U.S. patent application number 15/431317 was filed with the patent office on 2017-06-01 for surface appearance simulation systems and methods.
This patent application is currently assigned to Illinois Tool Works Inc.. The applicant listed for this patent is Illinois Tool Works Inc.. Invention is credited to Roger A. Fahlsing, Alan Kaufman.
Application Number | 20170151828 15/431317 |
Document ID | / |
Family ID | 50473783 |
Filed Date | 2017-06-01 |
United States Patent
Application |
20170151828 |
Kind Code |
A1 |
Fahlsing; Roger A. ; et
al. |
June 1, 2017 |
SURFACE APPEARANCE SIMULATION SYSTEMS AND METHODS
Abstract
A structural member includes a simulated surface appearance. The
structural member includes a substrate, plural intermediate layers,
and a top coat. The plural intermediate layers are applied over at
least one surface of the substrate, with at least some of the
plural intermediate layers configured to cooperate with each other
to provide a simulated appearance for the structural member. The
top coat is applied outward of the plural intermediate layers. The
top coat is relatively thin and is configured for use with exterior
applications. The top coat includes a base configured for UV
resistance and an additive configured to provide abrasion
resistance.
Inventors: |
Fahlsing; Roger A.;
(Valparaiso, IN) ; Kaufman; Alan; (Crown Point,
IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Illinois Tool Works Inc. |
Glenview |
IL |
US |
|
|
Assignee: |
Illinois Tool Works Inc.
Glenview
IL
|
Family ID: |
50473783 |
Appl. No.: |
15/431317 |
Filed: |
February 13, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13828122 |
Mar 14, 2013 |
9566607 |
|
|
15431317 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 38/08 20130101;
B05C 1/02 20130101; B44C 5/0476 20130101; Y10T 428/24802 20150115;
B05D 1/28 20130101; Y10T 428/24364 20150115; B05C 5/005 20130101;
B05D 3/067 20130101; B05D 1/12 20130101; B05C 9/12 20130101; B44F
9/02 20130101; B05D 1/305 20130101; B32B 3/263 20130101; Y10T
428/3154 20150401; B05D 3/068 20130101; B05C 9/14 20130101; B05B
9/03 20130101; B32B 2307/712 20130101; B32B 2307/744 20130101; Y10T
428/24372 20150115; B32B 3/10 20130101; B32B 27/322 20130101; B32B
2255/24 20130101; B05D 5/00 20130101; B32B 37/12 20130101; B05D
1/36 20130101 |
International
Class: |
B44C 5/04 20060101
B44C005/04; B05D 3/06 20060101 B05D003/06; B05D 1/12 20060101
B05D001/12; B05D 1/30 20060101 B05D001/30; B05D 1/28 20060101
B05D001/28; B05B 9/03 20060101 B05B009/03; B05B 15/00 20060101
B05B015/00; B05C 5/00 20060101 B05C005/00; B05C 9/12 20060101
B05C009/12; B05C 9/14 20060101 B05C009/14; B05C 1/02 20060101
B05C001/02; B32B 3/26 20060101 B32B003/26; B32B 37/12 20060101
B32B037/12; B05D 5/00 20060101 B05D005/00; B44F 9/02 20060101
B44F009/02; B05D 1/36 20060101 B05D001/36 |
Claims
1. A structural member having a simulated surface appearance, the
structural member comprising: a substrate; plural intermediate
layers applied over at least one surface of the substrate, two or
more of the plural intermediate layers configured to cooperate with
each other to provide a simulated appearance for the structural
member; and a top coat applied outward of the plural intermediate
layers, wherein the plural intermediate layers are interposed
between the substrate and the top coat, the top coat being
relatively thin and configured for use with exterior applications,
the top coat comprising a base configured for ultraviolet (UV)
resistance and including an additive configured to provide abrasion
resistance.
2. The structural member of claim 1, wherein the base of the top
coat comprises a fluoropolymer and the additive comprises plural
inorganic particles, the inorganic particles having a size and
distribution within the base configured for a particular
application.
3. The structural member of claim 2, wherein the fluoropolymer
comprises Polyvinylidene Fluoride (PVDF) and the inorganic
particles comprise an Aluminum Oxide (Al.sub.2O.sub.3).
4. The structural member of claim 1, wherein the plural
intermediate layers include a primer layer, a ground coat layer, a
print undertone layer, and a print layer.
5. The structural member of claim 1, wherein the plural
intermediate layers are configured to provide an appearance
corresponding to a wood grain.
6. The structural member of claim 1, wherein at least some of the
intermediate layers are arranged in a foil configured for
substantially simultaneous application of the at least some of the
intermediate layers to the substrate.
7. The structural member of claim 1, wherein the plural
intermediate layers are configured for thermal application and
wherein the top coat is configured for spray application.
8. The structural member of claim 1, wherein the additive includes
particles having a size, and wherein the thickness of the top coat
and the size of the particles are configured to provide a
texture.
9. A structural member coating system comprising: at least one
intermediate coating station configured to apply plural
intermediate layers over a substrate, at least some of the plural
intermediate layers configured to cooperate with each other to
provide a simulated appearance for the structural member; a top
coat application station configured to apply a top coat outward of
the plural intermediate layers, the top coat being relatively thin
and configured for use with exterior applications, the top coat
comprising a base configured for ultraviolet (UV) resistance and an
additive configured to provide abrasion resistance; and a curing
station configured for curing of the top coat after the top coat
has been applied, wherein the curing is configured to lock in a
positioning of the additive with the base.
10. The coating system of claim 9, wherein the at least one
intermediate coating station comprises a foil application station,
the foil application station configured to apply a foil to the
substrate, the foil comprising the plural intermediate layers.
11. The coating system of claim 9, wherein the at least one
intermediate layer station is configured to thermally apply the
plural intermediate layers, and wherein the top coat application
station is configured to at least one of spray or curtain coat the
top coat over an exterior of the plural intermediate layers.
12. The coating system of claim 9, wherein the additive includes
particles having a size, wherein the top coat application system is
configured to apply a thickness of the top coat configured to
provide a texture based on the size of the particles.
13. The coating system of claim 9, wherein the base of the top coat
comprises a fluoropolymer and the additive comprises plural
inorganic particles, the inorganic particles having a size and
distribution in the base configured for a particular application.
Description
RELATED APPLICATIONS
[0001] This application claims priority to and is a divisional of
U.S. patent application Ser. No. 13/828,122, filed Mar. 14, 2013,
entitled "Surface Appearance Simulation Systems and Methods," the
subject matter of which is incorporated herein by reference in its
entirety.
