of substrates 1754 and/or 1764 .
- Coating materials 1756 and/or 1766 may extend continuously around at least three, at least four, or all sides of at least one cross-section of substrates 1754 and/or 1764 .
- Coating materials 1756 and 1766 can be applied to respective first and second substrates 1754 and 1764 according to any suitable method.
- at least one of structural members 1752 and 1762 can be extrusion-coated structural members and at least a portion of coating materials 1756 and 1766 can be extrusion coated onto one or more surfaces of substrates 1754 and 1764 .
- coating materials 1756 and 1766 may be applied to substrates 1754 and 1764 in another manner, such as, for example, by injection molding, curtain coating, or other suitable method.
- the average thickness of coating material 1756 and/or 1766 applied to respective substrates 1754 and/or 1764 may lie within the ranges described in detail previously.
- protrusion 1772 can extend outwardly from main body portion 1770 for a maximum distance, shown as L 1 in FIG. 63 , for a distance of at least about 0.10 inches, at least about 0.25 inches, at least about 0.50 inches, at least about 1 inch, at least about 1.5 inches and/or not more than about 5 inches, not more than about 3 inches, not more than about 2.5 inches, not more than about 2 inches, or in the range of from about 0.10 to about 5 inches, about 0.10 to about 3 inches, about 0.10 to about 2.5 inches, about 0.10 to about 2 inches, about 0.25 to about 5 inches, about 0.25 to about 3 inches, about 0.25 to about 2.5 inches, about 0.25 to about 2 inches, about 0.50 to about 5 inches, about 0.50 to about 3 inches, about 0.50 to about 2.5 inches, about 0.50 to about 2 inches, about 1 to about 5 inches, about 1 to about 3 inches, about 1 to about 2.5 inches, about 1 to about 2 inches, about 1.5 to about 5 inches, about 1.5 to about 3 inches, about 1.5 to about 2.5 inches
- one of the pair of protrusions 1784 a,b may extend outwardly from main body portion 1780 for a different distance than the other.
- one or more of the protrusions may be disposed on opposite sides of main body portion 1780 and/or 1770 , thereby resulting in (N ⁇ 2) or (N ⁇ 3) recesses, depending on the specific configuration of structural member 1762 or 1752 .
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Architecture (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- General Engineering & Computer Science (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
Abstract
The present disclosure relates to extrusion-coated structural systems including at least one extruded profile member coupled to and extending outwardly from an extrusion-coated structural member, as well as methods of making and using the same. Structural systems of the present invention that include at least one extruded profile member may exhibit enhanced flexibility, functionality, and/or durability. Structural systems according to embodiments of the present invention can be suitable for use in a variety of applications, including in ready-to-assemble furniture or cabinetry applications or as building and construction materials such as wall board, flooring, trim, and the like.
Description
- This application is a divisional of U.S. patent application Ser. No. 14/496,529, filed on Sep. 25, 2014, which claims the benefit of U.S. Patent Provisional Application No. 61/892,599, filed on Oct. 18, 2013, the disclosures of which are incorporated herein by reference in their entirety.
- This invention relates to structural systems. In particular, the present invention relates to structural systems useful as furniture and in other applications, as well as methods of making and using the same.
- Ready-to-assemble items, such as furniture, shelving, and even construction-related materials, are widely used by consumers in a number of different applications. Although such items are generally more convenient than traditional items to manufacture, ship, store, and construct, conventional ready-to-assemble structures have room for improvement, both in terms of functionality and aesthetics. Further, many ready-to-assemble structures lack strength and durability and, oftentimes, have a limited usable life, especially when exposed to heavy use, rough service, and/or repeated assembly and disassembly. One proposed method of enhancing the strength, durability, and/or aesthetics of a ready-to-assemble structure is to apply a coating material to each of the components of the system. Unfortunately, many coating materials used in such applications exhibit poor adhesion to the underlying substrate and/or fail to exhibit a desirable final appearance, resulting in an overall low-quality product. Other coatings are difficult to apply or can only be applied to relatively simple substrates having planar surfaces without cuts 23,
- grooves, channels, or other complex geometries or geometric features, greatly limiting the design and functionality of the resulting system.
- Thus, a need exists for improved structural systems with greater durability, enhanced functionality, and a higher aesthetic value that are also simple to manufacture, ship, assemble, and use. Preferably, such structures would also be capable of being produced both conveniently and inexpensively, while still providing final products having a high level of quality.
- One embodiment of the present invention concerns an extrusion-coated structural system comprising: an extrusion-coated structural member comprising at least one substrate and a coating material extrusion coated onto at least a portion of the substrate, wherein the extrusion-coated structural member further comprises an extruded profile member formed of the coating material, wherein the extruded profile member extends outwardly from the substrate for a maximum distance that is at least two times greater than the average thickness of the coating material coated onto the substrate adjacent the extruded profile member.
- Another embodiment of the present invention concerns a method of making an extrusion-coated structural system, the method comprising extrusion coating a coating material onto at least a portion of a substrate to form an extrusion-coated structural member, wherein the extrusion coating forms at least one extruded profile member extending outwardly from the substrate for a maximum distance that is at least two times greater than the average thickness of the coating material coated onto the substrate proximate the extruded profile member.
- Yet another embodiment of the present invention concerns a method for assembling an extrusion-coated structural system, the method comprising the following steps: (a) providing a first extrusion-coated structural member comprising a substrate and a coating material extrusion coated onto at least a portion of the substrate, wherein the first extrusion-coated structural member comprises an extruded profile member formed of the coating material, wherein the extruded profile member extends outwardly from the substrate for a maximum distance that is at least two times greater than the average thickness of the coating material proximate the extruded profile member; (b) providing a second structural element presenting a contact surface; and (c) contacting at least a portion of the extruded profile member with the contact surface of the second structural element to form at least a portion of the structural system.
- Various embodiments of the present invention are described in detail below with reference to the attached drawing figures, wherein:
-
FIG. 1 is a schematic cross-sectional view of one embodiment of an extrusion-coated structural member having a reinforced region; -
FIG. 2 is a side perspective view of another embodiment of an extrusion-coated structural member having a reinforced region; -
FIG. 3 is a schematic cross-sectional view of another embodiment of the extrusion-coated structural member shown inFIG. 1 ; -
FIG. 4 is a side perspective view of one embodiment of an extrusion-coated structural system including at least one extrusion-coated structural member with a reinforced region; -
FIG. 5 is a side perspective view of another embodiment of an extrusion-coated structural system including at least one extrusion-coated structural member with a reinforced region; -
FIG. 6 is a side perspective view of yet another embodiment of an extrusion-coated structural system including at least one extrusion-coated structural member with a reinforced region; -
FIG. 7 is a side perspective view of one embodiment of an extrusion-coated structural system including multiple extrusion-coated structural members coupled to one another by a plurality of hardware members; -
FIG. 8 is a side perspective view of another embodiment of an extrusion-coated structural system including multiple extrusion-coated structural members coupled by a plurality of hardware members; -
FIG. 9 is a side perspective view of one embodiment of an extrusion-coated structural system including at least one extrusion-coated structural member having a structural recess and a hardware protrusion; -
FIG. 10 is another side perspective view of the extrusion-coated structural system depicted inFIG. 9 ; -
FIG. 11 is a schematic cross-section of the extrusion-coated structural system depicted inFIGS. 9 and 10 ; -
FIG. 12 is a partial perspective view of an extrusion-coated structural system configured according to one embodiment of the present invention, particularly illustrating an integrated hinge; -
FIG. 13 is a partial front perspective view of an extrusion-coated structural system configured according to another embodiment of the present invention, particularly illustrating an integrated drawer roller; -
FIG. 14 is the a partial rear perspective view of the extrusion-coated structural system depicted inFIG. 13 ; -
FIG. 15 is a side perspective view of an extrusion-coated structural system configured according to still another embodiment of the present invention, particularly illustrating an integrated shelf support in a unlocked configuration; -
FIG. 16 is another side perspective view of the extrusion-coated structural system depicted inFIG. 15 , with the extrusion-coated structural member in a locked configuration; -
FIG. 17 is a side perspective view of an extrusion-coated structural system configured according to still another embodiment of the present invention, particularly illustrating an integrated hinge; -
FIG. 18 is a side perspective view of the extrusion-coated structural system illustrated inFIG. 17 ; -
FIG. 19 is a magnified schematic cross-sectional view of the connecting region between the hardware protrusion and structural recess of the extrusion-coated structural system shown inFIGS. 17 and 18 ; -
FIG. 20 is a side view of another embodiment of an extrusion-coated structural system including an integrated hinge; -
FIG. 21 is a magnified schematic cross-sectional view of the connecting region between the hardware recess and structural protrusion of the extrusion-coated structural system shown inFIG. 20 ; -
FIG. 22 is a side perspective view of one embodiment of extrusion-coated structural system comprising a pair of extrusion-coated structural members; -
FIG. 23 is a schematic cross-sectional view of the extrusion-coated structural system depicted inFIG. 22 ; -
FIG. 24 is a side perspective view of one embodiment of an extrusion-coated structural system comprising a plurality of snap-on panels having both a protrusion and a recess; -
FIG. 25 is a side perspective view of another embodiment of an extrusion-coated structural system, arranged in a disassembled configuration; -
FIG. 26 is a side perspective view of the extrusion-coated structural system depicted inFIG. 25 , with the panels arranged in an assembled configuration; -
FIG. 27 is a side perspective view of another embodiment of an extrusion-coated structural system, arranged in a disassembled configuration; -
FIG. 28 is a side perspective view of the extrusion-coated structural system depicted inFIG. 27 , arranged in an assembled configuration; -
FIG. 29 is a side perspective view of another embodiment of an extrusion-coated structural system, arranged in a disassembled configuration; -
FIG. 30 is a side perspective view of the extrusion-coated structural system depicted inFIG. 29 , arranged in an assembled configuration; -
FIG. 31 is a side perspective view of one embodiment of an extrusion-coated structural member having an extruded profile member; -
FIG. 32 is a schematic cross-sectional view of the extrusion-coated structural member depicted inFIG. 31 ; -
FIG. 33 is a bottom perspective view of another embodiment of an extrusion-coated structural system having an extruded profile member; -
FIG. 34 is side perspective view of the extrusion-coated structural system depicted inFIG. 33 ; -
FIG. 35 is an end perspective view of one embodiment of an extrusion-coated structural system having an extrusion-coated structural member including a functional or aesthetic element; -
FIG. 36 is a side perspective view of the extrusion-coated structural system depicted inFIG. 35 ; -
FIG. 37 is a side perspective view of one embodiment of an extrusion-coated structural system having a bridging member; -
FIG. 38 is a break-away perspective view of the extrusion-coated structural system shown inFIG. 37 ; -
FIG. 39 is side perspective view of another embodiment of an extrusion-coated structural system comprising a bridging member, arranged in a flat configuration; -
FIG. 40 is a side perspective view of the extrusion-coated structural system depicted inFIG. 39 , arranged in a folded configuration; -
FIG. 41 is a side perspective view of the extrusion-coated structural system depicted inFIGS. 39 and 40 , arranged in another folded configuration; -
FIG. 42 is side perspective view of yet another embodiment of an extrusion-coated structural system comprising a bridging member, arranged in a flat configuration; -
FIG. 43 is a side perspective view of the extrusion-coated structural system depicted inFIG. 42 , arranged in a folded configuration; -
FIG. 44 is a side perspective view of the extrusion-coated structural system depicted inFIGS. 42 and 43 , also including a securing member; -
FIG. 45 is a side perspective view of one embodiment of an extrusion-coated structural system, arranged in a flat configuration; -
FIG. 46 is a side perspective view of the extrusion-coated structural system shown inFIG. 45 , arranged in a folded configuration; -
FIG. 47 is a top perspective view of another embodiment of an extrusion-coated structural system, arranged in a flat configuration; -
FIG. 48 is a side perspective view of the extrusion-coated structural system shown inFIG. 47 ; -
FIG. 49 is a side perspective view of the extrusion-coated structural system shown inFIGS. 47 and 48 , arranged in a folded configuration; -
FIG. 50 is a side perspective view of yet another embodiment of an extrusion-coated structural system, arranged in a flat configuration; -
FIG. 51 is a side perspective view of the extrusion-coated structural system shown inFIG. 50 , arranged in a folded configuration; -
FIG. 52 is a side perspective view of still another embodiment of an extrusion-coated structural system, arranged in a compressed configuration; -
FIG. 53 is a side perspective view of the extrusion-coated structural system shown inFIG. 52 , arranged in an extended configuration; -
FIG. 54 is a side perspective view of a further embodiment of an extrusion-coated structural system, arranged in a flat configuration; -
FIG. 55 is a side perspective view of the extrusion-coated structural system shown inFIG. 54 , arranged in an a folded configuration; -
FIG. 56 is a side perspective view of the extrusion-coated structural system shown inFIGS. 54 and 55 , arranged in an another folded configuration; -
FIG. 57 is a side perspective view of another embodiment of an extrusion-coated structural system, arranged in a flat configuration; -
FIG. 58 is a side perspective view of the extrusion-coated structural system shown inFIG. 57 , arranged in an a folded configuration; -
FIG. 59 is a side perspective view of the extrusion-coated structural system shown inFIGS. 57 and 58 , arranged in an another folded configuration; -
FIG. 60 is a schematic diagram of the major steps in a process for making an extrusion-coated structural member according to one embodiment of the present invention; -
FIG. 61 is a side perspective view of one embodiment of an extrusion-coated structural system comprising a pair of extrusion-coated structural members; -
FIG. 62 is a schematic cross-sectional view of the extrusion-coated structural system depicted inFIG. 61 ; -
FIG. 63 is a schematic cross-sectional view of the substrate components of the extrusion-coated structural members depicted inFIGS. 61 and 62 , depicted without coating material; -
FIG. 64 is a schematic cross-sectional view of one embodiment of a substrate subjected to strength testing as described in Example 3; and -
FIG. 65a is a side view of the flush configuration used to strength test a substrate as described in Example 3; -
FIG. 65b is a side view of the half configuration used to strength test a substrate as described in Example 3; and -
FIG. 65c is a side view of the outer configuration used to strength test a substrate as described in Example 3. - In one aspect, the present invention relates to extrusion-coated structural member and structural systems employing such structural members, as well as methods for making and using the same. Extrusion-coated structural systems configured according to embodiments of the present invention, can be more durable, easier to assemble, and provide enhanced aesthetic appearance over similar, conventionally-made articles. Additionally, structural systems of the present invention may be easier and/or less expensive to manufacture and/or ship, making these systems beneficial both for manufacturers and end users. Structural systems according to the present invention may be used in a variety of interior and exterior applications including, for example, as components of furniture or cabinetry, or as building materials such as flooring, wall covering, trim, molding, and the like.
- In one embodiment, the extrusion-coated structural system can include at least one extrusion-coated structural member comprising at least one substrate and a coating material extrusion coated onto at least a portion of the substrate. As used herein, the term “extrusion coated” refers to a substrate which has been coated, or at least partially coated, with a coating material via an extrusion coating process. Extrusion coating can also include forming at least one extruded profile member spaced apart and extending outwardly from the substrate. Specific embodiments of extrusion-coated structural members including extruded profile members will be discussed in detail shortly. The coating material applied via extrusion coating may comprise a resin and can be applied under pressure and/or at an elevated temperature, although neither is required. In some embodiments, the coating material applied via extrusion coating may comprise at least one thermosetting and/or thermoplastic resin, optionally in combination with additional components. Examples of suitable coating materials and types of substrates suitable for use in the extrusion-coated structural systems of the present invention will be discussed in detail shortly.
- In one embodiment, the extrusion-coated structural system can include at least one extrusion-coated structural member having a reinforced region. As used herein, the term “reinforced region” refers to an area of a structural member having increased strength and/or flexibility as compared to another area of the structural member. In one embodiment, the reinforced region or regions of the structural member may include a coating material applied with a greater thickness than the coating material applied to other regions of the substrate. For example, in one embodiment, the average thickness of the coating material applied to the reinforced region of the structural member can be at least about 2, at least about 3, at least about 4, at least about 5, at least about 10 times greater than the average thickness of the coating material applied to the remainder of the structural member. In some cases, the average thickness of the coating material in the reinforced region may be at least about 2, at least about 3, at least about 4, at least about 5, or at least about 10 times greater than the average thickness of the coating material applied to the substrate proximate the reinforced region. Additionally, or in the alternative, the maximum thickness of the coating material applied to the reinforced region may be at least about 2, at least about 3, at least about 5, at least about 10 times greater than the maximum thickness of the coating material applied to the remainder of the substrate and/or the average thickness of the coating material applied to the substrate proximate the reinforced region. The coating material applied to the reinforced region may be the same as, or different than, the coating material applied to the rest of the structural member.
