U.S. patent application number 10/962407 was filed with the patent office on 2005-04-21 for extruded foam plastic frame members.
This patent application is currently assigned to Royal Group Technologies Limited.. Invention is credited to Bordin, Fortunato, Edger, Ronald F., Gentile, Matthew, Lamanna, Felice, Shultis, Stephen H..
Application Number | 20050081475 10/962407 |
Document ID | / |
Family ID | 34427683 |
Filed Date | 2005-04-21 |
United States Patent
Application |
20050081475 |
Kind Code |
A1 |
Edger, Ronald F. ; et
al. |
April 21, 2005 |
Extruded foam plastic frame members
Abstract
Elongated frame members are provided having rigid framed plastic
cores with smooth hard outer skins and separately coextruded
plastic coatings covering separately selected areas of the skin.
The members may also be hollow. The invention further involves the
method and tooling for making same.
Inventors: |
Edger, Ronald F.;
(Woodbridge, CA) ; Shultis, Stephen H.;
(Woodbridge, CA) ; Lamanna, Felice; (Woodbridge,
CA) ; Bordin, Fortunato; (Woodbridge, CA) ;
Gentile, Matthew; (Woodbridge, CA) |
Correspondence
Address: |
Douglas S. Johnson
Ste. 301
133 Richmond Street West
Toronto
M5H 2L7
CA
|
Assignee: |
Royal Group Technologies
Limited.
|
Family ID: |
34427683 |
Appl. No.: |
10/962407 |
Filed: |
October 13, 2004 |
Current U.S.
Class: |
52/698 |
Current CPC
Class: |
B29C 44/22 20130101;
B29K 2105/04 20130101; B29C 48/0012 20190201; B29C 48/2665
20190201; B29C 48/12 20190201; B29C 48/11 20190201; B29C 48/90
20190201; B29C 48/901 20190201; B29C 48/908 20190201; B29C 48/21
20190201; B29C 48/09 20190201; B29C 48/335 20190201; B29L 2031/005
20130101 |
Class at
Publication: |
052/698 |
International
Class: |
E04C 005/00 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 15, 2003 |
CA |
2,445,094 |
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows:
1. An elongated extruded member having a predetermined profile
comprising a rigid extruded core of foamed plastic, having a thin
smooth hard outer skin protecting a foamed plastic substrate, said
skin having a first selected surface area covered with a first
coextruded plastic coating and a second selected surface area
covered with a second coextruded plastic coating.
2. An elongated extruded member as claimed in claim 1 in which said
core is hollowed with at least one hollow chamber running the
length thereof.
3. An elongated extruded member as claimed in claims 1 or 2 in
which said first and second coextruded plastic coatings are of the
same material.
4. An elongated extruded member as claimed in claims 1 or 2 in
which said first and second coatings are of different
materials.
5. An elongated extruded member as claimed in claims 1 or 2 in
which said first and second coextruded plastic coatings are colored
and have the same color.
6. An elongated extruded member as claimed in claims 1 or 2 in
which said first and second coextruded plastic coatings are colored
with their colors being different.
7. An elongated extruded member as claimed in claims 1 or 2 in
which said first and second coatings have the same thickness.
8. An elongated extruded member as claimed in claims 1 or 2 in
which said first and second coatings have different
thicknesses.
9. An elongated extruded member as claimed in claims 1 or 2 in
which said first and second coextruded plastic coatings have the
same thickness and are colored.
10. An elongated extruded member as claimed in claim 9 in which the
colors of said first and second coextruded plastic coatings are of
different material.
11. An elongated extruded member as claimed in claims 1 or 2 in
which said first and second coextruded plastic coatings have
different thicknesses and are colored.
12. An elongated extruded member as claimed in claim 11 in which
said first and second coextruded plastic coatings are of different
material.
13. An elongated extruded member as claimed in claim 12 in which
said first and second coextruded plastic coatings are colored and
have different colors.
14. An elongated extruded rigid frame member for a window or door
having a predetermined profile and having a surface or surfaces to
be exposed to the outside atmosphere and a surface or surfaces to
be exposed interiorly, said frame member comprising a rigid core of
foamed plastic material, having a smooth protective outer skin and
having a first coextruded plastic coating covering said surface or
surfaces to be exposed to the outside atmosphere, and a second
coextruded plastic coating covering said surface or surfaces to be
exposed interiorly.