BACKGROUND
[0002] The subject matter described herein generally relates to
systems and methods for providing improved appearance simulation
and/or abrasion resistance for exterior products.
BRIEF SUMMARY
[0003] One or more embodiments described herein provide for a
system (and method for providing the same) that provides for
improved appearance simulation and/or abrasion resistance, for
example, for a structural member or members. For example, the
system may provide a structural member having a high fidelity wood
grain appearance while also having a desirable level of resistance
to surface abrasion for use in exterior (or outdoor) applications.
One or more embodiments described herein provide for an exterior
product having a realistic simulated wood grain appearance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The present inventive subject matter will be better
understood from reading the following description of non-limiting
embodiments, with reference to the attached drawings, wherein
below:
[0005] FIG. 1 is a schematic view of one embodiment of a simulated
wood product;
[0006] FIG. 2 is overhead sectional view of a portion of one
embodiment of a simulated wood product;
[0007] FIG. 3 is a view of a simulated wood grain of one
embodiment;
[0008] FIG. 4 is a schematic view of a coating system in accordance
with an embodiment; and
[0009] FIG. 5 is a flowchart of one embodiment of a method for
providing a simulated wood product.
DETAILED DESCRIPTION
[0010] In accordance with one or more embodiments described herein,
a structural member coating system, method for coating structural
member, and coated structural members having a realistic simulated
appearance are disclosed.
[0011] Embodiments provide for high quality graphics in conjunction
with exterior durable materials for outdoor applications.
Embodiments provide enhanced appearance and/or other attributes
(e.g., durability) for structural members for exterior or outdoor
applications. A structural member including a substrate having
plural intermediate layers configured to provide a simulated
appearance and a top coat configured to provide desirable features
for exterior use may be provided. For example, a natural product
(e.g., wood having a grain) may be simulated using a man-made
material (e.g., plastic, composite, or the like) having performance
features desirable in outdoor applications (e.g., resistance to the
elements including sunlight, resistivity to abrasion, or the like).
Such features may be particularly desirable in horizontal
applications (such as decking or other surface across which foot
traffic is expected), as well as various challenging vertical or
other non-horizontal applications (such as garage doors or roofing)
that may be subject to a substantial level of abuse over an
expected life cycle. Structural members in accordance with various
embodiments may be employed as building materials such as decking,
fencing, wall panels, roofing, doors, trim, or the like. In some
embodiments, Polyvinyl Chloride (PVC), Acrylonitrile Butadiene
Styrene (ABS), other exterior grade plastics or composites, or the
like may be employed as a substrate to which a coating is
applied.
[0012] Exterior building materials may vary in appearance by one or
more of substrate color, design, pattern, or decorative effects.
The appearance and design of exterior building materials may be
limited by product specifications, requirements, or performance
needs. Performance targets, needs, or requirements may include for
example, ultraviolet (UV) durability, or the ability to resist
color fade, chalking, cracking, blistering, or the like due to
exposure from UV radiation (e.g., from sunlight), and/or resist
wear or damage from weather conditions, such as changing
temperatures, precipitation, or the like. As another example,
performance targets, needs, or requirements may include long term
wear, including abrasion resistance from foot traffic, contact with
plants, trees, or shrubs, wind abrasion from air borne dirt or
debris, or the like. As yet another example, performance targets,
needs, or requirements may include short term wear, or resistance
to scratches or impacts. As still another example, performance
targets, needs, or requirements may include chemical or stain
resistance or tolerance, such as tolerance of or resistance to
general cleaning chemicals, lawn care products, insecticides,
general household items, or the like. As one more example,
performance targets, needs, or requirements may include
installation and storage characteristics. For instance, exterior
building materials should be robust enough for handling by
contractors, home owners, or other individuals. Various embodiments
provide for desired characteristics for exterior applications, such
as the characteristics discussed above.
[0013] As indicated above, structural members formed in accordance
with various embodiments may be used in horizontal or vertical (or
other non-horizontal orientation such as slanted) applications.
Desired performance characteristics for horizontal applications may
differ from desired performance characteristics for vertical (or
other non-horizontal) applications. For example, a deck plank may
be considered in comparison to a wall panel. The deck plank may
require durability from foot traffic that a wall panel would not.
Various conventional exterior building products currently available
may suffer from limited design capability due to process limitation
or durability requirements for a particular application. Such
limitations may be particularly evident in applications where the
product is oriented horizontally and may be walked upon. For
example, in the decking industry, plastic or composite deck planks
may be decorated in a variety of ways to attempt to simulate a wood
appearance. One challenge facing these applications is to create a
realistic appearance while maintaining durability characteristics
to withstand foot traffic (e.g., walking, running, pet traffic, or
the like), weather/environment factors (UV, moisture, wind, rain,
mold, temperature change, or the like), and general considerations
(e.g., pool or spa chemicals, household cleaners, yard maintenance
materials such as insecticides or fertilizers, or the like).
[0014] Conventionally, materials used to simulate wood grain
appearance for exterior applications may be made based on wood or
wood composites originally configured for interior applications.
While such materials may have relatively good graphic images and
may provide wear resistance, such material (e.g., wood substrates)
may not hold up to exterior conditions (e.g., effects of weather
experience in exterior applications). For example, decorated
surfaces configured to simulate a wood grain for interior
applications may include paper in conjunction with highly
cross-linked polymer coatings. Such surfaces may not move
sufficiently with the normal or expected thermal expansion or
contraction of a plastic or plastic composite substrate in an
exterior application, which may lead to delamination of the
decorative surface. Various previous attempts to simulate real wood
(e.g., wood grain), for example as part of a plastic or composite
substrate, have not produced results as effective as may be
desired.
[0015] For example, macro embossing has been attempted to provide a
textured effect to simulate cathedrals or other grains in a wood
species. Macro embossing, however, does not provide a realistic
wood grain simulation, instead resembling a piece of textured
plastic. Further, macro embossing may be limited typically to solid
colors, but may have streaks of pigment or prints in some
applications.
[0016] As another example, variegation has been attempted using a
color effect within an extruded part, such as via the use of
different color pellets dropped into an extrusion process. However,
variegation also provides a poor simulation of wood grain, instead
resembling a streaked plastic part which may or may not be
textured. These and other attempted techniques have achieved less
than desirable results, for example, by providing poor simulation
and/or failing to provide durability required for outdoor use.
[0017] Embodiments disclosed herein provide systems and/or methods
for providing improved graphical simulation with durability
properties configured for outdoor use. For example, a decoration
may be provided using a transfer decoration (e.g., glued, thermally
transferred, or the like) that provides a polymer and pigment
combination that eliminates or reduces fading or degradation during
an exterior product lifetime. A clear topcoat may be used in
conjunction with the transfer decoration to provide one or more of
wear resistance, weather resistance, or anti-slip resistance.
