U.S. patent application number 13/035149 was filed with the patent office on 2011-06-23 for faux wood building materials and articles therefrom.
This patent application is currently assigned to ENVIO PRODUCTS, LLC. Invention is credited to Larry Schwartz.
Application Number | 20110151188 13/035149 |
Document ID | / |
Family ID | 43623745 |
Filed Date | 2011-06-23 |
United States Patent
Application |
20110151188 |
Kind Code |
A1 |
Schwartz; Larry |
June 23, 2011 |
FAUX WOOD BUILDING MATERIALS AND ARTICLES THEREFROM
Abstract
Building materials formed from synthetic polymer materials have
an appearance which simulates natural woods. The building materials
may be used in the construction of fences, sheds, decking
materials, indoor/outdoor furniture, railings and numerous other
products. The faux wood material is constructed to include
reinforcing fibers and voids for weight reduction. The aesthetic
appearance of the finished product can be enhanced by applying a
color wash which includes a polymer component and a color component
adhering to the surface of the material.
Inventors: |
Schwartz; Larry; (Boca
Raton, FL) |
Assignee: |
ENVIO PRODUCTS, LLC
Boca Raton
FL
|
Family ID: |
43623745 |
Appl. No.: |
13/035149 |
Filed: |
February 25, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12869066 |
Aug 26, 2010 |
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13035149 |
|
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61275191 |
Aug 26, 2009 |
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Current U.S.
Class: |
428/141 ;
428/318.6; 521/146 |
Current CPC
Class: |
A47C 5/12 20130101; Y10T
428/249988 20150401; C08J 9/0085 20130101; Y10T 428/249986
20150401; Y10T 428/24355 20150115 |
Class at
Publication: |
428/141 ;
428/318.6; 521/146 |
International
Class: |
B32B 3/26 20060101
B32B003/26; C08L 25/06 20060101 C08L025/06 |
Claims
1. A building material comprising: a load bearing body of synthetic
polymer material having reinforcement elements dispersed therein;
and a plurality of voids within said body whereby the weight of
said body is reduced.
2. The building material of claim 1, wherein at least a portion of
said synthetic polymer material comprises recycled scrap synthetic
polymer material.
3. The building material of claim 1, wherein said body comprises an
elongated body of rectangular cross section.
4. The building material of claim 1, wherein said body has an
irregular planar surface.
5. The building material of claim 4, wherein said irregular planar
surface includes pits therein.
6. The building material of claim 1, further including a wash
having a synthetic polymer component and a color component adhered
to at least a portion of a visible surface of said body, wherein
said synthetic polymer component comprises the same synthetic
polymer as said synthetic polymer material of said body.
7. The building material of claim 6, wherein the color of the color
component is different from the color of said body.
8. The building material of claim 1, wherein the plurality of voids
reduces the weight of said body by about 10% or greater.
9. A building material including recycled scrap synthetic polymer
material, comprising: a body in the shape of a load bearing
elongated board comprising synthetic polymer material having
reinforcement elements dispersed therethrough, and a plurality of
voids within said body whereby the weight of said body is reduced
by at least about 10%; and a portion of said synthetic polymer
material made from recycled scrap synthetic polymer material having
said reinforced elements dispersed therethrough and said plurality
of voids therein.
10. The building material of claim 9, further including a wash
having a polymer component and a color component adhered to at
least a portion of a surface of said board.
11. The building material of claim 9, wherein said body has an
irregular planar surface.
12. The building material of claim 11, wherein said irregular
planar surface includes pits therein.
13. The building material of claim 9, wherein said elements
comprise fibers.
14. The building material of claim 9, further including a wash
having a synthetic polymer component and a color component adhered
to at least a portion of a visible surface of said board, wherein
said synthetic polymer component comprises the same or different
synthetic polymer as said synthetic polymer material of said
body.
15. An article comprising: a plurality of elongated load bearing
bodies of predetermined cross-sectional shape, said bodies
comprising synthetic polymer material having reinforcement elements
dispersed therein and a plurality of voids whereby the weight of
the article is reduced; and wherein said plurality of bodies are
coupled together to form the article.
16. The article of claim 15, wherein said elements comprise
fibers.
17. The article of claim 15, further including a wash having a
polymer component and a color component adhered to at least a
portion of a surface of said bodies.
18. The article of claim 15, wherein the plurality of voids reduces
the weight of said bodies by about 10% or greater.
19. The article of claim 15, wherein at least a portion of said
synthetic polymer material comprises recycled synthetic polymer
material having said reinforcement elements dispersed therein and
said plurality of voids therein.
