Architectural profiles with removeable surface covers

Abstract

An architectural profile system comprises a profile and a surface cover. The profile comprises a first material, and the surface cover comprises a second material, wherein the first material and second material are different. The surface cover is removably attached to the profile with a mechanical attachment without adhering, laminating, welding, or coextruding the surface cover to the profile.

Description

ARCHITECTURAL PROFILES WITH REMOVEABLE SURFACE COVERSFIELD OF THE INVENTION

[0001] The present invention generally relates architectural profile systems having a removable surface cover.DESCRIPTION OF THE RELATED ART

[0002] Architectural profiles, such as window profiles, are frequently made of multiple materials that are permanently attached. A common material used to produce architectural profiles is polyvinyl chloride (PVC) resin, which is then capped with a capstock polymer. The capstock polymer is typically coextruded or adhered to the underlying PVC resin. The capstock polymer is used to provide durability or weatherability to the PVC resin.

[0003] Conventional architectural profiles present several issues at their end-of-life. One issue is the recyclability of the material. Because conventional architectural profiles are a single piece, most architectural profiles cannot be easily disassembled to have all of the components recycled separately. Damage to an architectural profile also requires replacement of the entire unit due to the single-material nature of the profiles. For example, if a window profile is damaged, the entire unit must be replaced.

[0004] Therefore, there is a need for architectural profiles that can address one or more of these problems.BRIEF SUMMARY OF THE INVENTION

[0005] The present invention provides an architectural profile system comprising a profile and a surface cover. The profile comprises a first material, and the surface cover comprises a second material, wherein the first material and the second material are different. The surface cover is removable attached to the profile with a mechanical attachment without adhering, laminating, welding, or coextruding the surface cover to the profile.A BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 shows a diagram of an architectural profile system according to an embodiment of the present invention.

[0007] FIG. 2 shows a diagram of an architectural profile system according to an embodiment of the present invention.

[0008] FIG. 3 shows a diagram of an architectural profile system according to an embodiment of the present invention.

[0009] FIG. 4 shows a diagram of an architectural profile system according to an embodiment of the present invention.

[0010] FIG. 5 shows a diagram of an architectural profile system according to an embodiment of the present invention.

[0011] FIG. 6 shows a diagram of an architectural profile system according to an embodiment of the present invention.DETAILED DESCRIPTION OF THE INVENTION

[0012] The present invention provides an architectural profile system comprising a profile and a surface cover removably attached to the profile.

[0013] As used herein, the terms “architectural profile system” and “architectural profile” refer to shaped structural elements used in construction, such as, for example, window profiles and door profiles. Window profiles provide both insulation and structural support for the glazing and seals.

[0014] The surface cover is removably attached to the profile using a mechanical attachment. By using a removable mechanical attachment, the surface cover and profile can be separated from one another. This may provide greater recyclability for the materials at the end-of-life of the architectural profile system by allowing each material to enter a separate recycle stream appropriate for that material.

[0015] Additionally, removably connecting the surface cover to the profile may permit the surface cover to be replaced if damaged. Rather than having to replace the entire architectural profile, which may require replacement of, for example, an entire window panel, the removable mechanical attachment may allow only the surface cover to be replaced.

[0016] Another benefit of a removable surface cover may be aesthetic. By providing a removable surface cover, one may choose a surface cover based on a desired appearance and be able to replace the surface cover without replacing the entire structural unit in which the architectural profile is used. The removable surface cover may also allow for more decorative choices by allowing the surface cover to be manufactured separately from the profile. For example, a surface cover may have a unique appearance mimicking that of architectural molding or millwork, allowing different surface covers to be used within a single project without requiring a different profile to be produced.

[0017] The profile comprises a first material, and the surface cover comprises a second material. The first material and second material comprise different materials. The first material may comprise any material conventional used for architectural profiles. For example, the first material of the profile may be selected from, but not limited to, acrylonitrilestyrene acrylate resins, polyester resins, polyvinyl resins, and fiberglass. Preferably, the first material comprises a polyvinyl chloride resin.

[0018] The second material of the surface cover may provide durability or weatherability to the architectural profile system. For example, the surface cover may comprise a material selected from aluminum and capstock resins. The term “capstock resin” is a term used in the art to refer to resins that offer protection to base resins. Capstock resins may include, for example, UV inhibitors, pigments, impact modifier, and other additives to improve properties, such as, UV resistance, whitening resistance, scratch and abrasion resistance, chemical resistance, and appearance. Examples of capstock resins include, for example, acrylic resins such as ACRYLIGARD™ CS-132 and ACRYLIGARD™ CS-134, both available from The Dow Chemical Co. Preferably, the surface cover comprises a capstock resin. More preferably, the surface cover comprises an acrylic capstock resin.

[0019] The surface cover is removably attached to the profile with a mechanical attachment. The surface cover is not adhered, laminated, or welded to the profile, nor is the surface cover coextruded to the profile. By removably attached the surface cover to the profile, the surface cover can be detached from the profile for recycling or replacement.

[0020] The mechanical attachment may comprise a click-on attachment, a snap-fit attachment, an interference- or friction-fit attachment, a mechanical fastener (e.g, screw, rivet, staple, brad, etc.), an interlocking attachment (e.g., dovetail or similar interlocking shape), or combinations thereof. More than one type of mechanical attachment may be used in the architectural profile system depending on the geometry and specifications of the profile. For example, if additional strength is required, more attachments may be used.