Further, one or more of stain resistance, chemical resistance,
solvent-resistance, or graffiti resistance may be provided.
[0018] For example, in embodiments, one or more layers may be
employed to provide a transfer decoration that realistically
simulates a desired appearance. The desired appearance may be one
or more of a variety of appearances. For example, a naturally
occurring appearance, such as wood, stone, ceramic, or the like may
be simulated. Additionally or alternatively, a graphic image, such
as a pattern (e.g., camouflage), a synthetic design, a logo, or the
like may be simulated.
[0019] In some embodiments, a base or "last down" layer may be
included, and be configured to facilitate bonding to a substrate or
laminating adhesive. A ground coat may be included. The ground coat
may provide overall background color and/or protect the substrate
from UV light. Further, a graphic image may be provided. In
embodiments, the graphic image may include two or more
corresponding printed images that are laid down to provide a
desired graphic appearance. In some embodiments, the ground coat
and the graphic image may utilize inorganic oxide, complex
inorganic colored pigment (CICP), exterior durable organic pigment,
or the like. In various embodiments, a topcoat bonding coat may be
provided, with the topcoat bonding coat configured to facilitate
the bonding of the topcoat to the transfer decoration. The various
layers (or materials used in the various layers) may cooperate
together to provide high-quality materials that are configured to
be durable for outdoor applications while still providing
aesthetically pleasing graphics.
[0020] FIG. 1 is a side view of a simulated wood product 100 made
from a plurality of layers that may be added or applied to a
substrate in accordance with an embodiment. It should be noted that
FIG. 1 is a schematic, conceptual depiction and is not intended to
be to scale. Different layers may have varying thicknesses in
various embodiments. In some embodiments, more layers of a given
type, less layers of a given type, more types of layers, and/or
less types of layers may be employed. For example, a given layer
depicted in FIG. 1 may not be present in various embodiments,
and/or a layer not depicted in FIG. 1 may be present in various
embodiments. Further, the illustrated embodiment is discussed in
the context of simulated wood grain, but other simulation may be
achieved in other embodiments. For example, other natural materials
such as stone, ceramic, tile, or the like may be simulated.
Further, graphic images such as patterns, designs, logos, or the
like may be provided in embodiments.
[0021] The simulated wood product 100 depicted in FIG. 1 includes
an intermediate portion 130 including a plurality of intermediate
layers 132, 134, 136, 138 disposed between a substrate 110 and a
top coat 120. The substrate 110 and/or one or more of the layers of
the intermediate portion 130 and/or the top coat 120 may be
comprised of durable exterior components. For example, the top coat
120 may have a durable formulation including inorganic particles.
In some embodiments, the top coat 120 may be a relatively thin
coating with a relatively lightly textured surface for slip and
durability enhancement. The intermediate portion 130 may provide a
realistic simulation of a cathedral or other wood grain pattern
that appears close to the surface (e.g., covered only by the
relatively thin top coat 120) and/or having a layered or
three-dimensional appearance. Cathedral grain may be understood as
a specific grain pattern characterized by a series of stacked "V"
and/or inverted "V" shapes. This pattern is common to flat cut or
plain sliced veneer. Other grain patterns may be simulated
additionally or alternatively in various embodiments. In FIG. 1,
the various layers are depicted only on top of the substrate 110,
but layers could be applied to the sides and/or bottom of the
substrate 110 as well in various embodiments. (See, e.g., FIG.
2)
[0022] Returning to FIG. 1, the substrate 110 may be a structural
member such as a plank, board, beam, sheet, or the like. In the
illustrated embodiment, the substrate 110 is a plank sized and
configured to be used for decking, and a number of such planks may
be used to provide the surface of a deck upon which people may
walk, stand, sit, or the like. The substrate 110 may be provided in
one or more predetermined lengths. In some embodiments, the
substrate may be plastic or composite. Generally speaking, the
substrate 110 is configured to provide the structural strength,
rigidity, and/or other properties that may be required or desired
for the simulated wood product 100. The various layers and top coat
120 are provided over one or more surfaces of the substrate 110 to
provide a realistic wood grain appearance to the simulated wood
product 100.
[0023] In the illustrated embodiment, the intermediate portion 130
is configured to provide a realistic simulation of a wood material,
for example a wood grain. The intermediate portion 130 includes a
plurality of layers (e.g., a visual effect simulation portion 140)
that cooperate to provide a wood-like appearance. By "cooperate,"
it is meant that a visual design or appearance on each of the
plurality of layers is based on the visual design or appearance on
one or more, or all, of the other layers in the plurality of
layers. For example, the spatial location of the design, the
arrangement of two or more designs, the spacing between designs,
and the like, on a first layer may be created in order to be
oriented in a designated or preselected relationship with the
design or appearance of one or more other designs on a second layer
(and/or on multiple other layers). The designs on the plurality of
layers can be arranged relative to each other such that, when the
layers are stacked on top of one another, a composite design is
created. The composite design may be a mixture or other combination
of the different designs on the different layers, and may be
different from the designs of one or more, or all, of the layers in
the plurality of layers. In an embodiment, the designs on the
layers do not physically or chemically mix with each other, but
remain separate to provide the composite design.
[0024] The intermediate portion also includes an adhesive layer 132
configured to help secure the intermediate portion 130 to the
substrate 110. The intermediate portion 130 thus may be seen as an
including an adhesive layer 132 as well as the visual effect
simulation portion 140. The use of layers, for example, as depicted
in FIG. 1, may provide realistic simulation of wood grain, allowing
for the appearance of visual depth to provide a realistic
simulation of wood grain. It should be noted that a given layer
depicted as an individual layer in FIG. 1 may be achieved or
replaced by multiple layers or sublayers. In various embodiments,
various layers may be applied sequentially to a substrate (e.g.,
one or more lower layers applied first, one or more intermediate
layers then applied after the one or more lower layers, and one or
more upper layers then applied after the one or more intermediate
layers). In other embodiments, the intermediate portion 130 may be
applied at a single time, with the various layers arranged, for
example, as a foil that is applied to the substrate 110. In still
other embodiments, for example, the adhesive layer 132 may first be
applied, with the visual effect simulation portion 140 subsequently
applied as a foil. In various embodiments one or more foils (with
each foil comprising a plurality of layers may be applied. For
example, all or some of the layers of the visual effect simulation
portion 140 may be provided as a foil. As another example, the
entire intermediate portion 130 may be provided as a foil.