20. The article of claim 15, further includes a wash having a
synthetic polymer component and a color component adhered to at
least a portion of a visible surface of said bodies, wherein said
synthetic polymer component comprises the same or different
synthetic polymer than said synthetic polymer material of said
bodies.
21. The article of claim 20, wherein the color of the color
component is different from the color of the bodies.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of the U.S. application
Ser. No. 12/869,066, filed on Aug. 26, 2010, entitled "Faux Wood
Building Materials And Articles Therefrom," the disclosure of which
is incorporated herein by reference. This application claims the
benefit of the filing date of the U.S. Provisional Patent
Application No. 61/275,191, filed Aug. 26, 2009, entitled "Faux
Wood Building Materials," the disclosure of which is hereby
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates in general to faux wood
building materials, and more particularly, to building materials
formed from synthetic polymer materials having an appearance which
simulate natural woods.
[0003] Natural wood, due to its strength and aesthetic
characteristics has been used in the construction of various
products for both indoor and outdoor application. For example, wood
such as oak, maple and pine have been used for indoor cabinetry,
flooring material, furniture products and other items. Cedar and
teak have found applications for patio furniture for both indoor
and outdoor use. Natural wood is a versatile product that has
extensive applications for construction of fences, sheds, decking
material, indoor/outdoor furniture, railings and numerous other
products.
[0004] Natural wood is a highly desirable building material for
various products due to its richness. However, some woods are less
suitable for certain products and use in outdoor environments which
are subject to wet conditions. For example, teak and cedar are
commonly used for outdoor furniture due to their weather resistance
characteristics. However, even these wood products are susceptible
to discoloration, splitting and other effects caused by the outdoor
environment. In addition, woods like teak are expensive and are
environmentally protected in certain regions.
[0005] Various synthetic polymers have been extruded or molded into
flat boards for use in the construction of outdoor furniture, such
as Adirondack chairs, picnic tables, picnic benches and other
outdoor products. However, the constructions of these products from
synthetic polymer material evidences a synthetic plastic look which
is less attractive compared to natural wood materials.
[0006] There is therefore a need for the construction of synthetic
plastic material which simulates natural wood to provide the
richness and desirable aesthetic characteristics of wood
products.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention describes a synthetic polymer building
material which simulates a wood product, yet due to its synthetic
nature, is suitable for outdoor use in harsh environments such as
sun, rain and snow.
[0008] The material of the present invention can be formed from a
number of synthetic polymer materials which can easily be
fabricated into various shapes such as elongated boards, as well as
other geometric shapes such as oval, polygonal, circular and the
like. The materials incorporate reinforcement elements such as
fibers to enhance the mechanical strength of the resulting product.
To decrease the weight of the materials, a blowing agent is blended
with the synthetic material during the manufacturing process. The
blowing agent in addition to creating voids within the material,
may also have the effect of forming a slightly uneven exterior
surface which enhances the natural appearance or wood simulating
effect of the material.
[0009] The polymers may include various color components which
result in the material having a solid color or other effects such
as marble look, striations or the like. In the preferred
embodiment, the resulting product is coated with a color wash of
suitable synthetic polymer material which bonds to the base
material. The wash may be applied uniformly, randomly or
selectively to create various aesthetic effects.
[0010] In one embodiment of the present invention there is
described an article of furniture comprising a frame comprising a
body of synthetic polymer material having reinforcement elements
dispersed therein, and a plurality of voids within the body whereby
the weight of the frame is reduced; and a seat portion coupled to
the frame for supporting an occupant.
[0011] The article of furniture further includes a backrest portion
coupled to the frame, wherein at least one of the seat portion or
the backrest portion comprises a woven panel from a plurality of
synthetic polymer yarns. The article further includes a wash having
a polymer component and a color component adhered to at least a
portion of a surface of the frame. The plurality of voids reduces
the weight of the frame by about 10% or greater.
[0012] In another embodiment of the present invention there is
described an article of furniture including recycled scrap
synthetic polymer material, comprising a frame in the shape of an
article of furniture comprising a body of synthetic polymer
material having reinforcement elements dispersed therethrough, a
plurality of voids within the body whereby the weight of the frame
is reduced; and a portion of the synthetic polymer material made
from recycled scrap synthetic polymer material having the
reinforced elements dispersed therethrough and the plurality of
voids therein.
[0013] In another embodiment of the present invention there is
described an article of furniture comprising a frame comprising a
body of synthetic polymer material having reinforced fibers
dispersed therethrough, a plurality of voids within the body
whereby the weight of the frame is reduced by about 10% or greater,
and a wash having a polymer component and a color component adhered
to at least a surface of the frame; a seat portion coupled to the
frame for supporting an occupant; and a backseat portion coupled to
the frame, at least one of the seat portion or the backrest portion
comprising a woven panel from a plurality of synthetic polymer
yarns.
