Polymer structural components including simulated textured surfaces and corresponding manufacturing methods

Abstract

A polymer structural component (100) includes a set polymer structural board (110), made by extrusion and having a face (114) and at least one side (112). The at least one side is angled relative to the face. The face includes a facade extending across the face to the at least one side. The facade includes a base color (154) and a texture color (152), where the texture color is printed on the facade with a texture characteristic. The texture color is different than the base color. The base color and the texture characteristic are configured to provide a simulated texture (150) on the facade.

Description

POLYMER STRUCTURAL COMPONENTS INCLUDING SIMULATED TEXTURED SURFACES AND METHODS FOR SAMETECHNICAL FIELD

[0001] The present invention relates to the field of structural components, specifically concerning advancements in polymer structures including simulated textures.BACKGROUND

[0002] Outdoor or interior structures, furniture or the like are formed with lumber. For example, flooring, decks, patios, walkways, ramps, steps, or the like are constructed from lumber planks, boards, panels, or the like. In some examples, polymer structures, polymer structural components, or polymer boards [sometimes called poly-lumber] are replacements for traditional wood lumber. Polymer structures, polymer structural components, or polymer boards are, in some examples, resistant to environmental matter, such as moisture, temperature fluctuations, particulates or the like.

[0003] In some examples, polymer structures, polymer structural components, or polymer boards include aesthetic surfaces to mimic or simulate the appearance of a traditional lumber product. In these examples, the polymer boards have an aesthetic surface adhered, coupled, or fastened [nailed, screwed, or bolted], or molded to a surface of a polymer component.

[0004] Optionally, polymer components include a coating such as polyurethane or acrylic applied over the aesthetic surface. The coating, in some examples, assists in the adhesion of the aesthetic coating to the polymer component. In other examples, the coating reduces damage, degradation, or indications of wear to the polymer component or the aesthetic surface.SUMMARY

[0005] Examples of a polymer structural components includes an extruded and set polymer structural board. The extruded and set polymer structural board includes a face and at least one side. The at least one side of the polymer structural board is, for instance, configured to be angled relative to the face. The face includes a facade extending across the face. Optionally, the facade extends across the face to the at least one side.

[0006] In some examples, the facade includes a base color and a texture color. For instance, the texture color is printed on the facade. Optionally, the base color is printed on the facade. For instance, the printed texture color is different than the base color. The printed texture color is printed to, for instance, simulate a texture characteristic. In an example, the base color and the texture characteristic are configured to simulate a texture on the facade.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 illustrates an example of a polymer structural component.

[0008] Figure 2A illustrates an example of a perspective view of a schematic of another example of a polymer structural component.

[0009] Figure 2B illustrates an example of a perspective view of a schematic of another example of a polymer structural component.

[0010] Figure 3A illustrates an example of a perspective view of a schematic of another example of a polymer structural component.

[0011] Figure 3B illustrates another example of a perspective view of a schematic of a polymer structural component.

[0012] Figure 4 illustrates another example of a perspective view of a schematic of a polymer structural component.

[0013] Figure 5 illustrates an example of a schematic of a polymer structural component system.

[0014] Figure 6 illustrates an example of a method of forming a polymer structural component.DETAILED DESCRIPTION

[0015] Structural components formed from naturally occurring materials, at times, present one or more technical problems. For example, boards, planks, slats, posts, panels, and frames formed from naturally occurring materials such as wood or stone are subject to deformation, decay, and warping over time. These materials are, for instance, susceptible to environmental conditions including moisture absorption, UV light exposure, temperature fluctuations, insect damage, and weathering from particulate matter. Even with regular maintenance such as staining and finishing, naturally occurring structural components, at times, deteriorate and optionally require replacement. Additionally, some naturally occurring materials exhibit inconsistent appearance and color variations, making it difficult to achieve uniform aesthetic results across multiple components or installations.

[0016] Some polymer structural components present technical challenges. For example, polymer structural components formed through extrusion or molding processes have profiles controlled by the forming process, resulting in inconsistent or unattractive appearances that fail to meet aesthetic specifications. Some approaches attempt to provide aesthetic appearances on polymer structural components, but each has limitations. For instance, painted colors applied to polymer surfaces provide limited detail resolution and durability. In another example, colors incorporated during molding or coextrusion cannot achieve the intricate or unique designs needed to convincingly simulate naturally occurring materials, such as wood grain with whirls, stone marbling with depth, or brick patterns with detail. In another example, laminating printed sheets onto polymer boards uses adhesive application or heat bonding processes that add manufacturing complexity and cost. In another instance, forming polymer structural components with physical surface textures forms additional challenges, as applying colors to textured areas is technically difficult and cost prohibitive due to the need to precisely locate colors within three-dimensional surface variations.

[0017] The present disclosure solves these technical problems by providing a polymer structural component with, for example, a simulatedtexture applied by printing on a surface after the polymer structural board is formed. The solution combines, for instance, environmental durability of polymer materials with the aesthetic appearance of naturally occurring materials, while reducing the limitations of painted, molded, coextruded, or laminated color applications.