[0025] The adhesive layer 132 is the portion of layer of the
intermediate portion 130 in the illustrated embodiment that is
positioned most closely to a surface of the substrate 110. The
adhesive layer is configured to adhere, bond, secure, or the like
the various other layers to the substrate 110. The adhesive layer
132 for example, may be a liquid. A liquid adhesive layer may be
applied to the substrate, for example, by a coating or spraying
operation. In some embodiments, the adhesive layer 132 may be heat
activated and thermally applied. In some embodiments, the adhesive
layer 132 may be applied before any other layers of the
intermediate portion 130, while in other embodiments, the adhesive
layer 132 may be applied at the same time as one or more additional
layers, for example as a foil comprising multiple layers that is
applied to the substrate 110, with the adhesive layer 132 of the
foil oriented most closely toward the surface of the substrate 110
to which the foil is to be applied. The adhesive layer 132 may be
configured to act as a primer layer for the visual effect
simulation portion 140 or a layer thereof. In some embodiments, a
primer layer may be positioned or applied above the adhesive layer
132.
[0026] The visual effect simulation portion 140 includes layers
that are configured to cooperate with each other to provide a
simulation of wood grain. One or more layers may have patterns that
are configured to coordinate or otherwise correspond with patterns
of one or more other layers, for example, with various portions of
a grain pattern provided by different layers. In some embodiments,
a leading edge of a grain may be provided by a first layer, an
intermediate portion of the grain provided by a second layer, and a
trailing edge of a grain provided by a third layer. Alternatively
or additionally, varying shadings between portions of a grain
pattern may be provided by a plurality of layers.
[0027] One or more of the layers may be substantially solid in
shade or color, for example, to provide a base color to the wood
simulation. One or more layers that include a pattern may be
applied above the substantially solidly colored layers. Layers that
include a pattern may be partially or fully transparent or
translucent allowing patterns from layers disposed beneath to show
through the given layer, so that the layers can provide visual
depth or have a three-dimensional appearance. For example, an
undertone or base color may be provided with varying patterns of
grain imposed on top. Such a layered grain simulation may provide a
more realistic simulation of wood grain than approaches using
lines, streaking, or the like drawn or otherwise formed in an
attempt to provide a profile or outline of wood grain. The visual
effect simulation portion 140 may be formed as a foil and applied
together (with or without the adhesive layer 132). The visual
effect simulation portion 140 may include one or more foils and be
applied in one or more steps. The visual effect simulation portion
140 may be applied at the same time as the adhesive layer 132 in
some embodiments, and may be applied subsequent to the adhesive
layer 132 in other embodiments. The visual effect simulation
portion 140 in the illustrated embodiment includes a ground coat
layer 134, a print undertone layer 136, and a print layer 138.
[0028] The ground coat layer 134 in the illustrated embodiment is
configured for exterior use and configured for durability. The
ground coat layer 134 in the illustrated embodiment is positioned
or applied above the adhesive layer 132 (e.g., with the adhesive
layer 132 interposed between the substrate 110 and the ground coat
layer 134.) In some embodiments, a primer layer (not shown in FIG.
1) may be interposed between the adhesive layer 132 and the ground
coat layer 134. The ground coat layer 134 of the illustrated
embodiment provides a base for additional layers of the visual
effect simulation portion. The ground coat layer 134 may be the
same color or a different color than the print undertone layer
136.
[0029] The print undertone layer 136 in the illustrated embodiment
is positioned above the ground coat layer 134 (e.g., with the
ground coat layer 134 interposed between the print undertone layer
136 and the substrate 110). In the depicted embodiment, the print
undertone layer 136 is configured for exterior use and configured
for durability. In various embodiments, the print undertone layer
136 may be the same color or shade as the ground coat layer 134, or
may be a different color or shade than the ground coat layer 134
(e.g., the print undertone layer 136 may be a lighter shade or
color than the ground coat layer 134). In some embodiments, the
print undertone layer may be translucent or have variable
translucence to allow a portion of the ground coat layer 134 to
appear through the print undertone layer. In other embodiments, the
print undertone layer may be substantially opaque and not allow
substantial visual appearance of any portion of the ground coat
layer 134. Generally, in various embodiments, the print undertone
layer 136 may be selected or configured to simulate a base color of
a given type or variety of wood (e.g., maple, pine, cedar, redwood,
or the like). In some embodiments, the print undertone layer 136
may be lighter in color than portions of the print layer 138 (or
sub-layers forming the print layer 138) to allow the appearance of
darker grain patterns over a lighter base color. In some
embodiments, the print undertone layer 136 may be substantially
uniform in color or shade distribution, while in other embodiments,
the print undertone layer 136 may have variance or gradation of
shade.
[0030] The print layer 138 may include a plurality of sublayers
(e.g., from 3-10 sublayers) configured to provide a realistic
layered depth effect. The print layer 138 in the illustrated
embodiment is configured to be durable for exterior use, and
configured to provide a high fidelity print simulation. For
example, the print layer 138 may be configured to provide a
realistic wood grain appearance over the print undertone layer 136.
One or more layers of the print layer 138 in the illustrated
embodiment are partially translucent or transparent to allow at
least a portion of a layer or sublayer therebeneath to be perceived
by viewer. For example, a portion of a sublayer configured to
simulate a grain pattern or portion of a grain pattern may be
substantially opaque while other portions of the sublayer may be
translucent or transparent. The print layer 138 may be formed of
one or more pre-printed sheets or foils that are configured to have
corresponding fiducial points that correspond with points of other
layers, with the various layers cooperating to provide a simulated
appearance. For example, each of a plurality of layers or sublayers
may contribute a discrete portion of an overall pattern (such as a
wood grain), with the contributions of the various layers or
sublayers aligned to provide a unified effect when the layers are
applied together. Thus, various portions of a grain pattern may be
lighter or darker and/or have the appearance of varying depth
relative to other portions of a grain pattern provided on other
layers or sublayers.
[0031] For example, some portions of a grain pattern may be lighter
(and/or be underneath one or more translucent layers) while other
portions may darker (and/or above other layers). For example, one
layer may be used to provide an interior portion of a grain (e.g.
quilt, flame, burr, knot, or the like) and may be relatively dark,
and a corresponding edge of the grain (e.g., an outer portion of a
knot, a ring, or the like) may be lighter. As another example, one
edge of a grain pattern may be darker and one edge lighter.
Further, multiple layers may cooperate to provide additional
shadings between portions of a grain pattern and/or additional
depth layers of a grain pattern. Thus, multiple layers or sublayers
may be employed to provide variations in shade and/or depth to
provide a realistic simulation of wood grain.
