Patent · US9744707B2 · B2 · US

Extrusion-coated structural members having extruded profile members

(11) Publication number

US9744707B2

(21) Application number

14/496,529

(22) Filing date

2014-09-25

(30) Priority date

2013-10-18

(43) Publication date

2017-08-29

(45) Date of grant

2017-08-29

(51) IPC

B29C 48/154; B29C 48/21; B29K 101/12; B29L 31/44; B29L 9/00; B32B 1/00; B32B 15/00; B32B 15/04; B32B 19/00; B32B 19/04; B32B 21/00; B32B 21/02; B32B 21/04; B32B 21/08; B32B 23/00; B32B 23/04; B32B 27/00; B32B 27/06; B32B 27/08; B32B 27/10; B32B 27/30; B32B 27/36; B32B 3/00; B32B 3/02; B32B 3/04; B32B 3/06; B32B 3/12; B32B 3/14; B32B 3/18; B32B 3/30; B32B 9/00; E04B 1/61; E04C 2/36; E05D 5/10; E05D 5/14; E05D 7/10; F16B 5/00; F16B 7/04; F16B 7/18

(52) CPC

B29C Shaping or joining of plastics; shaping of material in a plastic state, not otherwise provided for; after-treatment of the shaped products, e.g. repairing: 48/21, 47/025, 47/065, 48/154
B29K Indexing scheme associated with subclasses B29B, B29C or B29D, relating to moulding materials or to materials for {moulds, } reinforcements, fillers or preformed parts, e.g. inserts: 2101/12
B29L Indexing scheme associated with subclass B29C, relating to particular articles: 2009/00, 2031/44, 2031/446
B32B Layered products, i.e. products built-up of strata of flat or non-flat, e.g. cellular or honeycomb, form: 1/00, 15/00, 15/04, 19/00, 19/04, 21/00, 21/02, 21/04, 21/08, 2250/02, 2255/00, 2255/02, 2255/04, 2255/06, 2255/08, 2255/10, 2255/102, 2262/10, 2262/101, 23/00, 23/04, 2307/00, 2307/51, 2307/546, 2307/554, 2317/16, 2333/00, 2419/00, 2419/04, 2479/00, 27/00, 27/06, 27/08, 27/10, 27/30, 27/302, 27/308, 27/36, 3/00, 3/02, 3/04, 3/06, 3/12, 3/14, 3/18, 3/30, 9/00
E04B General building constructions; walls, e.g. partitions; roofs; floors; ceilings; insulation or other protection of buildings: 1/6129, 1/6179, 2001/6191
E04C Structural elements; building materials: 2/36
E05D Hinges or suspension devices for doors, windows or wings: 2005/102, 5/10, 5/14, 7/105
E05Y Indexing scheme associated with subclasses E05D and E05F, relating to construction elements, electric control, power supply, power signal or transmission, user interfaces, mounting or coupling, details, accessories, auxiliary operations not otherwise provided for, application thereof: 2800/29, 2900/00, 2900/20
F16B Devices for fastening or securing constructional elements or machine parts together, e.g. nails, bolts, circlips, clamps, clips or wedges; joints or jointing: 5/0012, 5/0016, 7/0473, 7/187
Y10T Technical subjects covered by former us classification: 29/49616, 428/23, 428/24521

(73) Assignee

EASTMAN CHEM CO

(72) Inventors

PEAVEY JENNIFER LYNNE; SASTHAV MOHAN; MERCER JR JAMES WILSON; CLEAR SCOTT ALLEN; CHEOWANICH CHANANDH

(54) Title

Extrusion-coated structural members having extruded profile members

(57) 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.

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Claims (13)

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.
The structural system 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.
The structural system of claim 1, wherein said extruded profile member is formed at the same time said coating material is extrusion coated onto said substrate.
The structural system of claim 1, wherein said extruded profile member comprises at least 5 percent of the total weight of said coating material used to form said first extrusion-coated structural member.
The structural system of claim 1, 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.
The structural system of claim 5, 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.
The structural system of claim 1, wherein said coating material is a resin coating comprising at least 30 percent of a resin material, based on the total weight of said coating material.
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, and wherein said extrusion-coated structural member further comprises a profile recess at least partially defined by said extruded profile 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.
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.
The structural system of claim 8 or 9, wherein said extruded profile member extends along at least 60 percent of the length of said extrusion-coated structural member.
The structural system of claim 8 or 9, 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.
The structural system of claim 8 or 9, 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.
The structural system of claim 8 or 9, 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.

Description

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, grooves, channels, or other complex geometries or geometric features, greatly limiting the design and functionality of the resulting system.

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Record as JSON

{
  "publication_number": "US9744707B2",
  "country": "US",
  "kind": "B2",
  "title": "Extrusion-coated structural members having extruded profile members",
  "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.",
  "claims": [
    "1. 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.",
    "2. The structural system 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.",
    "3. The structural system of claim 1, wherein said extruded profile member is formed at the same time said coating material is extrusion coated onto said substrate.",
    "4. The structural system of claim 1, wherein said extruded profile member comprises at least 5 percent of the total weight of said coating material used to form said first extrusion-coated structural member.",
    "5. The structural system of claim 1, 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.",
    "6. The structural system of claim 5, 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.",
    "7. The structural system of claim 1, wherein said coating material is a resin coating comprising at least 30 percent of a resin material, based on the total weight of said coating material.",
    "8. 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, and wherein said extrusion-coated structural member further comprises a profile recess at least partially defined by said extruded profile 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.",
    "9. 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.",
    "10. The structural system of claim 8 or 9, wherein said extruded profile member extends along at least 60 percent of the length of said extrusion-coated structural member.",
    "11. The structural system of claim 8 or 9, 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.",
    "12. The structural system of claim 8 or 9, 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.",
    "13. The structural system of claim 8 or 9, 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."
  ],
  "description_excerpt": "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.\n\nReady-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, grooves, channels, or other complex geometries or geometric features, greatly limiting the design and functionality of the resulting system.",
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  ],
  "assignees": [
    "EASTMAN CHEM CO"
  ],
  "inventors": [
    "PEAVEY JENNIFER LYNNE",
    "SASTHAV MOHAN",
    "MERCER JR JAMES WILSON",
    "CLEAR SCOTT ALLEN",
    "CHEOWANICH CHANANDH"
  ],
  "filing_date": "2014-09-25",
  "publication_date": "2017-08-29",
  "grant_date": "2017-08-29",
  "priority_date": "2013-10-18",
  "application_number": "US-201414496529-A",
  "family_id": "52826424",
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