[0014] The article of furniture where the color of the frame is
different from the color of the color component; and wherein the
seat portion and the backrest portion are formed as a bucket seat
attached to the frame.
[0015] In another embodiment of the present invention there is
described a building material comprising a body of synthetic
polymer material having reinforcement fibers disbursed therein; a
plurality of voids within the body whereby the weight of the body
is reduced by at least 10%; and a wash having a polymer component
and a color component adhered to at least a portion of the
body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The subject matter regarded as the invention is particularly
pointed out and distinctly claimed in the concluding portion of the
specification. The invention, however, both as to organization and
method of operation, together with features, objects, and
advantages thereof may best be understood by reference to the
following detailed description when read with the accompanying
drawings in which:
[0017] FIG. 1 is a perspective view of a segment of a building
material in the nature of simulated wood plank or board constructed
in accordance with one embodiment of the present invention.
[0018] FIGS. 2A and 2B are perspective views of a segment of a
building material in the nature of a simulated wood plank or board
constructed in accordance with other embodiments of the present
invention.
[0019] FIG. 3 is a perspective view of an outdoor storage chest
constructed from the materials of the present invention in
accordance with one embodiment thereof.
[0020] FIG. 4 is a perspective view of an article of furniture
constructed from the materials of the present invention in
accordance with one embodiment thereof.
DETAILED DESCRIPTION
[0021] In describing the preferred embodiments of the invention
illustrated in the drawings, specific terminology will be used for
the sake of clarity. However, the invention is not intended to be
limited to the specific terms so selected, and it is to be
understood that each specific term includes all technical
equivalents that operate in a similar manner to accomplish a
similar purpose.
[0022] Referring to the drawings, wherein like reference numerals
represents like elements, there is shown in FIG. 1 a section of an
elongated board or plank constructed in accordance with one
embodiment of the present invention, and designated generally as
reference numeral 100. The board 100 is formed from synthetic
polymer material and mixture thereof which possesses suitable
characteristics for its intended use. For example, for various
applications such as indoor and outdoor furniture, thermoplastic
materials such as polystyrene, polyvinyl chloride, polyethylene and
polypropylene are contemplated. The preferred material is
polystyrene. The board 100 can be made using conventional die
extrusion techniques. It is also contemplated that thermoset
polymer materials may be used for creating objects that can be
molded into predetermined shapes. Thus, it should be understood
that a wide variety of synthetic polymer materials may be used in
constructing the materials of the present invention.
[0023] To provide additional mechanical strength, the polymer
material may be mixed with reinforcement elements such as fibers
102 as is known in the art of reinforcement of synthetic polymers.
The fibers can be constructed as short elongated segments in the
nature of fine filaments, or other desirable forms as is known in
the reinforcement of synthetic polymers. The fibers can be
constructed from a variety of materials, for example, synthetic
polymers, fiberglass, carbon, metal and the like. The percentage of
loading of the material with the fibers will be dictated by the
polymer material composition, as well as the intended application
for the finished material, and the load bearing and mechanical
strength requirements.
[0024] In manufacturing the board 100, a blowing agent is also
included in order to form voids within the material thereby
reducing weight. Blowing agents are commonly used for this purpose
as is known in the synthetic polymer processing industry. Suitable
blowing agents and their use are known in the polymer arts. The
amount of the blowing agent is generally sufficient to reduce the
weight of the material by, for example, about 10% or greater. As
the amount of voids within the material decreases the mechanical
strength, the amount of blowing agent used will be dependent upon
the mechanical strength required of the resulting material based on
its intended application.
[0025] As shown in FIG. 1, the blowing agent forms voids 104 within
the cross-section of the material, and potentially small pits 106
randomly dispersed on the exterior surface of the finished board
100. In addition, it is contemplated that the blowing agent may
result in the surface 108 of the board 100 to have a slightly
irregular planar surface. It is also contemplated that some of the
fibers 102 may be visible randomly across the surface of the board
100. Thus, depending upon on the loading extent of the fibers 102
and the extent of the blowing agent, fibers 102 and pits 106 may or
may not appear on the surface of the board 100. Likewise, the
extent of the unevenness or irregularity of the surface of the
board 100 will be dependent upon the extent of the blowing agent
used.