[0032] In the illustrated embodiment, the print layer 138 includes
sublayers 138a, 138b, 138c. 3 sublayers are shown in the
illustrated embodiment; however, more or less sublayers may be
employed in other embodiments. FIG. 3 provides one example of a
grain pattern that may be provided by various sublayers. In FIG. 3,
a cathedral grain pattern 300 is provided having three grain
portions, namely a leading edge 302, an intermediate portion 304,
and a trailing edge 306. The various grain portions (and/or areas
303, 305 disposed between grain portions) may have various shadings
and depth appearances provided by use of different layers. For
example, the leading edge 302 may be provided by a grain pattern
included on the sublayer 138a, the intermediate portion 304 may be
provided by a grain pattern included on the sublayer 138b, and the
trailing edge 306 may be provided by a grain pattern included on
the sublayer 138c. In various embodiments, more than one grain
pattern may be provided by a given sublayer (e.g. one sublayer may
provide both the leading edge 302 and the trailing edge 306). Thus,
in the illustrated embodiment, the various grain portions 302, 304,
306 (and/or areas between or near the various grain patterns) may
have differing apparent depths, provide a realistic depth to the
simulated wood grain.
[0033] Alternatively or additionally, sublayers may cooperate to
provide a given grain pattern (e.g., one or more sublayers may
cooperate to provide the intermediate portion 304. In the
embodiment depicted in FIG. 3, the various sublayers are
coordinated so that the various grain patterns are positioned in
locations corresponding to one another, so that the "V" s formed by
the various layers are positioned a desired spacing apart from one
another and do not overlap or cancel one another out. In various
embodiments, other grain patterns may be simulated (e.g.,
quartersawn, flame, quilt, or the like).
[0034] Returning to FIG. 1, the top coat 120 is disposed above the
intermediate portion 130 (e.g., with the intermediate portion 130
interposed between the top coat 120 and the substrate 110. The top
coat 120 of the illustrated embodiment is relatively thin (e.g.,
having a relatively low thickness configured to allow the grain
simulation to appear close to the surface of the simulated wood
product 100) and is configured for use with exterior applications.
In an embodiment, the top coat 120 is relatively thin when a
thickness dimension of the top coat 120 is smaller than the
thicknesses of all other layers and portions of the structure. The
top coat 120 may be configured to provide good abrasion resistance
as well as UV resistance (e.g., resistance to fading of the print
layers due to exposure to sunlight. The top coat 120 may include a
base member configured for UV resistance and an additive configured
to provide abrasion resistance. The top coat 120 may be
substantially thinner than plastic caps used in some alternate
approaches.
[0035] The base member of the top coat 120 may be formed using a
polymer. For example, in various embodiments, one or more of a
urethane, acrylic, fluoropolymer, or other exterior durable polymer
system may be employed, for example, to provide light stability.
The base member may include one or more functional groups, for
example, to crosslink the top coat in order to improve certain
properties. As one example, the base member may include a hydroxal
functional group to crosslink with urethane or melamine containing
materials. As another example, the base member may include a
carboxal functional group to crosslink with aziradine or
oxazolidine containing materials. As still another example, the
base member may include a free radical functional group to
crosslink, for instance, using UV or E beam radiation. As yet
another example, the base member may include a cycloalphatic epoxy
functional to crosslink, for instance, using UV or E beam
radiation. In various embodiments, the base member may be water
based or 100% solids to minimize hazardous organic volatiles.
[0036] As indicated above the top coat may also include an additive
that is added to (e.g., disposed within) the base member. The
additive may include, for example, inorganic particles. The
inorganic particles may be configured to improve abrasion
resistance and/or provide anti-slip properties. In embodiments, the
additive may include particles having a hardness of about 5 MOL or
above. In various embodiments, the additive may have a low
refractive index to help maximize clarity of the top coat 120. For
example, the additive may have a refractive index of about 2.2 or
lower. The thickness of the additive (e.g., particle size) may be
configured such that the thickness is about 140% or less of the
thickness of the base member.
[0037] The thickness of the top coat 120 (e.g., the thickness of
the base member of the top coat 120) may be determined based on
wear requirements of a given application of an end product
utilizing the top coat 120. For example, in some embodiments, a
thickness of about 0.5 mil or above may be utilized to provide a
desired level of wear resistance. In some embodiments, multiple
coats may be applied to achieve a desired thickness. Further, in
some embodiments, the composition of the multiple coats may vary to
achieve a desired property. For example a first coat or layer of
the top coat 120 may have a first composition, and a subsequently
applied coat or layer may have a different composition.
[0038] The top coat 120, for example, may be sprayed, curtain
coated, or the like above the intermediate portion 130 after the
intermediate portion 130 has been applied to the substrate. In some
embodiments, the base may include a fluoropolymer. The
fluoropolymer, for example, may be Polyvinylidene Fluoride (PVDF).
The additive may include inorganic particles. The additive may
include, for example, Aluminum Oxide (Al.sub.2O.sub.3). The
inorganic particles may be sized and distributed in the base member
for a particular application. For example, the particles may be
sized and provided in a relative proportion relative to the
thickness of the top coat 120 such that at least some portions of
the particles provide an irregular surface to the top coat 120,
providing for a level of grip to one or more exterior surfaces of
the simulated wood product as well as abrasion resistance. The
additive may include particles having a size, and the thickness of
the top coat 120 and the size of the particles may be configured to
provide a texture. For example, as indicated above, in some
embodiments, the particle size may be about 140% of the thickness
of the base member or less. As another example, in some
embodiments, the particle size may be selected from a range between
about 50% to about 125% of the thickness of the base member. A
texture of the top coat 120 may be understood as a tactilely
perceptible non-uniform surface. The top coat 120 may have a
thickness configured to cooperate with the particle size of the
additive to provide for slip resistance (e.g., for people walking
on a deck, flooring, walkway, or other surface made with the
simulated wood product 100). In various embodiments, the top coat
120 may be disposed above a top, sides, and/or bottom of the
substrate 110.
[0039] As indicated above, the top coat 120 may be applied by
coating. For example, the top coat 120 may be roll coated, curtain
or side coated, spray coated, or the like. In some alternative
embodiments, a film could be glued or otherwise applied to a
graphic image to provide the top coat 120. The film, for example,
may be surface modified to provide one or more of a lower gloss,
anti-slip characteristics, or abrasion resistance. The film may be
composed of an exterior durable polymer (e.g., acrylic,
polycarbonate, urethane, or the like). In various embodiments, the
film may have a thickness between about 2 mil and about 5 mil. The
glue or adhesive may be a single component reactive urethane, or as
another example, a two component urethane. The glue or adhesive may
be light stable, and may be applied at a thickness configured to
provide excellent adhesion between the film and a decorative
graphic.