[0018] The present disclosure solves the challenges of applying colors to textured polymer structural components through inkjet printing with registered alignment. For instance, inkjet printing systems are able to align [such as precisely align, or substantially align) and register printed colors to specific texture features on a textured surface of a polymer structural component. For example, a registered inkjet printing process includes sensing the three-dimensional surface variations of the textured surface and adjusting ink deposition to align printed colors with specific texture features such as ridges, recesses, grooves, or raised portions. Registered printing allows for precise [including approximately precise) placement of texture colors that corresponds to and enhances the physical texture characteristics of the polymer structural component.

[0019] The polymer structural component includes, for example, a polymer structural board having one or more texture characteristics printed on one or more outer surfaces. In an example, one or more texture colors different from a base color are printed on the polymer structural board to form texture characteristics that simulate materials such as naturally occurring wood or stone, or other building materials such as brick or cement. The printing process, for instance, allows for detailed, simulated textures across the polymer structural board. Intricate features such as wood grain patterns, whirls, stone marbling, sediment layers, cracks, ridges, and brick indentations are achievable through the printing process.

[0020] In an example, the simulated texture has a relatively smooth profile that provides a visual impression of texture characteristics without corresponding three-dimensional surface variations. This smooth profile, for instance, reduces technical difficulties and, at times, reduces costs associated with applying colors to physically textured surfaces, while still providing convincing visual simulation of textured materials. The printedsimulated texture, optionally, provides an aesthetic appearance of naturally occurring materials while maintaining the durability and environmental resistance of polymer structural components against moisture, UV light, temperature fluctuations, mold, insects, and weathering. The polymer structural component is, optionally, suitable for interior or exterior applications including flooring, decking, patios, docks, walkways, furniture, railings, posts, and storage units.

[0021] Figure 1 is a representation of a polymer structural component 100. The polymer structural component 100 is an example of a structural component that includes an individual component or a component of an assembly [e.g., more than one polymer structural component 100 coupled together to form a larger structure]. The polymer structural component 100 optionally is an elongate structure that extends longitudinally and laterally. While illustrated as an elongate structure, the polymer structural component 100 is, in other examples, polygonal or rounded, or a combination of shapes or profiles.

[0022] The polymer structural component 100 illustrated in Figure 1 is an example of a polymer board 110. The polymer board 110 includes, for instance, a plank, a slat, a post, a panel, a frame, member, or the like. For instance, the polymer board 110 is assembled with one or more polymer boards 110 to form a structure, such as furniture, flooring, decking, housing, fence, or the like, that is suitable for indoor or outdoor use.

[0023] In an example, the polymer structural component 100 includes the polymer board 110 having at least one side surface 112. The at least one side surface 112 includes a thickness, or depth, of the polymer board 110. The at least one side surface 112 extends, for instance, between a first face 114 and a second face 116. The first face 114 opposes the second face 116 with the at least one side surface 112 extending between the first face 114 and the second face 116. In an example, each of the at least one side surface 112 form a perimeter 115 around the polymer board 110. The at least one side surface 112 includes, for instance, at least two side surfaces.

[0024] At least one of the at least one side surface 112 is in communication with an edge portion 120 of the polymer board 110. Theedge portion 120 includes, for instance, an area of either or both of the at least one side surface 112 or the first face 114 and second face 116 proximate to where the at least one side surface 112 and the first face 114 or the second face 116 join or meet. In some examples, the at least one edge portion 120 is angled or oriented transversely. For example, the angle includes the at least one side surface 112 and the first face 114 or the at least one side surface at least one side surface 112 and the second face 116 as sides of an angle forming the edge portion 120.

[0025] Illustrated in Figure 1 is an example of a polymer structural component 100 that includes a simulated texture 150. The simulated texture 150 includes, for instance, a visual appearance that mimics, replicates, imitates, or the like a naturally occurring material or traditional building material. The simulated texture 150 optionally includes lines, patterns, or other indications applied to the polymer board 110 that simulate, replicate, imitates or mimic an appearance of a texture of another material.

[0026] The simulated texture 150 includes a printed or applied texture color 152 on a base color that forms one or more texture characteristics 160 [e.g., wood grain, stone ridges, brick indentations, whirls, or the like). For example, the texture color 152 differs from a base color 154. The base color 154 includes, for example, the original color of the polymer board 110 after the polymer board 110 is formed. The base color 154 in some examples includes a color applied to one or more surfaces, such as the at least one side surface 112, first face 114 and the second face 116. Optionally the base color 154 can vary along a surface of the polymer board 110. In an example, additional colors are applied to the polymer board 110. The additional colors, in some examples, enhance the simulated texture 150. For example, the additional colors include one or more of lighter tones to simulate highlighted areas, darker tones to simulate shadowed areas, or accent colors to simulate specific features such as wood knots, stone veining, or sediment layers, wherein the additional colors form visual depth and complexity in the simulated texture 150. The additional colors are, optionally, applied with varying opacity and are registered to specific, ordesired, locations to cooperate with the base color 154 and the texture color 152 in forming a multi-layered, realistic appearance of the material being simulated.

[0027] The simulated texture 150 includes, at least, a combination of the printed or applied texture color 152 and the base color 154. The simulated texture 150 optionally simulates virtual [e.g., appearance of) depth and / or texture of another material. For example, the simulated texture 150 provides the overall impression of the texture characteristics across the panel, such as the appearance of lumber, stone, brick, or similar materials. In some instances, the polymer board 110 includes one or more simulated textures to enhance the appearance of the polymer board 110.