15. A frame member as claimed in claim 14 in which said core has at
least one hollow chamber running lengthwise thereof.
16. An elongated frame member as claimed in claim 14 or 15 in which
said foamed plastic material is a foamed PVC material.
17. A frame member as claimed in claim 15 in which said foamed
plastic material is a reinforced foamable PVC material.
18. An elongated extruded frame member as claimed in claim 14 or 15
in which said plastic coatings are of selected plastic materials
and are colored with selected colors
19. A method of extruding a rigid frame member with a predetermined
profile, said frame member having a foamed plastic core enveloped
in a thin smooth hard surface skin with a first selected area of
said surface skin having an applied coating of a first selected
plastic material and a second selected area of said surface skin
having an applied coating of a second selected plastic material,
said method comprising feeding a hot compressed foamable plastic
material under pressure through a die having an opening configured
to provide said predetermined frame member profile and containing a
splitter pin to divert the compressed pressure driven hot foamable
plastic material outwardly to produce a foamable extrudate flowing
under pressure through the space between the periphery of said pin
and the perimeter of said die opening, delivering a coating of said
first selected plastic material on to the outer surface of said
foamable extrudate over an area comprising said first selected
area, delivering a second coating of said second selected plastic
material on to a portion of the outer surface of said foamable
extrudate over an area comprising said second selected area,
foaming said hot coated foamable extrudate by pulling said hot
coated foamable extrudate from said die through a vacuum operated
calibrating and cooling chamber wherein the outer surface of said
hot extrudate on contacting the inner peripheral surface of said
calibrating and cooling chamber hardens to provide said hard thin
enveloping skin while the extrudate foams inwardly from said skin
to provide said foamed core enveloped with said skin.
20. A method as claimed in claim 19 in which said first and second
plastic coating materials are the same material.
21. A method as claimed in claim 19 in which said first and second
plastic coating materials are different materials.
22. A method as claimed in claim 19 in which said first and second
plastic coating materials are colored.
23. A method as claimed in claim 19 in which said first and second
plastic coating materials are colored with the color of one being
different from the color of the other.
24. A method as claimed in claim 19 in which said first and second
plastic coating materials have different thicknesses.
25. A method of extruding a rigid frame member with a predetermined
profile, said frame member having a hollow foamed plastic core
having at least one closed chamber running lengthwise thereof, said
core being enveloped in a thin smooth hard surface skin with a
first selected area of said surface skin having an applied coating
of a first selected plastic material and a second selected area of
said surface skin having an applied coating of a second selected
plastic material, said method comprising feeding a hot compressed
foamable plastic material under pressure through a die having an
opening configured to provide said predetermined frame member
profile and containing a splitter pin to divert the compressed
pressure driven hot foamable plastic material outwardly to produce
a foamable extrudate flowing under pressure through the space
between the periphery of said pin and the perimeter of said die
opening, delivering a coating of said first selected plastic
material on to the outer surface of said foamable extrudate over an
area comprising said first selected area, delivering a second
coating of said second selected plastic material on to a portion of
the outer surface of said foamable extrudate over an area
comprising said second selected area, pulling said hot coated
foamable extrudate from said die through a calibrating and cooling
chamber containing at least one cooling pin having an external
configuration corresponding to the desired internal shape of said
at least one hollow chamber wherein the outer surface of said hot
extrudate on contacting the inner peripheral surface of said
calibrating and cooling chamber hardens to provide said hard thin
enveloping skin while the extrudate foams inwardly from said skin
and around said cooling pin to provide said foamed hollow core.
26. A method as claimed in claim 25 in which said cooling pin is
cooled by delivering cooling water to said pin through said die and
returning such water from said pin through said die.
27. A method as claimed in claims 25 or 26 in which said first and
second plastic coating materials are the same material.
28. A method as claimed in claims 25 or 26 in which said first and
second plastic coating materials are different materials.
