U.S. patent application number 10/939578 was filed with the patent office on 2005-03-17 for apparatus and method for reinforcing a vinyl beam.
Invention is credited to Linford, Duane M., Linford, Paul M..
Application Number | 20050056822 10/939578 |
Document ID | / |
Family ID | 34278867 |
Filed Date | 2005-03-17 |
United States Patent
Application |
20050056822 |
Kind Code |
A1 |
Linford, Paul M. ; et
al. |
March 17, 2005 |
Apparatus and method for reinforcing a vinyl beam
Abstract
An apparatus and method are disclosed for reinforcing a vinyl
beam. The apparatus includes an elongated sleeve with walls and an
insert that may be slid into the sleeve to support the walls of the
sleeve. The insert may be made from multicolored thermoplastic
material and may be concealed within the sleeve. Contact points
extending from an exterior surface of the insert may facilitate
positioning the insert in the sleeve and may support the walls of
the sleeve. A method is also presented for reinforcing a vinyl
beam. The method comprises forming an insert from the material of a
cleansing die batch. Furthermore, the method may include forming an
insert from reprocessed rejected manufactured polymer stock.
Inventors: |
Linford, Paul M.; (Salt Lake
City, UT) ; Linford, Duane M.; (Salt Lake City,
UT) |
Correspondence
Address: |
KUNZLER & ASSOCIATES
8 EAST BROADWAY
SALT LAKE CITY
UT
84111
US
|
Family ID: |
34278867 |
Appl. No.: |
10/939578 |
Filed: |
September 13, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60502732 |
Sep 12, 2003 |
|
|
|
Current U.S.
Class: |
256/59 |
Current CPC
Class: |
B29K 2995/0021 20130101;
B29C 65/00 20130101; B29K 2995/002 20130101; B29L 2023/003
20130101; B29L 2031/10 20130101; B29C 63/18 20130101; B29D 99/0003
20130101; B29L 2031/003 20130101; B29K 2105/26 20130101; B29B
17/0042 20130101; B29L 2023/22 20130101; B29L 2009/001 20130101;
B29C 66/52272 20130101; Y02W 30/62 20150501; B29C 66/73921
20130101; B29C 65/565 20130101; B29C 66/545 20130101 |
Class at
Publication: |
256/059 |
International
Class: |
E04H 017/14 |
Claims
What is claimed is:
1. An apparatus for reinforcing a vinyl beam, the apparatus
comprising: an elongated sleeve having walls and an opening
configured to receive an insert; and the insert formed of
substantially the same material as the sleeve and configured to be
slideably inserted into the sleeve to support the walls of the
sleeve, the insert being concealable within the sleeve.
2. The apparatus of claim 1, wherein the insert further comprises a
plurality of contact points extending from an exterior surface of
the insert and configured to support the walls of the sleeve.
3. The apparatus of claim 2, wherein the plurality of contact
points has a contact surface area less than half of the internal
surface area of the sleeve.
4. The apparatus of claim 2, wherein the plurality of contact
points has a contact surface area less than a quarter of the
internal surface area of the sleeve.
5. The apparatus of claim 2, wherein the contact points together
with the insert have a cross-sectional diameter greater than an
interior cross-sectional diameter of the sleeve.
6. The apparatus of claim 1, wherein the exterior surface of the
insert comprises a textured surface.
7. The apparatus of claim 1, wherein the sleeve is formed of a
unicolored thermoplastic material.
8. The apparatus of claim 1, wherein the insert is formed of a
multicolored thermoplastic material.
9. The apparatus of claim 8, wherein the multicolored thermoplastic
material is recycled from waste vinyl material.
10. The apparatus of claim 1, wherein the insert is configured to
engage a beam member.
11. A method for reinforcing a vinyl beam, the method comprising:
forming an elongated sleeve from a first die batch having a uniform
first color, the elongated sleeve having walls and an opening
configured to receive an insert; initiating a cleansing die batch
having a second color; and forming an insert from material of the
cleansing die batch passing through thermoplastic component
manufacturing equipment, the insert configured to be slideably
inserted into the sleeve to support the walls of the sleeve, the
insert being concealable within the sleeve.