[0028] In certain examples, such as a polymer structural board 210 illustrated in Figure 2A, one or more texture characteristic 260 includes, but are not limited to, whirls, cracks, indentations, or other details that form virtual images of a naturally occurring material. In some examples, the virtual image enhances aesthetics of the board 210 through the incorporation of these details [e.g., whirls, cracks, indentations, or the like). A simulated texture 250 is optionally applied to a first face 214 of the polymer structural board 210 utilizing a printing process or method.Printing the simulated texture 250 is an example of a process used to form the one or more texture characteristic 260 on the polymer structural board 210. Printing includes, but is not limited to, inkjet printing, laser printing, screen printing, or the like.

[0029] As shown in Figure 2B, a printed texture color 252 is optionally applied to a first face 214 of the polymer structural board 210. In one example, the first face 214 is an exterior face and an opposing second face 216 faces a ground surface, an under surface, a wall surface, deck stringers, or the like. The printed texture color 252 is printed on a base color 254 of the first face 214 of the polymer structural board 210. The printed texture color 252, in some examples, includes more than one printed texture color 252 applied to the base color 254. The base color 254, in some examples, includes more than one base color 254 applied or formed along the first face 214 of the polymer structural board 210.

[0030] A facade 270, as shown in Figure 2B, includes, in an example, the base color 254 and the texture color 252. The base color 254, for example, is at least one of a color of the polymer structural board 210, or a color applied to the polymer structural board 210. In an example, the base color 254 applied to the polymer structural board 210 is painted, sprayed, printed or the like along the polymer structural board 210. For example, the base color 254 is applied to at least the first face 214 of the polymer structural board 210. In another example, and as discussed later with respect to Figure 3, the base color 254 is applied to at least one of one side surface 212a and an opposing side surface 212b. In yet another example, the base color base color 254 is applied to all of the faces and surfaces that form a perimeter of the polymer structural board 210. Optionally, base color 254 applied to one side or surface is the same as a base color of another side or surface. In another example, the base color 254 varies between the sides, surfaces, or the like.

[0031] The facade 270, for example, includes the texture color 252 applied on the base color 254. Optionally, the texture color 252 is a different color than the base color 254. The texture color 252 and the base color 254 cooperatively appear as a texture characteristic 260 on the facade 270. For example, the texture color 252 is printed on the base color 254 to form the one or more texture characteristic 260 that simulates one or more characteristics of a material other than the polymer structural component 200. For instance, the one or more texture characteristic 260 includes one or more feature of a naturally occurring material such as, but not limited to, wood grain, whirls, marbling, sediment, cracks, indentations, or combinations thereof. The one or more texture characteristic 260 optionally includes one or more components that form a simulated texture 250 applied to the facade 270. In at least one example, the simulated texture 250 forms a visual appearance of a material other than the polymer structural component 200 across at least a portion of the facade 270.

[0032] In another example, the simulated texture 250 includes one or more texture characteristic 260 distributed across the facade 270. For example, the texture color 252 is applied continuously along at least aportion of the facade 270. The texture color 252 is, optionally, applied with varying opacity to form depth in the simulated texture 250. For instance, the texture color 252 is printed continuously along a length of the polymer structural board 210 to simulate a grain pattern, sediment layers, or other continuous features of a naturally occurring material. The one or more texture characteristic 260 cooperatively form the simulated texture 250 across substantially all (e.g., greater than 85%, greater than 95%, 100%, or the like ] of the facade 270 in various examples. For instance, an overall impression of the one or more texture characteristic 260 forms the visual appearance of the material different than the polymer structural component 200. The simulated texture 250 optionally extends from one side surface 212a to an opposing side surface 212b of the polymer structural component 200 (see Figure 2A].

[0033] The simulated texture 250 on the facade 270 has, for instance, a smooth profile. The smooth profile provides a visual (e.g., virtual] impression of the texture characteristic 260 without three-dimensional surface variations. For example, the simulated texture 250 simulates ridges, indentations, or recesses of the material other than the polymer structural component 200 through application of the texture color 252 and the base color 254. The simulated texture 250 optionally mimics wood grain and whirls in wood (e.g., knots], stone marbling, or sediment layers without corresponding physical surface features. The simulated texture 250 is, optionally, printed on the facade 270 using a printing system, such as an inkjet printer, laser printer, or the like, to form a visual appearance of the material different from the polymer structural component 200.

[0034] The facade 270 optionally includes one or more graphic 265 such as an image or text printed on the polymer structural component 200, as illustrated in Figure 2B. In an example, the one or more graphic 265 is included on a surface, such as the first face 214, with the simulated texture 250. For instance, the one or more graphic 265 includes one or more of a logo, brand name, words, alphanumeric characters, signs, symbols, printed on the base color 254, printed over the texture characteristics 260, or printed as part of the simulated texture 250. The one or more graphic 265are, optionally, applied using an inkjet printer during the same printing process used to apply the texture color 252, wherein the one or more graphic 265 does not interfere with the visual appearance of the simulated texture 250.

