U.S. patent application number 12/099444 was filed with the patent office on 2009-10-08 for architectural building material.
Invention is credited to Steven W. Russell.
Application Number | 20090249722 12/099444 |
Document ID | / |
Family ID | 41131966 |
Filed Date | 2009-10-08 |
United States Patent
Application |
20090249722 |
Kind Code |
A1 |
Russell; Steven W. |
October 8, 2009 |
Architectural Building Material
Abstract
An architectural material comprising a bulk polymeric foam
material which includes additional structural support which
provides increased strength and durability at the front surface of
the architectural material. The architectural material includes a
mesh material which is disposed near the front surface of the
architectural material. The architectural material may additionally
include a barrier layer which further protects the surface of the
architectural material.
Inventors: |
Russell; Steven W.; (Fort
Myers, FL) |
Correspondence
Address: |
FREDERICK W. MAU II
1108 ROYAL AVENUE
ROYAL OAK
MI
48073
US
|
Family ID: |
41131966 |
Appl. No.: |
12/099444 |
Filed: |
April 8, 2008 |
Current U.S.
Class: |
52/309.4 ;
52/745.19 |
Current CPC
Class: |
B29L 2031/10 20130101;
E04F 19/02 20130101; B29C 44/1209 20130101; B29L 2031/722 20130101;
B29K 2105/04 20130101; E04F 2019/0404 20130101 |
Class at
Publication: |
52/309.4 ;
52/745.19 |
International
Class: |
E04C 1/00 20060101
E04C001/00 |
Claims
1. An architectural material comprising: a bulk polymeric foam
material; and a mesh material disposed within said polymeric
material at a position between the midpoint and the front surface
of said architectural material.
2. The architectural material according to claim 1, wherein said
mesh material is disposed proximate to the front surface of said
architectural material.
3. The architectural material according to claim 1, wherein said
mesh material is disposed within 3 cm from the front surface of
said architectural material.
4. The architectural material according to claim 1, wherein said
mesh material is disposed within 2 cm from the front surface of
said architectural material.
5. The architectural material according to claim 1, wherein said
mesh material is disposed within 1 cm from the front surface of
said architectural material.
6. The architectural material according to claim 1 further
comprising a barrier layer.
7. The architectural material according to claim 6, wherein said
barrier layer is formed from a gel-based precursor material, a
liquid based precursor material, or a powder based precursor
material.
8. The architectural material according to claim 6, wherein said
mesh material is at least partially disposed within said barrier
layer.
9. The architectural material according to claim 1, wherein said
polymeric foam material is polyurethane free rise foam.
10. The architectural material according to claim 9, wherein said
polyurethane free rise foam has a density in the range of 2 pounds
per cubic feet to about 25 pounds per cubic feet.
11. The architectural material according to claim 9, wherein said
polyurethane free rise foam has a density in the range of 8 pounds
per cubic feet to about 14 pounds per cubic feet.
12. The architectural material according to claim 1, wherein said
mesh material comprises metal, composite material, polymer
material, fiberglass, or any combination thereof.
13. The architectural material according to claim 1, wherein said
mesh material comprises a polymer coated fiberglass material.
14. The architectural material according to claim 1, wherein said
architectural material further comprises a topcoat layer.
15. A method for forming an architectural material comprising the
steps of: 1) applying a barrier precursor material to the inner
surface of the cavity of a mold; 2) placing a mesh material in said
mold proximate to the inner surface of the cavity of the mold; 3)
dispensing a polymeric foam precursor material into the cavity of
said mold; 4) sealing said mold; 5) placing said mold into a press;
6) removing said architectural material from said mold.
16. The method according to claim 1 further comprising the step of:
7) applying a topcoat layer to said architectural material.
17. A method for forming an architectural material comprising the
steps of: 1) placing a mesh material in a mold proximate to the
inner surface of the cavity of said mold; 2) dispensing a polymeric
foam precursor material into the cavity of said mold; 3) sealing
said mold; 4) placing said mold into a press; 5) removing said
architectural material from said mold.