12. The method of claim 11, further comprising inserting the insert
into the elongated sleeve.
13. The method of claim 11, further comprising forming a plurality
of contact points extending from an exterior surface of the insert
and configured to support the walls of the sleeve.
14. The method of claim 13, wherein the method comprises forming a
plurality of contact points having a contact surface area less than
half of the internal surface area of the sleeve.
15. The method of claim 13, wherein the method comprises forming a
plurality of contact points having a contact surface area less than
a quarter of the internal surface area of the sleeve.
16. The method of claim 11, further comprising forming the sleeve
by blow molding.
17. The method of claim 11, further comprising forming the insert
by extrusion.
18. The method of claim 11, further comprising forming a textured
surface on the exterior surface of the insert.
19. A method for reinforcing a vinyl beam, the method comprising:
reprocessing rejected manufactured polymer stock into a
multicolored die batch; and forming an insert from the multicolored
die batch, the insert configured to be slideably inserted into an
elongated sleeve to support the walls of the sleeve, the insert
being concealable within the elongated sleeve, the elongated sleeve
having walls and an opening configured to receive the insert.
20. The method of claim 11, further comprising forming a plurality
of contact points extending from an exterior surface of the insert
and configured to support the wails of the sleeve.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of and claims
priority to U.S. Provisional Patent Application No. 60/502,732
entitled "SYSTEM, METHOD, AND APPARATUS FOR MAKING A REINFORCED
VINYL PROFILE BEAM" and filed on Sep. 12, 2003 for Paul M. Linford
and Duane M. Linford which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to vinyl beams and more particularly
relates to apparatus and methods for reinforcing vinyl beams.
[0004] 2. Description of the Related Art
[0005] Generally, manufacturers form vinyl beams using extrusion
techniques well known to those of skill in the art. These
techniques, though, often waste excessive amounts of polymer stock
for several reasons. One form of waste occurs during polymer
processing because polymer stock is used to prime the extrusion
equipment. In addition, extruded products are commonly processed
from a single die batch, or batch of raw polymer pellets, in order
to provide certain aesthetic properties to a product, such as
uniformity in color. Polymer stock may be wasted because the exact
amount of polymer required to sufficiently satisfy a product demand
may not be available. For example, polymer may be sold/purchased in
a set quantity that does not correspond to the amount needed to
manufacture a particular product from a single die batch. As a
result, manufacturers may have excessive, unused polymer stock
remaining from a die batch.
[0006] A further source of waste in polymer processing occurs when
a manufacturer uses the same extruder to process polymers of
different colors. Waste occurs because one or more batches of
polymer must pass though the extruder to eliminate the color dye of
a previous batch. During this process, the color of the batch
(generally white) used to purge the old color mixes with the color
of the previous batch, resulting in a non-uniform color that does
not match any other die batch. Typically, stock from this
mixed-color, cleansing batch of polymer is discarded.
[0007] Additionally, extruded thermoplastic components may also be
wasted if the polymer swells after it passes though the die.
Swelling components are problematic when the components are to be
used in an assembly of components. If swelling or other defects
prevent the extruded parts from engaging each other properly, the
extruded parts become worthless and generally are discarded.
Discarded extruded parts may cost a manufacturer a significant
amount of time and money.
[0008] From the foregoing discussion, it should be apparent that a
need exists for an apparatus and method to reduce the amount of
material waste inherently produced during polymer processing,
particularly when applied to manufacturing vinyl beams.
Beneficially, such an apparatus and method would effectively
utilize multicolored and reprocessed thermoplastic material. The
present invention provides an apparatus and methods to use excess
polymer waste to reinforce a vinyl beam.
SUMMARY OF THE INVENTION
[0009] The present invention has been developed in response to the
present state of the art, and in particular, in response to the
problems and needs in the art that have not yet been fully solved
by currently available techniques to manufacture vinyl beams.
Accordingly, the present invention has been developed to provide an
apparatus and method for using multicolored and reprocessed
thermoplastic material to reinforce vinyl beams that overcome many
or all of the above-discussed shortcomings in the art.