[0035] Referring again to Figure 2A, the first face 214 includes, for example, the facade 270 that extends across at least a portion of the first face 214. Optionally, the facade 270 extends across the first face 214 such as from one side surface 212a to an opposing side surface 212b. In an example, the facade 270 extends across the entire [e.g., greater than 80%, greater than 95%, 100% or the like) first face 214 [e.g., from a first longitudinal end to a second longitudinal end and from a portion proximate to the first side to a portion proximate to the second side). A border 218 is optionally formed around the first face 214 and the facade 270 is applied within the border 218.

[0036] A simulated texture 350 is, optionally, applied [e.g., printed) on a first face 314 and at least one of a first side portion 320 and a second side portion 322 of the polymer structural board 310, as illustrated in Figure 3A. For example, the simulated texture 350 is applied on the first face 314 and on both the first side portion 320 and the second side portion 322, for the polymer structural board 310. The one or more texture characteristics 360, for example, extend from the first face 314 to the first side portion 320 or the second side portion 322.

[0037] In another example, the simulated texture 350 applied on at least one of the first side portion 320 or the second side portion 322 is not a continuation of the simulated texture 350 applied on the first face 314. For instance, the simulated texture 350 on the first side portion 320 or the second side portion 322 is not aligned with the simulated texture 350 on the first face 314. Optionally, the simulated texture 350 on one or both of the first or second side portions 320, 322 has a different appearance than that of the first face 314.

[0038] Optionally, the simulated texture 350 is applied partially along at least one of the first side portion 320 or the second side portion 322. For instance, the simulated texture 350 extends around one or both of a firstedge portion 320a (similar to edge portion 120 described related to Figure 1) and a second edge portion 320b. For example, the simulated texture 350 extends less than halfway along one or both of the first side portion 320 and the second edge portion 320b. In another example, the simulated texture 350 extends more than halfway along one or both of the first side portion 320 and the second edge portion 322, but does not extend to the first edge portion 320a or the second edge portion 320b of the first side portion 320 or the second side portion 322 opposed from the first edge portion 320a or the second edge portion 320b.

[0039] A simulated texture 352 is optionally applied on at least a portion of the face 315 of the rounded polymer structural component 302, as illustrated in Figure 3B. The simulated texture 352 is applied along the entire face 315, or a portion of the face 315, around the rounded polymer structural component 302. In an example, the simulated texture 350 applied on at least one of the first side portion 320 or the second side portion 322 is a continuation of the simulated texture 350 applied on the first face 314. The simulated texture 352, in examples, is printed on the face 315 similarly to the application of the simulated texture 350 of the polymer structural board 310. The simulated texture 352, for instance, extends around the curved face 315 to provide a consistent visual appearance from multiple viewing perspectives around the rounded polymer structural component 302. For instance, texture characteristics 360 such as wood grain patterns or stone marbling extend continuously around at least a portion of the circumference, wherein the simulated texture 352 maintains visual coherence as the rounded polymer structural component 302 rotates or is viewed from different positions.

[0040] Illustrated in Figure 4 is an example of a polymer structural component 311 including one or more textured surfaces 351. The one or more textured surfaces 351 includes one or more of ridges, troughs, protrusions, recesses, cavities, or the like, formed in or from a face 354 of the polymer structural component 311. The one or more textured surfaces 351 help with forming an appearance of a texture on the one or more textured surfaces 351. The texture can simulate, replicate, imitate, mimic, orthe like, the look and feel of a naturally occurring material or a material different than the polymer structural component 311. Optionally, the texture can include patterns, geometric stamps or the like that are formed into or from the face 354.

[0041] While illustrated as polygonal structure, rounded structures or a combination of angled and rounded structures are also contemplated. The one or more textured surfaces 351 can include one or more texture characteristics 361 applied to the polymer structural component 311 [e.g., board, panel, column, railing, bollard, baluster, posts, or the like]. For example, the one or more texture characteristics 361 are applied to an elongate polymer support beam. Optionally, the one or more texture characteristics 361 includes one or more characteristics that simulate a naturally occurring texture. The one or more texture characteristics 361 can be formed with the polymer structural component 311 during or after forming the polymer structural component 311.

[0042] In an example, the polymer structural component 311 is formed with a single color, such as a base color 355. In other examples, the polymer structural component 311 is formed using more than one base color 355. The one or more texture characteristics 361, in some examples, is enhanced with one or more additional colors, such as one or more texture color 353.

[0043] The one or more texture color 353, in an example, is applied with a printing system to the one or more texture characteristics 361 that protrude from a The printing system, in some instances, is similar to the printing system used to apply the texture color 252 to the polymer structural board 210, as discussed previously. In an example, the printing system is different from the printing system used to apply the texture color 252 to the polymer structural board 210, but implements an inkjet or laser printing method. Optionally, one or more texture color 353 is applied to the polymer structural component 311 with a registered printing system. For example, a registered inkjet printing process includes recognition of one or more three-dimensional surface variation of the textured surface. Printing is, for example, applied to the one or more texture characteristics 361 with ink deposition to align printed colors with one or more correspondingtexture feature such as ridges or recesses. For instance, registered inkjet printing includes applying colors through painting, spraying, or molding processes.