[0040] In connection with FIG. 1, a simulated wood product 100 is
discussed. In various embodiments, other materials (either natural
or man-made) may be simulated, such as stone, stucco, plaster, or
the like. A simulated appearance as discussed herein may be
understood as an appearance configured to appear different than a
natural appearance of a substrate in terms of pattern, texture, or
the like. In various embodiments, such a simulated appearance may
be achieve via a plurality of partially transparent or translucent
layers configured to provide a layered or three-dimensional effect.
Patterns of grain or other simulation may be provided having a
relatively repetitive appearance in some embodiments, while a
random appearance may be employed in other embodiments.
[0041] FIG. 2 is a side view of a simulated wood product 200
including a plurality of layers that have been applied or added to
a substrate 202. It should be noted that the thicknesses of various
layers in FIG. 2 are provided for clarity of illustration and are
not intended as a scale representation. For example, one or more
layers may be relatively thinner with respect to other layers
and/or the substrate. In various embodiments, varying types of
layers and/or numbers of layers or sub-layers may be employed.
Further, more or less layers or of a given type of layer may be
employed.
[0042] The simulated wood product 200 includes a substrate 202,
intermediate layers 204, and a top coat 206. The intermediate
layers 204 are interposed between the substrate 202 and the top
coat 206. At least some of the intermediate layers 204 are
configured to provide a simulated visual effect, such as to
simulate wood grain. The top coat 206 may be configured similarly
to the top coat 120 discussed above, and may be configured to
provide both UV and abrasion resistance.
[0043] The simulated wood product 200 includes a top 222, a bottom
220, a first side 224 and a second side 226. In the illustrated
embodiment, the top 222 is configured to be oriented in an outward
position relative to the bottom 220. For example, if the simulated
wood product 200 were to be used a horizontal application, such as
being utilized as a plank of a deck, the simulated wood product 200
is configured so that the top 222 would be facing outward, e.g., as
the surface upon which a person traversing the deck would walk. As
another example, if the simulated wood product 200 were to be used
in a non-horizontal application, such as a garage door, the
simulated wood product is configured so that the top 222 would be
facing outward (e.g., the bottom 224 positioned more proximate the
interior of the garage). In still other embodiments, the simulated
wood product 200 may be positioned so that both the top 222 and
bottom 220 are configured as facing outward, for example as part of
a back rest of a bench that may be formed as part of the deck, and
both the top 222 and bottom 220 may be provided with a simulated
wood grain.
[0044] In the embodiment depicted in FIG. 2, the intermediate
layers 204 and the top coat 206 are shown as covering the top 222,
the first side 224, and the second side 226. In various
embodiments, different arrangements may be employed. As one
example, the intermediate layers 204 and top coat 206 may be
applied only above or along the top 222. As another example, the
top coat 206 may be applied over a larger area than the
intermediate layers 204. For example, the intermediate layers 204
may be applied only along the top 222, while the top coat 206 may
be applied along the top 222 and one or more of the first side 224
or the second side 226. As still another example, the intermediate
layers 204 and top coat 206 may be provided along the entire
periphery of the substrate 202 (e.g., along the top 222, first side
224, bottom 220, and second side 226). In such an arrangement, any
surface of the simulated wood product may be considered as or
employed as a top or outer surface.
[0045] The substrate 202 may be similar in respects to the
substrate 110 discussed above in connection with FIG. 1. For
example, the substrate 202 may be a structural member such as a
plank, board, beam, sheet, or the like. In some embodiments, the
substrate 202 may be formed from one or more plastic or composite
materials. Generally speaking, the substrate 202 is configured to
provide a desired strength, rigidity, and/or other properties for a
given exterior application. The various layers and the top coat 206
are provided over one or more surfaces of the substrate 202 to
provide a realistic wood grain appearance as well as desired
additional properties such as UV resistance, resistance to
chemicals (such as cleaners, fertilizers, or the like), abrasion
resistance, slip resistance, or the like.
[0046] The intermediate layers 204 include a plurality of layers
(which may in some embodiments in turn include sublayers), and may
be configured similarly in certain respects to the intermediate
portion 130 discussed above in connection with FIG. 1. One or more
of the intermediate layers 204 may be applied to the substrate 202
at the same time. In some embodiments, one or more of the
intermediate layers 204 may be applied to the substrate at a
different time than one or more others of the intermediate layers
204. In the illustrated embodiments, the intermediate layers 204
are configured to provide a realistic simulation of a wood
material, for example a wood grain. It should be noted that a given
layer depicted as an individual layer in FIG. 2 may be achieved or
replaced by multiple layers or sublayers.
[0047] The adhesive layer 210 may be similar in certain respects to
the adhesive layer 132 discussed in connection with FIG. 1. For
example, generally, the adhesive layer is configured to adhere,
bond, secure, or the like the various other layers to the substrate
202. The adhesive layer 210 in some embodiments may be a liquid. In
some embodiments, the adhesive layer 210 may be heat activated and
thermally applied, for example as a foil or as an exterior layer of
a foil.
[0048] The ground layer 212 may be similar in certain respects to
the ground coat layer 134 discussed in connection with FIG. 1.
Generally, the ground coat 212 of the illustrated embodiment is
configured to provide a base for additional layers positioned above
(e.g., farther from an exterior surface of the substrate 202). The
ground coat 212 may be the same color or a different color than the
print undertone layer 214.
[0049] The print undertone layer 214 may be configured similarly in
certain respects to the print undertone layer 136 discussed in
connection with FIG. 1. For example, the print undertone layer 214
may be translucent or have variable translucence to allow a portion
of the ground coat layer 212 to appear through the print undertone
layer 214, while in other embodiments, the print undertone layer
214 may be substantially opaque. The print undertone layer 136 may
be selected or configured to simulate a base color of a given type
or variety of wood. The print undertone layer may be substantially
uniform in color or shade distribution, or may have variance or
gradation of shade.
[0050] The print layer 216 may be configured similarly to the print
layer 138 discussed above in connection with FIG. 1. For example,
the print layer 216 may include a plurality of sublayers (not shown
in FIG. 2) configured to provide a realistic layered depth effect.
The print layer 216 may be formed of one or more pre-printed sheets
or foils that are configured to have corresponding patterns or
sub-patterns that cooperate with each other to form a coordinated
pattern, such as a wood grain pattern, that includes contributions
from a plurality of layers. Thus, various portions of a grain
pattern may be lighter or darker and/or have the appearance of
varying depth relative to other portions of a grain pattern.