[0026] Referring to FIG. 2A, there is illustrated a board 108
constructed in accordance with another embodiment of the present
invention. The board 108 differs from the board 100 by the
inclusion of a wash 110 over the exterior surfaces of the board to
provide a more faux wood appearance. The wash 110 is in the nature
of a coating or paint composition which adheres or bonds to the
surface of the material forming the board 108. The wash composition
typically will include a polymer film forming component, a solvent,
and a color component. A variety of colors may be used. The solvent
typically will be suitable for dissolving the polymer component, as
well as being a solvent for the material forming the board 100. In
a preferred embodiment, the polymer component will also be the same
polymer used for constructing the board 100. In this manner, the
wash will adhere strongly to the surface of the board 100. Examples
of suitable wash compositions and methods of applying same to a
synthetic polymer material are disclosed in U.S. Pat. No.
7,472,961, the disclosure of which is incorporated herein by
reference, and a copy of which is attached hereto.
[0027] As shown in FIG. 2A, the wash is bonded over only a portion
of the surface of the board 108, allowing underlying portions of
the board to be exposed. The wash 110 may be applied over the
entire surface of the board 108, and selected and/or random
portions removed using a suitable solvent and optionally a rag for
removing the wash. In such case, the pits 106 will be filled with
the wash composition, becoming filled pits 109 taking on the color
of the wash. It is also contemplated that the wash 110 may applied
randomly on the surface of the board 108 using any suitable
technique desired. In the embodiment shown in FIG. 2A, the wash is
not uniformly applied to the board 108, creating a random painted
effect with the imperfections such as pits 109 and fibers 102 being
partially visible on the non-coated areas.
[0028] Referring to FIG. 2B, there is shown a board 108' where the
wash 100 is applied over the entire surface of the board to form a
more uniform coating.
[0029] The boards 100, 108, 108' can be constructed in a variety of
sizes and shapes. For example, the boards may be rectangular,
octagonal, triangular, square, or circular or in other shapes, and
continuously extruded in a variety of lengths. The boards may be
thick, or thin, depending upon their application. In addition,
sheets of the aforementioned material may be formed, and various
shapes cut from the sheets as desired. The scrap material by virtue
of using thermoplastic material can be recycled. The boards, as
previously noted, can be used in a variety of applications, for
example, for construction of fences, barns, sheds, indoor and
outdoor furniture, patio furniture, frame for chairs, and the like.
The surface of the boards in addition to including a wash 110, may
also be machine finished such as having a hammer finish, or using
other tooling and engraving machines to create various
irregularities or patterns in the surface.
[0030] Turning to FIG. 3, there is illustrated a storage chest 112
constructed from any one of or combination of the boards 100, 108,
108' as previously described. The boards are used as conventional
wood boards. In this regard, the boards 100, 108, 108' can be cut
using conventional sawing techniques, and drilled with holes as may
be required. The boards may be attached together using screws
intended for plastic materials. In addition, it is also
contemplated that adhesives may be used to join the boards
together.
[0031] Turning now to FIG. 4, there is illustrated an article of
furniture in the nature of a chair 120 having a frame 122
constructed from the faux wood building materials in accordance
with the present invention. By way of illustration only, the frame
122 forms a plurality of legs 124 for supporting the article on an
underlying surface. The frame 122 further includes cross braces 126
and, optionally, sidearms 128. In the illustrative embodiment, the
sidearms 128 are formed as an extension of the front legs 124. A
plurality of cross members 130 delineates a seat portion 132 and
backrest portion 134. The seat and/or backrest portions may be
formed from a woven panel constructed from a plurality of woven
synthetic polymer yarns such as disclosed in, for example, U.S.
Pat. No. 7,472,961. The woven panels may be attached directly to
portions of the frame 122 or through additional structure which may
be attached to the frame 122. For example, the seat and backrest
portions 132, 134 may be constructed as a bucket seat which is
separately manufactured and assembled to a frame 122 previously
assembled using the faux wood building materials disclosed pursuant
to the present invention.
[0032] Although the invention herein has been described with
reference to particular embodiments, it is to be understood that
these embodiments are merely illustrative of the principles and
applications of the present invention. For example, it is not
required that the boards have a faux wood appearance. Rather, the
wash may be applied to provide any other appearance that may be
desired. In addition, the boards may be used without a wash. In
another aspect of the present invention, scrap or unused material
left over when making articles may be recycled with virgin material
for making articles therefrom. The ability to recycle the scrap
material results in the generation of little waste material. It is
therefore to be understood that numerous modifications may be made
to the illustrative embodiments and that other arrangements may be
devised without departing from the spirit and scope of the present
invention as defined by the appended claims.
* * * * *