[0010] The apparatus, in one embodiment, is configured to
strengthen a vinyl beam. The apparatus includes an elongated sleeve
and an insert formed of substantially the same material as the
sleeve. The sleeve may have walls and an opening to receive the
insert, which may be slid into the sleeve to support the walls.
Preferably, the insert is concealed within the sleeve.
Consequently, multicolored thermoplastic material may be used to
form the insert.
[0011] The apparatus is further configured, in one embodiment, to
include a plurality of contact points extending from an exterior
surface of the insert. The contact points facilitate positioning
the insert in the sleeve. Furthermore, the contact points may
engage the walls of the sleeve to help secure the insert. In one
embodiment, the exterior surface of the insert may further include
a textured surface. The textured surface increases the surface area
of the insert to facilitate securing the insert with an
adhesive.
[0012] A method of the present invention is also presented for
reinforcing a vinyl beam. The method in the disclosed embodiments
substantially includes the steps necessary to carry out the
functions presented above with respect to the operation of the
described apparatus. In one embodiment, the method includes forming
an elongated sleeve from a first die batch having a uniform first
color. Then a cleansing die batch is initiated using a second
color. The insert is formed from the material of the cleansing die
batch passing through thermoplastic component manufacturing
equipment. The method also may include inserting the insert into
the elongated sleeve. Using the non-uniform, discolored, extruded
material of the cleansing die batch to form a concealable insert
allows a manufacturer to essentially eliminate the waste
traditionally associated with changing the colors of extruded
thermoplastic material.
[0013] In a further embodiment, the method for reinforcing a vinyl
beam includes reprocessing rejected manufactured polymer stock into
a multicolored die batch. This may include grinding rejected vinyl
products or multicolored cleansing batches. Then the multicolored
die batch may be used to form an insert that may be concealable
within an elongated sleeve. As a result, undesired extruded
material, such as multicolored stock or deformed thermoplastic
components, may be used to form a useful insert.
[0014] Reference throughout this specification to features,
advantages, or similar language does not imply that all of the
features and advantages that may be realized with the present
invention should be or are in any single embodiment of the
invention. Rather, language referring to the features and
advantages is understood to mean that a specific feature,
advantage, or characteristic described in connection with an
embodiment is included in at least one embodiment of the present
invention. Thus, discussion of the features and advantages, and
similar language, throughout this specification may, but do not
necessarily, refer to the same embodiment.
[0015] Furthermore, the described features, advantages, and
characteristics of the invention may be combined in any suitable
manner in one or more embodiments. One skilled in the relevant art
will recognize that the invention may be practiced without one or
more of the specific features or advantages of a particular
embodiment. In other instances, additional features and advantages
may be recognized in certain embodiments that may not be present in
all embodiments of the invention.
[0016] These features and advantages of the present invention will
become more fully apparent from the following description and
appended claims, or may be learned by the practice of the invention
as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In order that the advantages of the invention will be
readily understood, a more particular description of the invention
briefly described above will be rendered by reference to specific
embodiments that are illustrated in the appended drawings.
Understanding that these drawings depict only typical embodiments
of the invention and are not therefore to be considered to be
limiting of its scope, the invention will be described and
explained with additional specificity and detail through the use of
the accompanying drawings, in which:
[0018] FIG. 1A is an end view illustrating one embodiment of an
insert according to the present invention;
[0019] FIG. 1B is an end view illustrating one embodiment of a
reinforced vinyl beam including an insert;
[0020] FIG. 2 is an end view illustrating an alternative embodiment
of a reinforced vinyl beam with an insert;
[0021] FIG. 3A is a perspective view of one embodiment of a
reinforced vinyl beam with holes;
[0022] FIG. 3B is a front view of a fence assembly comprising an
embodiment of a reinforced vinyl beam of the present invention;
[0023] FIG. 4 is a flow chart illustrating a method for reinforcing
a vinyl beam using multicolored thermoplastic material according to
one embodiment of the present invention; and
[0024] FIG. 5 is a flow chart illustrating a method for reinforcing
a vinyl beam using rejected manufactured polymer stock according to
an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Reference throughout this specification to "one embodiment,"
"an embodiment," or similar language means that a particular
feature, structure, or characteristic described in connection with
the embodiment is included in at least one embodiment of the
present invention. Thus, appearances of the phrases "in one
embodiment," "in an embodiment," and similar language throughout
this specification may, but do not necessarily, all refer to the
same embodiment.