18. The method according to claim 1 further comprising the step of:
6) applying a topcoat layer to said architectural material.
Description
FIELD OF THE INVENTION
[0001] The present invention generally relates to architectural
building materials. More particularly, the present invention
relates to architectural building materials having a natural
appearance.
BACKGROUND
[0002] Natural materials such as stone, wood, cement and brick are
popular for use on the interior and exterior of buildings,
particularly for architectural applications. Such materials may be
used as moldings, wall coverings, railings, pillars, facades and
other interior and exterior details. Natural materials, however,
can be expensive and difficult to install. Natural materials, such
as stone, can be very heavy which can limit their application or
require the use of additional structural support. Molded cement
pieces similarly require additional support when used as for such
applications. Furthermore, natural materials, such as wood, may
degrade over time and require periodic replacement and or
treatment.
[0003] Due to some of the problems associated with natural
materials for architectural applications, artificial materials have
been created which can be molded to have the appearance of natural
materials such as wood, stone, brick, and cement. Such materials
may be molded into any type form and have the appearance of stone,
concrete, brick, and wood. Examples of polymeric materials include
polyurethane foam, polystyrene foam, and polyethylene foam. The
artificial materials are lightweight and can be formed into any
shape and/or size while having the appearance of natural materials.
The weight of the materials allows the artificial pieces to be
easily installed without the need for any additional structural
support. The artificial materials are also very durable and can
withstand fading over time. Furthermore, artificial materials are
much more inexpensive than natural materials.
[0004] Artificial materials, however, may not be as durable and
strong as natural materials with respect to resisting attack from
birds and rodents. Birds and rodents may be able to easily destroy
such materials as compared natural materials such as stone, cement,
and brick. For instance, birds such as woodpeckers have a much
easier time digging into artificial materials as compared to stone
or cement counterparts. Also, artificial materials may be easily
chipped or deformed when contacted forcefully by inanimate objects,
such as sticks, branches, poles, tools, etc. As such, there is a
need in the art for artificial architectural materials having
increased durability and strength to resist attack from birds and
rodents and forceful contact from inanimate objects.
SUMMARY OF THE INVENTION
[0005] Disclosed herein, is an architectural material comprising a
bulk polymeric foam material and a mesh material disposed within
the polymeric material. The mesh material may be disposed within
the polymeric foam material at a position between the midpoint and
the front surface of the architectural material. The mesh material
may be disposed proximate to the front surface of the architectural
material. The mesh material is preferably disposed within 3 cm from
the front surface of the architectural material. More preferably,
the mesh material may be disposed within 2 cm from the front
surface of the architectural material. Most preferably, the mesh
material is disposed within 1 cm from the front surface of the
architectural material.
[0006] The architectural material may further comprise a barrier
layer. The barrier layer may be formed from a gel-based precursor
material, a liquid based precursor material, or a powder based
precursor material. The mesh material may be at least partially
disposed within the barrier layer. The architectural material may
also comprise a topcoat layer which may be applied on the barrier
layer or the polymeric foam material.
[0007] The polymeric foam material may be comprised of polyurethane
free rise foam. The polyurethane free rise foam may have a density
in the range of 2 pounds per cubic feet to about 25 pounds per
cubic feet. Preferably, the polyurethane free rise foam may have a
density in the range of 8 pounds per cubic feet to about 14 pounds
per cubic feet.
[0008] The mesh material may comprise metal, composite material,
polymer material, fiberglass, or any combination thereof.
Preferably, the mesh material comprises a polymer coated fiberglass
material.