[0044] The combination of physical texture and associated printed colors, for example, forms a visual complexity in simulating naturally occurring materials. For instance, one or more texture color 353 printed in recesses of a wood grain texture, as one or more texture characteristics 361, enhances the appearance of depth. A second texture color or the one or more texture color 353, printed on raised portions, in some examples, highlights grain features. Printing on a textured surface using multi-color applications that follow the contours of the physical texture, optionally, enhance visual effects not achievable on smooth surfaces. Additionally, the physical texture provides tactile realism that complements the visual appearance formed by the printed colors. Printing on a polymer structural component 311 that includes one or more texture characteristics 361, for instance, results in a polymer structural component 311 that simulates, and enhances, both the visual and tactile characteristics of naturally occurring materials such as wood, stone, or brick.

[0045] As illustrated in Figure 5, a polymer component system 400 includes a plurality of polymer structural components, such as a first polymer structural board 410a, a second polymer structural board 410b, and a third polymer structural board 410c. The first polymer structural board 410a includes a first facade 475a, the second polymer structural board 410b includes a second facade 475b, and the third polymer structural board 410c includes a third facade 475c. The first facade 475a optionally couples with, contacts, or is positioned adjacent to the second facade 475b. The second facade 475b optionally couples with, contacts, or is positioned adjacent to the third facade 475c. In one example, the second facade 475b and the third facade 475c each include a second simulated texture 453. The second simulated texture 453 on the second facade 475b is similar to the second simulated texture 453 on the third facade 475c. For instance, the second simulated texture 453 forms a continuous pattern [e.g., a continuous wood grain) across the second facade 475b and the third facade 475c.

[0046] In an example, the first facade 475a includes a first simulated texture 451 that differs from the second simulated texture 453 on the second facade 475b and the third facade 475c. For example, the first simulated texture 451 includes one or more first texture characteristics 460a that simulate wood grain with whirls or a continuous grain pattern formed by a first texture color 452a applied on a first base color 454a. The second simulated texture 453 includes one or more second texture characteristics 460b [optionally different from the first texture characteristics 460a] that simulate another style or pattern of wood grain with whirls or a continuous grain pattern [e.g., slightly misaligned or aligned] formed by a second texture color 452b applied on a second base color 454b. The second texture color 452b and the second base color 454b, optionally, differ from the first texture color 452a and the first base color 454a. Optionally, the second texture color 452b and the second base color 454b are the same relative to the first texture color 452a and the first base color 454b. In another example, the first simulated texture 451 and the second simulated texture 453 differ in one or more texture characteristics 460a, 460b, such as variations in grain patterns, color distribution, or simulated material features [e.g., knots, whirls, or the like].

[0047] In an example where the first facade 475a differs from the second facade 475b and the third facade 475c, the first polymer structural board 410a has the first base color 454a that differs from the second base color 454b of the second polymer structural board 410b and the third polymer structural board 410c. The first polymer structural board 410a, the second polymer structural board 410b, and the third polymer structural board 410c optionally have a combination of similar and different colors for the base color 454a, 454b and the texture color 452a, 452b. For instance, the first polymer structural board 410a, the second polymer structural board 410b, and the third polymer structural board 410c optionally have a plurality of different texture colors applied on the base color to form the respective one or more texture characteristics 460a, 460b. The second polymer structural board 410b and the third polymer structural board 410c optionally have a similar base color 454b and texture color 452b to form thesecond simulated texture 453 that appears continuous [e.g., slightly misaligned, aligned) across the second facade 475b and the third facade 475c.

[0048] Figure 6 illustrates a method of forming a polymer structural component, 500. A method 500 of forming a polymer structural component includes forming a polymer structural board from a molten polymer, 510. The molten polymer is, for instance, extruded or applied to a mold to form the polymer structural board. Optionally, the molten polymer is extruded or pultruded according to one or more desired or specified dimensions or profiles for the polymer structural board. In another example, the molten polymer is applied to a mold having the desired dimensions and profile. The polymer is set such as by cooling or solidifying to form a set polymer structural board having at least a face and one or more side portions. For instance, the one or more side portions of the polymer structural board are angled relative to the face.

[0049] The polymer structural board is formed from, for example, one or more of a polymer material including one or more of polyethylene, polypropylene, polyvinyl chloride, polystyrene, acrylonitrile butadiene styrene, polyester, or combinations thereof. The polymer used in the polymer structural board optionally includes one or more of a virgin polymer, a recycled polymer, or a blend of virgin and recycled polymer.

[0050] The method 500 includes applying a facade to the set polymer structural board after the polymer is set, 520. For example, the facade is applied to one or more faces or surfaces of the set polymer structural board, 521. Applying the facade includes applying a base color on the polymer structural board 522. Applying a base color includes, in an example, use of the base color of the polymer structural board. Applying a base color 522 includes, in an example, applying a color the same, different, or similar to the polymer structural board.

[0051] For instance, the base color is applied to the polymer structural board by printing, painting, or spraying the color on at least one of the face and / or one or more side portions. In one example, the base color is applied partially, substantially continuously [e.g., slightly misaligned], orcontinuously across the face of the polymer structural board. The base color optionally extends from the face to at least one of the one or more side portions. In one example, the base color on the face is similar to the base color applied to the one or more side portions. In another example, the base color applied to the face differs from the base color applied to at least one of the one or more side portions.

[0052] The facade optionally extends continuously from a first edge portion to a second edge portion of the face. The first edge portion and the second edge portion each include an edge portion where the face meets the one or more side portions. The facade is, optionally, applied to at least one of the one or more side portions.