- Turning now to
FIGS. 1-3 , several embodiments of extrusion-coated structural members including at least one reinforced region are provided. Turning first toFIG. 1 , one embodiment of an extrusion-coatedstructural member 10 that includes at least one reinforcedregion 12 is shown. As shown inFIG. 1 ,structural member 10 comprises at least onesubstrate 14 and acoating material 16 coated onto at least a portion ofsubstrate 14. Preferably, coatingmaterial 16 has been extrusion coated ontosubstrate 14. Reinforcedregion 12 ofstructural member 10 is shown as including at least onestructural recess 18 extending inwardly from anouter surface 20 a ofsubstrate 14. Acoating material 22 extrusion can have been extrusion coated onto at least a portion ofstructural recess 18 or, alternatively, the coating may have been applied in another manner, such as, for example, via brushing, spraying, and/or dipping.Coating material 22 can be the same as, or different than, coatingmaterial 16 coated onto the outer surfaces 20 a-d ofsubstrate 14. - The average thickness of
coating material 22, measured from theupper surface 26 ofcoating material 22 to the bottom 28 ofrecess 18, may be greater than the average thickness ofcoating material 16 applied to a near-recessexternal surface 24 ofsubstrate 14. For example, in one embodiment, the average thickness ofcoating material 22 withinstructural recess 18 can be at least about 1.5, at least about 2, at least about 5 times thicker than the average thickness ofcoating material 16 applied to near-recessexternal surface 24. Additionally, the maximum thickness ofcoating material 22 withinstructural recess 18 can be at least about 2, at least about 3, at least about 5, at least about 10 times and/or not more than about 100, not more than about 50, not more than about 25, not more than about 15 times greater than the maximum thickness ofcoating material 16 applied to near-recessexternal surface 24 and/or than the average thickness ofcoating material 16 applied to the at least a portion of surfaces 20 a-d ofsubstrate 14. - In one embodiment, the maximum thickness of
coating material 22 withinstructural recess 18 can be in the range of from about 1.5 to about 100, about 1.5 to about 50, about 1.5 to about 25, about 1.5 to about 15, about 2 to about 100, about 2 to about 50, about 2 to about 25, about 2 to about 15, about 3 to about 100, about 3 to about 50, about 3 to about 25, about 3 to about 15, about 5 to about 100, about 5 to about 50, about 5 to about 25, about 5 to about 15, about 10 to about 100, about 10 to about 50, about 10 to about 25, about 10 to about 15 times greater than the maximum thickness ofcoating material 16 applied to near-recessexternal surface 24 and/or than the average thickness ofcoating material 16 applied to the at least a portion of surfaces 20 a-d ofsubstrate 14. - The average thickness of
coating material 16 coated onto surfaces 20 a-d and/or near-recessexternal surface 24 ofsubstrate 14 can be at least about 0.001, at least about 0.005, at least about 0.010 inches and/or not more than about 0.025, not more than about 0.020, not more than about 0.015 inches, or in the range of from about 0.001 to about 0.025 inches, about 0.001 to about 0.020 inches, about 0.001 to about 0.015 inches, about 0.005 to about 0.025 inches, about 0.005 to about 0.020 inches, about 0.025 to about 0.015 inches, about 0.010 to about 0.025 inches, about 0.010 to about 0.020 inches, about 0.010 to about 0.015 inches. The average thickness ofcoating material 22 disposed withinrecess 18 can be at least about 0.001 inches, at least about 0.005 inches, at least about 0.01 inches, at least about 0.02 inches and/or not more than about 0.50 inches, not more than about 0.25 inches, not more than about 0.10 inches, not more than about 0.05 inches, depending on the specific configuration of the structural member. The average thickness of average thickness ofcoating material 22 disposed withinrecess 18 can be in the range of from about 0.001 to about 0.50 inches, about 0.001 to about 0.25 inches, about 0.001 to about 0.10 inches, about 0.001 to about 0.05 inches, about 0.005 to about 0.50 inches, about 0.005 to about 0.25 inches, about 0.005 to about 0.10 inches, about 0.005 to about 0.05 inches, about 0.01 to about 0.50 inches, about 0.01 to about 0.25 inches, about 0.01 to about 0.10 inches, about 0.01 to about 0.05 inches, about 0.02 to about 0.50 inches, about 0.02 to about 0.25 inches, about 0.02 to about 0.10 inches, about 0.02 to about 0.05 inches. - In one embodiment,
structural recess 18 can be at least partially, or entirely, filled withcoating material 22. For example, in one embodiment, at least about 40 percent, at least about 50 percent, at least about 60 percent, at least about 75 percent, at least about 80 percent, or at least about 90 percent of at least one lateral cross-section ofstructural recess 18 can be filled withcoating material 22. In the same or another embodiment, at least about 40 percent, at least about 50 percent, at least about 60 percent, at least about 75 percent, at least about 80 percent, or at least about 90 percent, at least about 95 percent of the total volume ofstructural recess 18 can be filled withcoating material 22. In one embodiment, coatingmaterial 22 can fillstructural recess 18 beyond the inlet ofstructural recess 18 defined bysubstrate 14, such that theuppermost surface 26 ofcoating material 22 applied tostructural recess 18 can be continuous withcoating material 16 coated onto near-recessexternal surface 24, as shown in the embodiments depicted inFIGS. 1-3 . - Extrusion-coated
structural member 10 can include any suitable number ofstructural recesses 18. In one embodiment depicted inFIG. 1 , extrusion-coatedstructural member 10 can include a singlestructural recess 18, while in another embodiment, examples of which are shown inFIGS. 2 and 3 , extrusion-coatedstructural member 10 can include a plurality ofstructural recess 18 extending from one or more outer surfaces 20 ofsubstrate 14. In one embodiment,structural member 10 can include at least 2, at least 4, at least 5 and/or not more than 20, not more than 15, not more than 10 recesses, or can include about 2 to about 20, about 4 to about 15, or about 5 to about 10 recesses extending from one or more surfaces 20 ofsubstrate 14. Whensubstrate 14 includes more than onerecess 18, the structural recesses may have the same size, shape, and/or be coated with the same type of coating material, or at least one of the size, shape, and/or coating material applied to one or more ofstructural recesses 18 may be different than the size, shape, and/or coating material applied to one or more of the other ofstructural recesses 18. - When
structural member 10 includes more than one structural recess, all or a portion of the recesses may extend from the same surface and/or one or more recesses may extend from a different surface than one or more other recesses. When one or more recesses extend from different surfaces, the surfaces may be adjacent surfaces, such as, for example, surfaces 20 a and 20 b inFIG. 3 . Alternative, the different surfaces from which the recesses extend may be opposite surfaces, such as, for example, surfaces 20 a and 20 c shown inFIG. 2 . When at least a portion of the recesses extend from opposite surfaces, the recesses can be arranged in a staggered configuration, as shown inFIG. 2 , or at least a portion of therecesses 18 can be directly opposed from one another. The spacing between adjacentstructural recesses 18 extending from a single surface 20 a-d can be at least about 5 percent, at least about 10 percent, at least about 20 percent and/or not more than 50 percent, not more than about 40 percent, not more than about 30 percent of the total length of the surface 20 a-d from which therecesses 18 extend. The spacing between adjacentstructural recesses 18 extending from a single surface 20 a-d can be in the range of from about 5 to about 50 percent, about 5 to about 40 percent, about 5 to about 30 percent, about 10 to about 50 percent, about 10 to about 40 percent, about 10 to about 30 percent, about 20 to about 50 percent, about 20 to about 40 percent, about 20 to about 30 percent. - In one embodiment, the ratio of the depth (dr) of
structural recess 18 to the dimension ofsubstrate 14 parallel to the depth ofstructural recess 18 can be at least about 0.10:1, at least about 0.25:1, at least about 0.50:1 and/or not more than about 0.99:1, not more than about 0.90:1, not more than about 0.85:1, or in the range of from about 0.10:1 to about 0.99:1, about 0.10:1 to about 0.90:1, about 0.10:1 to about 0.85:1, about 0.25:1 to about 0.99:1, about 0.25:1 to about 0.90:1, about 0.25:1 to about 0.85:1, about 0.50:1 to about 0.99:1, about 0.50:1 to about 0.90:1, about 0.50:1 to about 0.85:1. As used herein, the “depth” of a structural recess is defined as the distance that the structural recess extends into the substrate. For example, as shown in the embodiment depicted inFIG. 1 , whenstructural recess 18 of extrusion-coatedstructural member 10 extends inwardly fromsurface 20 a, which defines the thickness (T) or shortest dimension ofsubstrate 14, the depth (dr) ofstructural recess 18 is parallel tosurfaces FIG. 1 as defining the width (W), or second longest dimension, of thesubstrate 14. Thus, in this embodiment, the ratio of the depth (dr) ofstructural recess 18 to the width ofsubstrate 14 can fall within the ranges described above. - Alternatively, according to another embodiment depicted in
FIG. 2 , ifstructural recess 18 extends from asurface 20 a that defines the width (W) ofsubstrate 14, the depth (dr) of thestructural recess 18 is parallel to the thickness (T) ofsubstrate 14. Thus, in this embodiment, the ratio of the depth (dr) ofstructural recess 18 to the thickness ofsubstrate 14 may fall within one or more ranges described above. In further embodiments (not shown inFIGS. 1 and 2 ), the structural recess of the structural member may extend through the entire width or thickness of the structural member such that the ratio of the depth of the recess to the dimension of the substrate parallel to the depth of the structural recess can be about 1:1. - Similarly, the “width” of the structural recess (wr) refers to the dimension of the structural recess parallel to the surface from which the structural recess extends. For example, as shown in the embodiment in
FIG. 1 , if thestructural recess 18 extends from anouter surface 20 a ofsubstrate 14 that defines the thickness (T) ofsubstrate 14, the width (wr) ofstructural recess 18 may be parallel to the thickness (T) ofsubstrate 14. Alternatively, as shown in the embodiment depicted inFIG. 2 , if thestructural recess 18 extends from anouter surface 20 a ofsubstrate 14 that defines the width (W) ofsubstrate 14, the width (wr) ofstructural recess 18 can be parallel to the width (W) ofsubstrate 14. The ratio of the width of the structural recess to the dimension of the substrate parallel to the width of the structural recess can be at least about 0.005:1, at least about 0.010:1, at least about 0.025:1 and/or not more than about 0.2:1, not more than about 0.10:1, not more than about 0.05:1, or ratio of the width of the structural recess to the dimension of the substrate parallel to the width of the structural recess can be in the range of from about 0.005:1 to about 0.2:1, about 0.005:1 to about 0.1:1, about 0.005:1 to about 0.05:1, about 0.010:1 to about 0.2:1, about 0.010:1 to about 0.1:1, about 0.010:1 to about 0.05:1, about 0.025:1 to about 0.2:1, about 0.025:1 to about 0.1:1, about 0.025:1 to about 0.05:1. - In one embodiment, the width and/or depth of the structural recess can be substantially constant, while, in another embodiment, one or both recess dimensions may change along the length of the recess. According to one embodiment, the ratio of the maximum width of the structural recess (wr) to its maximum depth (dr) can be at least about 0.001:1, at least about 0.01:1, at least about 0.05:1, at least about 0.10:1, at least about 0.50:1, at least about 1:1 and/or not more than about 5:1, not more than about 4:1, not more than about 2:1, not more than about 1:1, not more than about 0.50:1, not more than about 0.25:1, not more than about 0.10:1.
- The ratio of the maximum width of the structural recess (wr) to its maximum depth (dr) can be in the range of from about 0.001:1 to about 5:1, about 0.001:1 to about 4:1, about 0.001:1 to about 2:1, about 0.001:1 to about 1:1, about 0.001:1 to about 0.5:1, about 0.001:1 to about 0.25:1, about 0.001:1 to about 0.10:1, about 0.01:1 to about 5:1, about 0.01:1 to about 4:1, about 0.01:1 to about 2:1, about 0.01:1 to about 1:1, about 0.01:1 to about 0.5:1, about 0.01:1 to about 0.25:1, about 0.01:1 to about 0.10:1, about 0.05:1 to about 5:1, about 0.05:1 to about 4:1, about 0.05:1 to about 2:1, about 0.05:1 to about 1:1, about 0.05:1 to about 0.5:1, about 0.05:1 to about 0.25:1, about 0.05:1 to about 0.10:1, about 0.1:1 to about 5:1, about 0.1:1 to about 4:1, about 0.1:1 to about 2:1, about 0.1:1 to about 1:1, about 0.1:1 to about 0.5:1, about 0.1:1 to about 0.25:1, about 0.5:1 to about 5:1, about 0.5:1 to about 4:1, about 0.5:1 to about 2:1, about 0.5:1 to about 1:1, about 1:1 to about 5:1, about 1:1 to about 4:1, about 1:1 to about 2:1.
- The structural recess may extend along at least a portion of the length, or longest dimension, of the structural member. In one embodiment, the structural recess may be an elongated recess and can extend along a portion of the length of the structural member such that the ratio of the length of the structural recess (not shown in
FIGS. 1 and 2 ) to the length of the structural member (L) can be at least 0.50:1, at least about 0.60:1, at least about 0.75:1, at least about 0.85:1, at least about 0.90:1 and/or not more than about 1:1, not more than about 0.95:1, not more than about 0.90:1. The structural recess may extend along at least about 50 percent, at least about 60 percent, at least about 70 percent, at least about 80 percent, or at least about 90 percent of the total length of the substrate. - The ratio of the length of the structural recess to the length of the structural member (L) can be in the range of from about 0.50:1 to about 1:1, about 0.50:1 to about 0.95:1, about 0.50:1 to about 0.90:1, about 0.60:1 to about 1:1, about 0.60:1 to about 0.95:1, about 0.60:1 to about 0.90:1, about 0.75:1 to about 1:1, about 0.75:1 to about 0.95:1, about 0.75:1 to about 0.90:1, about 0.85:1 to about 1:1, about 0.85:1 to about 0.95:1, about 0.85:1 to about 0.90:1, about 0.90:1 to about 1:1, about 0.90:1 to about 0.95:1.
- In another embodiment, the structural recess may not be an elongated slot and can be, for example, a shortened slot or a hole. According to this embodiment, the ratio of the length of the structural recess to the length of the structural member can be not more than about 0.50:1, not more than about 0.40:1, not more than about 0.30:1, not more than about 0.20:1, not more than about 0.10:1. The structural recess may extend along not more than about 50 percent, not more than about 40 percent, not more than about 30 percent, not more than about 20 percent, not more than about 10 percent of the total length of the substrate. Additionally, the ratio of the length of the structural recess to its maximum width can be at least about 0.25:1, at least about 0.50:1, at least about 0.75:1 and/or not more than about 1.5:1, not more than about 1.1:1, not more than about 0.90:1, or in the range of from about 0.25:1 to about 1.5:1, about 0.25:1, to about 1.1:1, about 0.25:1 to about 0.90:1, about 0.50:1 to about 1.5:1, about 0.50:1, to about 1.1:1, about 0.50:1 to about 0.90:1, about 0.75:1 to about 1.5:1, about 0.75:1, to about 1.1:1, about 0.75:1 to about 0.90:1.
- Although shown in
FIGS. 1-3 as being formed within a single substrate, the structural recess may also be collectively defined by two or more substrates positioned proximate one another. The structural recess can have any suitable cross-sectional shape, such as, for example, a square shape, a rectangular shape, a semi-circular shape, a triangular shape, or other polygonal shape. - Extrusion-coated structural systems configured according to the present invention can include one or more extrusion-coated
structural members 10 as described above. For example, in one embodiment depicted inFIG. 4 , extrusion-coatedstructural system 110 can include a pair of extrusion-coatedstructural members 112 a,b, which each include asubstrate 114 a,b and acoating material 116 a,b extrusion coated onto at least a portion ofsubstrate 114 a,b. As shown in the embodiment inFIG. 4 , each ofstructural members region structural members 112 a,b are joined. In another embodiment (not shown), only one ofsubstrates regions 113 a,b include one or a plurality ofstructural recesses 118 extending inwardly from at least onesurface substrates 114 a,b.Structural recesses 118 may be coated with a coating material having a thickness greater than the coating material coated ontosubstrate 114 a,bproximate recesses 118 and/or may be further configured according to one or more embodiments described previously with respect toFIGS. 1-3 . - Extrusion-coated structural systems configured according to embodiments of the present invention may also include one or more additional components such as, for example, one or more hardware components. Turning now to
FIGS. 5-7 , several examples of extrusion-coated structural systems that include at least one extrusion-coated structural member and at least one hardware component are provided. Referring first toFIG. 5 , an extrusion-coatedstructural member 150 is illustrated as generally comprising asubstrate 152 and acoating material 154 extrusion-coated on to at least a portion ofsubstrate 152. In the embodiment shown inFIG. 5 ,coating material 154 has been applied to at least about 90 percent, at least about 95 percent, at least about 99 percent, or all of the outer surfaces 170 a-d ofsubstrate 152. - Additionally, extrusion-coated
structural member 150 comprises astructural recess 156 extending inwardly fromouter surface 170 a ofsubstrate 152 and at least one near-recessexternal surface proximate recess 156.Structural recess 156 is at least partially coated with a coating material, which can be the same as or different than,coating material 154 applied to one or both of near-recessexternal surfaces 158 a,b. In the embodiment shown inFIG. 5 , the coating material is continuous with at least a portion ofcoating material 154 applied to near-recessexternal surfaces 158 a and/or 158 b. - As depicted in the embodiment shown in
FIG. 5 ,structural recess 156 ofstructural member 150 is an elongated recess having a cross-sectional shape that remains substantially constant along its length.Structural recess 156 can include abroad portion 160 and anarrow portion 162, withnarrow portion 162 being closer to near-recess external surface 158.Structural recess 156 also presents arecess attachment surface 166, which can be at least partially defined by coating material.Recess attachment surface 166, which extends generally between near-recessexternal surfaces 158 a,b, can be configured to receive at least a portion of ahardware component 168, illustrated inFIG. 5 as a screw, so that, when inserted intostructural recess 156, at least a portion ofhardware member 168 can be at least partially supported byrecess attachment surface 166. - As used herein, the term “hardware member” refers to any component separate from the structural member used to enhance the functionality, strength, and/or aesthetic characteristics of the structural member or system. Examples of hardware members can include, but are not limited to, screws, bolts, nuts, slides, rollers, handles, pins, and supports. However, in one embodiment, the hardware members included in structural systems of the present invention can also include other substrates, or portions of thereof, such as, for example, boards, shelves, trim, and other similar components. In another embodiment, the hardware member may be defined by one or more other extrusion-coated structural members and/or itself may be an extrusion-coated structural member. When configured for insertion into a structural recess, such as
structural recess 156,hardware member 168 may include at least onehardware protrusion 172.Hardware protrusion 172 can be of any suitable size and/or shape, and may be threaded, as illustrated in the embodiment shown inFIG. 5 . - When
hardware protrusion 172 is inserted intostructural recess 156, at least a portion ofrecess attachment surface 166 may be configuredsupport hardware protrusion 172. As used herein, the term “support” means to restrict or prevent motion in at least one direction.Structural recess 156 ofstructural member 150 may be configured such thathardware protrusion 172 directly contacts at least a portion ofrecess attachment surface 166, orrecess attachment surface 166 can include at least one layer of intervening material (not shown inFIG. 5 ) disposed between at least a portion ofrecess attachment surface 166 andhardware protrusion 172. - When present, the intervening material layer can be made of any suitable material and may comprise one or more materials different than
coating material 154 applied to near-recess external surface 158. The intervening material layer can add functionality to the recess and/or may improve its aesthetic characteristics or durability. In one embodiment, the intervening material layer can be a friction-modifying layer to either enhance or reduce the friction betweenrecess attachment surface 166 andhardware protrusion 172. In one embodiment, the intervening material layer can be a friction enhancing layer capable of increasing the friction betweenrecess attachment surface 166 andhardware protrusion 172 by at least about 5 percent, at least about 10 percent, or at least about 15 percent and may be, for example, a coating material comprising a medium or coarse grit of a layer or sand paper. In another embodiment, the intervening material layer can be a friction-reducing layer configured to reduce the friction betweenrecess attachment surface 166 andhardware protrusion 172 by at least about 5, at least about 10, at least about 15 percent. Suitable materials for inclusion in the friction-reducing intervening layer can include, for example, TEFLON® or other similar materials. - When structural recess is at least partially coated with coating material 159, the withdrawal force required to remove
hardware protrusion 172 fromstructural recess 156 may be higher than if the coating material were not present. For example, in one embodiment, the withdrawal force required to removehardware protrusion 172 fromstructural recess 156, once inserted, may be at least about 300 pounds, at least about 350 pounds, at least about 400 pounds, at least about 450 pounds, at least about 475 pounds, at least about 500 pounds, measured according to ASTM D1037 and as further described in Example 1. In contrast, the withdrawal force required to remove the same hardware component from a similarly-configured but uncoated structural recess may be less than about 300 pounds. Extrusion-coatedstructural member 150 may be useful in furniture or cabinetry applications, for example, wherein increased withdrawal strength may be beneficial to increase the durability of the structural system. - Turning now to
FIG. 6 , another embodiment of an extrusion-coatedstructural system 200 including an extrusion-coatedstructural member 210 is provided. In the embodiment shown inFIG. 6 , the extrusion-coatedstructural member 210 includes asubstrate 212 and acoating material 214 coated onto at least a portion of thesubstrate 212.Substrate 212 is also illustrated as comprising plurality of structural recesses, including anelongated slot 216 and a plurality ofholes 218, each at least partially filled with thecoating material 214. Extrusion-coatedstructural system 210 further includes a plurality of hardware members 220 a-d, shown inFIG. 6 as a plurality of screws, each comprising ahardware protrusion 222 a-d configured for insertion into at least one, or both, ofstructural recesses -
Elongated slot 216 can extend along at least a portion of the length of extrusion-coatedstructural member 210 and, in one embodiment, may present arecess attachment surface 224 that may optionally be threaded. Each ofhardware protrusions 222 a-d of hardware members 220 a-d can be configured for insertion into elongatedslot 216, and, in one embodiment, may be configured for insertion at multiple locations along the length ofelongated slot 216. Additionally, in one embodiment, two or more hardware protrusions, such as, for example,protrusions 222 a,b shown inFIG. 6 , may be configured for simultaneous insertion into elongatedslot 216, such that two ormore hardware protrusions 222 a,b may be at least partially supported byrecess attachment surface 224. Although not shown inFIG. 6 , at least a portion ofrecess attachment surface 224 may include at least one intervening material layer. - Additionally, as shown in the embodiment depicted in
FIG. 6 , extrusion-coatedstructural member 210 can include a plurality ofholes 218 each extending inwardly from an outer surface. As shown inFIG. 6 , at least a portion (or all) ofholes 218 may be at least partially, or entirely, filled withcoating material 214. Thehardware protrusion 222 a-d of each of hardware members 220 a-d may be configured for insertion into one or more ofholes 218 and, as shown inFIG. 6 , two ormore hardware protrusion 222 c,d may be received into separate holes (structural recesses) 218 at the same time. Extrusion-coatedstructural system 210 may be useful in furniture or cabinetry applications when it may be advantageous to adjust the position of the hardware member, such as, for example, in shelving or cabinetry applications. - Turning now to
FIG. 7 , one embodiment of an extrusion-coatedstructural system 250 comprising more than one extrusion-coated structural members 252 a-c and a plurality of hardware members 266 a-d is provided. In the embodiment depicted inFIG. 7 , extrusion-coatedstructural system 250 includes at least three extrusion-coated structural members 252 a-c that each includes a substrate 254 a-c and a coating material 256 a-c extrusion coated onto to at least a portion of each substrate 254 a-c. Each ofsubstrates structural recesses 253 a,b and 255 a,b spaced apart from one another along the width ofsubstrates 254 a,b. In the embodiment shown inFIG. 7 , each ofstructural recesses 253 a,b and 255 a,b comprise elongated slots extending along at least a portion of the length ofsubstrates 254 a,b that are at least partially filled with coating material 256. Each ofslots 253 a,b and 255 a,b present a respectiverecess attachment surface 258 a,b and 260 a,b (260 a not shown) formed of the coating material. Additionally, each ofrecesses 253 a,b and 255 a,b include arecess inlet 257 a,b and 259 a,b (259 a not shown) defined by anouter surface 262 a,b ofsubstrate 254 a,b. Although shown as being uncoated inFIG. 7 ,outer surfaces 262 a,b ofsubstrates 254 a,b may also be at least partially coated withcoating material 256 a,b. - Additionally, as shown in
FIG. 7 ,substrate 254 c includes four structural recesses 262 a-d spaced apart from one another and extending through the entire thickness ofsubstrate 254 c. Each of structural recesses 262 a-d are at least partially coated withcoating material 256 c and may present at least one recess attachment surface 264 a-d defined by coatingmaterial 256 c. Alternatively, structural recesses 262 a-d may be formed in extrusion coatedmember 252 c aftersubstrate 254 c has been extrusion coated and, in that embodiment, structural recesses 262 a-d may not be coated with a coating material. - Extrusion-coated
structural system 250 further comprises four hardware members, shown as screws 266 a-d, each comprising a hardware protrusion 268 a-d, shown inFIG. 7 as being threaded hardware protrusions. As shown inFIG. 7 , each of hardware protrusions 268 a-d of hardware members 266 a-d are configured for insertion intorespective recess inlets 257 a,b and 259 a,b (259 a not shown) via structural recess 262 a-b ofsubstrate 254 c. Once inserted, a portion ofhardware protrusion 268 a, for example, can be at least partially supported byrecess attachment surface 264 a ofstructural recess 262 a andrecess attachment surface 258 a ofelongated recess 253 a ofsubstrate 254 a. Ifstructural recess 262 a is not coated with coating material 256, thehardware protrusion 268 a can be at least partially supported, or in direct contact with, a surface ofstructural recess 262 a. Similarly,hardware protrusions 268 b-d inserted into and through respectivestructural recesses 262 b-d can be received intoinlets 257 b and 259 a (not shown) and 259 b ofelongated recesses 253 b and 255 a,b. Once inserted, a portion ofhardware protrusions 268 b-d may be at least partially supported by respective recess attachment surfaces 264 b-d (or asurface 262 b-d ofstructural recesses 262 b-d if uncoated) and recess attachment surfaces 258 b, 260 a (not shown), and 260 b. - Turning now to