[0051] The top coat 206 may be configured similarly in certain
respect to the top coat 120 discussed above in connection with FIG.
1. For example, the top coat 206 depicted in FIG. 2 is configured
to be relatively thin (e.g., having a relatively low thickness
configured to allow the grain simulation to appear close to the
surface of the simulated wood product 200), and is configured for
use with exterior applications. In the illustrated embodiment, the
top coat 206 includes a base member 207 configured for UV
resistance and an additive 208 configured to provide abrasion
resistance. In some embodiments, the base member 207 may include a
fluoropolymer, such as PVDF. The additive 208 may include inorganic
particles, for example, including Aluminum Oxide
(Al.sub.2O.sub.3).
[0052] FIG. 4 is a schematic view of a system 400 configured to
provide a simulated wood product, such as the simulated wood
product 100 or the simulated wood product 200 discussed above. The
various zones or stations of the system 400 are joined by a
transport mechanism such as the substrate transport 440. The
substrate transport 440 may be configured, for example, as a
conveyor belt or the like. The various zones may be part of one
generally continuous line disposed at a single generally contiguous
location or facility, or alternatively may be configured as two or
more separate lines located remotely at one or more facilities.
[0053] The system 400 includes a first zone 410, a second zone 420,
and a third zone 430 linked by the substrate transport 440. In the
illustrated embodiment, the first zone 410 is configured as a
decorating zone or station configured to add an adhesive as well as
a visual simulation effect (e.g., wood grain) portion that may
include a plurality of layers (e.g., base coat, undertone, print
layer). The second zone 420 may be configured as a top coat
application zone or station, and the third zone 430 may be
configured as a drying and/or curing zone or station configured to
dry or cure the top coat that has been applied to the substrate. In
various embodiments, each zone depicted in FIG. 4 may be broken
into a plurality of zones or sub-zones (e.g., multiple zones for
adding an adhesive layer separately from other layers, adding
decorative layers sequentially, or the like) and/or additional
zones, stations, or processes may be employed.
[0054] In the illustrated embodiment, the first zone 410 is
configured to receive a substrate 450 (e.g., a substrate such as
the substrate 110 or the substrate 202 discussed elsewhere herein)
conveyed by the substrate transport 440, and to apply an exterior
foil 414 that is configured to provide a visual simulation (e.g., a
wood grain simulation) to the substrate 450. In the illustrated
embodiment, the first zone 410 is configured as an intermediate
coating station configured to apply plural intermediate layers to
the substrate 450. The exterior foil 414 may include a plurality of
intermediate layers as discussed elsewhere herein and may be
laminated or transferred to the substrate 450 using heat activated
adhesive in some embodiments, and may be wet applied in other
embodiments. In the illustrated embodiment, the first zone 410
includes a pressure roller 412 configured to apply the exterior
foil 414 to one or more surfaces of the substrate 450 to provide a
decorated substrate 460. The roller pressure may be applied at
various angles to cover all surfaces of the substrate 460 that
require decoration. In some embodiments multiple rollers may be
employed (e.g., a first roller to apply a foil to the top of a
substrate and a second roller to apply a foil to the side of a
substrate). A single foil may be applied to more than one surface
of the substrate, or each surface of the substrate to receive a
decoration may receive a foil sized and configured for that
particular surface. In alternate embodiments, an adhesive and/or
primer layer may be applied initially before other layers, and/or
one or more layers may be applied sequentially using a plurality of
zones or sub-zones. In the illustrated embodiment, after the
exterior foil 414 is applied to the substrate 450 to provide a
decorated substrate 460, the decorated substrate 460 is advanced in
direction 402 to the second zone 420.
[0055] At the second zone 420, the decorated substrate 460 receives
a top coat (e.g., top coat 120, top coat 206). In the illustrated
embodiment, the second zone 420 includes a spraying station 422
configured to spray the top coat onto the decorated substrate 460.
In alternate embodiments, the second zone 420 may be configured to
coat the decorated substrate 460 using a curtain coating process or
other coating process. In various embodiments, the top coat may be
applied to a single surface of the decorated substrate 460 (e.g.,
the top) or multiple surfaces of the decorated substrate 460 (e.g.,
top and sides; top, bottom, and sides). The second zone 420 is
configured to apply the top coat as a relatively thin coating or
layer that allows for the grain pattern provided by the
intermediate layers to be close to the surface as seen by an
observer. The thickness of the top coat and the size of particles
added to the top in various embodiments are matched to provide an
abrasion resistance required or desired for a given application.
After the top coat is applied, the decorated substrate 460 with the
top coat applied is advanced in direction 402 to the third zone
430.
[0056] The third zone 430 of the depicted embodiment is configured
as a drying or curing zone for drying or curing the top coat. The
third zone may include a drying or curing station 432 including one
or more of a heater, blower, or the like to dry or cure the top
coat. The third zone 430 of the illustrated embodiment may be
configured to dry or cure the top coat such that an additive of the
top coat is locked into position and/or creates a bond to the
decorated surfaces of the decorated substrate 460. The additive may
be positioned such that a portion of at least some of the particles
of the additive are located above the coating surface of the top
coat base to allow for texture. Such positioning may create a slip
resistant surface, enhance abrasion and long term wear, and/or may
enhance short term wear, for example due to scratching or the like.
After the drying or curing, the simulated wood product 470, now
having a cured or dried top coat above a decorative intermediate
portion, may be advanced along direction 402 out of the drying or
curing station 422 and cooled before further transport. Once
cooled, the simulated wood product 470 is ready for transport to a
sales location, distribution location, and/or installation location
and is ready for installation and use.
[0057] FIG. 5 is a flowchart of one embodiment of a method 500 for
providing a simulated wood product. The method 500 may be used in
conjunction, for example, with one or more embodiments of the
system 400 shown in FIG. 3 and described herein, and/or used to
provide a simulated wood product such as simulated wood product 100
or simulated wood product 200 shown in FIGS. 1 and 2, respectively,
and described herein. In various embodiments, certain steps may be
omitted or added, certain steps may be combined, certain steps may
be performed simultaneously, certain steps may be performed
concurrently, certain steps may be split into multiple steps,
certain steps may be performed in a different order, or certain
steps or series of steps may be re-performed in an iterative
fashion.
[0058] At 502, a substrate (e.g., substrate 110 or substrate 202 is
provided. The substrate may be configured for use in an exterior
application (e.g., decking, roofing, garage door, or the like). A
simulated appearance will be applied to the substrate as part of
the method 500. In the depicted embodiment, the substrate will be
provided with a simulated wood grain appearance.
