US 9,744,707 B2Granted

Extrusion-coated structural members having extruded profile members

AssigneeEastman Chemical Company

InventorsJennifer Lynne Peavey, Mohan Sasthav, James Wilson Mercer, Jr., Scott Allen Clear, Chanandh Cheowanich

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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.

Claims13

Dependent claims

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 said substrate,
wherein said extrusion-coated structural member further 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 coated onto said substrate adjacent said extruded profile member,
wherein at least 75 percent of the total volume of said extruded profile member is formed of said coating material,
wherein said extrusion-coated structural member further comprises a profile recess at least partially defined by said extruded profile member,
wherein said substrate comprises natural wood, medium-density fiberboard, particle board, oriented strand board, plastic, metal, fiberglass-reinforced thermoset or thermoplastic polymers, or combinations thereof, and
wherein said coating material comprises at least one resin selected from the group consisting of polyesters, copolyesters, polycarbonates, poly(acrylonitrile-styrene-acrylate) (ASA), poly(acrylonitrile-butadiene-styrene) (ABS), poly(styrene-acrylonitrile) (SAN), cellulose esters and mixtures thereof,
wherein said coating material has an average thickness in the range of from about 0.001 inches to about 0.25 inches and wherein said coating material extends continuously around at least three sides of at least one cross-section of said substrate,
wherein said extruded profile member extends along at least 60 percent of the length of said extrusion-coated structural member, and further comprising at least one functional member disposed within said profile recess, 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.

6 more elements

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 said substrate,
wherein said extrusion-coated structural member further 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 coated onto said substrate adjacent said extruded profile member,
wherein at least 75 percent of the total volume of said extruded profile member is formed of said coating material,
wherein said extrusion-coated structural member further comprises a profile recess at least partially defined by said extruded profile member,
wherein said profile recess presents a profile recess attachment surface formed of said coating material;
further comprising a second structural member comprising a structural protrusion, wherein said structural protrusion is configured for insertion into said profile recess so that said structural protrusion is at least partially supported by at least a portion of said profile recess attachment surface,
wherein said profile recess attachment surface defines at least one coating cavity and/or at least one coating projection, and wherein said structural protrusion comprises at least one structural projection and/or at least one structural cavity, wherein (i) said structural protrusion is configured for insertion into said coating cavity of said profile recess attachment surface and/or (ii) said coating projection is configured for insertion into said structural cavity of said structural protrusion when said structural protrusion is inserted into said profile recess, and
wherein at least a portion of said structural protrusion is coated with a second coating material, wherein said structural projection and/or said structural cavity are formed of said second coating material.

6 more elements

Dependencies are inferred from the claim text.

Facts

Application: 14/496,529Filed 25 Sep 2014 · us provisional application
Priority: 18 Oct 2013
Published: US 2015/0110988 A123 Apr 2015
Granted: 29 Aug 2017
Term ends: Not estimatedThe source records don’t support an estimate.

Classification81 codes

B29C 48/21
The components being layers: the layers being joined at their surfaces
B29C 48/154
Incorporating preformed parts or layers, e.g. extrusion moulding around inserts: coating solid articles, i.e. non-hollow articles
B32B 1/00
Layered products having a non-planar shape
B32B 3/00
Layered products comprising a layer with external or internal discontinuities or unevennesses