29. A method as claimed in claims 25 or 26 in which said first and
second plastic coating materials are colored.
30. A method as claimed in claims 25 or 26 in which said first and
second plastic coating materials are colored with the color of one
being different from the color of the other.
31. A method as claimed in claims 25 or 26 in which said first and
second plastic coating materials have different thicknesses.
32. A die for use in extruding a rigid frame member with a
predetermined profile, said frame member having a hollow foamed
plastic core having at least one closed chamber running lengthwise
thereof, said core being enveloped in a thin smooth hard surface
skin with a first selected area of said surface skin having an
applied coating of a first selected plastic material and a second
selected area of said surface skin having an applied coating of a
second selected plastic material, said die having an opening
extending therethrough from an entrance to an outlet, said die
opening being configured to provide said desired frame member
profile, a torpedo splitter pin having a pointed head mounted in
said die with its said head at the entrance to said die opening and
its end at the outlet of said die opening, a first passage for
delivering a first coating material leading in from the exterior of
said die and opening to the interior of said die opening at a first
position adjacent the die opening outlet, a second passage for
delivering a second coating material leading from the exterior of
said die to the interior of said die opening at a second location
adjacent the die opening outlet, a cooling water inlet passage
leading from the exterior of said die into the interior of said die
and into said splitter pin and out said end of said splitter pin
and a return cooling water passage leading from said end of said
splitter pin and out of said splitter pin and out through the die
to the exterior thereof.
Description
FIELD OF THE INVENTION
[0001] This invention is directed to elongated extruded plastic
members having profiles for use in forming frames including
particularly window and door frames and, more particularly, to such
members having foamed plastic bodies or cores with smooth hard
enveloping outer skins and with separately coextruded coatings on
selected surface areas of said outer skins. The invention is
particularly directed to such members in which the cores are
hollowed to have at least one internal closed chamber running the
length thereof.
[0002] The invention further relates to the method and tooling for
producing such members.
BACKGROUND OF THE INVENTION
[0003] The use of wood in forming frames such as window and door
frames has been greatly replaced by frames formed from extruded
members and, in particular, extruded rigid plastic members whose
desired profiles can be accurately produced without requiring the
meticulous work needed to provide a detailed wood frame profile and
whose weatherability and insulating properties are vastly superior
to those of wood. Moreover, such plastic members are free from
other problems encountered with wood such as splintering, rotting
and destruction by insects.
[0004] While frame members of metal such as aluminum and steel have
often been used, such frame members lack the insulation qualities
of plastic frames and they have their own particular problems being
subject to corrosion and rust and requiring quite considerable
maintenance.
[0005] With respect to extruded plastic frames, U.S. Pat. Nos.
5,406,768 and 5,497,594 disclose the production of an extruded wood
fiber reinforced thermoplastic frame members for use in framing
doors and windows. These members are not foamed and comprises a
hollow cross section having a rigid relatively thick exterior shell
or wall with at least one internal support web and one internal
fastener anchor. Such members have to be coated, i.e. painted if
their applications call for any color other than their natural
color.
[0006] U.S. Pat. No. 3,216,068 discloses a sealing strip which has
a foamed main body having an outer layer of moisture impervious
polyvinyl resin fused thereto. However, the main body is formed of
a foamed flexible polyvinyl resin and the functioning of this
product depends on its ability to deform and then recover which
properties are not suitable for frame members which have to be
rigid.
[0007] U.S. Pat. No. 6,054,207 discloses structural components such
as deck planks made from extruded composite foam material
comprising from about 90 to 50 wt % of a vinyl polymer and 10 to 50
wt % of wood fiber. Such components, which are relatively
expensive, do not themselves have hard smooth surfaces but require
a coating or layer of cap stock to provide such desired surfaces
and to increase weatherability over and above such purpose
additives made to the composite foam material.
[0008] U.S. Pat. No. 5,965,075 discloses a triple extrusion method
of forming frame members. This method involves the extruding of a
plastic foam material to provide the rigid body of the members
while coextruding a fluid coating material to at least one surface
of the foam material and also coextruding a flange of flexible
material bonded to the foam material. The frame members produced by
this process have solid cores of foamed plastic with single
coextruded coatings.