FIG. 8 , another embodiment of an extrusion-coatedstructural system 300 is illustrated as generally comprising a pair of extrusion-coatedstructural members hardware members 316 a,b. As shown inFIG. 8 , each of extrusion-coatedstructural members substrate coating material respective substrates Coating materials FIG. 8 ,substrate 318 comprises a singlestructural recess 326, whilesubstrate 320 comprises twostructural recesses Structural recesses respective inlet 325 a,b and an outlet (not shown) and extend through the entire thicknessrespective substrates Structural recess 330 includes arecess inlet 338 defined on anouter surface 336 ofsubstrate 320. As shown inFIG. 8 ,structural recess 330 is at least partially coated by coatingmaterial 324 and presents arecess attachment surface 332 at least partially formed of the coating material. - Extrusion-coated
structural system 300 further comprises two hardware members, shown inFIG. 8 as abolt 316 a and anut 316 b, configured for insertion into one or more ofstructural recesses structural members FIG. 8 , bolt 316 a, which comprises ahardware protrusion 344, can be configured for insertion into and throughstructural recesses structural recesses hardware protrusion 344. In one embodiment, at least a portion of one or both ofstructural recesses material hardware protrusion 344 may be supported by at least one recess attachment surface (not shown) formed ofcoating material broad portion 334 ofstructural recess 330 viarecess inlet 338 and coupled withhardware protrusion 344 ofbolt 316 a withinstructural recess 330. In this manner, extrusion-coatedstructural members nut 316 b andprotrusion 344 ofbolt 316 a from view withinrecess 330, thereby enhancing the aesthetics of theentire system 300. - When the extrusion-coated structural system of the present invention includes at least one hardware member insertable into a structural recess, at least a portion of the hardware member can be configured for movement within the recess, once inserted. For example, in one embodiment when the recess is an elongated recess, the hardware member, or portion thereof, may be configured to move in said recess in the direction of elongation of said recess. Alternatively, the hardware protrusion may be movable in a direction substantially perpendicular to the direction of elongation of the recess, while, in another embodiment, the hardware member or protrusion may be configured to rotate within the structural recess. The movement of the hardware member within the structural recess may be at least partially inhibited, either by at least one locking mechanism which can selectively restrain the movement of the hardware protrusion within the recess, and/or by the physical dimensions of the hardware protrusion and/or structural recess. Several embodiments of extrusion-coated and hardware integrated systems comprising a movable hardware protrusion are provided in
FIGS. 9-19 . - Turning initially to
FIGS. 9-11 , one embodiment of an extrusion-coatedstructural system 350 is provided. Extrusion-coatedstructural system 350 illustrated inFIGS. 9-11 includes an extrusion-coatedstructural member 352 comprising asubstrate 354 and acoating material 356 extrusion coated to at least a portion ofsubstrate 354.Substrate 354 comprises astructural recess 358, which is at least partially coated withcoating material 356.Structural recess 358 presents arecess attachment surface 360 configured to at least partially support ahardware member 362 whenhardware member 362 is inserted intostructural recess 358. In the embodiment shown inFIGS. 9-11 ,hardware member 362 comprises a hardware protrusion, shown inFIGS. 9-11 as a pair ofmovable plates 364 a,b, disposed in abroad portion 368 ofstructural recess 358. -
Hardware member 362 can further comprises a locking mechanism, shown as bolt orfastener 370, at least partially disposed innarrow portion 372 ofstructural recess 358.Locking mechanism 370 can be a threaded member, as particularly shown inFIG. 11 , and may be configured for rotation to selectively permit and inhibit movement of one or both ofplates 364 a,b withinstructural recess 358. For example, as shown inFIGS. 9 and 10 , rotation of lockingmechanism 370, as indicated byarrow 380, can causeupper plate 364 a ofhardware member 362 to move in a direction generally perpendicular to the direction of extension ofrecess 358, as indicated byarrow 382 inFIG. 9 . Opposite rotation of lockingmechanism 370, indicated by dashedarrow 384 inFIG. 10 , may moveupper plate 364 a in the opposite direction. - Turning now to
FIG. 12 , another embodiment of an extrusion-coated structural system 400 is illustrated as generally comprising an extrusion-coatedstructural member 412 and ahardware member 420. Extrusion-coatedstructural member 412 comprises asubstrate 414 and acoating material 416 extrusion coated onto at least a portion ofsubstrate 414.Structural member 412 comprises at least onestructural recess 418, which is at least partially coated withcoating material 416, which presents arecess attachment surface 422 withinstructural recess 418. In one embodiment depicted inFIG. 12 , at least a portion ofrecess attachment surface 422 may be formed by a portion of at least oneextruded profile member 424 formed ofcoating material 416 and extending outwardly fromsubstrate 414. Additional embodiments of extrusion-coated structural members including extruded profile members will be discussed in detail shortly. -
Hardware member 420, illustrated inFIG. 12 as comprising a hinge, may be fastened to a secondstructural member 421, which may optionally be another extrusion-coated structural member.Hardware member 420 can comprise ahardware protrusion 428 having anarrow portion 430 and abroad portion 432. During assembly,broad portion 432 ofhardware member 420 may be inserted intobroad section 436 ofstructural recess 418 whilenarrow portion 430 ofhardware member 420 can be inserted intonarrow section 434 ofrecess 418, such thathardware protrusion 428 may be at least partially supported by a portion ofrecess attachment surface 422, which may optionally include at least one intervening material layer disposed therein. Additionally, once inserted,hardware protrusion 428 may be configured for movement withinrecess 418 and, more particularly, may be configured for rotation withinrecess 418. Whenbroad portion 432 ofhardware protrusion 428 is wider thannarrow section 434 ofstructural recess 418, as shown inFIG. 12 , removal of hardware protrusion, once received instructural recess 418, is inhibited in at least one direction. In one embodiment, extrusion-coated structural system 400 may be a cabinet,structural member 421 may be a cabinet box or support, and extrusion-coatedstructural member 412 can be a cabinet door. - Another extrusion-coated
structural system 450 configured according to one embodiment of the present invention is illustrated as generally comprising an extrusion-coatedstructural member 452 and at least onehardware member 460. Extrusion-coatedstructural member 452, shown inFIGS. 13 and 14 , as being a portion of a drawer or door, comprises asubstrate 454 and acoating material 456 extrusion-coated onto at least a portion ofsubstrate 454.Substrate 454 comprises astructural recess 458, illustrated inFIGS. 13 and 14 as an elongated recess that extends along at least a portion of the length ofsubstrate 454. - In one embodiment,
coating material 456 may also be applied to at least a portion ofstructural recess 458, thereby forming arecess attachment surface 464 from the coating material.Recess attachment surface 464 can be configured to at least partially support ahardware protrusion 462 of at least one hardware member, shown inFIGS. 13 and 14 as aroller 460, whenhardware protrusion 462 is inserted intostructural recess 458. As shown inFIGS. 13 and 14 , when inserted intostructural recess 458, at least a portion of hardware protrusion may directly contact at least a portion ofrecess attachment surface 464. Alternatively, at least a portion ofrecess attachment surface 464 may be coated with at least one intervening material layer such thathardware protrusion 462 may be in contact with the intervening layer when inserted intorecess 458. When present, the intervening layer may be coated onto only a portion ofstructural recess 458 and, whenrecess 458 includes an elongated recess, for example, the partial intervening layer may be disposed at either terminal end ofrecess 458. - As illustrated in
FIGS. 13 and 14 ,structural recess 458 can include abroad section 466 and anarrow section 468 configured to receive abroad portion 470 and anarrow portion 472 ofhardware protrusion 462. When inserted instructural recess 458,hardware protrusion 462 may be movable withinstructural recess 458 in a direction substantially parallel to the direction of extension ofrecess 458. The movement ofhardware protrusion member 462 withinstructural recess 458 may be at least partially restrained by the physical dimensions ofhardware protrusion 472 and/orhardware recess 458. In one embodiment, extrusion-coatedstructural system 450 may include multiple rollers, each having at least one hardware protrusion configured for simultaneous receipt intostructural recess 458. - Turning now to
FIGS. 15 and 16 , another extrusion-coatedstructural system 500 configured according to embodiments of the present invention is provided. Extrusion-coatedstructural system 500 comprises an extrusion-coatedstructural member 512 and at least onehardware member 520. Extrusion-coatedstructural member 512 comprises twosubstrates 514 a,b and acoating material 516 extrusion-coated onto at least a portion ofsubstrates 514 a,b shown inFIGS. 15 and 16 . Extrusion-coatedstructural system 500 further comprises a bridgingmember 515 formed ofcoating material 516 and extending fromsubstrate 514 a to 514 b in order tocoupling substrates 514 a,b to one another. As shown inFIGS. 15 and 16 , bridgingmember 515 is configured to permit movement ofsubstrates decoupling substrates - As shown in
FIGS. 15 and 16 , the extrusion-coatedstructural member 512 comprises astructural recess 518 collectively defined bysubstrates 514 a,b.Structural recess 518 is an elongated recess at least partially coated withcoating material 516.Structural recess 518 presents arecess attachment surface 524 configured to at least partially support at least a portion ofhardware member 520, shown as a shelf support pin inFIGS. 15 and 16 , whenhardware member 520 is inserted intostructural recess 518. Thebroad portion 526 ofhardware member 520 can be configured for receipt into thebroad section 528 ofstructural recess 518, while thenarrow portion 530 ofhardware member 520 may be configured for receipt into anarrow section 532 ofstructural recess 518. - Once inserted into
structural recess 518,hardware member 520 may be movable withinrecess 518 in a direction substantially parallel to the direction of extension ofrecess 518. In one embodiment,structural member 512 can be shiftable between a locked position and an unlocked position by pivoting at least one ofsubstrates 514 a,b relative to the other via bridgingmember 515. Whenstructural member 512 is in an unlocked position, as shown inFIG. 15 , the movement of hardware protrusion 522 withinstructural recess 518 may be permitted, but whenstructural member 512 is in a locked position, as shown inFIG. 16 , movement of hardware protrusion 522 withinstructural recess 518 is substantially prevented. When in the locked position, at least one dimension of thestructural recess 518 is smaller than when thestructural member 512 is in the unlocked position. Although illustrated inFIGS. 15 and 16 as only including asingle hardware member 520, it should be understood that any suitable number of hardware members could be inserted intostructural recess 518 and, in one embodiment,structural recess 518 may be configured to receive multiple hardware protrusions 522 simultaneously. - Another embodiment of an extrusion-coated
structural system 550 is depicted inFIGS. 17-19 . Extrusion-coatedstructural system 550 includes an extrusion-coatedstructural member 552 and at least onehardware member 560. As shown inFIGS. 17-19 , extrusion-coatedstructural member 552 includes asubstrate 554 and acoating material 556 extrusion coated onto at least a portion ofsubstrate 554.Structural member 552 further comprises at least onestructural recess 558 at least partially coated withcoating material 556.Structural recess 558 presents arecess attachment surface 564 configured to at least partially support at least a portion of ahardware protrusion 562 of ahardware member 560. When received instructural recess 558,hardware protrusion 562 may directly contactrecess attachment surface 564 or at least a portion ofhardware protrusion 562 may contact at least one layer of intervening material (not shown). - As particularly shown in
FIG. 19 ,structural recess 558 comprises abroad portion 566 and anarrow portion 568 andhardware protrusion 562 includes abroad section 570 and anarrow section 572. When inserted instructural recess 558, thenarrow section 572 ofhardware protrusion 562 is configured for receipt in thenarrow portion 568 ofstructural recess 558 andbroad portion 570 ofhardware protrusion 562 can be configured for insertion in thebroad portion 566 ofstructural recess 558. Once inserted, pullout ofhardware protrusion 562 fromstructural recess 558 may be inhibited in at least one direction. Additionally,hardware protrusion 562 may be configured to move withinstructural recess 558 and, more particularly, may be configured to rotate, thereby changing the position ofhardware member 560, as shown inFIG. 18 . - According to another embodiment of the present invention, the extrusion-coated structural member can additionally, or alternatively, include at least one structural protrusion presenting at least one protrusion attachment surface formed of the coating material. When the structural system includes at least one structural member having a structural protrusion, the system may also include at least one hardware member comprising at least one hardware recess configured to receive the structural protrusion therein. Once inserted into the hardware recess, at least a portion of the protrusion attachment surface may be at least partially supported by the hardware recess. In one embodiment, the protrusion attachment surface may maintain direct contact with the hardware recess, while, in another embodiment, the protrusion attachment surface and/or the hardware recess may include at least one intervening material layer disposed thereon, such that the protrusion attachment contacts the intervening material layer when inserted in the hardware recess. Several embodiments of extrusion-coated structural systems including a hardware protrusion are illustrated in
FIGS. 20-24 . - Turning now to
FIGS. 20 and 21 , one embodiment of an extrusion-coatedstructural system 600 is illustrated as generally comprising an extrusion-coatedstructural member 612 and at least onehardware member 620. Extrusion-coatedstructural member 612 includes asubstrate 614 and acoating material 616 extrusion coated onto at least a portion ofsubstrate 614. Extrusion-coatedstructural system 600 illustrated inFIGS. 20 and 21 is similar to the extrusion-coatedstructural system 550 depicted inFIGS. 17-19 , except extrusion-coatedstructural member 612 ofsystem 600 comprises astructural protrusion 618 andhardware member 620 comprises ahardware recess 622. - As shown in
FIGS. 20 and 21 ,structural protrusion 618 can be at least partially coated withcoating material 616 and may present aprotrusion attachment surface 624 formed ofcoating material 616. In one embodiment, at least one intervening layer, shown inFIG. 21 aslayer 623, may be disposed on at least a portion ofstructural protrusion 618. Additionally, in one embodiment, at least a portion ofhardware member 620 may also be coated with acoating material 621, including, for example, at least a portion ofhardware recess 622. Whenhardware recess 622 is at least partially coated withcoating material 621, as shown inFIG. 21 ,hardware recess 622 may present a hardwarerecess attachment surface 625 formed ofcoating material 621. Whenstructural protrusion 618 is inserted inhardware recess 622, at least a portion of the protrusion attachment surface 624 (or, if present, intervening layer 623) ofhardware protrusion 618 may be at least partially supported by hardwarerecess attachment surface 625. In another embodiment,hardware recess 624 may also include at least one intervening layer (not shown) disposed on at least a portion of hardwarerecess attachment surface 625. -
Structural protrusion 618 also includes a near-protrusion surface 635 formed ofcoating material 616 and located proximatestructural protrusion 618. In one embodiment,coating material 616 formingprotrusion attachment surface 624 ofstructural protrusion 618 may be continuous with the coating material forming near-protrusion surface 635. As shown inFIGS. 20 and 21 ,structural protrusion 618 includes abroad portion 626 and anarrow portion 628, withnarrow portion 628 ofstructural protrusion 618 being closer to near-protrusion surface 635 thanbroad portion 626. Broad andnarrow portions structural protrusion 618 can be configured for respective insertion into abroad section 630 andnarrow section 632 of hardware recess. In one embodiment,broad portion 626 ofstructural protrusion 618 can be wider thannarrow section 632 ofhardware recess 622, such that, when inserted intohardware recess 622, pull out ofstructural protrusion 618 may be inhibited in at least one direction. Once inserted inhardware recess 622,structural protrusion 618 may be configured to move withinhardware recess 622, thereby permitting movement ofhardware member 620 in a direction as generally indicated byarrow 648 inFIG. 20 . - In one embodiment, extrusion-coated
structural systems structural member hardware members - Referring now to
FIGS. 22 and 23 , another embodiment of an extrusion-coatedstructural system 1650 is illustrated as generally comprising two extrusion-coatedstructural members FIGS. 22 and 23 , one of extrusion-coatedstructural members 1652 may comprise aprotrusion 1658, while the other 1660 may include arecess 1662 configured to receiveprotrusion 1658. Although each ofrecess 1662 andprotrusion 1658 are defined by respective extrusion-coatedstructural members structural members protrusion 1658 may either be a hardware protrusion insertable intostructural recess 1662 of extrusion-coatedstructural member 1660 or may be a structural protrusion receivable in ahardware recess 1662 of extrusion-coatedstructural member 1660. - As shown in
FIGS. 22 and 23 , each of extrusion-coatedstructural members substrate coating material respective substrates protrusion 1658 and/orrecess 1662 may be coated withrespective coating materials protrusion 1658 and/orrecess 1672 present respective protrusion and recess attachment surfaces 1664, 1674 formed ofcoating material Coating materials protrusion 1658 and/orrecess 1662 may include at least one intervening layer disposed on at least a portion of a recess and protrusion attachment surfaces 1664, 1674. Whenprotrusion 1658 is inserted intorecess 1662,protrusion attachment surface 1664 can be at least partially supported byrecess attachment surface 1674.Protrusion attachment surface 1664 may be directly contacted withrecess attachment surface 1674, as shown inFIG. 22 , or, if, present,protrusion attachment surface 1664 and/orrecess attachment surface 1674 may contact an intervening layer disposed on at least a portion of the attachment surface of the other. - In one embodiment, extrusion-coated
structural system 1650 may be useful as, for example, a door or window jamb, with extrusion-coatedstructural members - Another embodiment of an extrusion-coated
structural system 650 is illustrated inFIG. 24 as generally comprising a plurality of connectable extrusion-coated structural members 652 a-c, portions of which are shown inFIG. 24 . Each extrusion-coated structural member 652 a-c includes a respective substrate 654 a-c at least partially coated with a coating material 656 a-c. Each of coating materials 656 a-c can be the same, or at least one of coating materials 656 a-c may be different than one or more of the other coating materials 656 a-c. As shown inFIG. 24 , each of extrusion-coated structural members 652 a-c comprises a protrusion 658 a-c (658 c not shown inFIG. 24 ) and a recess 660 a-c (660 a not shown inFIG. 24 ). As described above with the embodiment depicted inFIGS. 22 and 23 , each of protrusions 658 a-c may be considered structural or hardware protrusions and each of recesses 660 a-c may be considered structural or hardware recesses. - As shown in
FIG. 24 , one of more ofprotrusions 658 a,b and/orrecesses 660 b,c can be at least partially coated with respective coating material 656 a-c. One or more ofprotrusions 658 a,b may present aprotrusion attachment surface 664 a,b at least partially formed ofcoating material 656 a,b-c. Optionally, at least a portion of theprotrusion attachment surface 664 a,b may be defined by or comprise at least one intervening material layer (not shown inFIG. 24 .). In one embodiment shown inFIG. 24 , at least a portion of one or more protrusion attachment surfaces 664 a,b may have a thickness that is at least 1 percent, at least about 2 percent, or at least about 5 percent greater than the average thickness of the remainder ofprotrusion attachment surface 664 a,b. In the same or another embodiment, at least a portion of at least oneprotrusion attachment surface 664 a,b may have a thickness that is at least 1 percent, at least about 2 percent, or at least about 5 percent less than the average thickness of thecoating 656 a,b coated onto the remainder ofprotrusion attachment surface 664 a,b. Additionally, in one embodiment, at least a portion of protrusion attachment surfaces 664 a,b may have a thickness at least 1 percent, at least about 2 percent, or at least about 5 percent greater than or less than the average thickness of thecoating material 656 a,b forming a near-protrusion surface 668 a,b ofstructural member 652 a,b. - Similarly, in the same or another embodiment, one or more of
recesses 660 b,-c may present arecess attachment surface 662 b,c formed ofcoating material 656 b,c. In one embodiment shown inFIG. 24 , at least a portion of one or more recess attachment surfaces 662 b,c may have a thickness that is at least 1 percent, at least about 2 percent, or at least about 5 percent greater than the average thickness of the remainder ofrecess attachment surface 662 b,c. In the same or another embodiment, at least a portion of at least onerecess attachment surface 662 b,c may have a thickness that is at least 1 percent, at least about 2 percent, or at least about 5 percent less than the average thickness of the remainder ofrecess attachment surface 662 b,c. Additionally, in one embodiment, at least a portion of recess attachment surfaces 662 b,c may have a thickness at least 1 percent, at least about 2 percent, or at least about 5 percent greater than or less than the average thickness of thecoating material 656 b,c forming a near-recess surface 670 b,c (670 c not shown) of structural member 652 a-c. - In one embodiment, at least a portion of one or more of protrusion attachment surfaces 664 a,b of
protrusions 658 a,b can include at least one coating cavity (not shown inFIG. 24 ) and/or at least one coating projection. In one embodiment, protrusion attachment surfaces 664 a,b may include two or more coating cavities (not shown) or two ormore coating projections 680 a,b, as illustrated inFIG. 24 . In one embodiment, one or more ofprotrusions 658 a,b may include both coating cavities and protrusions. The ratio of the maximum height of the coating projections, or the minimum thickness of the coating cavities, when present, to the average thickness of thecoating material 656 a,b coated ontoprotrusion 658 a,b can be at least about 0.05:1, at least about 0.10:1, at least about 0.25:1, at least about 0.50:1 and/or not more than about 1:1, not more than about 0.95:1, not more than about 0.75:1, or in the range of from about 0.05:1 to about 1:1, about 0.05:1 to about 0.95:1 about 0.05:1 to about 0.75:1, about 0.10:1 to about 1:1, about 0.10:1 to about 0.95:1 about 0.10:1 to about 0.75:1, about 0.25:1 to about 1:1, about 0.25:1 to about 0.95:1 about 0.25:1 to about 0.75:1, about 0.50:1 to about 1:1, about 0.50:1 to about 0.95:1 about 0.50:1 to about 0.75:1. In another embodiment (not shown inFIG. 24 ), at least a portion of one or more coating projections and/or one or more coating recesses may be defined within a portion of substrate 654. - In the same or another embodiment, at least a portion of one or more recess attachment surfaces 662 b,c can include at least one coating cavity and/or at least one coating projection (not shown). In one embodiment, recess attachment surfaces 662 b,c may include two or more coating projections (not shown) or two or
more coating cavities 682 a,b, as illustrated inFIG. 24 . In one embodiment,recess 660 b may include both coating cavities and protrusions. The ratio of the minimum thickness of coating cavities, or the maximum height of the coating projections, when present, to the average thickness of the coating material coated onto recess can be at least about 0.05:1, at least about 0.10:1, at least about 0.25:1, at least about 0.50:1 and/or not more than about 1:1, not more than about 0.95:1, not more than about 0.75:1, or in the range of from about 0.05:1 to about 1:1, about 0.05:1 to about 0.95:1 about 0.05:1 to about 0.75:1, about 0.10:1 to about 1:1, about 0.10:1 to about 0.95:1 about 0.10:1 to about 0.75:1, about 0.25:1 to about 1:1, about 0.25:1 to about 0.95:1 about 0.25:1 to about 0.75:1, about 0.50:1 to about 1:1, about 0.50:1 to about 0.95:1 about 0.50:1 to about 0.75:1. In another embodiment (not shown inFIG. 24 ), at least a portion of one or more coating projections and/or one or more coating recesses may be defined within a portion ofsubstrate 654 b,c. - In the embodiment depicted in
FIG. 24 ,protrusion attachment surface 664 a of extrusion-coatedstructural member 652 a is illustrated as comprising a pair ofcoating projections 680 a,b disposed on generally opposing sides ofprotrusion 658 a. As shown inFIG. 24 ,protrusion 658 a of extrusion-coatedstructural member 652 a is configured for insertion into arecess 660 b of extrusion-coatedstructural member 652 b.Recess attachment surface 662 b ofrecess 660 b can include at least one coating cavity, shown inFIG. 24 as a pair of coatingcavities 682 a,b, disposed on generally opposing sides of recess 660. Upon insertion ofprotrusion 658 a into recess 660 a,coating projections 680 a,b may also be inserted intocorresponding coating cavities 682 a,b thereby further securing and supportingprotrusion 658 a within recess 660 a. When extrusion-coatedstructural system 650 includes two or more extrusion-coated structural members 652 a-c, as shown inFIG. 24 , each structural member 652 a-c may include similar features such that each structural member 652 a-c may be coupled to one or more other structural members 652 a-c as generally shown inFIG. 24 . The extrusion-coatedstructural system 650 depicted inFIG. 24 may be particularly useful in construction applications as, for example, wall or floor panels. - According to another embodiment of the present invention, one or more recesses or protrusions defined by an extrusion-coated structural member can be at least partially formed by an extruded profile member formed of the coating material. As used herein, the term “extruded profile member” refers to a portion of an extrusion-coated structural member that is separate, but extends outwardly from, at least a portion of one or more substrates included in the structural member. In one embodiment, the extruded profile member may extend outwardly from the substrate of the extrusion-coated structural member and may also extend along at least a portion of the length of the substrate.