[0026] Furthermore, the described features, structures, or
characteristics of the invention may be combined in any suitable
manner in one or more embodiments. In the following description,
numerous specific details are provided to give a thorough
understanding of embodiments of the invention. One skilled in the
relevant art will recognize, however, that the invention may be
practiced without one or more of the specific details, or with
other methods, components, materials, and so forth. In other
instances, well-known structures, materials, or operations are not
shown or described in detail to avoid obscuring aspects of the
invention.
[0027] FIGS. 1A and 1B illustrate selected embodiments of an insert
100 and a reinforced vinyl beam 110. The insert 100 may include
contact points 102, an exterior surface 104, and a textured surface
108. The reinforced vinyl beam 110 of FIG. 1B may include an insert
100, a sleeve 106, an opening 111, a hollow section 112, and walls
114. The insert 100 is preferably configured to fit concealed
within a hollow sleeve 106.
[0028] In the depicted embodiment, the insert 100 has the shape of
a capital "I", commonly known as an I-beam. Alternatively, the
insert 100 may have various cross-sectional shapes including "X",
"O", "C", or any other cross-sectional shape. A cross-section of
the insert 100 may correspond to the general shape of the interior
of the sleeve 106. Alternatively, the cross-section of the insert
100 may circumscribe the interior of the sleeve 106. The insert 100
supports the walls 114 of the sleeve 106.
[0029] In the depicted embodiment, the insert 100 comprises contact
points 102. The contact points 102, which extend from the insert's
exterior surface 104, may contact the sleeve 106 when the insert
100 is within the sleeve 106. In certain embodiments, the contact
points 102 facilitate inserting the insert 100 into the sleeve 106.
Because the contact points 102 extend beyond the exterior surface
104 of the insert 100, direct contact between the insert 100 and
the walls 114 of the sleeve 106 is minimized, reducing friction
associated with sliding the insert 100 along the interior of the
sleeve 106. In one embodiment, the contact surface area of the
insert 100 is less than half of the internal surface area of the
sleeve 106. In a further embodiment, the contact surface area of
the insert 100 is less than a quarter of the internal surface area
of the sleeve 106. Inserting the insert 100 into the sleeve
facilitates concealing the insert 100.
[0030] The contact points 102 support the walls 114 of the sleeve
106. Preferably, the contact points 102 are designed to extend the
"effective diameter" of the insert 100 to exceed the diameter of
the sleeve 106. Consequently, the contact points 102 press against
the sleeve 106 to form a tight friction-fit when the insert 100 is
installed. To secure the insert 100, an adhesive may be applied to
the insert 100 in the space between the walls 114 of the sleeve 106
and the exterior surface 108 of the insert 100.
[0031] In one embodiment, the raised contact points 102 run
continuously along the length of the insert 100. Alternatively, the
contact points 102 may extend for a specific distance or extend
intermittently along the surface 104. In addition, while a pair of
contact points 102 are illustrated, those of skill in the art
recognize that the insert 100 may include a plurality of contact
points 102 organized in various configurations. In alternative
embodiments, the insert 100 may not include contact points 102.
[0032] In the depicted embodiment, the insert 100 additionally
includes a textured surface 108. The textured surface 108 increases
the surface area available for bonding the insert 100 to an
adhesive. Alternatively, the insert's exterior surface 104 may be
smooth or may be a combination of both textured and smooth.
Preferably, the textured surface 108 is formed when the insert 100
is formed.
[0033] The insert 100 may selectively extend the length of the
sleeve 106 to support the hollow sleeve 106 only in areas of
potentially high lateral stress. Alternatively, the insert 100 may
extend the entire length of the sleeve 106. The number and size of
inserts 100 within a hollow sleeve 106 may vary according to the
structural design of a particular reinforced vinyl beam 110.