[0009] It is the object of this invention to provide elongated
rigid extruded plastic members having precision profiles
particularly for use in forming frames which members have superior
properties and provide superior performance to existing such
members.
[0010] It is a further object of the invention to provide such
extruded rigid plastic frame members which have thin smooth
polished protective enveloping surface skins with selected areas of
these surface skins separately coated with separate plastic
coatings or cap stocks. According to this aspect of the invention,
it is the object to enable selected areas of the surface skins to
be coated with coating of different materials and/or different
colors and/or different thicknesses.
[0011] It is a further object to provide such plastic frame members
which are hollow and are relatively light in weight.
[0012] It is still a further object to provide such plastic members
at relatively low cost.
[0013] These and other objects and features of the invention will
appear from the following detailed description taken with the
accompanying drawings.
SUMMARY OF THE INVENTION
[0014] In its widest aspect the invention resides in providing
elongated extruded frame members having desired profiles with cores
of foamed plastic preferably foamed PVC, foamed to provide a core
enveloping thin tough smooth outer skin, the cores having
separately coextruded plastic, preferably PVC, skin coatings on
selected areas of their outer skins which coatings may be of the
same or different material compositions, and/or the same or
different colors, and/or the same or different thicknesses.
[0015] In a particularly preferred aspect, the invention resides in
providing such frame members with hollowed cores which have at
least one hollow chamber running the length thereof.
[0016] In another aspect, the invention further resides in
providing such frame members in which the profiles have refined
details provided by the coatings.
[0017] Again, in another aspect, the invention further involves the
method and tooling for producing such extruded frame members. In
this connection, the method comprises feeding a hot compressed
foamable plastic material under pressure through a die having an
opening configured to provide the predetermined frame member
profile. The die contains a splitter pin to divert the compressed
pressure driven hot foamable plastic material outwardly to produce
a foamable extrudate flowing under pressure through the space
between the periphery of the pin and the perimeter of the die
opening. At the same time, a first plastic coating material is
delivered through the die onto the outer surface of the foamable
extrudate over a first selected area or areas thereof while a
second plastic coating material is also delivered through the die
onto the outer surface of the foamable extrudate over a second
selected area or areas thereof. The hot coated foamable extrudate
is then pulled from the die through a calibrating and cooling
chamber wherein the outer surface of the hot coated extrudate on
contacting the inner peripheral surface of the calibrating and
cooling chamber freezes or hardens. This forms a smooth hard thin
enveloping core layer or skin from which the extrudate foams
inwardly to form the coated skin enveloped foamed core.
[0018] In another important aspect of the method of the invention,
the calibrating and cooling chamber is provided with at least one
cooling pin located therein. This cooling pin has an external
configuration corresponding to the desired internal shape of the at
least one hollow chamber. As the hot extrudate foams inwardly from
the outer skin, it foams around the cooling pin where it hardens to
form the hollow chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a diagrammatic view illustrating the tooling and
method of producing foamed frame members having selected surface
areas separately coated with selected plastic coatings in
accordance with the invention;
[0020] FIG. 2 is a broken away exploded perspective view of the
tooling represented by the diagrammatic showing of FIG. 1;
[0021] FIG. 3 is an exploded perspective view of the components of
the die shown in the tooling drawing of FIG. 2;
[0022] FIG. 4 is a broken away exploded perspective view
illustrating the introduction of the cooling pin into the cooling
and calibrating chamber;
[0023] FIG. 5 is an end view of the frame profile produced by the
tooling illustrated in FIGS. 2 to 4;
[0024] FIG. 6 is a broken away perspective view of a more
complicated frame profile embodying the invention produced in
accordance with the principles of the method of the present
invention;
[0025] FIGS. 7 and 8 are end views of other frame profiles
embodying the invention.
DETAILED DESCRIPTION ACCORDING TO THE PREFERRED EMBODIMENTS OF THE
PRESENT INVENTION
[0026] Referring to the schematic drawing FIG. 1, an extrudable hot
compressed foamable plastic material or composition 1 is extruded
from an extruder 2 into a die generally designated at 3 which
contains a torpedo shaped splitter or diverter pin 4 which spreads
the hot compressed foamable material 1 around the pin 4 into the
space 5 between the perimeter of the pin 4 and the periphery of the
die opening 6 which is configured to provide the desired frame
member profile.
