Extrusion coating of elongated substrates
AssigneeEastman Chemical Company
InventorsTony Wayne Helton, Steven Lee Stafford, Aaron Grills, Subramanian Easwaran Iyer
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Abstract
The present disclosure relates to extrusion coating systems, extrusion coated substrates, and processes for making the same. In some aspects, extrusion coating systems as described herein may include an at least partially insulated outlet wall, which may facilitate production of coated substrates exhibiting a very desirable surface texture and appearance. Coated substrates of the present invention may be utilized in a variety of end applications, including, but not limited to, interior and exterior construction materials for homes, buildings, and furniture.
Claims20
A system for extrusion coating a thermoplastic resin coating material onto an elongated substrate, said system comprising:
- a die for contacting an elongated substrate with a molten thermoplastic resin coating material to produce a coated substrate,
- wherein said die comprises an inlet wall, an outlet wall, and a coating chamber disposed at least partially therebetween,
- wherein said inlet wall comprises a die inlet for receiving said elongated substrate into said die and said outlet wall comprises a die outlet for discharging said coated substrate from said die;
- an extruder for introducing the thermoplastic resin coating material into the die;
- an insulating member affixed to said outlet wall,
- wherein said insulating member has a thermal conductivity less than the thermal conductivity of said outlet wall and comprises a shaped passageway configured to at least partially surround said die outlet to allow said coated substrate exiting said die outlet to pass through said insulating member;
- and
- a quench zone located adjacent said insulating member for cooling said coated substrate discharged from said shaped passageway of said insulating member,
- a second insulating member disposed between said coating chamber and said outlet wall, wherein said second insulating member has a thermal conductivity less than the thermal conductivity of said outlet wall,
- a feed system located upstream of said die for introducing said substrate into said die inlet, wherein said fee system includes a pushing device operable to push said elongated substrate into said die inlet;
- wherein said coated substrate has a length of at least 5 feet;
- wherein said elongated substrate comprises natural wood, wood composites, medium-density fiber board, particle board, oriented strand board, plastic, cellularized PVC, foam, metal, fiberglass, ceramics, cement and combinations thereof;
- and wherein said resin coating material comprises one or more of polyesters, copolyesters, polycarbonates, acrylics, cellulose esters, polyolefins, nylons, and polyvinylchloride.
Dependencies are inferred from the claim text.