[0053] Applying the facade, optionally, further includes printing a texture color on at least the face to form a texture characteristic, 530. In an example, the texture color is a different color than the base color. For example, the texture color is printed on the base color using a printing system, such as an inkjet printer, laser printer, or the like. The texture color is printed on the base color to simulate the texture characteristic. The texture characteristic in some examples differs from an appearance of the polymer structural board without the texture color.

[0054] The texture characteristic includes, for example, a visual impression of a textured characteristic on the facade. For instance, the texture color is printed on the face to form the simulated texture 540. The simulated texture, in an example, simulates one or more of wood grain, whirls, marbling, sediment layers, cracks, ridges, stone patterns, brick patterns, or the like. The texture color is, optionally, applied with varying opacity to form depth [e.g., the look of depth, virtual depth, or the like) in the simulated texture. The simulated texture optionally is applied to substantially all [e.g., greater than 85%, greater than 95%, 100%, or the like) of the face from the first edge portion to the second edge portion.

[0055] The method optionally includes printing the texture color on at least one of the one or more side portions, 532. For example, the texture color is printed on the one or more side portions to form the texture characteristic on the one or more side portions. The texture characteristicprinted on the one or more side portions optionally includes a continuation of the texture characteristic from the face. For instance, the texture characteristic extends from the face across an edge portion including the face and an associated side portion. In another example, the texture characteristic on the one or more side portions is discontinuous [e.g., different, divergent, inconsistent) from the texture characteristic on the face.

[0056] The method 500 optionally includes applying a protective coating over the facade after printing the texture color, 550. For instance, the protective coating includes one or more of polyurethane or acrylic applied over the base color and the texture color on the face.

[0057] In an example, after the polymer structural board is cooled, the method 500 optionally includes trimming the polymer structural board at a repeated interval of the simulated texture to avoid repetition of the simulated texture on a single polymer structural board.

[0058] Optionally, the method described above for forming simulated texture characteristic, can be implemented to apply a texture color to one or more texture characteristics of the polymer structural component. For instance, the polymer structural component includes one or more textured surfaces that includes one or more of ridges, troughs, protrusions, recesses, cavities, or the like, formed in or from a face of the polymer structural component. As stated previously the texture can simulate, replicate, imitate, mimic, or the like, the look and feel of a naturally occurring material or a material different than the polymer structural component. Optionally, the texture can include patterns, geometric stamps or the like that are formed into or from the face .

[0059] The texture color is printed, for instance, on a polymer structural component including one or more physical, or tactile, texture characteristics. For instance, a registered print includes a recognition of one or more three-dimensional surface variation of the textured surface. The texture color is, for instance, applied to or printed on a designated texture characteristic, such as to a ridge, trough, or the like. In an example, additional colors are applied to one or more of the texture characteristicsthat protrude or extend from a face of the polymer structural component or to the texture characteristic that is recessed or formed into the face of the polymer structural component. The additional colors, in some examples, enhance the simulated texture. For example, the additional colors include one or more of lighter tones to simulate highlighted areas, darker tones to simulate shadowed areas, or accent colors to simulate specific features such as wood knots, stone veining, or sediment layers, wherein the additional colors form visual depth and complexity in the simulated texture.

[0060] In an example, the polymer structural board is a component of a polymer structural board system. The polymer structural board system includes at least two polymer structural components with at least one polymer structural component including a facade. The facade, in an example, is applied to a polymer structural component, as stated previously. The set of polymer structural components are, optionally, joined, coupled, or arranged adjacent to each other to form a structure such as a deck, patio, walkway, dock, indoor flooring, or furnishings such as benches, tables, chairs, or storage units, 560.ASPECTS

[0061] Aspect 1 can include subject matter such as a polymer structural component comprising: an extruded and set polymer structural board, the extruded and set polymer structural board having: a face and at least one side; wherein the at least one side is configured to be angled relative to the face; the face including a facade extending across the face to the at least one side; and the facade includes a base color and a texture color; wherein the texture color is printed on the facade with a texture characteristic, and the texture color is different than the base color; wherein the base color and the texture characteristic are configured to provide a simulated texture on the facade.

[0062] Aspect 2 can include, or can optionally be combined with the subject matter of Aspect 1, to optionally include the facade includes a smooth profile having a visual impression of the texture characteristic.

[0063] Aspect 3 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 1 or 2 to optionally include the base color is applied along the face; and wherein the texture color provides a visual impression of the texture characteristic.

[0064] Aspect 4 Aspect 4 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 1 to 3 to optionally include the base color is printed along the face.

[0065] Aspect 5 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 1 to 4 to optionally include the base color is provided by the extruded and set polymer structural board.

[0066] Aspect 6 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 1 to 5 to optionally include the texture characteristic is printed on the base color, the texture characteristic including a virtual image of one or more of wood grain, whirls, marbling, or sediments.

[0067] Aspect 7 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 1 to 6 to optionally include the extruded and set polymer structural board is configured have the simulated texture of a wood board.