[0027] As this hot compressed foamable extrudate flows through the
die, a first plastic coating or cap stock material is delivered to
a first selected surface area or areas of the extrudate through
passageway 7 through the die to provide a thin plastic coating or
cap stock to such first selected extrudate surface area or
areas.
[0028] A second plastic coating or cap stock material is delivered
to a second selected area or areas of a surface of the extrudate
through passageway 8 through the die 3 to provide a thin plastic
coating or cap stock to such second selected extrudate surface area
or areas. Thus, in effect, two cap stocks are separately fed to
coat two different selected areas of the surface of the extrudate
as the foamable extrudate flows through the die 3 so that these cap
stocks are separately coextruded with the foamable extrudate.
[0029] The foamable plastic composition 1 is preferably a foamable
polyvinyl chloride (PVC) and/or a chlorinated polyvinyl chloride
(CPVC) containing the usual process aids, fillers, reinforcing
fibrous materials, stabilizers, lubricants and blowing agents such
as azodicarbonamide and the like as will be understood by those
skilled in the art.
[0030] The plastic coating or cap stock materials delivered through
passageway 7 and 8 can be any conventional cap stock which is known
for this purpose as is well known to those skilled in the art which
may be a PVC material, a blend of acrylic and PVC material an
acrylic styrene acrylonitrile (ASA) and blends of ASA with
polyvinyl chloride. Because these coatings or cap stock materials
contain ultra violet stabilizers where their exposure requires
same, minimal use of such stablizers is required in the foamable
composition
[0031] As in the conventional extruding process, the hot coated
extrudate is pulled from the die by a suitable puller (not shown)
through cooling and sizing calibrators 9 whose passageways 10 are
configured to match the configuration of the outlet of the die
3.
[0032] A thermal break 12 between the die 3 and the first
calibrator 9 provides a requisite degree of isolation between the
calibrator and the hot die.
[0033] In the embodiment shown in FIG. 1, a cooling pin 13 is
located within the calibrator's passageway 10. This cooling pin is
cooled by circulating cooling water, the water being fed in by a
passageway 14 leading in from the periphery of the die 3 through
the die, through the splitter pin and thermal break, into the inlet
passage 15 of the cooling pin 13 where it circulates through the
pin being returned from the outlet passage 16 of the cooling pin to
the outlet passage 17 leading through the thermal break and
splitter pin and out to the periphery of the die 3 as
illustrated.
[0034] As the coated foamable extrudate in its hot compressed state
is drawn into the passageway 10 of the first calibrator 9, the
sudden increase in space between the perimeter of the calibrator
opening 10 and the cooling pin 13 allows the highly compressed
extrude to expand or foam under the action of the blowing agent or
agents. Since the outer surface of the foaming extrudate is in
contact with the peripheral wall 11 of the passageway 10 it hardens
due to the much lower temperature of this surface whose temperature
would be of the order of about 40.degree. F. while the termperature
of the extrudate would be of the order of about 380.degree. F. This
hardening or "freezing" of the surface of the extrudate forms a
thin hard smooth skin enveloping the extrudate which then foams
inwardly from this skin to surround the cooling pin 13. This hard
outer skin of the foamed plastic forms an isolation barrier which
protects the softer material or substrate which it encapsulates
from impact damage.
[0035] In this connection, it will be noted that the density of the
core is greatest at the skin layer against which pressure is
exerted as the extrudate foams inwardly. Because of its greater
density, the skin contains the greatest concentration of additives
including any ultra violet agents incorporated into the foamable
compositions.
[0036] Of course, added to the protection of the core provided by
the enveloping hard skin, including any contained ultra violet
agent, are the coextruded cap stocks overlying the areas of this
enveloping skin to which they have been applied.
[0037] As the layer of foamed plastic which forms the core of the
extrusion is a relatively thick layer, it is difficult for this
layer to precisely follow the contours of the profile of the
calibrator passageway 10. On the other hand, the thin coextruded
coatings or cap stock can intimately conform to the wall of the
calibrator passageway to provide precision to the details of the
profile as well as coating the selected surfaces.