- In one embodiment, the extruded profile member may extend outwardly from the substrate for a maximum distance that is at least about two, at least about five, at least about ten, at least about 20 times greater than the average thickness of the coating material extruded onto the substrate at a location adjacent the extruded profile member. The average thickness of the coating material extrusion coated onto the substrate at a location adjacent the extruded profile member can be within the ranges described previously. The ratio of the maximum thickness of the extruded profile member to the average thickness of the coating material extrusion coated onto the substrate at a location adjacent the extruded profile member can be at least about 1:1, at least about 2:1, at least about 3:1 and/or not more than about 10:1, not more than about 8:1, not more than about 6:1, or in the range of from about 1:1 to about 10:1, about 1:1 to about 8:1, about 1:1 to about 6:1, about 2:1 to about 10:1, about 2:1 to about 8:1, about 2:1 to about 6:1, about 3:1 to about 10:1, about 3:1 to about 8:1, about 3:1 to about 6:1.
- In the same or another embodiment, the extruded profile member may extend along at least about 50 percent, at least about 60 percent, at least about 70 percent, at least about 80 percent, or at least about 90 percent of the total length of the substrate, such that the ratio of the length of the extruded profile member to the ratio of the length of the substrate is at least about 0.50:1, at least about 0.60:1, at least about 0.70:1, at least about 0.80:1, or at least about 0.90:1. The extruded profile member can extend continuously along the length of the substrate.
- The extruded profile member can be at least partially, or nearly entirely, formed of the coating material applied onto the substrate during formation of the extrusion-coated structural member and may, for example, be formed simultaneously during the extrusion coating process used to produce the extrusion-coated structural member, additional details of which will be discussed in detail shortly. In one embodiment, not more than about 20, not more than about 10, not more than about 5, not more than about 2 percent of the total volume of the extruded profile member may be occupied by the substrate and, in the same or another embodiment, at least about 5 percent, at least about 10 percent, at least about 15 percent, at least about 20 percent, or at least about 25 percent of the total weight of coating material applied to the substrate to form the extrusion-coated structural member may be used to form the extruded profile member.
- In one embodiment, the extruded profile member of an extrusion-coated structural member may at least partially define at least one profile recess and/or at least one profile protrusion. When present, the profile recess may at least partially define a profile recess attachment surface configured to contact and at least partially support a hardware, structural, or profile protrusion inserted therein. Similarly, when present in the extrusion-coated structural member, the profile protrusion at least partially defined by the extruded profile member may present a protrusion profile attachment surface configured to contact at least a portion of a structural recess, a hardware recess, and/or a profile recess when inserted therein. In one embodiment, the extruded profile member can define at least about 50, at least about 60, at least about 70, at least about 80, or at least about 90 percent of the total area of recess attachment and/or profile attachment surfaces, and, in one embodiment, the entirety of the recess and/or profile attachment surfaces may be defined by the extruded profile member.
- According to one embodiment, at least a portion of the profile recess attachment surface and/or the profile protrusion attachment surface can comprise one or more coating cavities and/or coating projections. When present, the coating cavities and/or projections may extend along at least a portion of the profile protrusion and/or profile recess attachment surfaces and can define areas of coating have a thickness that is at least about 1, at least about 2, at least about 3, at least about 5 percent greater than the average thickness of the profile protrusion and/or profile recess attachment surfaces.
- In one embodiment, the profile protrusion attachment surface of an extruded profile member can include two or more coating cavities and/or two or more coating projections. In one embodiment, the profile protrusion attachment surface may include both coating cavities and protrusions. The ratio of the maximum height of the coating projections or the minimum thickness of the coating cavities, when present, to the average thickness of the coating material forming the profile protrusion attachment surface can be at least about 0.05:1, at least about 0.10:1, at least about 0.25:1, at least about 0.50:1 and/or not more than about 1:1, not more than about 0.95:1, not more than about 0.70:1, or in the range of from about 0.05:1 to about 1:1, about 0.05:1 to about 0.95:1, about 0.05:1 to about 0.70:1, about 0.10:1 to about 1:1, about 0.10:1 to about 0.95:1, about 0.10:1 to about 0.70:1, about 0.25:1 to about 1:1, about 0.25:1 to about 0.95:1, about 0.25:1 to about 0.70:1, about 0.50:1 to about 1:1, about 0.50:1 to about 0.95:1, about 0.50:1 to about 0.70:1.
- In the same or another embodiment, at least a portion of one or more profile recess attachment surfaces can include at least one coating cavity and/or at least one coating projection. In one embodiment, the profile recess attachment surface may include both coating cavities and protrusions. The ratio of the maximum height of the coating projections or the minimum thickness of the coating cavities, when present, to the average thickness of the coating material forming the profile recess attachment surface can be at least about 0.05:1, at least about 0.10:1, at least about 0.25:1, at least about 0.50:1 and/or not more than about 1:1, not more than about 0.95:1, not more than about 0.70:1, or in the range of from about 0.05:1 to about 1:1, about 0.05:1 to about 0.95:1, about 0.05:1 to about 0.70:1, about 0.10:1 to about 1:1, about 0.10:1 to about 0.95:1, about 0.10:1 to about 0.70:1, about 0.25:1 to about 1:1, about 0.25:1 to about 0.95:1, about 0.25:1 to about 0.70:1, about 0.50:1 to about 1:1, about 0.50:1 to about 0.95:1, about 0.50:1 to about 0.70:1.
- Several embodiments of extrusion-coated structural systems that include two or more extrusion-coated structural members having at least one extruded profile member are provided in
FIGS. 25-30 . Turning initially toFIGS. 25 and 26 , an extrusion-coatedstructural system 700 is illustrated as generally comprising a pair of extrusion-coatedstructural members structural members substrate coating material substrate Coating materials FIGS. 25 and 26 , extrusion-coatedstructural member 722 comprises astructural protrusion 728 at least partially coated with acoating material 726 and extrusion-coatedstructural member 712 includes aprofile recess 718 at least partially defined byextruded profile member 730. In one embodiment shown inFIGS. 25 and 26 ,profile recess 718 can be entirely formed byextruded profile member 730 and may not be defined bysubstrate 714. -
Profile recess 718 can present a profile recess attachment surface 740 that is at least partially formed fromcoating material 726 used to form extrudedprofile member 730. In the embodiment shown inFIGS. 25 and 26 , at least a portion of profile recess attachment surface 740 comprises a plurality of coating cavities 742. Alternatively, profile recess attachment surface could additionally include at least one coating projection or could alternatively include only coating projections (not shown inFIGS. 25 and 26 ). Further, as shown inFIGS. 25 and 26 , the profileprotrusion attachment surface 738 presented bystructural protrusion 728 can also include one ormore coating projections 744 and/or one or more coating cavities (not shown) spaced along profileprotrusion attachment surface 738. - The coating cavities 742 and
projections 744 respectively defined by profile recess and profile protrusion attachment surfaces 740 and 738 may have the maximum height and/or minimum depth, relative to the average thickness of the coating material forming profile recess and/or profile protrusion attachment surfaces as described in detail previously. Further, although shown inFIGS. 25 and 26 as comprising generally semi-circular cavities, coating cavities 742 and/orcoating projections 744 could have any desirable shape. Further, as illustrated inFIGS. 25 and 26 , each of coating cavities 742 andcoating projections 744 can extend along at least a portion of the length ofsubstrates profile member 730 andstructural protrusion 728. - To assemble extrusion-coated
structural system 700,profile protrusion 728 may be inserted intoprofile recess 718 such that at least a portion of profile recess attachment surface is in direct contact with at least a portion ofprofile protrusion 728. When inserted intoprofile recess 718, at least a portion, or all, of thecoating projections 744 disposed on profile protrusion attachment surface 783 ofprotrusion 728 can be inserted into a corresponding coating cavity 742 defined by profile recess attachment surface 740 ofrecess 718. In one embodiment, one ofcoating projections 744 ofprofile protrusion 728 may be insertable into more than one coating cavities 742 ofprofile recess 718 such that the position of extrusion-coatedstructural members - Turning now to
FIGS. 27 and 28 , one embodiment of an extrusion-coatedstructural system 750 is illustrated as generally comprising a pair of extrusion-coatedstructural members structural members substrate coating material substrates structural system 750 is similar to extrusion-coatedstructural system 700 described previously with respect toFIGS. 25 and 26 , except each of extrusion-coatedstructural members structural system 750 includes an extrudedprofile member FIGS. 27 and 28 , each of extrudedprofile members profile projections 772 a,b and 782 a,b and aprofile recess - As shown in particular by
FIG. 28 , extrusion-coatedstructural members profile projection 772 b ofextruded profile member 770 intoprofile recess 784 of extrudedprofile member 780 and, at the same time, insertingprofile projection 782 b ofextruded profile member 780 intoprofile recess 774 of extrudedprofile member 770. In this way, at least a portion of theattachment surface 786 presented byextruded profile member 780 can be in contact with at least a portion of the attachment surface 776 presented byextruded profile member 770. Although shown inFIGS. 27 and 28 as having a generally beveled shape, extrudedprofile member - Turning now to
FIGS. 29 and 30 , another embodiment of an extrusion-coatedstructural system 800 similar to the extrusion-coatedstructural system structural system 800 includes a plurality of extrusion-coatedstructural members 812 that each includes asubstrate 814 and acoating material 816 extrusion coated onto at least a portion ofsubstrate 814.Coating materials 816 coated onto eachsubstrate 816 can be the same as, or different than, thecoating material 816 coated onto one or moreother substrates 814. As shown inFIGS. 29 and 30 , each ofstructural members 812 comprises an extrudedprofile member 820 and arecess 822 configured to receive theprofile member 820 of anothersubstrate 814. In one embodiment,substrate 814 includes acoating material 816 which can at least partially definerecess 822, while, in another embodiment (not shown),recess 822 can be entirely formed ofcoating material 816. - To assemble extrusion-coated
structural system 800, the extrudedprofile member 820 of one extrusion-coated structural member may be inserted into therecess 822 of a second extrusion-coated structural member to thereby couple structural members 812 a and b to each other. Optionally, extrudedprofile member 820 may be further secured inrecess 822 through use of adhesive (not shown) or by treating the points of connection amongst the assembledstructural members 812 using, for example, heat or ultrasonic energy. Once secured, one or more of thestructural members 812 may be moved relative to one or more other structural member in order to form the assembled structural member into a variety of shapes, preferably without uncoupling the individualstructural members 812 from one another. Although shown as including only 4 extrusion-coatedstructural members 812,structural system 800 may include any suitable number of structural members, such as, for example, at least 2, at least 4, at least 6 and/or not more than 20, not more than 15, not more than 10. Extrusion-coatedstructural system 800 may be useful in a wide variety of applications but, in particular, may be utilized in a construction application as, for example, floor or wall paneling. - Turning now to
FIGS. 31 and 32 , another embodiment of an extrusion-coatedstructural member 852 including an extrudedprofile member 870 is provided. Extrusion-coatedstructural member 852 includes asubstrate 854 and acoating material 856 extrusion coated onto at least a portion ofsubstrate 854. In one embodiment, the extrusion-coatedstructural member 852 includes at least oneextruded profile member 870 that extends outwardly fromsubstrate 854 for a maximum distance, indicated by the letter L inFIG. 32 , of at least about 0.25 inches, at least about 0.5 inches, at least about 0.75 inches and/or not more than 4 inches, not more than about 3 inches, not more than about 2 inches. the extrusion-coatedstructural member 852 includes at least oneextruded profile member 870 that extends outwardly fromsubstrate 854 for a maximum distance in the range of from about 0.25 to about 4 inches, about 0.25 to about 3 inches, about 0.25 to about 2 inches, about 0.5 to about 4 inches, about 0.5 to about 3 inches, about 0.5 to about 2 inches, about 0.75 to about 4 inches, about 0.75 to about 3 inches, about 0.75 to about 2 inches. - According to one embodiment, the ratio of the maximum distance, L, of extension of
extruded profile member 870 fromsubstrate 854 to the maximum thickness of the extruded profile member may be at least about 0.5:1, at least about 1:1, at least about 2:1, at least about 5:1 and/or not more than about 20:1, not more than about 15:1, not more than about 10:1, not more than about 8:1, not more than about 6:1. The ratio can be in the range of from about 0.5:1 to about 20:1, about 0.5:1 to about 15:1, about 0.5:1 to about 10:1, about 0.5:1 to about 8:1, about 0.5:1 to about 6:1, about 1:1 to about 20:1, about 1:1 to about 15:1, about 1:1 to about 10:1, about 1:1 to about 8:1, about 1:1 to about 6:1, about 2:1 to about 20:1, about 2:1 to about 15:1, about 2:1 to about 10:1, about 2:1 to about 8:1, about 2:1 to about 6:1, about 5:1 to about 20:1, about 5:1 to about 15:1, about 5:1 to about 10:1, about 5:1 to about 8:1, about 5:1 to about 6:1. In the embodiment depicted inFIGS. 31 and 32 ,structural member 852 can comprise aprofile cavity 818 that is at least partially, or nearly entirely, defined byextruded profile member 870. Extrudedprofile member 870 depicted inFIGS. 31 and 32 comprises a shock absorbing member shiftable between an extended position, as indicated by the solid lines inFIG. 32 , and a compacted position, as indicated by the dashed lines inFIG. 32 . Upon contact with a surface of a second structural member (not shown),shock absorbing member 870 can shift from an extended position to a compacted position, thereby absorbing or lessening at least a portion of the contact energy transferred between the structural members. Extrusion-coatedstructural member 852 may be useful as a door or drawer in a variety of furniture or cabinetry applications. - Additional embodiments of extrusion-coated structural systems including extruded profile member are provided in
FIGS. 33-36 . Each of extrusion-coatedstructural system 900 and extrusion-coatedstructural member 952 respectively depicted inFIGS. 33 and 34 andFIGS. 35 and 36 include at least one extrusion-coated structural member and one or more extruded profile member used to enhance the aesthetic appeal and/or functionality of the structural system. For example, in the embodiments depicted inFIGS. 33 and 34 , extrusion-coatedstructural system 900 comprises two extrusion-coatedstructural members substrate coating material substrate - As shown in
FIGS. 33 and 34 , one of extrusion-coatedstructural member 912 includes a first elongatedstructural recess 918 and at least two otherstructural recesses 917 a,b configured to receive a portion of two hardware members, shown inFIGS. 33 and 35 as comprisingscrews 930 a,b. The other extrusion-coated structural member 920 includes an extruded profile member, shown as atab 940, extending outwardly from one of thesurfaces 915 a ofsubstrate 924, continuous withcoating material 926 applied to surface 915 a.Tab 940 includes a pair ofprojections 942 a,b configured to be received withinstructural recess 918 of extrusion-coatedstructural member 912. When inserted intostructural recess 918, as shown inFIG. 34 ,tab 940 may be suitable for hiding one or more hardware members, such asscrew 930 a from view when thestructural members structural system 900. Thus, extrudedprofile member 940 may be used to increase the aesthetic properties of a structural system. - Turning now to
FIGS. 35 and 36 another embodiment of an extrusion-coatedstructural member 952 exhibiting enhanced functional and/or aesthetic characteristics are provided. As shown inFIGS. 35 and 36 , extrusion-coatedstructural member 952 comprises asubstrate 954 and acoating material 956 extrusion coated onto at least a portion ofsubstrate 954. As shown in the embodiment depicted inFIGS. 35 and 36 ,structural member 952 includes an extrudedprofile member 970 extending outwardly from at least a portion ofsubstrate 954 and being continuous withcoating material 956 coated onto the portion ofsubstrate 954 adjacentextruded profile member 970. Rather than include an unsupported terminal end, like another embodiment of extruded profile member previously discussed, extrudedprofile member 970 illustrated inFIGS. 35 and 36 extends between and is supported by each of a first andsecond portion 953 a,b ofsubstrate 954. As a result, extrudedprofile member 970 forms a portion ofprofile recess 958, although less than 50 percent of the total area of the inner surface area ofprofile recess 958 is defined byextruded profile member 970. - In one embodiment shown in
FIGS. 35 and 36 ,profile recess 958 can be configured to receive at least one functional and/or aesthetic member to enhance the functionality and/or aesthetic characteristics of the structural member and/or structural system. Examples of suitable functional and/or aesthetic members suitable for insertion into a profile recess, such asprofile recess 958, can include, but are not limited to, piping, electrical conduit or wires, cables, lighting elements or fixtures, LED elements, and combinations thereof. In the embodiment shown inFIGS. 35 and 36 , aplurality LED elements 980 can be inserted intoprofile recess 958 to enhance the functionality and/or aesthetics ofstructural member 952. - According to one or more other embodiments of the present invention, one or more structural systems as described herein may include at least one bridging member coupling two or more substrates to one another in order to permit movement of at least one substrate relative to the other. In one embodiment, the structural system of the present invention can comprise at least two substrates and at least one bridging member coupling the first and second substrates to one another. The bridging member can be formed of a coating material extrusion coated onto at least a portion of the first and second substrates and may extend from at least a portion of the one of the substrates to at least a portion of one of the other substrates to thereby form an extrusion-coated structural member.