[0068] Aspect 8 can include subject matter such as a polymer structural component system comprising: one or more set polymer structural boards including a first set polymer structural board and a second set polymer structural board, each of the one or more set polymer structural boards having: a face having a first face edge portion and a second face edge portion opposing the first edge portion; a side in communication with one of the first face edge portion or the second face edge portion, the side oriented transversely with the face; a facade extending along the face from the first edge portion to the second edge portion, the facade having: a base color and a texture color; wherein the texture color is printed on the facade with a texture characteristic, and the texture color is different than the base color; wherein the texture color and the texture characteristic together simulate a texture on the facade; and the first set polymer structural board includes afirst facade and the second set polymer structural board includes a second facade.

[0069] Aspect 9 can include, or can optionally be combined with the subject matter of Aspect 8, to optionally include the first facade aligns with the second facade and the simulated texture of the first polymer structural board joins with the simulated texture of the second polymer structural board.

[0070] Aspect 10 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 8 or 9 to optionally include the facade includes a smooth profile having a visual impression of the texture characteristic.

[0071] Aspect 11 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 8 to 10 to optionally include the base color is printed across the face and the texture color is printed on the base color.

[0072] Aspect 12 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 8 to 11 to optionally include the first polymer structural board includes a first texture color, and the second polymer structural board includes a second texture color.

[0073] Aspect 13 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 8 to 12 to optionally include the side portion including: a side facade having a side facade base color and a side facade texture color.

[0074] Aspect 14 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 8 to 13 to optionally include the side facade base color is the same as the base color and the side facade texture color is the same as the texture color.

[0075] Aspect 15 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 8 to 14 to optionally include the texture characteristic is printed on the base color and the side facade base color and the texture characteristic including a virtual image of one or more of wood grain, whirls, marbling, or sediment.

[0076] Aspect 16 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 8 to 15 to optionally include the side portion includes a side facade having a side facade texture characteristic that is a continuation of the texture characteristic.

[0077] Aspect 17 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 8 to 16 to optionally include the one or more set polymer structural boards is an extruded set polymer structural board.

[0078] Aspect 18 can include subject matter such as a method of forming a polymer structural component having a simulated texture comprising: forming a polymer structural board from a molten polymer; setting the polymer structural board, the set polymer structural board having a face and one or more sides; wherein the one or more sides are angularly oriented relative to the face; applying a facade to the face continuously from a first face edge portion to a second face edge portion, applying the facade includes: providing a base color; printing a texture color on the face; wherein the texture color is different than the base color; and providing a simulated texture including the base color and the texture color; wherein printing the texture color simulates a texture characteristic on the face.

[0079] Aspect 19 can include, or can optionally be combined with the subject matter of Aspect 18 to optionally include extruding a polymer to form the polymer structural board.

[0080] Aspect 20 can include, or can optionally be combined with the subject matter of Aspects 18 or 19 to optionally include the simulated texture includes one or more of wood grain, whirls, marbling, sediment, cracks, or ridges.

[0081] Aspect 21 can include, or can optionally be combined with the subject matter of Aspects 18 to 20 to optionally include applying a side facade to the one or more sides including: printing the texture color on the one or more sides; providing the simulated texture on the one or more sides.

[0082] Aspect 22 can include, or can optionally be combined with the subject matter of Aspects 18 to 21 to optionally include providing the base color includes printing the base color continuously on the polymer structural board.

[0083] Aspect 23 can include subject matter such as a polymer structural component comprising a polymer structural board including at least one face, wherein at least one texture characteristic includes at least one of a ridge or recess formed along at least a portion of the at least one face, and a facade extending along the face from a first edge portion to a second edge portion. The facade includes a base color and a texture color, wherein the texture color is configured to be printed on the texture characteristic, and the texture color is different than the base color.

[0084] Aspect 24 can include, or can optionally be combined with the subject matter of Aspect 23, to optionally include wherein the texture characteristic simulates a texture of a building material.

[0085] Aspect 25 can include, or can optionally be combined with the subject matter of Aspect 23, to optionally include wherein the texture color is configured to be printed using a registered print.

[0086] Aspect 26 can include, or can optionally be combined with the subject matter of Aspect 23, to optionally include wherein the facade includes a plurality of texture colors, wherein the recess includes a first texture color and the ridge includes a second texture color different from the first texture color.

[0087] The above description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the disclosed concepts can be practiced. These embodiments are also referred to herein as "aspects” or "examples.” Such aspects or examples can include elements in addition to those shown or described. However, the description also contemplates aspects or examples in which only those elements shown or described are provided. Moreover, the description also contemplatesaspects or examples using any combination or permutation of those elements shown or described (or one or more features thereof), either with respect to a particular aspects or examples (or one or more features thereof), or with respect to other Aspects (or one or more features thereof) shown or described herein.

[0088] In the event of inconsistent usages between this document and any documents so incorporated by reference, the usage in this document controls.

[0089] In this document, the terms "a” or "an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of "at least one” or "one or more.” In this document, the term "or” is used to refer to a nonexclusive or, such that "A or B” includes "A but not B,” "B but not A,” and "A and B,” unless otherwise indicated. In this document, the terms "including” and "in which” are used as the plain-English equivalents of the respective terms "comprising” and "wherein.” Also, in the following claims, the terms "including” and "comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. 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.