[0038] The frame members produced by the invention with their rigid
foamed cores with their enveloping hard smooth surfaces and their
separately coextruded cap stocks covering selected areas provide
highly valuable frame members for framing windows, doors and the
like. Such frame members, for example, will have surfaces which
will be exposed to the exterior of the building and subjected to
all of the weathering elements and, in particular, ultra violet
radiation whereas other surfaces of the frame will be exposed to
the interior of the building where they will not be subjected to
the same radiation. Also, of course, the sides of the frame member
exposed to the exterior of the building may be required to be
colored one color while the sides exposed to the interior of the
building are required to be colored in a different color.
[0039] By separately coextruding the cap stocks, the one cap stock
can be colored to suit the customers choice for the outside color
of the building and the other cap stock can be colored to suite the
choice of the customer's color for the inside of the building. This
choice may involve the different colors on opposite sides of the
frame member but also the same color. Moreover, having the two
separately coextruded cap stocks, the thicknesses of the cap stocks
can be varied so that they are the same or different or, again, the
compositions of the cap stocks can be the same or different
depending on the customer's requirements.
[0040] Where the frame member is to be welded to other frame
members, the invention provides for increasing the thickness of the
cap stock covering that area so that the cap stock thickness will
be such that, on cleaning the weld area, the underlying core will
not be exposed which would require painting to cover up.
[0041] By extruding the frame members as hollow frame members by
the use of the cooling pin 13 which forms an internal hollow
chamber running the length of the extrusion, the weight of the
frame members formed by the process is reduced without sacrificing
required rigidity and the insulation properties of the frame
members are enhanced.
[0042] While FIG. 1 shows a single cooling pin to produce a single
hollow chamber, it will be understood that additional cooling pins
to produce additional hollow chambers running the length of the
extrusions can be provided.
[0043] With reference to FIG. 2, it will be seen that the die 3
comprises four separate sections in the form of a front plate 18, a
front intermediate plate 18', a spider plate 19, a rear
intermediate plate 20 and a back plate 21. The splitter pin 4 is
provided with wings 22 by means of which it is mounted in the
spider plate 19 as illustrated particularly in FIG. 3.
[0044] The die 3 is maintained in heated condition by heaters
23.
[0045] Supply of the first cap stock material to the passageway 7
is provided through inlet connection 24 while the supply of the
second cap stock material to the passageway 8 is provided through
inlet connector 25. The inlet water to the cooling pin water
circulating circuit inlet passage 14 is provided through pipe 26
while the return of the water from the outlet passage 16 of the
cooling pin circulating circuit is delivered through pipe 27.
[0046] As shown in FIG. 2, the front plate 17 has locating
projections 28 which register with the locating receptacles 29
provided on the first calibrating unit 9 as shown in FIG. 4.
[0047] The configuration of the die opening 6 along with the
configuration of the cooling pin 13 produces the extruded frame
member 30 illustrated in FIG. 5 having a foamed hollowed plastic
core 30' with a smooth hard enveloping protective skin 31 portions
of which will bear the first cap stock 32 delivered through
passageway 7 and portions of which will bear the second cap stock
33 delivered through passageway 8.
[0048] While the tooling disclosed produces the simple frame
profile of FIG. 5, it will be understood that the frame profiles
may take much more complicated forms as illustrated by the frames
34, 35 and 36 shown in FIGS. 6, 7 and 8 respectively wherein in
each case the foamed cores indicated at 37, 38 and 39 respectively
are hollowed and the exterior surfaces have selected areas covered
by one selected cap stock 40 while other selected areas are covered
by a second separately applied cap stock 41.
[0049] It will be understood that other variations may be made in
the frame members according to the invention and, for instance, in
the case of a very small cross section picture frame, the die could
omit the cooling pin with the result that the frame member would
have a foamed solid core with hard smooth protective enveloping
skin having selected areas bearing separately coextruded cap stocks
as desired.
[0050] It will be understood that these and other variations may be
made without departing from the scope of the appended claims.
* * * * *