[0009] Also disclosed herein is a method for forming an
architectural material in a mold. The method may comprise the steps
of 1) placing a mesh material in the mold proximate to the inner
surface of the mold cavity, 2) dispensing a polymeric foam
precursor material into the mold cavity, 3) sealing the mold, 5)
placing the mold into a press, and 6) removing the architectural
material from the mold. The method may further comprise the step of
applying a barrier precursor material to the inner surface of the
cavity of the mold prior to placing the mesh material into the
mold. The method may also comprise the step of applying a topcoat
layer to the architectural material when removed from the mold.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1, is a depiction of an architectural material in
accordance with the present invention.
[0011] FIG. 2, is a depiction of an architectural material
including a barrier layer in accordance with the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE
INVENTION
[0012] In accordance with the present invention there is provided
an architectural material having increased strength and durability.
The architectural material has increased strength and durability at
the front surface of the architectural material to increase
resistance to attack from birds, rodents, insects and other
creatures while maintaining a decorative face. The increased
strength and durability at the surface of the material further
prevents damage to the material which may be caused from forceful
contact with inanimate objects or exposure to inclement
weather.
[0013] A depiction of an architectural material in accordance with
the present invention is shown in FIG. 1. The architectural
material 10 generally comprises a bulk material layer 20 and a mesh
material 30. The bulk material layer 20 generally comprises a high
density polymeric foam material. The mesh material 30 may be
disposed within the bulk material layer 20. Preferably, the mesh
material is disposed in the bulk layer at a position between the
midpoint and the front surface of the architectural material. The
midpoint of the architectural material 10 is defined herein as a
point within the architectural material that is halfway between the
front surface 40 of the architectural material and the portion of
the back surface 50 of the architectural material furthest from the
front surface of the architectural material. The back surface 50 of
the architectural material is defined herein as the surface
opposite the front surface of the architectural material. More
preferably, the mesh material 30 is disposed within the bulk
material layer 20 proximate to the front surface 40 of the
architectural material. The mesh material being disposed proximate
to the front surface of the architectural material provides
increased durability and strength to the front surface of the
architectural material. Specifically, the mesh material may be
disposed within 3 cm from the front surface of the architectural
material. More preferably, the mesh material may be disposed within
2 cm from the front surface of the architectural material. Most
preferably, the mesh material may be disposed within 1 cm from the
front surface of the architectural material.
[0014] The architectural material may further comprise a barrier
layer as depicted in FIG. 2. The barrier layer 60 may be a thin
layer disposed on the front surface 40 of the architectural
material 10. The barrier layer 60 is located adjacent to the bulk
layer 20 such that the barrier layer 60 coats the surface of the
bulk layer 20. The barrier layer may provide the color and
appearance of the architectural material 101. The barrier layer may
also protect the architectural material from weathering and/or
fading. Alternatively to being disposed within the bulk layer, the
mesh material may be disposed in the barrier layer or at the
transition between the bulk layer and the barrier layer.
[0015] The bulk layer 20 generally comprises a high density
polymeric foam material. Examples of polymeric foam materials are
polyurethane foam, polyethylene foam, and polystyrene foam.
Polyurethane foam is the preferred material for the bulk layer of
the architectural material. Polyurethane foam material has a fast
cure rate which enables finished parts to be produced after cooling
in two to fifteen minutes. While polyurethane foam is the preferred
embodiment of the present invention, any type polymeric foam
material may be used in accordance with the present invention.
[0016] The polyurethane foam may be formed by mixing a first
component A with a second component B. When mixed, component A and
component B react exothermically to form a polyurethane foam. The
final density of the polyurethane foam can be controlled by
modifying the starting materials and/or modifying the amount of
material placed into the mold. The polyurethane foam in the bulk
layer nay have a density in the range of 2 pounds per cubic feet to
about 25 pounds per cubic feet. Preferably, the density of the
polyurethane foam is in the range of 8 pounds per cubic feet to
about 14 pounds per cubic feet.
[0017] The first component A is a resin component generally
containing one or more polyols and the second component B is a
material containing one or more isocyanate compounds. Component A
and component B may be mixed in a ratio of 1:1 by volume. The ratio
of component A to component B may vary from 1:10 to 10:1.