[0090] Geometric terms, such as "parallel,” "perpendicular,” "round,” or "square,” are not intended to require absolute mathematical precision, unless the context indicates otherwise. Instead, such geometric terms allow for variations due to manufacturing or equivalent functions. For example, if an element is described as "round” or "generally round,” a component that is not precisely circular (e.g., one that is slightly oblong or is a many-sided polygon) is still encompassed by this description.

[0091] The above description is intended to be illustrative, and not restrictive. For example, the above-described aspects or examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art uponreviewing the above description. The Abstract is provided to comply with 37 C.F.R. §1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as aspects, examples, or embodiments, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the disclosed concepts should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

CLAIMSWhat is claimed is:

1. A polymer structural component comprising:an extruded and set polymer structural board, the extruded and set polymer structural board having:a face and at least one side;wherein the at least one side is configured to be angled relative to the face;the face including a facade extending across the face to the at least one side; andthe facade includes a base color and a texture color; wherein the texture color is printed on the facade with a texture characteristic, and the texture color is different than the base color;wherein the base color and the texture characteristic are configured to provide a simulated texture on the facade.

2. The polymer structural component of claim 1, wherein the facade includes a smooth profile having a visual impression of the texture characteristic.

3. The polymer structural component of claim 1, wherein the base color is applied along the face;wherein the texture color provides a visual impression of the texture characteristic.

4. The polymer structural component of claim 1, wherein the base color is printed along the face.

5. The polymer structural component of claim 1, wherein the base color is provided by the extruded and set polymer structural board.

6. The polymer structural component of claim 1, wherein the texture characteristic is printed on the base color, the texture characteristic including a virtual image of one or more of wood grain, whirls, marbling, or sediments.

7. The polymer structural component of claim 1, wherein the extruded and set polymer structural board is configured to have the simulated texture of a wood board.

8. A polymer structural component system comprising:one or more set polymer structural boards including a first set polymer structural board and a second set polymer structural board, each of the one or more set polymer structural boards having:a face having a first face edge portion and a second face edge portion opposing the first edge portion;a side in communication with one of the first face edge portion or the second face edge portion, the side oriented transversely with the face;a facade extending along the face from the first edge portion to the second edge portion, the facade having:a base color and a texture color;wherein the texture color is printed on the facade with a texture characteristic, and the texture color is different than the base color;wherein the texture color and the texture characteristic together simulate a texture on the facade; andthe first set polymer structural board includes a first facade, and the second set polymer structural board includes a second facade.

9. The polymer structural component system of claim 8, wherein the first facade aligns with the second facade and the texture simulated on the facade of the first polymer structural board joins with a texture simulated on the second polymer structural board.

10. The polymer structural component system of claim 8, wherein the facade includes a smooth profile having a visual impression of the texture characteristic.

11. The polymer structural component system of claim 8, wherein the base color is printed across the face, and the texture color is printed on the base color.

12. The polymer structural component system of claim 8, wherein the first polymer structural board includes a first texture color, and the second polymer structural board includes a second texture color.

13. The polymer structural component system of claim 8, the side portion including:a side facade having a side facade base color and a side facade texture color.

14. The polymer structural component system of claim 13, wherein the side facade base color is the same as the base color and the side facade texture color is the same as the texture color.

15. The polymer structural component system of claim 13, wherein the texture characteristic is printed on the base color and the side facade base color and the texture characteristic including a virtual image of one or more of wood grain, whirls, marbling, or sediment.

16. The polymer structural component system of claim 8, wherein the side portion includes a side facade having a side facade texture characteristic that is a continuation of the texture characteristic.

17. The polymer structural component system of claim 8, wherein the one or more set polymer structural boards is an extruded set polymer structural board.

18. A method of forming a polymer structural component having a simulated texture comprising:forming a polymer structural board from a molten polymer; setting the polymer structural board, the set polymer structural board having a face and one or more sides;wherein the one or more sides are angularly oriented relative to the face;applying a facade to the face continuously from a first face edge portion to a second face edge portion, applying the facade includes:providing a base color;printing a texture color on the face;wherein the texture color is different than the base color; andproviding a simulated texture including the base color and the texture color;wherein printing the texture color simulates a texture characteristic on the face.

19. The method of forming the polymer structural component of claim 18, including extruding a polymer to form the polymer structural board.

20. The method of forming the polymer structural component of claim 18, wherein the simulated texture includes one or more of wood grain, whirls, marbling, sediment, cracks, or ridges.

21. The method of forming the polymer structural component of claim 18, including applying a side facade to the one or more sides including:printing the texture color on the one or more sides; and providing the simulated texture on the one or more sides.

22. The method of forming the polymer structural component of claim 18, wherein providing the base color includes printing the base color continuously on the polymer structural board.

23. A polymer structural component comprising:a polymer structural board including at least one face; at least one texture characteristic includes at least one of a ridge or recess form along at least a portion of the at least one face;a facade extending along the at least one face face from a first edge portion to a second edge portion, the facade including:a base color and a texture color;wherein the texture color is configured to be printed on the texture characteristic, and the texture color is different than the base color.

24. The polymer structural component of claim 23, wherein the texture characteristic simulates a texture of a building material.

25. The polymer structural component of claim 23, wherein the texture color is configured to be printed includes a registered print.

26. The polymer structural component of claim 23, wherein the facade includes a plurality of texture colors;wherein the recess includes a first texture color and the ridge includes second texture color different from the first texture color.

Images