- According to one embodiment, the bridging member may be the only connection between the substrates being coupled. In one embodiment, the maximum thickness of the bridging member can be greater than the average thickness of the coating material applied to the substrate adjacent the bridging member, while, in another embodiment, the maximum thickness of the bridging member can be approximately the same as the average thickness of the coating material applied to the substrate adjacent the bridging member. The ratio of the maximum thickness of the bridging member to the average thickness of the coating material applied to the substrate proximate the bridging member can be at least about 0.9:1, at least about 1:1, at least about 1.5:1, at least about 2:1 and/or not more than about 10:1, not more than about 8:1, not more than about 6:1. The ratio of the maximum thickness of the bridging member to the average thickness of the coating material applied to the substrate proximate the bridging member can be in the range of from about 0.9:1 to about 10:1, about 0.9:1 to about 8:1, about 0.9:1 to about 6:1, about 1:1 to about 10:1, about 1:1 to about 8:1, about 1:1 to about 6:1, about 1.5:1 to about 10:1, about 1.5:1 to about 8:1, about 1.5:1 to about 6:1, about 2:1 to about 10:1, about 2:1 to about 8:1, about 2:1 to about 6:1.
- In another embodiment, the ratio of the bridging member to the thickness, or shortest dimension, of the substrate can be at least about 0.005:1, at least about 0.01:1, at least about 0.05:1 and/or not more than 0.50:1, not more than about 0.25:1, not more than about 0.10:1, or in the range of from about 0.005:1 to about 0.50:1, about 0.005:1 to about 0.25:1, about 0.005:1 to about 0.10:1, about 0.01:1 to about 0.50:1, about 0.01:1 to about 0.25:1, about 0.01:1 to about 0.10:1, about 0.05:1 to about 0.50:1, about 0.05:1 to about 0.25:1, about 0.05:1 to about 0.10:1.
- The maximum thickness of the bridging member can be at least about 0.005 inches, at least about 0.010 inches, at least about 0.050 inches, at least about 0.075 inches and/or not more than about 0.75 inches, not more than about 0.50 inches, not more than about 0.25 inches, or not more than about 0.15 inches. The bridging member can have a substantially constant thickness, or at least one portion of the bridging member can have a thickness different than at least one other portion of the bridging member. The ratio of the maximum thickness of the bridging member to the maximum thickness of the substrates being coupled can be at least about 0.001:1, at least about 0.005:1, at least about 0.010:1, at least about 0.050:1 and/or not more than about 0.5:1, not more than about 0.25:1, not more than about 0.20:1.
- The substrates coupled by the at least one bridging member can have any suitable shape and/or size and can be arranged in any suitable configuration. In one embodiment, the length, width, and depth of each of the substrates being coupled may be the same or substantially the same, while, in another embodiment, at least one of the substrates being coupled may have a length, width, and/or depth different than the length, width, and/or depth of at least one other substrates being coupled. As used herein, the term “substantially” means within 5 percent. According to one embodiment, three or more substrates may be coupled with at least one bridging member and at least one of the substrates may have a different size, shape, and/or orientation than at least one of the others. In one embodiment, all of the substrates coupled with the bridging member may have the same size, shape, and/or orientation of each of the other substrates.
- The position of the substrates within the extrusion-coated structural system may vary, depending on the specific design and use of the system. In one embodiment, the substrates of the structural system may be positioned in a side-by-side arrangement such that lengths and thicknesses of adjacent substrates are substantially parallel to one another and the widths are substantially aligned. As used herein, the term “substantially” means within 5° and “aligned” means extending along the same axis. In another embodiment, the substrates of the structural system may be configured in a “top-to-bottom” arrangement such that lengths and widths of adjacent substrates are substantially parallel to one another and the thicknesses are substantially aligned. Further, in yet another embodiment, the substrates may be arranged in an “end-to-end” arrangement such that widths and thicknesses of adjacent substrates are substantially parallel to one another and the lengths are substantially aligned. In a still further embodiment, the substrates may be arranged in a “nested” arrangement, wherein one or more substrates are positioned within a recess or cavity defined by one or more other substrates. Various embodiments having substrates arranged in each of these configurations will be discussed in detail shortly.
- In one embodiment, the structural systems that include at least one bridging member may be shiftable between a flat configuration, wherein the bridging member extends between the first and second substrates in a substantially planar fashion, and a folded configuration, wherein at least a portion of the bridging member is bent, flexed, folded, or otherwise arranged in a non-planar way. According to one embodiment, the bridging member may be configured to permit movement of the substrates from a flat configuration to a folded configuration (and back to a flat configuration) without decoupling the substrates from one another. During the shifting, one of the substrates can be moved relative to the other by, for example, bending, rotating, or flexing at least a portion of the bridging member. In one embodiment, the bridging member may be configured to permit a maximum angular range of motion of at least about 15°, at least about 30°, at least about 45°, at least about 60°, at least about 75°, at least about 90°, at least about 135° and/or not more than about 180°, not more than about 135°, not more than about 90°, not more than about 75° of one substrate relative to the other.
- When in the flat configuration, the substrates of the structural system may be spaced apart from one another to define a gap, and at least a portion of the bridging member may extend across the gap from at least a portion of one substrate to at least a portion of the other. The gap may be at least partially defined by opposing surfaces of each of the substrates which can be, in some cases, aligned substantially parallel to each other, when the structural system is in the flat configuration. In another embodiment, the opposing surfaces of adjacent substrates may be oriented at an alignment angle of at least about 5°, at least about 15°, at least about 30°, at least about 45°, at least about 60° and/or not more than about 160°, not more than about 135°, not more than about 110°, or not more than about 90° with respect to one another.
- When present, one or more dimensions of the gap defined between the substrates may change as the structural system is shifted from a flat configuration to a folded configuration and, in some cases, the gap may not be present when the structural system is in a folded configuration. When configured in the flat configuration, the width of the gap, if present, may be constant along the length and/or depth of the gap. Alternatively, the width the gap may change (i.e., increase and/or decrease) along the length and/or depth thereof. As used herein, the “length” of the gap is measured in a direction parallel to the direction of extension of the substrates, and the “width” of the gap is measured in a direction parallel to the direction of extension of the bridging member. As used herein the “depth” of the gap is measured in a direction perpendicular to both the width and the length of the gap and, in one embodiment, can be parallel to the thickness of the substrates being coupled. In one embodiment, the ratio of the minimum width of the gap to the maximum width of the gap may be at least about 0.25:1, at least about 0.50:1, at least about 0.75:1 and/or not more than about 1:1, not more than about 0.90:1, not more than about 0.85:1 and/or the ratio of the depth of the gap to the maximum width of the gap can be at least about 0.10:1, at least about 0.25:1, at least about 0.40:1 and/or not more than about 3:1, not more than about 2:1, not more than about 1:1, not more than about 0.85:1.
- Several embodiments of extrusion-coated structural systems including a structural member having at least one bridging member are provided in
FIGS. 37-58 . Turning first toFIGS. 37 and 38 , one embodiment of an extrusion-coatedstructural member 1010 is illustrated as generally comprising a pair ofsubstrates members substrate 1012 to at least a portion ofsubstrate 1014. In one embodiment,substrates substrates members members structural member 1010. - In one embodiment depicted in
FIGS. 37 and 38 , at least a portion ofsubstrates outer surfaces 1022 a (1022 b not shown) of onesubstrate 1012 and one or more of theouter surface 1024 a (1024 b not shown) of theother substrate 1014 collectively form at least onecomposite surface 1040 a,b as shown inFIG. 38 . In one embodiment, bridgingmembers composite surfaces 1040 a,b from at least a portion ofouter surfaces 1022 a,b ofsubstrate 1012 to at least a portion ofouter surfaces 1024 a,b ofsubstrate 1014 thereby forming extrusion-coatedstructural member 1010. In one embodiment shown inFIGS. 37 and 38 , the extrusion-coated structural member may define an interiorstructural recess 1018, which can optionally be configured to receive one or more functional or aesthetic elements (not shown), such as, for example, one or more elements listed above. - Turning now to
FIGS. 39-41 , another embodiment of an extrusion-coatedstructural system 1050 is illustrated as comprising a pair ofsubstrates member 1060coupling substrates Bridging member 1060 can be formed of acoating material 1056 and may extend from at least a portion ofsubstrate 1052 to at least a portion ofsubstrate 1054. Whensubstrates coating material 1056, as shown in the embodiment inFIGS. 39-41 , at least a portion of thecoating material 1056 disposed onsubstrates member 1060. - When
structural system 1050 is configured in a flat configuration, as generally shown inFIG. 39 ,substrates gap 1070. As shown inFIG. 39 ,gap 1070 is at least partially defined by opposingsurfaces respective substrates coating material 1056 and may be continuous with the material used tocoat substrates coating material 1056 used to form bridgingmember 1070. - As
structural system 1050 is shifted from a flat configuration to one or both of the folded configurations shown inFIGS. 40 and 41 , the size and/or shape ofgap 1070 may change. For example, when shiftingstructural system 1050 from a flat configuration to a folded configuration, the size ofgap 1070 may increase, while, when shiftingstructural system 1050 from a folded configuration to a flat configuration, the size ofgap 1070 may decrease. Structural systems configured similarly tostructural system 1050 may have a variety of end uses and, in one embodiment, may be suitable for use as a trim piece or other component in a variety of indoor and/or outdoor construction applications. - Referring now to
FIGS. 42-44 , yet another embodiment of an extrusion-coatedstructural system 1100 configured according to the present invention is provided. Extrusion-coatedstructural system 1100 comprises a pair ofsubstrates member 1120 extending between at least a portion ofsubstrates structural system 1100 is similar to the extrusion-coatedstructural system 1050 depicted inFIGS. 39-41 , with at least the following differences. - When
structural system 1100 is arranged in a flat configuration, as shown inFIG. 42 ,substrates gap 1130 there between. In contrast togap 1070 depicted inFIGS. 39-41 , opposingsurfaces substrates FIGS. 42-44 are not parallel, but instead are angularly aligned with one another at an alignment angle, shown as ⊖ inFIG. 42 , measured fromsurface 1132 ofsubstrate 1112 to surface 1134 ofsubstrate 1114. In one embodiment, the alignment angle can beat least about 5°, at least about 15°, at least about 30°, at least about 45°, at least about 60° and/or not more than about 160°, not more than about 135°, not more than about 110°, or not more than about 90°. Additionally, as particularly shown inFIG. 42 , the width ofgap 1130 changes along its depth. For example, as shown inFIG. 42 , the width of the gap narrowsnearer bridging member 1120, such thatgap 1130 has a general “V”-shaped cross-section. - When
structural system 1100 is shifted between a flat configuration, as shown inFIG. 42 , to a folded configuration, as shown inFIG. 43 ,gap 1130 is no longer present and opposingsurfaces FIG. 43 ,substrates structural member 1120 inFIG. 44 , to thereby securestructural system 1100 in a folded configuration. Alternatively, other recess configurations and other types of hardware may be used or, in one embodiment, an adhesive material such as, for example, double-sided tape or glue, may also be used to securestructural system 1100 in a folded configuration.Hardware member 1120 may be used to securestructural system 1100 in a folded configuration permanently or may be removable such thatstructural system 1100 can be shifted back to a flat configuration, as shown inFIG. 42 . - Turning now to
FIGS. 45 and 46 , another embodiment of an extrusion-coatedstructural system 1150 is illustrated as generally comprising a plurality of substrates 1152 a-f and acoating material 1156 extrusion coated onto at least a portion of substrates 1152 a-f. In one embodiment, substrates 1152 a-f may be coupled to one another by at least onebridging member 1170 extending from one or more of the substrates 1152 a-e to one or more other substrates 1152 a-e. According to the embodiment shown inFIGS. 45 and 46 , bridgingmember 1170 may be asingle bridging member 1170 extending continuously from a first substrate, shown assubstrate 1152 a, along the length ofstructural system 1150 to a last substrate, shown as 1152 e. Alternatively, each of bridgingmembers 1170 a-d may have been separately formed and may, in one embodiment, be formed of a coating material different thancoating material 1156 and/or may discontinuous with at least a portion ofcoating material 1156. -
Structural system 1150, as shown inFIGS. 45 and 46 , may be formed in any suitable manner. In one embodiment, several individual, but similarly shaped, substrates 1152 a-e may be simultaneously extrusion coated while maintaining a space between the substrates to thereby form a bridgingmember 1170 that spans at least a portion of the space between substrates 1152 a-e. In another embodiment, a single elongated substrate may be at least partially coated withcoating material 1156 and a plurality of gaps 1174 a-e may then be cut into the coated substrate at various locations along its length to thereby form substrates 1152 a-e, as shown inFIG. 46 . When cutting gaps 1174 a-e,coating material 1156 extending along at least one of the surfaces of substrate 1152 may remain intact, thereby formingbridging member 1170, as shown inFIGS. 45 and 46 . -
Structural system 1150 can be shiftable between a flat configuration, as illustrated inFIG. 45 , and a folded configuration, as illustrated inFIG. 46 . In one embodiment, when in a folded configuration, at least onesurface 1162 a of asubstrate 1152 a may be contacted with at least onesurface 1162 f of anothersubstrate 1152 f to thereby form a closed configuration as generally shown inFIG. 46 . When in said closed configuration,structural system 1150 may have a circular or polygonal shape, depending, in part, on the size, shape, and number of individual substrates. In the embodiment shown inFIG. 46 ,structural system 1150 may be configured so that bridgingmember 1170 forms a continuousexternal surface 1173 amongst substrates 1152 a-f. In one embodiment, a securing device, including, for example, a hardware member or adhesive material (not shown) may be used, if desired, to securesurfaces - Referring now to
FIGS. 47-49 , another extrusion-coatedstructural system 1200 is illustrated as comprising a plurality of substrates 1212 a-h and a coating material 1216 extrusion coated onto at least a portion of substrates 1212 a-h. Substrates 1212 a-h may be coupled to one another by at least onebridging member 1240 extending along at least a portion of one or more of the substrates 1212 a-h. Extrusion-coatedstructural system 1200 is similar to the extrusion-coatedstructural system 1150 described previously with respect toFIGS. 45 and 46 , with at least the following differences. - As shown in
FIGS. 47-49 ,structural system 1200 includes a plurality of substrates 1212 a-h spaced apart from one another to form a plurality of gaps 1230 a-g. Each of gaps 1230 a-g is at least partially defined by opposing surfaces of adjacent substrates 1212 a-h which are aligned substantially parallel to one another. Further, as shown inFIG. 48 , the width of each of gaps 1230 a-g can be substantially constant over the depth of the gaps 1230 a-g and, as shown in one embodiment depicted inFIG. 47 , the direction of extension one or more gaps 1230 a-g may or may not be substantially parallel with the direction of extension of one or more other gaps 1230 a-g and/or with one or more edges 1213 a,b ofstructural system 1200. As a result, whenstructural system 1200 is shifted into a folded configuration, as shown inFIG. 49 , bridgingmember 1240 may form acontinuous surface 1236 located inside the closed portion ofstructural system 1200. Additionally, rather than contract when the structural system is shifted into a folded configuration at least a portion of gaps 1230 a-g ofstructural system 1200 expand whenstructural system 1200 is shifted from a flat configuration to a folded configuration, as particularly shown inFIGS. 48 and 49 . - Referring now to
FIGS. 50 and 51 , yet another embodiment of an extrusion-coatedstructural system 1250 is illustrated as comprising a plurality of substrates 1252 a-h and acoating material 1256 extrusion coated onto at least a portion of substrates 1252 a-h. As shown inFIGS. 50 and 51 , at least a portion ofcoating material 1256 may be formed into a bridgingmember 1240 extending from at least a portion of one or more substrates 1252 a-h to at least a portion of one or more other substrates 1252 a-h. In one embodiment shown inFIGS. 50 and 51 , bridgingmember 1240 may extend continuously between each of substrates 1252 a-h, while, in another embodiment (not shown), at least a portion of bridgingmember 1240 may not be continuous along the length of substrates 1252 a-h. As shown inFIGS. 50 and 51 , at least a portion of substrates 1252 a-h may not contact one another, but, instead, may only be connected by bridgingmember 1240. - Similar to previously-discussed structural system,
structural system 1250 can be shiftable between a flat configuration, as shown inFIG. 50 , and a folded configuration, as generally depicted inFIG. 51 . When in the flat configuration,structural system 1250 includes a plurality of gaps 1270 a-g defined between opposing surfaces of adjacent substrates 1252 a-h. In the embodiment shown inFIG. 50 , the opposing surfaces of adjacent substrates 1252 a-h may be angularly oriented with respect to one another and may also be at least partially coated withcoating material 1256. When shifted to the folded configuration, at least one dimension of at least a portion of gaps 1270 a-g may change and, as shown in the embodiment depicted inFIG. 51 , gaps 1270 a-g may contract whenstructural system 1250 is shifted to the folded configuration. Once in the folded configuration,structural system 1250 may have a generally rounded or arcuate shape, making it particularly suitable for use in construction applications, particularly those for curved walls or surfaces. - Referring now to
FIGS. 52 and 53 , still another embodiment of an extrusion-coatedstructural system 1300 is illustrated as comprising a pair ofsubstrates coating material 1316 extrusion coated onto at least a portion ofsubstrates structural system 1300 comprises a pair of bridgingmembers substrate 1312 to at least a portion of theother substrate 1314. Bridgingmembers coating material 1316, which may, in one embodiment, be continuous with at least a portion of thecoating material 1316 coated ontosubstrates FIGS. 52 and 53 , bridgingmember 1340 may be the only connection member betweensubstrates - As shown in the embodiment depicted in
FIGS. 52 and 53 ,substrates gap 1344 across which bridgingmember structural system 1300 may be shiftable between an extended configuration, as shown inFIG. 53 , and a contracted configuration, as generally shown inFIG. 52 . When arranged in an extended configuration,gap 1344 betweensubstrates structural system 1300 is arranged in a contracted configuration. At least a portion of the transition between an extended and a contracted configuration may folding or bending at least one of bridgingmember gap 1344, as shown inFIG. 52 . - In one embodiment, at least one functional element (not shown), such as, for example, piping, electrical conduit, wires, cables, lighting elements or fixtures, and combinations thereof, may be inserted into
gap 1344 whenstructural system 1300 is in an extended configuration shown inFIG. 53 , and thereafter,system 1300 may be shifted to a retracted configuration, as depicted inFIG. 52 , to hold, support, or just hide the functional element withingap 1344. In one embodiment,structural system 1300 may be particularly useful in as a furniture component or a construction material. In addition to enhancing the aesthetics of the ultimate article or material,structural system 1300 may also provide additional functionality as a holding device for a variety of functional elements. - Turning now to
FIGS. 54-56 , one embodiment of an extrusion-coatedstructural system 1350 is shown as comprising a plurality ofsubstrates coating material 1358 extrusion coated onto at least a portion ofsubstrates Structural system 1350 further includes a bridgingmember 1370 extending between at least a portion ofsubstrate member 1372 extending between at least a portion ofsubstrate FIGS. 54-56 ,substrates structural system 1350 are arranged in a nested configuration, with at least a portion ofsubstrates cavity 1382 at least partially defined bysubstrate 1356 and/orsubstrate 1352 being at least partially disposed within acavity 1384 defined bysubstrate 1354. In one embodiment,substrates structural system 1350, while, in another embodiment, each ofsubstrates -
Structural system 1350 can be configured to be shifted between a flat configuration, shown inFIG. 53 , to at least one extended configuration, shown inFIGS. 54 and 55 usingbridging members 1370 and/or 1372. To shiftstructural system 1350 from a flat configuration, as shown inFIG. 53 , to an assembled configuration, as shown inFIGS. 54 and 55 , bridgingmembers 1370 and/or 1372 may be bent, rotated, or otherwise flexed so that the position of one ofsubstrates substrates substrates FIGS. 53-55 , one of bridgingmember 1370 may be configured to rotate, move, bend, or flex in a different direction than theother bridging member 1372, such that one or more ofsubstrates other substrates structural system 1350 may be particularly useful for furniture or cabinetry applications, including, for example, in modular furniture applications. In addition to being simpler to assemble, such structural system may also be simpler and/or less expensive to manufacture and ship than similar conventional items. - Turning now to
FIGS. 57-59 , a further embodiment of an extrusion-coatedstructural system 1400 is illustrated as comprising a plurality ofsubstrates substrates FIGS. 57-59 ,structural system 1400 also includes at least onebridging member 1440 extending between at least a portion of two or more ofsubstrates substrates gaps FIG. 57 , each ofgaps structural system 1400 in a desired end configuration. - According to one embodiment shown in
FIG. 57 , the position of one or more ofsubstrates other substrates member 1440. For example,structural system 1400 may be shifted between a flat position, as shown by the solid lines inFIG. 57 , to a folded configuration, shown by the dashed lines inFIG. 57 and the solid lines inFIG. 58 , by movingsubstrates arrows substrates FIG. 58 , a hardware member, shown aspanel 1436, may be inserted into astructural recess 1438 collectively defined bysubstrates FIG. 59 , may be used in a variety of furniture or cabinetry applications. Additionally, one or more additional hardware members (not shown), such a shelves and shelf supports, hinges, slides, and the like may also be included in structural system 1450, depending on its specific end use. In one embodiment, structural system 1450 can be used as a cabinet box, a drawer, a shelf, a dresser, or any other suitable item. - Several extrusion-coated structural systems configured according to embodiments of the present invention have been discussed in detail above. Although one or more features of these systems may have only been described with reference to one or a few of the embodiments illustrated in the Figures, it should be understood that the particular embodiments described above are exemplary and one or more features described with respect to one embodiment above could be used in a structural system configured according to another embodiment and still fall within the scope of the present invention. Similarly, one or more features of structural system described above could be combined to form another structural system not particularly illustrated without departing from the spirit of the present invention.