Preferably, the amount by volume of component A is greater than the
amount by volume of component B. This ensures complete reaction of
all component B (isocyanate material).
[0018] The first component A may generally comprise a polyether
polyol blend. Examples of polyol compounds include any difunctional
or polyfunctional hydroxyl compounds having a molecular weight
below about 1800 such as, 1,2- and 1,3-propylene glycol; 1,4- and
2,3-butylene glycol; 1,6-hexane diol; 1,8-octane diol; neopentyl
glycol; cyclohexane dimethanol (1,4-bis-hydroxy-methyl
cyclohexane); 2-methyl-1,3-propane diol; glycerol; trimethylol
propane; 1,2,6-hexane triol; 1,2,4-butane triol; trimethylolethane;
pentaerythritol; quinitol; mannitol and sorbitol; methyl glycoside;
diethylene glycol; triethylene glycol; tetraethylene glycol;
polyethylene glycols; dipropylene glycol; dibutylene glycol and
polybutylene glycols.
[0019] The first component A may additionally include one or more
blowing agents and/or catalytic agents. Blowing agents may be used
to tailor the cellular structure of the polyurethane foam. The
catalytic agents may be used to help the reaction between component
A and component B progress and/or aid the final curing process of
the material. The first component may also include one or more
structural additives which increase the rigidity and strength of
the material. Such additives may include fiberglass, cementitiuos
materials, and other type filler materials. To provide color and
varied surfaces to the architectural material, colorants,
dispersion dyes and pigments may be added to component A. To reduce
ultraviolet oxidation and enhance weathering anti-oxidation and
ultraviolet adsorber additives may also be included in component
A.
[0020] The second component B is generally an isocyanate material.
In particular, the isocyanate material may be polymeric
diphenylmethane diisocyanate. Examples of other conventional
isocyanates that may be included in component B include organic
aromatic and aliphatic polyisocyanates or mixtures thereof. Organic
aromatic polyisocyanates for example may be
2,4-toluenediisocyanate, 2,6-toluenediisocyanate, p-phenylene
diisocyanate, naphthalene diisocyanate, polymethylene polyphenyl
isocyanates, 1,6-hexamethylene diisocyanate, 1,4-cyclohexyl
diisocyanate, 1,4-bis isocyanoctomethyl-cyclohexane and mixtures
thereof.
[0021] The mesh material 30 may be any type mesh material formed
from polymer materials, composite materials, fiberglass, metal, or
any combination thereof. Preferably the mesh material is a polymer
coated fiberglass mesh. An example of polymer coated fiberglass
mesh is 921 Sto Armor Mat from Sto Corporation. Any size mesh may
be used in accordance with the present invention. Preferably the
size of the mesh is in the range of 0.0625 inches to 0.5 inches.
More preferably, the size of the mesh is in the range of 0.125 to
0.25 inches. The mesh material may be flexible or rigid. The
thickness of the mesh material may vary so as to provide the
desired flexibility or rigidity of the mesh material. The thickness
of the mesh material may be in the range of 0.0625 inches to 0.025
inches. Preferably, the mesh is able to conform to the shape of the
front surface of the architectural material. The area of the mesh
material is preferably approximate to the area of the front surface
of the architectural material such that the mesh material and the
front surface of the architectural material have similar lengths
and widths. This allows the mesh material to be positioned along
the entire length and width of the front surface of the
architectural material.
[0022] The barrier layer 60 is generally comprised of a protective
coating which is applied onto the surface of the architectural
material. The barrier layer may have a density higher than the bulk
layer material. The barrier layer may be applied onto the inner
surface of a mold prior to introduction of the bulk layer material
into the mold. When applied onto the inner surface of the mold
cavity, the precursor material is preferably fully cured before the
bulk layer material is introduced into the mold cavity. Introducing
the bulk material into the mold cavity when the barrier material is
not fully cured may result in formation of weak area in the
architectural material. The barrier layer may also be applied onto
the surface of the architectural material upon removal from the
mold.