[0021] Preferably, the surface cover is disposed over at least a portion of a visible surface of the profile. For example, for a window profile, the surface cover may be disposed over at least a portion of the visible surface of the window profile when observed from inside or outside of the building in which the window is installed. More preferably, the surface cover is disposed over the entire visible surface of the profile.

[0022] The surface cover may be structured to conform to an outer surface of the profile. For example, the surface cover may have the same geometry as the outer surface of the profile.

[0023] Alternatively, the surface cover may have an outer surface that differs from the outer surface of the profile. For example, the outer surface of the surface cover may have a decorative millwork or molding appearance.

[0024] The outer surface of the surface cover may also comprise a decorative pattern, such as, for example, a wood grain, or a different surface finish (e.g., matte, glossy) compared to the profile.

[0025] Examples of architectural profile systems are shown in FIGS. 1 to 6.

[0026] In FIG. 1 , architectural profile system 100 comprises a profile 110 and a surface cover 120. Surface cover 120 comprises two click-on mechanical attachments 121 that click on to corresponding receivers 111 on profile 110. An outer surface 124 of surface cover 120 conforms to and has the same geometry as outer surface 114 of profile 110.

[0027] A second embodiment is shown in FIG. 2. In FIG. 2, architectural profile system 200 comprises a profile 210 and a surface cover 220. Surface cover 220 comprises two snap-fit mechanical attachments 221 that snap onto corresponding receivers 211 on profile 210. Receivers 211 may be in the form of an indentation or hole to receive the snap-fit mechanical attachments 221 .

[0028] In a third embodiment shown in FIG. 3, architectural profile system 300 comprises a profile 310 and a surface cover 320. Screws 330 are used to mechanical attach surface cover 320 to profile 310 through holes 321 and 311 in the surface cover 320 and profile 310, respectively.

[0029] A fourth embodiment is shown in FIG. 4. In FIG. 4, architectural profile system 400 comprises a profile 410 and a surface cover 420. Surface cover 420 comprises two interference fit mechanical attachments 421 that fit onto corresponding receivers 411 on profile 410. Receivers 411 are in the form of protrusions from the profile 410 and are configured such that interference fit mechanical attachments 421 stay in place on the corresponding receivers 411 by a friction fit which causes the interference fit mechanical attachments 421 to expand when installed.

[0030] FIG. 5 shows a fifth embodiment comprising architectural profile system 500 having a profile 510 and a surface cover 520. Surface cover 520 comprises two dovetail mechanical attachments 521 that fit onto corresponding channels 511 on profile 510. Dovetail mechanical attachments 521 slide into the channels 511 to connect the surface cover 520 to profile 510.

[0031] A sixth embodiment is shown in FIG. 6, in which architectural profile system 600 comprises a profile 610 and a surface cover 620. Surface cover 620 comprises two click-on mechanical attachments 621 that click on to corresponding receivers 611 on profile 610. An outer surface 624 of surface cover 620 has a decorative geometric surface 614 that differs from the planar outer surface 614 of profile 610.

[0032] The architectural profile systems shown in FIGS. 1 to 6 are illustrative of various embodiments of the present invention. The shape and layout of the profiles may vary based on the desired use. For example, various T-slots or connection points may be included on the profile to allow connection to other features. The shape and geometry of the surface cover may be adapted such that the surface cover does not interfere with those connection points.

Claims

CLAIMSWhat is claimed is:

1. An architectural profile system comprising: a profile comprising a first material; and a surface cover comprising a second material, wherein the first material and second material are different; wherein the surface cover is removably attached to the profile with a mechanical attachment without adhering, laminating, welding, or coextruding the surface cover to the profile.

2. The system according to claim 1, wherein the removable mechanical attachment is selected from the group consisting of a click-on attachment, a snap-fit attachment, an interference-fit attachment, a mechanical fastener, an interlocking attachment, and combinations thereof.

3. The system according to claim 1 or claim 2, wherein the surface cover is attached to the profile with at least two removeable mechanical attachments.

4. The system according to any one of the preceding claims, wherein the profile is a window profile.

5. The system according to any one of the preceding claims, wherein the surface cover is disposed over at least a portion of a visible surface of the profile.

6. The system according to claim 5, wherein the surface cover is disposed over the entire visible surface of the profile.

7. The system according to any one of the preceding claims, wherein the first material comprises a material selected from the group consisting of acrylonitrile styrene acrylate resins, polyester resins, polyvinyl resins, and fiberglass.

8. The system according to claim 7, wherein the first material comprises a polyvinyl chloride resin.

9. The system according to any one of the preceding claims, wherein the second material comprises a material selected from the group consisting of aluminum and a capstock resin.

10. The system according to claim 9, wherein the second material comprises a capstock resin.

11. The system according to claim 10, wherein the second material comprises an acrylic capstock resin.

12. The system according to any one of the preceding claims, wherein the surface cover conforms to a surface of the profile.

13. The system according to any one of the preceding claims, wherein the surface cover has an outer surface that is the same or different than an outer surface of the profile.

14. The system according to claim 13, wherein the outer surface of the surface cover has a decorative shape.

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