- In another aspect, the present invention relates to methods of assembling one or more of the extrusion-coated structural systems described in detail above. For example, in one embodiment, one or more structural systems of the present invention may be assembled by contacting at least a portion of one structural member with another structural member to form at least a portion of the structural system. In one embodiment, the contacting can include joining one structural member to another by, for example, inserting a hardware protrusion into a structural recess so that the hardware protrusion is at least partially supported by at least a portion of a recess attachment surface and/or inserting a structural protrusion into a hardware recess so that the protrusion attachment surface is at least partially supported by at least a portion of the hardware recess. In one embodiment, at least one of the structural members is a reinforced structural member including a reinforced region proximate the location where the structural members are joined. The action of inserting the protrusion into the recess may include, for example, sliding, rotating, or snapping a protrusion into its corresponding recess, and the protrusion, once inserted, may be configured for movement within the recess as discussed in detail previously.
- In another embodiment, the contacting can include contacting at least a portion of a structural member with one or more extruded profile members of a second substrate, as discussed in detail previously. In one embodiment wherein the extruded profile member includes a profile recess, the contacting can include inserting a hardware, structural, or profile protrusion into the profile recess, while, in another embodiment, the contacting can include inserting a profile protrusion defined by the extruded profile member into a structural, profile, or hardware recess. Subsequent to the contacting, at least one hardware member, or an adhesive material, may be used to secure the structural member in a desired configuration.
- Assembly of an extrusion-coated structural system can also include adjustment of the position of one or more structural member relative to one or more other structural members and, may, for example, be done using a bridging member. When the structural system comprises a bridging member, the adjustment of the relative position of one or more substrates can be accomplished without decoupling the substrates and may be accomplished within the an angular range of motion as described previously.
- Once assembled, the structural system of the present invention may remain assembled or, in one embodiment, at least a portion, or all, of the structural system may be disassembled. Disassembly can generally be carried out by repeating the steps of assembly in reverse and may include, for example, re-adjustment of the positions of one or more substrates, removal of a hardware or profile protrusion from a structural recess, removal of a structural protrusion from a hardware or profile recess, and/or breaking of contact between two or more substrates. When disassembled, structural systems of the present invention exhibit little or no damage to the component parts, and in some cases, such as structural systems including at least one bridging member, the substrates may not be uncoupled during disassembly.
- Once disassembled, the components can be shipped or stored in a disassembled state and/or may be reassembled at a different time, sometimes in a slightly different configuration. For example, in one embodiment, the structural system of the present invention can include at least one adjustable component, configured to be arranged within the structural system in more than one position. In one embodiment, this may include a structural member having multiple hardware insertion points or a structural member having an extruded profile member configured to contact more than one additional structural member. The flexibility of design, along with the ability for repeated use may be unique and beneficial features of the extrusion-coated structural systems of the present invention.
- In another aspect, the present invention relates to methods of making extrusion-coated structural systems, including the extrusion-coated structural systems described above. In one embodiment, the method of making one or more of the extrusion-coated structural systems or extrusion-coated structural members of the present invention can include extrusion coating at least one coating material onto at least a portion of one or more substrates. As discussed previously, the term “extrusion coating” refers to a process for applying a fluid coating material onto at least a portion of a substrate, optionally under pressure and/or at an elevated temperature. As used herein, the term “extrusion coating” can include applying different thickness of coating to different regions of the substrate and also encompasses the formation of one or more extruded profile members extending outwardly from the substrate, whether or not the profile member includes underlying substrate. Further details regarding the methods for making extrusion-coated structural members according to embodiments of the present invention will be discussed in detail below, with reference to
FIG. 60 . - Referring now to
FIG. 60 , a schematic flow diagram of anextrusion coating system 1512 configured according to one embodiment of the present invention is provided.Coating system 1512 is illustrated as comprising apretreatment zone 1514, adrying zone 1516, anoptional staging area 1518, an extrusion coating die 1520, a quenchzone 1522, and an optionalpost treatment zone 1524. As shown inFIG. 60 , one or more substrates can be sequentially passed throughpretreatment zone 1514, dryingzone 1516, andoptional staging area 1518 before being introduced into extrusion coating die 1520, which is configured to facilitate contact between at least a portion of the surface of the substrate or substrates and at least one coating material introduced into die 1520 from acoating source 1530. The resulting coated article can be cooled inquench zone 1522 before being optionally treated in apost treatment zone 1524. If not further processed in post-treatment inzone 1524, the cooled, coated substrate may simply be removed fromcoating system 1512, as indicated byline 1526. -
Coating system 1512 can be configured to process any substrate capable of being extrusion coated and suitable for use in extrusion-coated structural systems according to embodiments of the present invention. The substrates used may be rigid or substantially rigid substrates and can have any suitable dimensions. According to one embodiment, the substrate being coated for use in one or more extrusion-coated structural systems described above may have a length, or largest dimension, of at least about 5 feet, at least about 6 feet, at least about 8 feet, at least about 10 feet, at least about 12 feet and/or not more than about 25 feet, not more than about 20 feet, or not more than about 15 feet. In the same or another embodiment, the substrate can have a length in the range of from about 5 feet to about 25 feet, about 8 feet to about 20 feet, or about 10 feet to about 15 feet. The substrate can also have a width, or second largest dimension, of at least about 1 inch, at least about 2 inches, or at least about 4 inches and/or not more than about 10 inches, not more than about 8 inches, or not more than about 6 inches, or in the range of from about 1 to about 10 inches, about 2 to about 8 inches, or about 4 to about 6 inches. The thickness, or shortest dimension, of the substrate being coated incoating system 1512 can be at least about 0.10 inches, at least about 0.25 inches, at least about 0.5 inches and/or not more than about 4 inches, not more than about 2 inches, or not more than about 1 inch, or in the range of from about 0.10 to about 4 inches, about 0.25 to about 2 inches, or about 0.5 to about 1 inch. - Substrates being extrusion coated in
coating system 1512 and suitable for use in the extrusion-coated structural system described herein made of a variety of substrate materials. In one embodiment, the substrates coated incoating system 1512 can comprise a single material, while, in another embodiment, the substrate can be a composite of two or more different materials. Examples of suitable materials can be one or more of natural wood, wood composites, plastics including cellularized PVC and other foams, metal, fiberglass-reinforced thermoset or thermoplastic polymers, ceramics, cement, and combinations thereof. In the same or another embodiment, the substrate material comprises medium-density fiber board (MDF), particle board, oriented strand board (OSB), high-density fiberboard (HDF), wood-filled plastic, wood-plastic composites, ultra-light density fiber board (LDF), plywood, and combinations thereof. - The coating material applied to the substrate in
coating system 1512 can be any coating material exhibiting sufficient processability and adhesion to the selected substrate. In one embodiment, the coating material may have an elongation at break, as measured by ASTM D882, of at least about 1 percent, at least about 5 percent, at least about 10 percent, at least about 25 percent, at least about 40 percent, at least about 55 percent, at least about 70 percent and/or not more than about 250 percent, not more than about 200 percent, not more than about 150 percent, or not more than 100 percent. - The elongation at break of the coating material used in one or more embodiments described herein may be in the range of from about 1 to about 250 percent, about 1 to about 200 percent, about 1 to about 150 percent, about 1 to about 100 percent, about 5 to about 250 percent, about 5 to about 200 percent, about 5 to about 150 percent, about 5 to about 100 percent, about 10 to about 250 percent, about 10 to about 200 percent, about 10 to about 150 percent, about 10 to about 100 percent, about 25 to about 250 percent, about 25 to about 200 percent, about 25 to about 150 percent, about 25 to about 100 percent, about 40 to about 250 percent, about 40 to about 200 percent, about 40 to about 150 percent, about 40 to about 100 percent, about 55 to about 250 percent, about 55 to about 200 percent, about 55 to about 150 percent, about 55 to about 100 percent, about 70 to about 250 percent, about 70 to about 200 percent, about 70 to about 150 percent, about 70 to about 100 percent.
- The coating material can have a yield stress of at least about 5 MPa, at least about 10 MPa, at least about 15 MPa, at least about 20 MPa, at least about 25 MPa and/or not more than about 50 MPa, not more than about 45 MPa, not more than about 40 MPa, or not more than about 35 MPa, measured according to the procedure provided in ASTM D882. The yield stress of the coating material used in one or more embodiments described herein can be in the range of from about 5 to about 50 MPa, about 5 to about 45 MPa, about 5 to about 40 MPa, about 5 to about 35 MPa, about 10 to about 50 MPa, about 10 to about 45 MPa, about 10 to about 40 MPa, about 10 to about 35 MPa, about 15 to about 50 MPa, about 15 to about 45 MPa, about 15 to about 40 MPa, about 15 to about 35 MPa, about 20 to about 50 MPa, about 20 to about 45 MPa, about 20 to about 40 MPa, about 20 to about 35 MPa, about 25 to about 50 MPa, about 25 to about 45 MPa, about 25 to about 40 MPa, about 25 to about 35 MPa. This may be in contrast, for example, to conventional coatings like paints, which have a yield stress of less than 1 MPa.
- The coating material can also have a percent yield strain of at least about 1 percent, at least about 2 percent, at least about 5 percent and/or not more than about 8 percent, not more than about 6 percent, as calculated by ASTM D882. This may be, in some cases, lower than conventional coatings, such a paint, which may exhibit a percent yield strain greater than 9 percent. The coating material used herein may also have a modulus of at least about 10 MPa, at least about 50 MPa, at least about 100 MPa, at least about 500 MPa, at least about 1000 MPa, at least about 1200 MPa and/or not more than about 2500 MPa, not more than about 2000 MPa, not more than about 1500 MPa, measured according to ASTM D882. The modulus of the coating material can be in the range of from about 10 to about 2500 MPa, about 10 to about 2000 MPa, about 10 to about 1500 MPa, about 50 to about 2500 MPa, about 50 to about 2000 MPa, about 50 to about 1500 MPa, about 100 to about 2500 MPa, about 100 to about 2000 MPa, about 100 to about 1500 MPa, about 500 to about 2500 MPa, about 500 to about 2000 MPa, about 500 to about 1500 MPa, about 1000 to about 2500 MPa, about 1000 to about 2000 MPa, about 1000 to about 1500 MPa, about 1200 to about 2500 MPa, about 1200 to about 2000 MPa, about 1200 to about 1500 MPa.
- The coating material may comprise one or more polymers or resins, such as thermoplastic polymers or resins capable of being applied to the substrate in a molten or melted form. The coating material may be a resin coating comprising at least one thermoplastic and/or at least one thermosetting resin. In one embodiment, the resin can be present in the coating material in an amount of at least about 30 weight percent, at least about 40 weight percent, at least about 50 weight percent, at least about 60 weight percent and/or not more than about 99 weight percent, not more than about 90 weight percent, not more than about 85 weight percent, based on the total weight of the composition.
- Suitable thermoplastic resins can be those having one or more properties within certain ranges. For example, in one embodiment, the thermoplastic resin employed in the coating material extrusion coated onto the substrate may have a glass transition temperature of at least about 60° C., at least about 70° C., at least about 80° C. and/or not more than about 150° C., not more than about 140° C., or not more than about 130° C. The glass transition temperature can be in the range of from about 60 to about 150° C., about 60 to about 140° C., about 60 to about 130° C., about 70 to about 150° C., about 70 to about 140° C., about 70 to about 130° C., about 80 to about 150° C., about 80 to about 140° C., about 80 to about 130° C.
- In the same or another embodiment, the thermoplastic resin can have an inherent viscosity (I.V.), measured at 25° C. in 60/40 wt/wt phenol/tetrachloroethane, of at least about 0.50, at least about 0.65, at least about 0.69 dL/g and/or not more than about 1.4, not more than about 1.2, not more than about 1.0, not more than about 0.9, not more than about 0.85 dL/g, or in the range of from about 0.50 to about 1.4 dL/g, about 0.50 to about 1.2 dL/g, about 0.50 to about 1.0 dL/g, about 0.50 to about 0.9 dL/g, about 0.50 to about 0.85 dL/g, about 0.65 to about 1.4 dL/g, about 0.65 to about 1.2 dL/g, about 0.65 to about 1.0 dL/g, about 0.65 to about 0.9 dL/g, about 0.65 to about 0.85 dL/g, about 0.69 to about 1.4 dL/g, about 0.69 to about 1.2 dL/g, about 0.69 to about 1.0 dL/g, about 0.69 to about 0.9 dL/g, about 0.69 to about 0.85 dL/g.
- In addition, the thermoplastic resin may be amorphous, crystalline, or semi-crystalline and can have a crystallization half-time of at least about 5, at least about 50, at least about 100, at least about 1000, at least about 10,000 minutes measured at 170° C. The crystallization half time of the polyester, as used herein, may be measured using methods well-known to persons of skill in the art. The crystallization half time of the polyester, t1/2, was determined by measuring the light transmission of a sample via a laser and photo detector as a function of time on a temperature controlled hot stage. This measurement was done by exposing the polymers to a temperature, Tmax, and then cooling it to the desired temperature. The sample was then held at the desired temperature by a hot stage while transmission measurements were made as a function of time. Initially, the sample was visually clear with high light transmission and became opaque as the sample crystallizes. The crystallization half-time is the time at which the light transmission was halfway between the initial transmission and the final transmission. Tmax is defined as the temperature required to melt the crystalline domains of the sample (if crystalline domains are present). The sample is heated to Tmax to condition the sample prior to crystallization half time measurement. The absolute Tmax temperature is different for each composition.
- The thermoplastic resin utilized in the coating material may be chosen from linear thermoplastic resins, branched thermoplastic resins, hyperbranched thermoplastic resins, and star-shaped thermoplastic resins. Non-limiting examples of suitable thermoplastic resins include polyesters, copolyesters, acrylics, polycarbonates and mixtures thereof. Additional non-limiting examples include poly(ethylene terephthalate) (PET), PETG copolyester, poly(methyl methacrylate) (PMMA), poly(acrylonitrile-styrene-acrylate) (ASA), poly(acrylonitrile-butadiene-styrene) (ABS), poly(styrene-acrylonitrile) (SAN) and mixtures thereof. Examples of thermoplastic resins include, but are not limited to, EASTAR copolyester 6763, a PETG available from Eastman Chemical Company; LURAN HD, a SAN available from BASF; TERLURAN GP-22, an ABS available from BASF; Modified Acrylate, a PMMA available from Degussa; and CENTREX 833, an ASA available from Lanxess. In one embodiment, the thermoplastic resin used in the coating material can be selected from the group consisting of polyesters, copolyesters, polycarbonates, polymethyl methacrylate (PMMA), including impact-modified PMMA, poly(acrylonitrile-styrene-acrylate) (ASA), poly(acrylonitrile-butadiene-styrene) (ABS), poly(styrene-acrylonitrile) (SAN), cellulose esters and mixtures thereof. According to one embodiment, the resin coating can include a copolyester comprising at least 80 mole percent of acid residues from terephthalic acid, derivatives of terephthalic acid and mixtures thereof, at least 80 mole percent of glycol residues from ethylene glycol and 1,4-cyclohexanedimethanol, wherein the acid residues are based on 100 mole percent of acid residues and the glycol residues are based on 100 mole percent of glycol residues.
- According to another embodiment, the coating material can comprise at least one polyester that includes 70 to 100 mole percent acid residues from terephthalic acid, 0 to 30 mole percent aromatic dicarboxylic acid residues having up to 20 carbon atoms, and 0 to 10 mole percent of aliphatic dicarboxylic acid residues having up to 16 carbon atoms wherein the acid residues are based on 100 mole percent acid residue. The resin coating could also comprise a polyester comprising 80 to 100 mole percent acid residues from terephthalic acid, 0 to 20 mole percent aromatic dicarboxylic acid residues having up to 20 carbon atoms, and 0 to 10 mole percent of aliphatic dicarboxylic acid residues having up to 16 carbon atoms wherein the acid residues are based on 100 mole percent acid residues. In another embodiment, the resin coating can comprise a polyester comprising 90 to 100 mole percent acid residues from terephthalic acid, 0 to 10 mole percent aromatic dicarboxylic acid residues having up to 20 carbon atoms, and 0 to 10 mole percent of aliphatic dicarboxylic acid residues having up to 16 carbon atoms wherein the acid residues are based on 100 mole percent acid residues.
- In addition to the resin component, the coating material may also include one or more additional components, including, for example, at least one opacity modifier, at least one gloss modifier, at least one impact modifier, and combinations thereof. When included, the opacity modifier can be present in the coating material in an amount of at least about 0.5 percent, at least about 1 percent, at least about 2 percent and/or not more than about 20 percent, not more than about 15 percent, not more than about 10 percent, based on the total weight of the coating material. The opacity modifier can be present in the coating material in an amount in the range of from about 0.05 to about 20 percent, about 0.05 to about 15 percent, about 0.05 to about 10 percent, about 1 to about 20 percent, about 1 to about 15 percent, about 1 to about 10 percent, about 2 to about 20 percent, about 2 to about 15 percent, about 2 to about 20 percent, based on the total weight of the coating material. Non-limiting examples of suitable opacity modifiers include metal oxides and metal salts, such as, for example, zinc oxide (ZnO), mica, white lead, barium sulfate (BaSO4), zinc sulfide (ZnS), antimony oxide and titanium dioxide (TiO2).
- In the same or another embodiment, the coating material can include at least about 1, at least about 5, at least about 10 and/or not more than about 50, not more than about 40, not more than about 30 weight percent, based on the total weight of the coating material, of one or more gloss modifiers. The coating material can include gloss modifiers in an amount in the range of from about 1 to about 50 percent, about 1 to about 40 percent, about 1 to about 30 percent, 5 to about 50 percent, about 5 to about 40 percent, about 5 to about 30 percent, 10 to about 50 percent, about 10 to about 40 percent, about 10 to about 30 percent, based on the total weight of the coating material.
- Non-limiting examples of suitable inorganic fillers include talc (magnesium silicate), silica, kaolin clay, alumina and calcium carbonate (CaCO3). Examples of polymeric fillers include, but are not limited to, BLENDEX BMAT (a cross-linked styrene acrylonitrile in a polystyrene matrix) available from Chemtura and Galata Chemicals, ECDEL elastomers available from Eastman Chemical Company and PARALOID KM-377 (an acrylate polymer) available from Rohm and Haas and The Dow Chemical Company.
- Additionally, in one embodiment, the coating material can further include at least one impact modifier present in the coating material in an amount of at least about 0.5 percent, at least about 1 percent, at least about 2 percent and/or not more than about 20 percent, not more than about 15 percent, not more than about 10 percent, based on the total weight of the coating material. The impact modifier may be present in the coating composition in an amount in the range of from about 0.5 to about 20 percent, about 0.5 to about 15 percent, about 0.5 to about 10 percent, about 1 to about 20 percent, about 1 to about 15 percent, about 1 to about 10 percent, about 2 to about 20 percent, about 2 to about 15 percent, about 2 to about 10 percent, based on the total weight of the coating composition. Non-limiting examples of the at least one impact modifier include polymers based on a polyolefin rubbery segment, sometimes also referred to as a rubbery phase, polymers based on a polyether rubbery phase, polymers based on an acrylic rubbery phase and polymers based on a butadiene and/or isoprene rubbery phase. In an embodiment, the at least one impact modifier is chosen from poly(acrylonitrile butadiene styrene) (ABS) polymers.
- In addition, in one embodiment, one or more other application-specific additives could also be used. Such additional additives may include, but are not limited to, gloss modifiers, opacity modifiers, impact modifiers, adhesion modifiers, pigments, flame retardants, UV absorbers, antioxidants, colorants, and optical brighteners. Generally, for polymeric formulations that are to be used as primers, an opaque white coloring is desired. Titanium dioxide a widely used white pigment, but a variety of other metal oxides and salts may be used. The amount of the additive or additives employed in the coating material can vary, and, in one embodiment, can be at least about 0.01 weight percent, at least about 0.5 weight percent, at least about 0.75 weight percent and/or not more than about 5 weigh percent, not more than about 2.5 weight percent, or not more than about 1 weight percent, based on the total weight of the coating composition. The total amount of additives present in said coating composition can be in the range of from about 0.01 to about 5 weight percent, about 0.01 to about 2.5 weight percent, about 0.01 to about 1 weight percent, about 0.5 to about 5 weight percent, about 0.5 to about 2.5 weight percent, about 0.5 to about 1 weight percent, about 0.75 to about 5 weight percent, about 0.75 to about 2.5 weight percent, about 0.75 to about 1 weight percent, based on the total weight of the coating material.