[0034] Referring now to FIG. 1B, the insert 100 is inserted in an
opening 111 of a sleeve 106. The sleeve 106 may be made from
thermoplastic material and may be elongated, forming a beam. In one
embodiment, the sleeve is unicolored for aesthetic purposes. The
walls 114 of the sleeve 106 create a hollow section 112. The insert
100 may be positioned within the hollow section 112. Preferably,
the inserts 100 create a snug fit between the insert 100 and the
walls 114 of the sleeve 106. The sleeve 106 of the depicted
embodiment has a substantially square cross-section. Those of skill
in the art will recognize, however, that the insert 100 and sleeve
106 may comprise a variety of shapes, sizes, and material
properties.
[0035] As mentioned above, the raised contact points 102 may be
sized to extend slightly beyond the interior diameter of the sleeve
106. In this manner, the contact points 102, wedged between the
I-beam insert 100 and the sleeve 106, bias the I-beam insert 100
against the walls 114.
[0036] In one embodiment, the insert 100 is formed by extrusion,
and the sleeve 106 is formed by blow molding. Any suitable method,
however, may be used to form the sleeve 106 or the insert 100. In
certain embodiments, the sleeve 106 may be made of a variety of
materials suitable for concealing an insert 100, including
aluminum, fiberglass, wood, and the like. Preferably, the insert
100 is made from multicolored and reprocessed thermoplastic
material, which we be discussed in greater detail with relation to
FIGS. 4-5.
[0037] FIG. 2 illustrates an alternative embodiment of a reinforced
vinyl beam 200 in which the insert 202 and the sleeve 204 are
cylindrical. Accordingly, the insert 202 has a slightly smaller
diameter than the sleeve 204, such that the insert 202
circumscribes the sleeve 204. To provide a snug fit between the
insert 202 and the sleeve 204, the insert 202 includes two raised
contact points 206. As depicted, a gap 208 may be provided between
the exterior surface 210 of the insert 202 and the wall 212 of the
sleeve 204. This gap 208 allows for relaxed tolerances when
manufacturing the reinforced vinyl beam 200 and may be filled with
an adhesive to bind the insert 202 to the sleeve 204. As described
above, the exterior surface 210 of the insert 202 and the inner
surface 213 of the wall 112 of the sleeve 204 may be textured to
increase the surface area available for bonding.
[0038] FIG. 3A illustrates one embodiment of a reinforced vinyl
beam 110 having at least one insert 100 sized to support an
elongated sleeve 106. To provide greater support, the sectioned
inserts 100 may be positioned within the sleeve 106 near areas of
weak structural integrity. For example, the insert 100 in the
illustrated embodiment is positioned section 112 provides a space
in which the hole 300 may receive a beam member, such as a vinyl
fence slat (not shown), a fence rail (not shown), or the like. The
insert 100, consequently, may serve as a stop for a beam member
inserted into the hole 300. In alternative embodiments, the insert
100 may further be configured to engage the beam member.
[0039] As depicted, holes 300 maybe positioned on a side of the
sleeve 106 adjacent to the side contacting the insert 100. The
I-shaped insert 100 allows the sleeve 106 to be cut easily without
damaging the insert 100. In this example, although the holes 300
may weaken the sleeve 106 structurally, the insert 100 compensates
for the loss in structural integrity and reinforces the sleeve 106
near the hole 300.
[0040] Because the insert 100 is hidden from view, the present
invention increases the range of color diversity possible for the
inserts 100 without affecting the aesthetic quality of the sleeve
106. The increased compatibility of different colors also allows
manufactures to use recycled materials or materials from different
die batches to form the insert 100, thus reducing the cost and
waste that generally results from the polymer processing.
[0041] FIG. 3B illustrates a fence assembly 310 having an upright
post 312 anchored into the ground 314. The cross-members 316 engage
the upright post 312. A number of slats (not shown) may be joined
to the cross members 316 to improve the privacy function of the
fence assembly 310. Preferably, the reinforced vinyl beam 110
illustrated in FIG. 3A is implemented in the upright posts 312
and/or cross-members 316. In addition, the concealed insert 310 may
engage and support the cross-members 316.