[0059] At 504, intermediate layers are applied to the substrate.
One or more of the intermediate layers may be applied sequentially
and/or at once. The intermediate layers may be configured to
provide a simulated wood grain appearance to the substrate, and may
be applied to one or more surfaces of the substrate. The
intermediate layers may include sub-layers. In the depicted
embodiment, the intermediate layers include a primer/adhesive
layer, a ground coat layer, a print under tone layer, and a print
layer. In some embodiments, the various layers may be combined and
provided as a foil including a heat activated adhesive/primer layer
that is oriented toward a surface of the substrate, with the foil
being thermally applied to the substrate. In the illustrated
embodiment, the application of intermediate layers may include a
plurality of sub-steps discussed below.
[0060] At 506, a primer/adhesive layer (e.g., 132, 210) is applied
to one or more surfaces of the substrate. In some embodiments, the
primer/adhesive layer may be applied separately to the substrate
from the other layers, while in other embodiments the
primer/adhesive layer may be provided as an adhesive layer of a
foil including one or more additional intermediate layers. In some
embodiments, the primer/adhesive layer is a liquid that is wet
applied to the substrate, while in other embodiments the
primer/adhesive layer may be thermally applied or laminated to the
substrate.
[0061] At 508 a ground coat (e.g., 134, 212) is applied. In some
embodiments, the ground coat may be applied to the adhesive/primer
layer as part of forming a foil to be applied to the substrate,
while in other embodiments, the ground coat may be applied to an
adhesive/primer layer that has already been applied to the
substrate.
[0062] At 510, a print under tone layer (e.g., 136, 214) is
applied. The print under tone layer may include 2 or more sublayers
in some embodiments. In various embodiments, the print under tone
layer (or one or more sublayers thereof) may be applied to the
ground coat layer as part of forming a foil to be applied to the
substrate, while in other embodiments, the print under tone layer
(or one or more sublayers thereof) may be applied above a ground
coat layer that has already been applied to the substrate (e.g., to
an adhesive/primer layer previously applied to the substrate).
[0063] At 512, a print layer (e.g., 138, 216) is applied. The print
layer may include 2 or more sublayers in some embodiments. In
various embodiments, the print layer (or one or more sublayers
thereof) may be applied to the print under tone layer as part of
forming a foil to be applied to the substrate, while in other
embodiments, the print layer (or one or more sublayers thereof) may
be applied above a print undertone layer that has already been
applied to the substrate (e.g., to a ground coat previously applied
to the substrate).
[0064] At 514 a top coat (e.g, 140, 206) is applied above the print
layer. The top coat may be applied by a spraying or coating process
above one or more surfaces of a substrate (e.g., above an
intermediate layer that has previously been applied to the
substrate). The top coat may be configured for exterior use, for
example to provide UV resistance to prevent or reduce fading of a
print layer due to sunlight. In the illustrated embodiment, the top
coat is formed before application by steps 516 and 518.
[0065] At 516, a base member (e.g., 207) is provided. The base
member, for example, may be UV resistant. The base member, however,
may not provide a desired or required slip and/or abrasion
resistance for exterior applications such as decking. At 518, an
additive (e.g., 208) is added to the base member to, for example,
provide improved abrasion resistance. The additive, for example,
may include inorganic particles. In the embodiment depicted in FIG.
5, the thickness of the top coat and the size and distribution of
the additive are selected to provide a desired slip resistance
and/or abrasion or wear resistance.
[0066] At 520, the top coat is cured or dried. The top coat may be
cured or dried to lock the additive in position within the top coat
and create a bond to decorative surface. Particles of the additive
may be positioned to provide improved or enhance slip resistance,
long term wear resistance, and/or short term wear resistance.
[0067] Thus, in various embodiments, a product having a simulated
appearance (e.g., wood grain) is provided. The simulated appearance
may be provided by a plurality of layers providing a depth to the
visual simulation. Further, the simulated appearance product may be
provided with a top coat configured to be thin enough to allow the
simulated appearance to be close to the outermost surface of the
simulated appearance product while still providing desired
characteristics (e.g., UV resistance, chemical resistance, wear
resistance, slip resistance, or the like) for exterior applications
(e.g., decking). For example, embodiments may provide UV durability
of 10 or more years of fade and/or chalk resistance. Embodiments
may provide long term wear resistance to allow for foot traffic or
other performance needs. Embodiments may provide short term wear
resistance to allow for increased resistance to scratching or the
like. Embodiments may provide chemical and stain resistance from
general household chemicals and cleaners. Embodiments may provide
for improved ease of installation and storage, for example, as the
relatively thin top coat that is permanently bonded to the
decorative layers may eliminate or reduce separation of a top layer
due to part flexure, expansion or contraction (e.g., due to
temperature fluctuations experienced in exterior applications),
cutting during or prior to installation, application of screws or
other fasteners, or the like.
[0068] It is to be understood that the above description is
intended to be illustrative, and not restrictive. For example, the
above-described embodiments (and/or aspects thereof) may be used in
combination with each other. In addition, many modifications may be
made to adapt a particular situation or material to the teachings
of the inventive subject matter without departing from its scope.
While relative dimensions described herein are intended to define
the parameters of the inventive subject matter, they are by no
means limiting and are example embodiments. Many other embodiments
will be apparent to one of ordinary skill in the art upon reviewing
the above description. The scope of the inventive subject matter
should, therefore, be determined with reference to the appended
claims, along with the full scope of equivalents to which such
claims are entitled. In the appended claims, the terms "including"
and "in which" are used as the plain-English equivalents of the
respective terms "comprising" and "wherein." Moreover, in the
following claims, the terms "first," "second," and "third," etc.
are used merely as labels, and are not intended to impose numerical
requirements on their objects. Further, the limitations of the
following claims are not written in means-plus-function format and
are not intended to be interpreted based on 35 U.S.C. .sctn.112,
sixth paragraph, unless and until such claim limitations expressly
use the phrase "means for" followed by a statement of function void
of further structure.
[0069] The foregoing description of certain embodiments of the
present inventive subject matter will be better understood when
read in conjunction with the appended drawings. To the extent that
the figures illustrate diagrams of functional blocks of various
embodiments, the functional blocks are not necessarily indicative
of the division between hardware or circuitry. Thus, for example,
one or more of the functional blocks may be implemented in a single
piece of hardware or equipment. The various embodiments are not
limited to the arrangements and instrumentality shown in the
drawings.
* * * * *