- Referring back to
FIG. 60 , the substrate can initially be introduced into apretreatment zone 1514, which can comprise one or more stages configured to prepare the substrate for coating. For example,pretreatment zone 1514 can include one or more milling stages for forming an initial blank stock, or precursor, substrate into a substrate having a desired shape by milling and/or cutting the substrate to a desired profile and/or length. In another embodiment, one or more recesses or cavities may also be cut into the precursor substrate to thereby provide a substrate ready for extrusion coating. - Optionally,
pretreatment zone 1514 may also comprise at least one cleaning stage for removing particles of dirt, dust, or other debris from the surface of the substrate before coating. The cleaning stage may comprise a high pressure steam cleaning, a high pressure air cleaning, a solvent cleaning, a water bath cleaning, and/or any other cleaning process appropriate for the particular type of substrate employed incoating system 1512. In one embodiment,pretreatment zone 1514 may include a stain bath for staining at least a portion of the substrate prior to coating. - Following pretreatment, the substrate can then be introduced into
drying zone 1516, wherein at least a portion of the surface of the substrate may be heated to thereby facilitate removal of at least some of the volatile materials within the substrate, if present. Once removed from dryingzone 1516, the substrate can pass throughoptional staging area 1518 before being introduced intodie 1520 via afeed system 1528, which may be configured to properly align the one or more substrates being coated with at least one inlet of die 1520 (not shown). - In one embodiment,
feed system 1528 can comprise a plurality of rollers, positioned above and below the substrate (not shown), which are configured to engage and push the substrate or substrates intodie 1520.Feed system 1528 may be configured to supply one or more substrates into die 1520 in a substantially continuous manner, such that, for example, the individual substrate members are fed to thedie 1520 in a butt-to-butt manner, where contact is maintained between the back end of a first substrate member and the front end of a second substrate member fed behind the first substrate member. According to another embodiment, two substrates may be fed into die 1520 spaced apart from one another and the space between the substrates may be maintained during the coating process. - As the substrate is introduced into
die 1520, at least a portion of the surface of the substrate can be contacted with a coating material introduced into die 1520 fromcoating source 1530.Coating source 1530 can be any suitable system or apparatus for providing a coating, and, in one embodiment, may be an extruder. The temperature in thedie 1520 during the coating process can be any temperature sufficient to maintain the incoming coating material in a liquid or substantially liquid state. In one embodiment, the temperature in die 1520 during coating can be at least about 50° C., at least about 100° C., at least about 200° C. and/or not more than about 500° C., not more than about 400° C., not more than about 300° C., or in the range of from about 50 to about 500° C., about 50 to about 400° C., about 50 to about 300° C., about 100 to about 500° C., about 100 to about 400° C., about 100 to about 300° C., about 200 to about 500° C., about 200 to about 400° C., about 200 to about 300° C. The pressure in die 1520 during the coating step can be at least about 25 pounds per square inch (psi), at least about 50 psi, at least about 100 psi and/or not more than about 5,000 psi, not more than about 3,500 psi, not more than about 2,000 psi, not more than about 1,500 psi, not more than 1,000 psi, or in the range of from about 25 to about 5,000 psi, about 25 to about 3,500 psi, about 25 to about 2,000 psi, about 25 to about 1,500 psi, or about 25 to about 1,000 psi, about 50 to about 5,000 psi, about 50 to about 3,500 psi, about 50 to about 2,000 psi, about 50 to about 1,500 psi, or about 50 to about 1,000 psi, about 100 to about 5,000 psi, about 100 to about 3,500 psi, about 100 to about 2,000 psi, about 100 to about 1,500 psi, or about 100 to about 1,000 psi. - The coating may be applied to at least a portion, or substantially all, of the surface of the substrate such that at least about 50 percent, at least about 65 percent, at least about 75 percent, at least about 85 percent, or at least about 95 percent of the total surface area of substrate is covered with a coating material. Thus, in one embodiment, one or more sides of an n sided substrate (wherein n is an integer between 3 and 10, inclusive) may be left partially or totally uncoated, such that n−1 sides are completely coated by the material. In another embodiment, the entirety of the outer surface of the substrate may be coated such that all sides of the substrate are completely encapsulated by the coating material. The average thickness of the coating material may be in the ranges discussed previously.
- When the substrate includes a structural recess and/or a structural protrusion as discussed previously, the extrusion coating step carried out in die 1520 may include applying at least one coating material to one or more surfaces presented by the structural recess and/or the structural protrusion, thereby forming the recess attachment or protrusion attachment surfaces described above. In one embodiment, when the substrate includes a structural recess, the coating material extruded onto the recess surface may be sufficient to at least partially fill the structural recess with coating material. For example, in one embodiment, the maximum thickness of the coating material within the structural recess may be at least 2 times greater than the thickness of the coating material forming the near recess external surface of the extrusion-coated structural member.
- In one embodiment, a second coating material may be applied to at least a portion of the substrate, including at least one recess and/or protrusion surface, either by extrusion coating or any other suitable method. In one embodiment, the first and second coating materials can be applied in an alternating or “striped” pattern, while, in another embodiment, at least a portion of one of the coating materials may overlap or be layered with the other. According to one embodiment, the second coating material may also be applied to the substrate by extrusion coating, simultaneous with, or subsequent to, application of the first coating material.
- Referring back to
FIG. 60 , the extrusion coated structuralmember exiting die 1520 may be routed to a cooling or quenchzone 1522, wherein the extrusion-coated structural member can be cooled via contact with a cooling fluid. In one embodiment, the cooling performed in cooling or quenchzone 1522 may be sufficient to reduce the surface temperature of the coated substrate by at least about 5° C., at least about 10° C., at least about 15° C., at least about 20° C., at least about 25° C., or at least about 30° C. Examples of suitable cooling fluids can include air, an inert gas, and/or water and quenchzone 1522 may or may not have a pressure greater than atmospheric. Subsequent to quenchzone 1522, the cooled extrusion-coated structural member can be optionally sent to apost-treatment zone 1524, wherein one or more additional processing and/or treatment steps may be carried out. In one embodiment,post-treatment zone 1524 can employ one or more processes to alter at least one property of the extrusion-coated structural member and may also include other post-coating treatments such as milling, cutting, or even assembling and/or packaging. - According to one embodiment of the present invention, structural members as described herein may exhibit enhanced properties or characteristics as compared to similarly-configured, but uncoated or conventionally-coated (e.g., painted), substrates. For example, in some cases, application of one or more coating materials as described herein to a substrate that comprises at least one protrusion may result in a structural member having increased strength and/or durability, and which may be less likely to crack or fail during use.
- Turning now to
FIGS. 61-63 , one example of astructural system 1750 that includes a pair ofstructural members FIGS. 61-63 as including only a firststructural member 1752 and a secondstructural member 1762, it should be understood thatstructural system 1750 can include any suitable number of structural members, including, for example, at least about 2 structural members, at least about 5 structural members, at least about 10 structural members, and/or not more than about 100 structural members, not more than about 75 structural members, not more than about 50 structural members, or not more than about 30 structural members. When more than two structural members are employed instructural system 1750, one or both ofstructural members FIGS. 61-63 . - Additionally, although represented being configured similarly to
structural system 1650 depicted inFIGS. 22 and 23 , it should also be understood that enhanced properties as described in further detail below may also be present in a variety of other structural systems configured according to aspects of the present invention, including one or more of the structural systems described in detail previously. - Turning again to
FIGS. 61 and 62 , each ofstructural members substrate coating material respective substrates substrates coating materials 1756 and/or 1766 may, in some embodiments, coat only a portion of the surface area ofrespective substrates - In one embodiment,
coating materials 1756 and/or 1766 may be applied to (coated onto) at least about 50 percent, at least about 60 percent, at least about 70 percent, at least about 80 percent, at least about 90 percent, at least about 95 percent, or at least about 99 percent of the total surface area ofsubstrates 1754 and/or 1764.Coating materials 1756 and/or 1766 may extend continuously around at least three, at least four, or all sides of at least one cross-section ofsubstrates 1754 and/or 1764. In some cases, all or nearly all of the surface area ofsubstrates 1754 and/or 1764 may be coated so that, for example, less than about 10 percent, less than about 5 percent, less than about 2 percent, less than about 1 percent of the total surface area ofsubstrates 1754 and/or 1764 is not coated with the coating material. -
Coating materials second substrates structural members coating materials substrates coating materials substrates coating material 1756 and/or 1766 applied torespective substrates 1754 and/or 1764 may lie within the ranges described in detail previously. -
Coating materials Coating material 1756 applied tosubstrates 1754 may be the same as, or different than,coating material 1766 applied tosubstrate 1764. In one embodiment,coating materials 1756 and/or 1766 can comprise at least one resin, which may be a thermoplastic or thermosetting resin. Exemplary resins include, but are not limited to, those selected from the group consisting of polyesters, acrylics, cellulose esters, nylons, polyolefins, polyvinyl chloride, acrylonitrile-butadiene-styrene (ABS) copolymers, styrene-acrylonitrile copolymers (SAN), other styrene-based polymers and copolymers, polycarbonates, and combinations thereof. In addition to one or more of the resins listed above,coating material 1756 and/or 1766 can further include at least one other additive of the type and/or in the amount described in detail previously. -
Substrates Substrates 1754 and/or 1764 can be formed of the same material or may be formed of different materials, and any additional structural members (not shown inFIGS. 61 and 62 ) may also comprise the same or a different material thansubstrates 1754 and/or 1764. Additionally, one or both ofsubstrates 1754 and/or 1764 may be formed of two or more different materials. In one embodiment, the average density ofsubstrates 1754 and/or 1764 can be at least about 30 lb/ft3, at least about 35 lb/ft3, at least about 40 lb/ft3, at least about 45 lb/ft3 and/or not more than about 65 lb/ft3, not more than about 60 lb/ft3, not more than about 55 lb/ft3, not more than about 50 lb/ft3. - In one embodiment,
substrates 1754 and/or 1764 can comprise a non-natural wood material. As used herein, the term “non-natural wood material” refers to any material that includes at least one component other than natural wood. Examples of components other than natural wood can include, but are not limited to, binders, adhesives, plastics, and other materials. Some non-natural wood substrates may include a wood composite (or engineered wood) material that comprises smaller bodies of wood bound together by adhesive, plastic, or other binder material. Specific examples of wood composite materials include, but are not limited to, medium density fiber board (MDF), high density fiberboard (HDF), particle board, oriented strand board (OSB), wood-filled plastic, wood-plastic composites, ultra-light density fiber board (LFB), plywood, and combinations thereof. Other types of non-natural wood materials may not include wood fibers and may, for example, be selected from the group consisting of plastics, glass, metals, foams, fiberglass-reinforced thermoset or thermoplastic polymers, and combinations thereof. -
Substrates substrates 1754 and/or 1764 may comprise a material selected from the group consisting of wood composites, plastics, foams, fiberglass-reinforced thermoset or thermoplastic polymers, and combinations thereof.Substrates 1754 and/or 1764 may also comprise a material selected from the group consisting of medium density fiber board (MDF), high density fiberboard (HDF), particle board, oriented strand board (OSB), wood-filled plastic, wood-plastic composites, ultra-light density fiber board (LFB), plywood, plastic, fiberglass-reinforced thermoset or thermoplastic polymers, foam, cellularized PVC, and combinations thereof. - As shown in one embodiment depicted in
FIGS. 61-63 ,substrate 1754 includes amain body portion 1770 and at least oneprotrusion 1772 extending outwardly frommain body portion 1770. Although shown as including only one protrusion, it should be understood thatsubstrate 1754 may include any suitable number of protrusions, depending on the specific configuration and end use ofstructural member 1752 and/orstructural system 1750. Whensubstrate 1754 includes more than one protrusion, additional protrusions may be located on the same side, or one a different side, ofmain body portion 1770 thanprotrusion 1772 shown inFIG. 61-63 . - In one embodiment, the ratio of the maximum thickness of
main body portion 1770, shown as dimension T1 inFIG. 63 , to the maximum thickness ofprotrusion 1772, shown as dimension T2 inFIG. 63 , can be at least about 1.25:1, at least about 1.5:1, at least about 1.75:1 and/or not more than about 5:1, not more than about 3:1, not more than about 2.5:1, not more than about 2:1. The ratio of the maximum thickness ofmain body portion 1770 to the maximum thickness of protrusion 1772 (T1:T2) can be in the range of from about 1.25:1 to about 5:1, about 1.25:1 to about 3:1, about 1.25:1 to about 2.5:1, about 1.25:1 to about 2:1, about 1.5:1 to about 5:1, about 1.5:1 to about 3:1, about 1.5:1 to about 2.5:1, about 1.5:1 to about 2:1, about 1.75:1 to about 5:1, about 1.75:1 to about 3:1, about 1.75:1 to about 2.5:1, about 1.75:1 to about 2:1. - The maximum thickness of
main body portion 1770 can at least about 0.10 inches, at least about 0.50 inches, at least about 0.75 inches, at least about 1 inch and/or not more than about 3 inches, not more than about 2.5 inches, not more than about 2 inches, not more than about 1.5 inches and/or the maximum thickness ofprotrusion 1772 can be at least about 0.10 inches, at least about 0.50 inches, at least about 0.75 inches, and/or not more than about 2.5 inches, not more than about 2 inches, not more than about 1.5 inches.Main body portion 1770 can have a maximum thickness in the range of from about 0.10 to about 3 inches, about 0.10 to about 2.5 inches, about 0.10 to about 2 inches, about 0.10 to about 1.5 inches, about 0.50 to about 3 inches, about 0.50 to about 2.5 inches, about 0.50 to about 2 inches, about 0.50 to about 1.5 inches, about 0.75 to about 3 inches, about 0.75 to about 2.5 inches, about 0.75 to about 2 inches, about 0.75 to about 1.5 inches, about 1 to about 3 inches, about 1 to about 2.5 inches, about 1 to about 2 inches, about 1 to about 1.5 inches and/orprotrusion 1772 can have a maximum thickness in the range of from about 0.10 to about 2.5 inches, about 0.10 to about 2 inches, about 0.10 to about 1.5 inches, about 0.50 to about 2.5 inches, about 0.50 to about 2 inches, about 0.50 to about 1.5 inches, about 0.75 to about 2.5 inches, about 0.75 to about 2 inches, about 0.75 to about 1.5 inches. - In one embodiment,
protrusion 1772 can extend outwardly frommain body portion 1770 for a maximum distance, shown as L1 inFIG. 63 , for a distance of at least about 0.10 inches, at least about 0.25 inches, at least about 0.50 inches, at least about 1 inch, at least about 1.5 inches and/or not more than about 5 inches, not more than about 3 inches, not more than about 2.5 inches, not more than about 2 inches, or in the range of from about 0.10 to about 5 inches, about 0.10 to about 3 inches, about 0.10 to about 2.5 inches, about 0.10 to about 2 inches, about 0.25 to about 5 inches, about 0.25 to about 3 inches, about 0.25 to about 2.5 inches, about 0.25 to about 2 inches, about 0.50 to about 5 inches, about 0.50 to about 3 inches, about 0.50 to about 2.5 inches, about 0.50 to about 2 inches, about 1 to about 5 inches, about 1 to about 3 inches, about 1 to about 2.5 inches, about 1 to about 2 inches, about 1.5 to about 5 inches, about 1.5 to about 3 inches, about 1.5 to about 2.5 inches, about 1.5 to about 2 inches. - The ratio of the maximum distance that protrusion 1772 extends outwardly from main body portion 1770 (L1) to the maximum thickness of protrusion 1772 (T2) can be at least about 0.10:1, at least about 0.50:1, at least about 1:1, at least about 1.1:1, at least about 1.25:1, at least about 1.5:1 and/or not more than about 5:1, not more than about 3:1, not more than about 2.5:1, not more than about 2:1. The ratio of the maximum distance that protrusion 1772 extends outwardly from
main body portion 1770 to the maximum thickness of protrusion 1772 (L1:T2) can be in the range of from about 0.10:1 to about 5:1, about 0.10:1 to about 3:1, about 0.10:1 to about 2.5:1, about 0.10:1 to about 2:1, about 0.50:1 to about 5:1, about 0.50:1 to about 3:1, about 0.50:1 to about 2.5:1, about 0.50:1 to about 2:1, about 1:1 to about 5:1, about 1:1 to about 3:1, about 1:1 to about 2.5:1, about 1:1 to about 2:1, about 1.1:1 to about 5:1, about 1.1:1 to about 3:1, about 1.1:1 to about 2.5:1, about 1.1:1 to about 2:1, about 1.25:1 to about 5:1, about 1.25:1 to about 3:1, about 1.25:1 to about 2.5:1, about 1.25:1 to about 2:1. - The ratio of the maximum distance that protrusion 1772 extends outwardly from main body portion 1770 (L1) to the maximum thickness of main body portion (T1) can be at least about 0.05:1, at least about 0.10:1, at least about 0.25:1, at least about 0.50:1, at least about 0.75:1 and/or not more than 3:1, not more than about 2.5:1, not more than about 2:1, not more than about 1.5:1, or in the range of from about 0.05:1 to about 3:1, about 0.05:1 to about 2.5:1, about 0.05:1 to about 2:1, about 0.05:1 to about 1.5:1, about 0.10:1 to about 3:1, about 0.10:1 to about 2.5:1, about 0.10:1 to about 2:1, about 0.10:1 to about 1.5:1, about 0.25:1 to about 3:1, about 0.25:1 to about 2.5:1, about 0.25:1 to about 2:1, about 0.25:1 to about 1.5:1, about 0.50:1 to about 3:1, about 0.50:1 to about 2.5:1, about 0.50:1 to about 2:1, about 0.50:1 to about 1.5:1, about 0.75:1 to about 3:1, about 0.75:1 to about 2.5:1, about 0.75:1 to about 2:1, about 0.75:1 to about 1.5:1.