[0023] The barrier layer may be formed from a precursor material in
liquid or gel form. The gel or liquid precursor material may be
water or solvent based. Once dry, the precursor gel or liquid
material forms the barrier layer on the architectural material. The
barrier layer may include pigments which provide the desired color
to the architectural material. The barrier layer may also include
additives which protect the architectural material from weathering
and fading. An example of a gel-type material that may be utilized
as the barrier layer is a modified wollostanite mineral
fiber-reinforced polyester gel coat material. Such material is
applied onto the surface of a mold and cured prior to addition of
the polyurethane foam precursor components. An example of a liquid
material an acrylic barrier coating. A specific type of acrylic
barrier coating may be WB White Barrier Coating as supplied from
Berkley Products Company of Akron, Pa. Such materials may provide
excellent chip resistance to the architectural material while
providing an aesthetically appealing surface.
[0024] The barrier layer may also be formed from a powdered
material. The powdered material may be applied to the mold cavity
prior to introducing the bulk layer material into the mold. The
powdered material may remain in powder form prior to the
polyurethane material being introduced into the mold cavity.
Alternatively, the powdered material may be wetted with water or
solvent based liquid prior to the polyurethane material being
introduced into the mold cavity to form a precursor material as
previously described. When wetted, the precursor material is
preferably allowed to cure prior to the bulk material being
introduced to the mold cavity.
[0025] The architectural material may further include a top coat
material. The topcoat is generally applied on top of the barrier
coat. When a barrier layer is not used, the topcoat may be applied
directly onto the bulk layer. The topcoat may be selected from any
type of paint, either latex or oil based. Preferably, the topcoat
is a latex based exterior grade paint. The topcoat may also be
selected from any type of protective coatings.
[0026] A high density polyurethane foam architectural material in
accordance with the present invention may be formed via a molding
process. The mold cavity used in the molding process may be any
type mold cavity typically used to cast polymeric foam materials.
Preferably, the mold cavity is formed from a polymeric silicone
material which has rigid structural support. Prior to a mixture of
component A and component B being introduced into the mold cavity,
the mold cavity may be treated with a mold release agent to aid in
removal of the finished part from the mold.
[0027] When forming the architectural material, the mesh material
is first placed into the mold cavity. If a barrier layer is
included in the architectural material, a precursor barrier
material may be applied onto the inner surface of the mold cavity
prior to the mesh material being placed in the mold. The precursor
barrier material may be cured, partially cured, or uncured prior to
the mixture of component A and component B being introduced into
the mold. To hold the mesh material in place and to ensure its
placement proximate to the front surface of the architectural
material, the mesh material may be adhered to the precursor barrier
material, and/or held into place via one or more structural
supports. The structural supports may be selected from pins, tacks,
staples, clips, and the like.
[0028] Once the mesh material is placed in the mold, component A
and component B are mixed and subsequently dispersed into a mold
cavity where component A and component B react to form a high
density polyurethane foam. Once component A, component B, and the
mesh material are placed into the mold, the mold cavity is seated
such that the reaction product, the polyurethane foam, expands and
completely fills the mold cavity. The sealed mold cavity may then
be placed into a press to prevent the polyurethane foam from
expanding beyond the mold cavity. The mold is retained in the press
from two to fifteen minutes which allows the polyurethane foam to
cure and cool.
[0029] The density of the polyurethane foam may additionally be
controlled by varying the amount of component A and component B
placed into the mold cavity. The reaction between component A and
component B is exothermic which provides heat that may be used to
help fuse the barrier layer with the bulk layer of the
architectural material.
[0030] While there have been described what are believed to be the
preferred embodiments of the present invention, those skilled in
the art will recognize that other and further changes and
modifications may be made thereto without departing from the spirit
of the invention, and it is intended to claim all such changes and
modifications as fall within the true scope of the invention.
* * * * *