Structural building component having a decorative overmolding, apparatus for fabricating such an article and its method of manufacture

Abstract

A structural building component, such as a column, bracket, trellis, railing, beam or the like, has a construction defined by a rigid aluminum, metal, steel, iron or structural composite member having an exterior surface substantially overmolded with a decorative preferred Thermo-Set Polyaspartic Aliphatic Polyurea polymer composition to form an overmolding devoid of visible seams and fasteners with no post finishing required.The overmolding has exceptional adhesion to the underlined aluminum, metal, steel, iron or structural composite member. The overmolding method incorporates a resilient mold apparatus enabling the formation of a cladding layer having a decorative outer surface imparting the authentic appearance and texture of a non-polymeric, naturally occurring wood, stone, metal, or other desired finishes.

Description

BACKGROUND OF THE INVENTION [0001]1. Field of the Invention[0002]The present invention relates generally to structural building components. More particularly, the invention relates to a structural building component, such as a support column, bracket, trellis, railing, beam or the like having a decorative overmolding, and a molding apparatus and method for fabricating such a component.[0003]2. Description of the Prior Art[0004]In construction of commercial, and even residential, building structures, it is frequently found to be necessary or desirable to substantially enclose or cover all or a portion of structural building components in order to provide a neat, attractive, or up-scaled appearance. Such need or desirability occurs both in the construction of new building structures and in renovation or remodeling of existing building structures. In the past, however, the components and materials required for enclosing or covering all or a portion of a building structure have generall...

AI Technical Summary

Benefits of technology

[0008]The present invention is generally directed to a structural building component, such as a column, bracket, trellis, railing, beam or the like, having an exterior surface substantially covered with a decorative Thermo-Set resin including, Polyaspartic Aliphatic Polyurea, Aromatic Polyurea, Aromatic Polyurethane, Unsaturated Polyester and Epoxy overmolding, and a molding apparatus and method for fabricating such a component. The overmolded components are relatively inexpensive to manufacture, transport and install, while providing a neat, attractive and up-scaled appearance, devoid of visible seams and fasteners. The overmolding is preferably comprised of a unique Polyaspartic Aliphatic Polyurea polymeric composition resulting in an overmolded layer with no post finishing required and the option of using other Thermo-Set resins including, Aromatic Polyurea, Aromatic Polyurethane, Unsaturated Polyester or Epoxy, having exceptional adhesion to the underlying aluminum, metal, steel, iron or structural composite member. The overmolding process used to fabricate the building component incorporates a unique, specially-designed mold apparatus enabling the formation of a cladding layer having a decorative outer surface imparting the authentic appearance and texture of a non-polymeric, naturally occurring wood, stone, metal, or other desired finishes.

[0009]The overmolding method is particularly well suited for automated, high volume, cost-efficient production requiring relatively inexpensive equipment and materials, and employing minimal components and fabrication steps.

[0010]Together, the molding composition and manufacturing method enable production of the preferred overmolding Polyaspartic Aliphatic Polyurea decorative overmolding having excellent structural benefits, dimensional stability, exterior color retention, and environmental durability with no post finishing required.

Problems solved by technology

The overlay structures of the prior art, while providing some aesthetic improvement to the building component, have been relatively expensive to manufacture, transport, and install, and have frequently lacked a neat and attractive appearance, largely due to visible, unattractive seams and to the necessity for the use of fasteners or other mounting devices that are visible in the finished installation.

In addition, such conventional components or materials for such cladding and covering applications have sometimes necessitated the use of relatively expensive, highly-skilled personnel for installation, and have often been unable to conveniently accommodate electrical wiring and other components.

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