- As shown in
FIGS. 61-63 , secondstructural member 1762 may also include amain body portion 1780 and at least oneprotrusion 1784 a extending outwardly frommain body portion 1780. According to one embodiment shown inFIGS. 61-63 , secondstructural member 1762 may also comprise asecond protrusion 1784 b also extending outwardly frommain body portion 1780. Each of the dimensions and ratios discussed previously with respect tomain body portion 1770 andprotrusion 1772 of firststructural member 1752 may also be applicable tomain body portion 1780 and at least one ofprotrusions 1784 a and/or 1784 b ofsubstrate 1764. Although shown as extending frommain body portion 1780 for similar maximum distances, shown as L2 forprotrusion 1784 a and L3 forprotrusion 1784 b inFIG. 63 , one of the pair ofprotrusions 1784 a,b may extend outwardly frommain body portion 1780 for a different distance than the other. In one embodiment, the ratio of the maximum distance that protrusion 1784 a extends outwardly from main body portion 1780 (L2) to the maximum distance that protrusion 1784 b extends outwardly from main body portion 1780 (L3) can be at least about 0.5:1, at least about 0.60:1, at least about 0.75:1, at least about 0.85:1, at least about 0.95:1 and/or not more than about 0.99:1, not more than about 0.95:1, not more than about 0.85:1, not more than about 0.75:1. Alternatively, the ratio of L2 to L3 can be 1:1, as generally shown inFIG. 63 . - In one embodiment, the pair of
protrusions main body portion 1780 ofsubstrate 1764 may at least partially define at least onerecess 1782.Recess 1782 can have any suitable dimensions and, in one embodiment, can be configured to receive a protrusion (such asprotrusion 1772 of substrate 1754) to couplestructural members recess 1782, shown as dimension WR inFIG. 63 , can be sufficient to permitprotrusion 1772, having a maximum thickness T2 to be inserted, or at least partially inserted, therein. In one embodiment, the ratio of the maximum thickness ofprotrusion 1772 to the width ofrecess 1782 can be at least about 0.75:1, at least about 0.85:1, at least about 0.95:1 and/or not more than 0.99:1, not more than about 0.95:1, not more than about 0.90:1, or in the range of from about 0.75:1 to about 0.99:1, about 0.75:1 to about 0.95:1, about 0.75:1 to about 0.90:1, about 0.85:1 to about 0.99:1, about 0.85:1 to about 0.95:1, about 0.85:1 to about 0.90:1, about 0.90:1 to about 0.99:1, about 0.90:1 to about 0.95:1. - The width of
recess 1782 can be at least about 0.10 inches, at least about 0.50 inches, at least about 0.75 inches, and/or not more than about 2.5 inches, not more than about 2 inches, not more than about 1.5 inches, or can be in the range of from about 0.10 to about 2.5 inches, about 0.10 to about 2 inches, about 0.10 to about 1.5 inches, about 0.50 to about 2.5 inches, about 0.50 to about 2 inches, about 0.50 to about 1.5 inches, about 0.75 to about 2.5 inches, about 0.75 to about 2 inches, about 0.75 to about 1.5 inches. The ratio of the width ofrecess 1782 to the maximum distance of the longer ofprotrusions - Although shown as including a pair of
protrusions 1784 a,b, it should be understood thatsubstrate 1764 may include any suitable number of additional protrusions, depending on the specific configuration and end use ofstructural member 1762 and/orstructural system 1750. Whensubstrate 1764 includes additional protrusions, one or more additional recesses may also be defined. For example, substrate 1764 (and/or substrate 1754) may include N protrusions extending outwardly from main body portion 1780 (or main body portion 1770), wherein N is an integer between 1 and 10, between 2 and 8, or between 2 and 5. In another embodiment, N can be 1. Whensubstrate 1764 and/or 1754 includes N protrusions, it may also comprise or define N−1 recesses between the N protrusions. In some cases, one or more of the protrusions may be disposed on opposite sides ofmain body portion 1780 and/or 1770, thereby resulting in (N−2) or (N−3) recesses, depending on the specific configuration ofstructural member - As particularly shown in
FIG. 62 ,main body portion 1770 ofsubstrate 1754 can present at least onebody surface 1773 andprotrusion 1772 ofsubstrate 1754 can present at least oneprotrusion surface 1775, which intersect to form ajunction 1774 disposed betweenmain body portion 1770 andprotrusion 1772. Similarly,main body portion 1780 ofsubstrate 1764 can present at least onebody surface 1789 and each ofprotrusions protrusion surface body surface 1789 to form a pair ofjunctions main body portion 1780 can present anotherbody surface 1783 and at least one ofprotrusions FIG. 62 as being protrusion 1784 a) can present anotherprotrusion surface 1785 with can intersect withbody surface 1783 to form anotherjunction 1786. Alternatively,body surface 1783 andprotrusion surface 1785 may lie in substantially the same plane, thereby makingjunction 1786 substantially planar. - In one embodiment, it may be advantageous for at least a portion of
coating material 1756 applied tosubstrate 1754 and/or at least a portion ofcoating material 1766 applied tosubstrate 1764 to at least partially cover at least one ofjunctions 1774 ofsubstrate 1754, and/or one or more ofjunctions substrate 1764. Two or more, three or more, or all ofjunctions coating material 1756 and/orcoating material 1766 such that at least a portion of thecoating material 1756 and/or 1766 extends continuously between at least a portion of adjacent protrusion and body surfaces. For example, when junction 1744 is at least partially coated withcoating material 1756, at least a portion ofcoating material 1756 can extend continuously betweenprotrusion surface 1775 andbody surface 1773. Similarly, whenjunction 1786 is at least partially coated withcoating material 1766, at least a portion ofcoating material 1766 may extend continuously betweenprotrusion surface 1785 andbody surface 1783. Alternatively, at least one ofjunctions FIGS. 61 and 62 .) - According to one embodiment of the present invention, application of coating material to all or part of one or
more junctions structural member 1752 and/or 1762, even when the structural member is made from a non-wood substrate as described above. In one embodiment,structural member 1752 and/or 1762 may exhibit enhanced peak stress tolerances, measured by, for example, the peak stress increase as compared to an identically-configured, but uncoated substrate. For example, in one embodiment,structural member 1752 and/or 1762 may exhibit a peak stress increase, measured at the outer edge ofprotrusion 1772 and/or 1784 a or b, of at least about 50 percent, at least about 75 percent, at least about 90 percent, at least about 100 percent, at least about 125 percent, at least about 150 percent, measured along the outer edge of the protrusion (i.e., measured in the outer configuration as shown inFIG. 65c ), as compared to an identically-configured but uncoated substrate. The method for determining the peak stress increase of a coated substrate is described in Example 3, below. - As discussed previously, extrusion-coated structural systems of the present invention have a wide variety of applications including, for example, as furniture or cabinetry items and/or in several indoor and outdoor construction and building end uses. In one embodiment, one or more extrusion-coated structural systems described herein may be used in cabinetry applications as doors, side walls, drawers, cabinet boxes, and other similar components, and may be used in furniture applications as shelves, tables, desks, drawers, cabinets, chairs, and the like. Specific construction uses can include, but are not limited to, wall board, floor board, trim, door jambs or casing, window jambs or casing, crown molding, chair railing, frames, mantels, accent boxes, and the like.
- The various aspects of the present invention can be further illustrated and described by the following Examples. It should be understood, however, that these Examples is included merely for purposes of illustration and is not intended to limit the scope of the invention, unless otherwise specifically indicated.
- Three samples each of five different substrates, including four types of particle board with ANSI grades M-0, M-1, M-S, and M-2, and medium density fiberboard were assembled. One sample of each of the five types of substrates was coated with EASTMAN™ CS10-1201IF white resin commercially available from Eastman Chemical Company (Tennessee, USA) to an average coating thickness of approximately 0.012 inches.
- The screw withdrawal force required to remove a one-inch, #10 type AB screw from the each of the uncoated and coated samples for each type of substrate was measured according to ASTM D1037,
Section 16. The lead hole diameter was 0.125 inches and the screw penetration depth was 0.667 inches. The results are summarized in Table 1, below. -
TABLE 1 Results of Screw Withdrawal Force Testing Sample Coated, lbf Uncoated, lbf ANSI M-0 258 273 ANSI M-1 239 214 ANSI M-S 261 266 ANSI M-2 328 362 - Another sample of MDF was obtained and a channel measuring approximately 0.75 by 0.375 inches was cut into center portion of the substrate. The channeled substrate was then coated with the coating material described in Table 1, and the average screw withdrawal force for a screw inserted into the central portion of the coated channel was measured as described above. Table 2, below, summarizes the results for the screw withdrawal force test for the coated MDF samples with and without a channel over several runs.
-
TABLE 2 Screw Withdrawal Force for MDF With and Without Channel MDF Without Channel MDF With Channel Run Withdrawal Force, lbf Withdrawal Force, lb f1 263 478 2 286 532 Average 275 505 - Several substrates each having cross-sectional shapes similar to the
split jamb substrate 1764 illustrated inFIGS. 61-63 were formed using medium density fiberboard (MDF) with an average a density between 42 and 51 lb/ft3. The fiber board, which is commercially available from Langboard, Inc. (Georgia, USA), was formed into 18 individual substrates, each having a nominal length, designated as Ls inFIG. 63 , of about 3 inches and a nominal thickness, shown as dimension Ts inFIG. 63 , of about 0.35 to about 0.37 inches. Additionally, six other substrates having a similar cross-sectional shape were also formed using finger-jointed pine (FJP) with the same nominal dimensions. The exact dimensions of each of these substrate are provided in Table 3, below. - Three of the MDF substrates and three FJP substrates, respectively labeled CO-1 through CO-3 and CO-4 through CO-6 in Table 4 below, were retained as controls and were not coated. The remaining MDF and FJP substrates were divided first by material and then into groups of three and were coated, in triplicate, with several different coatings. A latex paint, commercially available as BEHR Ultra Pure White 3050 Interior Semi-Gloss Enamel from Behr Process Corporation, was used to as a comparative coating material and was used to coat three of the MDF substrates to an average thickness of 9 mils (e.g., Substrates C-1 through C-3) and three others to an average thickness of 12 mils (e.g., Substrates C-4 through C-6).
- The remaining MDF substrates, labeled I-1 through I-9 in Table 4, and the three FJP substrates, labeled I-10 through I-12 in Table 4, were coated with one of two resin-containing coating materials using an extrusion coating process as described below. The first resin-containing coating material (Coating A) was EASTMAN™ CS10-1201IF white resin commercially available from Eastman Chemical Company, and the second resin-containing coating material (Coating B) was an impact-modified acrylic polymer, OPTIX CA 1000E-2, commercially available from Plaskolite, Inc. Coating A was applied to six of the MDF substrates (e.g., Substrates I-1 through I-6) and three of the FJP substrates (e.g., Substrates I-10 through I-12), and Coating B was applied to the remaining three MDF substrates (e.g., Substrates I-7 through I-9). Average thicknesses of the coatings applied to each of Substrates I-1 through I-12 are summarized in Table 4 below.
- After being preheated in an oven and held in a staging area, Substrates I-1 through I-12 were individually passed through a die assembly that included a die outlet conforming to the cross-sectional shape of each of Substrates I-1 through I-12. Coating A was fed through a 2½ inch extruder during the coating of Substrates I-1 through I-6 and I-9 thorough I-12, and Coating B was similarly applied to Substrates I-7 through I-9. During application of Coating A to Substrates I-1 through I-6 and I-9 through I-12, the melt temperature was held at 500° F., while the melt temperature of Coating B applied to Substrates I-7 through I-9 was maintained at 550° F. In both cases, the die temperature was the same as the melt temperature, and the melt pressure was between 400 and 900 psi. Upon removal from the die assembly, each of the substrates was allowed to cool. Substrates I-1 through I-3 had an average coating thickness of 16 mils, while the average coating thickness of Substrates I-4 through I-6 was 23 mils. Substrates I-7 through I-9 had an average coating thickness of 25 mils, and Substrates I-10 through I-12 had an average coating thickness of about 11 mils.
- Four additional samples were prepared, each having a substrate shaped similarly to
substrate 1822 shown inFIG. 64 . Each of these samples, which were portions of a wainscot panel, was formed from high density fiberboard having an average density between 51 and 62 lb/ft3. Each of substrate had a nominal length of 3 inches and a nominal thickness of 0.1 inches. The exact dimensions of each sample are provided in Table 4, below. - One of the substrates, labeled CO-7 in Table 4, was retained as a control and was left uncoated. Substrate C-7 was painted with the BEHR Ultra White latex paint as described previously and, upon drying, had an average paint thickness of 5 mils. The remaining two substrates, I-13 and I-14, were extrusion coated with respective Coatings A and B, as described previously. Both substrates had an average coating thickness of 11 mils.
- Each of the Substrates CO-1 through CO-7, C-1 through C-7, and I-1 through I-14 were then subjected to strength testing as described in Example 3, below.
- Each of the substrates prepared in Example 2 above were separately subjected to a strength test to determine the peak (maximum) load (in pounds-force) and peak (maximum) stress (in pounds per square inch) achievable by each substrate, according to the following method.
- Control Substrate CO-1 was placed in a 50 kN MTS Insight material testing frame having a 0.629-inch diameter compression probe, shown as
probe 1920 inFIGS. 65a-c . The first control Substrate CO-1 was arranged in a “flush” position such that the outer edge of thecompression probe 1920 was parallel with the outer edge of the substrate CO-1, as shown inFIG. 65a and compression of the substrate was then initiated at a speed of 0.20 inches per minute. During compression, the load (force) and pressure applied to the substrate viacompression probe 1920 was measured and recorded using the MTS Simplified Compression Method run using the TestWorks software package (commercially available from MTS Systems Corporation, Eden Prairie, Minn.). - Compression of the substrate was continued until the substrate broke or cracked and the maximum load and pressure achieved just prior to breakage were recorded as the peak load and pressure. Tests were conducted in a similar manner with the two other uncoated substrates, CO-2 and CO-3, except the position of
compression probe 1920 was varied. As shown inFIG. 65b , Substrate CO-2 was tested with theprobe 1920 in a “half” position, such that the mid-line of the probe was resting on the outer edge of Substrate CO-2, while Substrate CO-3 was tested in an “outer” position, such that the other edge ofprobe 1920 is parallel to Substrate CO-3, as shown inFIG. 65c . Results for the peak load and peak stress for each of Substrates CO-1 through CO-3 are summarized in Table 4, below. - Similar strength tests were carried out on Substrates CO-4 through CO-6 (uncoated FJP), Substrates C-1 through C-3 (9 mil thick paint on MDF), Substrates C-4 through C-6 (12 mil thick paint on MDF), Substrates I-1 through I-3 (16 mil thick Coating A on MDF), Substrates I-4 through I-6 (23 mil thick Coating B on MDF), Substrates I-7 through I-9 (25 mil thick Coating B on MDF), and Substrates I-10 through I-12 (11 mil thick Coating A on FJP).
- One substrate from each group (Substrates C-1, C-4, I-1, I-4, I-7, and I-10) was tested in a flush position, one substrate from each group (e.g., Substrates C-2, C-5, I-2, I-5, I-8, and I-11) was tested in a half position, and one substrate from each group (e.g., Substrates C-3, C-6, I-3, I-6, I-9, and I-12) was tested in an outer position. In addition to measuring the peak load and peak stress for each painted or coated substrate, increase in peak stress, as compared to the uncoated substrate tested in the same position (i.e., flush, half, or outer), was also calculated according to the following formula: (Peak Stress Coated Substrate−Peak Stress of Uncoated Substrate)/(Peak Stress (psi) of Uncoated Substrate), expressed as a percentage. Values for peak load, peak stress, and peak stress increase, measured in the flush, half, and outer positions, for each of the coated substrates C-1 through C-6 and I-1 through I-12 are provided in Table 4, below.
-
TABLE 4 Strength Test Results for Several Substrates Coating Substrate Dimension Peak Thick- Overall Protrusion Peak Peak Stress ness Test Length Thickness Load Stress Increase Functional Substrate Material Type (mils) Configuration (inches) (inches) (lbf) (psi) (%) Part? CO-1 MDF None — Flush 2.966 0.351 10.51 10.06 — N CO-4 FJP None — Flush 2.958 0.340 33.892 33.620 — — C-1 MDF Paint 9 Flush 2.989 0.361 12.70 11.78 17 N C-4 MDF Paint 12 Flush 2.998 0.363 14.83 13.62 35 N I-7 MDF Coating B 25 Flush 2.960 0.373 28.12 25.48 153 Y I-1 MDF Coating A 16 Flush 3.030 0.374 33.99 29.98 198 Y I-4 MDF Coating A 23 Flush 2.978 0.374 29.42 26.48 163 Y I-10 FJP Coating A 11 Flush 2.986 0.379 57.994 51.260 57 — CO-2 MDF None — Half 2.918 0.351 6.588 6.48 — N CO-5 FJP None — Half 2.918 0.341 17.776 17.840 — — C-2 MDF Paint 9 Half 2.994 0.360 7.280 6.78 5 N C-5 MDF Paint 12 Half 3.012 0.360 7.990 7.360 14 Y I-8 MDF Coating B 25 Half 2.950 0.373 17.18 15.58 140 Y I-2 MDF Coating A 16 Half 3.028 0.375 19.52 17.23 166 Y I-5 MDF Coating A 23 Half 2.962 0.373 17.93 16.24 151 Y I-11 FJP Coating A 11 Half 3.004 0.378 31.914 28.100 80 — CO-3 MDF None — Outer 2.971 0.347 5.642 5.46 — N CO-6 FJP None — Outer 2.948 0.341 15.682 15.600 — — C-3 MDF Paint 9 Outer 2.995 0.362 5.621 5.20 −5 N C-6 MDF Paint 12 Outer 3.003 0.363 5.836 5.36 −2 N I-9 MDF Coating B 25 Outer 2.951 0.372 13.31 12.10 122 Y I-3 MDF Coating A 16 Outer 3.028 0.375 15.34 13.53 148 Y I-6 MDF Coating A 23 Outer 2.959 0.373 14.25 12.90 136 Y I-12 FJP Coating A 11 Outer 2.986 0.377 25.354 22.520 62 — - In addition, each of Substrates CO-7, C-7, I-13, and I-14 was also strength tested in a similar manner, except each was only tested in an outer position. The results for peak load, peak stress, and peak stress increase for Substrates CO-7, C-7, I-13, and I-14 are summarized in Table 5, below.
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TABLE 5 Strength Test Results for Additional Substrates Coating Substrate Dimension Peak Thick- Overall Protrusion Peak Peak Stress ness Length Thickness Load Stress Increase Functional Substrate Type (mils) (inches) (inches) (lbf) (psi) (%) Part? CO-7 None — 2.965 0.088 29.23 111.8 — N C-7 Paint 5 2.979 0.099 25.42 86.10 −23 N I-13 Coating A 11 2.984 0.099 53.66 180.7 62 Y I-14 Coating B 11 2.956 0.103 62.95 207.2 85 Y - Additionally, after testing, each substrate was visually examined to determine whether or not, once cracked, it could be used. The results of these visual observations for each of the substrates tested are summarized in the last columns of Tables 4 and 5. As shown particularly in Table 4, increasing the paint thickness by 33 percent (from 9 mils to 12 mils) has no observable impact on the strength of the painted substrate. It is not expected that further increases to the paint thickness would show different results, in particular because of the discontinuous microstructure of paint.
- The preferred forms of the invention described above are to be used as illustration only, and should not be used in a limiting sense to interpret the scope of the present invention. Obvious modifications to the exemplary embodiments, set forth above, could be readily made by those skilled in the art without departing from the spirit of the present invention.
- The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of the present invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims.
Claims (19)
1. A method of making an extrusion-coated structural system, said method comprising:
extrusion coating a coating material onto at least a portion of a substrate to form an extrusion-coated structural member,
wherein said extrusion coating forms at least one extruded profile member extending outwardly from said substrate for a maximum distance that is at least two times greater than the average thickness of said coating material coated onto said substrate proximate said extruded profile member,
wherein at least 75 percent of the total volume of said extruded profile member is formed of said coating material, and
wherein said extrusion-coated structural member further comprises a profile recess at least partially defined by said extruded profile member.
2. The method of claim 1 , wherein said coating material is applied to said substrate at the same time that said extruded profile member is formed.
3. The method of claim 1 , wherein said extruded profile member extends outwardly from said substrate for a maximum distance that is at least five times greater than the average thickness of said coating material coated onto said substrate adjacent said extruded profile member.
4. The method of claim 1 , wherein at least about 5 percent of the total weight of said coating material applied during said extrusion coating is used to form said extruded profile member.
5. The method of claim 1 , wherein not more than about 10 percent of the total volume of said extruded profile member is occupied by said substrate.
6. The method of claim 1 , further comprising, subsequent to said extrusion coating, inserting at least one functional member into said profile recess.
7. The method of claim 1 , further comprising, subsequent to said extrusion coating, cooling said extrusion-coated structural member in a quench zone.
8. The method of claim 1 , wherein said coating material has a glass transition temperature in the range of from about 60° C. to about 150° C.
9. The method of claim 1 , wherein said coating material comprises at least one resin selected from the group consisting of polyesters, copolyesters, polycarbonates, polymethyl methacrylate (PMMA), impact-modified PMMA, poly(acrylonitrile-styrene-acrylate) (ASA), poly(acrylonitrile-butadiene-styrene) (ABS), poly(styrene-acrylonitrile) (SAN), cellulose esters and mixtures thereof.
10. The method of claim 1 , wherein said extrusion coating includes applying said coating material continuously to at least three sides of at least one cross-section of said substrate.
11. The method of claim 1 , wherein said substrate comprises natural wood, medium-density fiberboard, particle board, oriented strand board, plastic, cellularized PVC, foam, metal, fiberglass-reinforced thermoset or thermoplastic polymers, or combinations thereof.
12. A method for assembling an extrusion-coated structural system, said method comprising:
(a) providing a first extrusion-coated structural member comprising a substrate and a coating material extrusion coated onto at least a portion of said substrate,
wherein said first extrusion-coated structural member comprises an extruded profile member formed of said coating material,
wherein said extruded profile member extends outwardly from said substrate for a maximum distance that is at least two times greater than the average thickness of said coating material proximate said extruded profile member,
wherein at least 75 percent of the total volume of said extruded profile member is formed of said coating material, and
(b) providing a second structural element presenting a contact surface; and
(c) contacting at least a portion of said extruded profile member with said contact surface of said second structural element to form at least a portion of said structural system.
13. The method of claim 12 , wherein said extruded profile member defines a profile recess, wherein said second structural element is a second extrusion-coated structural member or a second hardware member, wherein said contacting includes inserting a structural protrusion of said second extrusion-coated structural member, when present, into said profile recess or inserting a hardware protrusion of said hardware member, when present, into said profile recess.
14. The method of claim 13 , wherein said structural system is a door jamb, a window jamb, wall paneling, floor paneling, or an item of furniture.
15. The method of claim 12 , wherein said second structural element is a function member, wherein said contacting includes inserting said functional member into said profile recess and contacting at least a portion of said profile recess with said contact surface, wherein said functional member is selected from the group consisting of piping, electrical or plumbing conduit, wire, cables, lighting fixtures, LED elements, and combinations thereof.
16. The method of claim 12 , further comprising, subsequent to said contacting, breaking contact between said extruded profile member and said contact surface of said second structural element to thereby disassemble at least a portion of said structural system and subsequently re-contacting at least a portion of said extruded profile member with said contact surface of said second structural element to thereby reassemble said structural system.
17. The method of claim 12 , wherein said first extrusion-coated structural member is a door or drawer and said second structural element is a cabinet box or door frame or door jamb.
18. The method of claim 12 , wherein said coating material comprises at least one resin selected from the group consisting of polyesters, copolyesters, polycarbonates, polymethyl methacrylate (PMMA), impact-modified PMMA, poly(acrylonitrile-styrene-acrylate) (ASA), poly(acrylonitrile-butadiene-styrene) (ABS), poly(styrene-acrylonitrile) (SAN), cellulose esters and mixtures thereof.
19. The method of claim 12 , wherein said substrate comprises natural wood, medium-density fiberboard, particle board, oriented strand board, plastic, cellularized PVC, foam, metal, fiberglass-reinforced thermoset or thermoplastic polymers, or combinations thereof.
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US20150110988A1 (en) | 2015-04-23 |
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