[0042] Typically, the elongated sleeves 106 of the fence assembly
310 are a uniform color. The inserts 100, which are not visible,
may be either a uniform color or mixed. Preferably, the inserts 100
are made from remainder die batches and/or waste vinyl components
of various colors that are ground up and recycled. In this manner,
multicolored inserts 100 ma be provided while still providing an
aesthetically appealing fence assembly 310. Furthermore, using
concealed inserts 100 allows manufacturers to utilize thermoplastic
material aesthetically unsuitable for exterior use, but still
structurally sound and suitable for support purposes.
[0043] The schematic flow chart diagrams that follow are generally
set forth as logical flow chart diagrams. As such, the depicted
order and labeled steps are indicative of one embodiment of the
presented method. Other steps and methods may be conceived that are
equivalent in function, logic, or effect to one or more steps, or
portions thereof, of the illustrated method. Additionally, the
format and symbols employed are provided to explain the logical
steps of the method and are understood not to limit the scope of
the method. Although various arrow types and line types may be
employed in the flow chart diagrams, they are understood not to
limit the scope of the corresponding method. Indeed, some arrows or
other connectors may be used to indicate only the logical flow of
the method. For instance, an arrow may indicate a waiting or
monitoring period of unspecified duration between enumerated steps
of the depicted method. Additionally, the order in which a
particular method occurs may or may not strictly adhere to the
order of the corresponding steps shown.
[0044] FIG. 4 illustrates a flow chart of a method 400 for
reinforcing a vinyl beam 110. The method 400 utilizes multicolored
thermoplastic material to form the insert 100 of a reinforced vinyl
beam 110. First, an elongated sleeve 106 is formed 402. The
elongated sleeve 106 may be formed 402 by extrusion or blow molding
techniques from a common die batch having a consistent first color,
or by any other appropriate method. Next, a cleansing die batch
having a second color, such as white, for example, is initiated
404, as is known in the art. Then, an insert 100 is formed 406 from
material of the cleansing die batch. The insert may be formed from
multicolored or a uniform colored thermoplastic material.
[0045] Of course, complete die batches of one or more colors, or a
combination of remainder die batches, may be used to form one or
more inserts 100. However, because the inserts 100 are concealed,
cleansing die batches are preferably used to limit the amount of
vinyl material wasted during polymer processing. The insert 100 is
then installed 406 into the sleeve 106 to form a reinforced vinyl
beam 110. In certain embodiments, the insert 100 is bonded to the
wall 114 of the sleeve 106 by an adhesive. As mentioned, the sleeve
106, which conceals the insert 100, preferably has a uniform color
and an aesthetically pleasing appearance.
[0046] FIG. 5 illustrates a flow chart of a method 500 for
reinforcing vinyl beams 110 from recycled materials. First, an
elongated hollow sleeve 106 is formed 502 as mentioned above. Next,
rejected manufactured polymer stock is reprocessed 504 into a
multicolored die batch or uniform die batch. In one embodiment, the
rejected thermoplastic material is ground into a die batch. Then,
the die batch of recycled materials may be used to form 506 a
concealable insert 100. In one embodiment, a multicolored die batch
is extruded to form 506 an insert 100. Finally, the insert 100 may
be installed 508 into a hollow sleeve 106. An insert 100 may also
be formed from other suitable types of recycled material. The
method 500 reduces the amount of thermoplastic material wasted
during polymer processing by recycling unwanted materials and
creating a desirable product.
[0047] The method 400 and method 500 may further include forming
contact points 102 and a textured surface 108 on the exterior
surface 104 of the insert 100. The insert 100 may then be inserted
into a sleeve 106 to form a reinforced vinyl beam 110.
[0048] The present invention may be embodied in other specific
forms without departing from its spirit or essential
characteristics. The described embodiments are to be considered in
all respects only as illustrative and not restrictive. The scope of
the invention is, therefore, indicated by the appended claims
rather than by the foregoing description. All changes which come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
* * * * *