Textured polymer structural components and methods

Abstract

A polymer structural component, in examples, includes a molded and set elongate polymer support. The molded and set elongate polymer support includes one or more faces. At least one face of the one or more faces includes one of a convex profile or concave profile. The elongate polymer support is configured to transition from an untextured configuration to a textured configuration. The untextured configuration includes at least one face of the one or more faces having an undisturbed molded surface. The textured configuration includes a texture characteristic continuously applied along the undisturbed molded surface.

Description

TEXTURED POLYMER STRUCTURAL COMPONENTS AND METHODSCLAIM FOR PRIORITY

[0001] This application claims the benefit of priority of U.S. Provisional Application No. 63 / 761,645, filed February 21, 2025, which is hereby incorporated by reference in its entirety.TECHNICAL FIELD

[0002] The present invention relates to the field of structural components, specifically concerning advancements in polymer beams including simulated textures.BACKGROUND

[0003] Outdoor structures and accessories, such as outdoor furniture, railings, fences, decks, posts, and related components, used in residential, commercial, institutional, or recreational environments can provide functional, safety-related, and / or aesthetic benefits. In some instances, such structures are exposed to environmental conditions including moisture, ultraviolet radiation, temperature variation, wind, and mechanical loading. Outdoor structures are optionally formed to satisfy various performance considerations, such as durability, structural integrity, ease of installation, maintenance requirements, and visual appearance.

[0004] Fencing, railings, posts, and barrier systems are, for example, built or arranged to designate boundaries, provide protection, restrict access, and / or support other structural or decorative applications. Such systems can be used in residential, commercial, agricultural, and / or industrial environments, and can have forms according to functional, aesthetic, cultural, and / or regulatory considerations. In some implementations, fencing and railing systems include multiple interconnected components, such as posts, rails, infill members, fasteners, and / or mounting interfaces that can align, interface, or transfer loads. In various implementations, some systems can include vertically orientedposts, horizontally or angularly oriented rails or members, and intermediate elements arranged in patterns or assemblies selected, for instance, to meet particular spatial or design objectives.SUMMARY

[0005] A polymer structural component can include a molded and set elongate polymer support can include one or more faces. At least one face of the one or more faces can include at least one of a convex profile or a concave profile. The elongate polymer support can include an untextured configuration to a textured configuration. In the untextured configuration the at least one face of the one or more faces can include an undisturbed molded surface. In the textured configuration, a texture characteristic can be continuously applied along the undisturbed molded surface of the at least one face of the one or more faces.

[0006] A system for forming a texture characteristic along an elongate polymer beam can include an imprint apparatus including a receiving pathway extending along the imprint apparatus. The imprint apparatus can include at least one stamp or at least one stamp supported by the imprint apparatus and positioned relative to the receiving pathway. The at least one stamp can include one or more of a concave profile or a convex profile. The at least one stamp can include one or more texture characteristics formed on a surface of the at least one stamp. The system can include a molded elongate polymer structural component including one or more faces. Each face of the one or more faces can include a molded surface. The at least one convex stamp concave profile can include a complementary profile to the convex profile and the at least one concave stamp can include a complementary profile to the convex profile. The at least one stamp can be configured to imprint the texture characteristic on the molded surface.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figures 1A and IB illustrate examples of an elongate polymer structural component of the prior art.

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

[0009] Figure 2B illustrates a schematic of an example of a cross section of a polymer structural component.

[0010] Figure 3 illustrates an example of a perspective view of a polymer structural component including an accessory.

[0011] Figure 4A illustrates an example of an imprinting apparatus and a stamp having a convex profile.

[0012] Figure 4B illustrates an example of a close-up view of a stamp having a convex profile.

[0013] Figures 5A - 5C illustrate an example of a method to apply at least one texture characteristic to a polymer structural component.

[0014] Figures 6A - 6B illustrate an example of another method to apply at least one texture characteristic to a polymer structural component.

[0015] Figure 7 illustrate a schematic of a perspective view of another polymer structural component.DETAILED DESCRIPTION

[0016] Exterior and interior structures include, for example, support structures. Supports structures and structural components include, for example, support beams and associated components. In some examples, the support structures include foundational or load bearing components that hold or retain associated components in place. Support structures include, for instance, materials, components, medium or the like, that are foundational to a construction. In some examples, exterior and interior support beams or support structures are formed from naturally occurring materials, such as wood [e.g., lumber], stone, concrete, metals [including alloys], or the like.

[0017] Some support structures and structural components include support beams such as railings, pillars, columns, bollards, balusters, fencing, boards, or the like. At times support beams are made from materials like wood, steel, or concrete. In examples, these materials present challenges, particularly in environments exposed to moisture or temperaturefluctuations. For instance, naturally occurring materials warp, decay, corrode, crack or the like, over time.

[0018] In some examples, outdoor or interior structures, structural components, furniture, or the like are formed with lumber. For example, flooring, decks, railings, patios, walkways, ramps, steps, or the like are constructed from lumber planks, boards, panels, posts, or the like. In other examples, outdoor or interior structures are formed from stone, brick, concrete, or the like. 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 can be subject to one or more of 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, coating, or other protective measures, naturally occurring structural components, at times, deteriorate or are damaged and optionally require replacement.

[0019] Polymer structural components can be used as a replacement for naturally occurring materials or traditional building materials. Some polymer structural components can present technical challenges. Some approaches attempt to provide aesthetic appearances on polymer structural components, but can present limitations. For instance, painted colors applied to polymer surfaces can 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 can technically difficult and costprohibitive due to the need to precisely locate colors within three-dimensional surface variations.

[0020] Polymer-based materials can be used for exterior or interior applications, such as support structures. However, polymer-based materials can appear artificial [e.g., does not have an appearance of a naturally occurring material]. Methods for applying a texture characteristic to polymer structural components to form surfaces, or faces, that form at least a partial appearance of a naturally occurring material can present challenges. For instance, when a polymer structural component sets, after molding, the polymer structural component can deform, such as shrink, and can result in uneven or undesired surface textures or forms.

[0021] In some examples, instead of forming a texture during molding, polymer structural components can have a texture applied to one or more surfaces. In some examples, polymer structural components can deform, or shrink, after molding and can include surfaces that present challenges to application of a consistent texture.

[0022] For instance, setting or cooling a polymer structural component can result in surface concavity. The surface concavity can present challenges to applying a consistent texture. This issue is, for example, compounded when attempting to apply textures that simulates or mimics natural materials or traditional building materials.

[0023] Optionally, polymer structural components, such as boards, panels, columns, railings, bollards, balusters, fencing, can include aesthetic surfaces that can include a visual appearance that simulates, mimics, replicates, imitates, or the like a naturally occurring material or traditional building material. The visual appearance can include a texture including ridges, troughs, protrusions, extensions, recesses, indentations, or the like that can be applied to a polymer structure. The texture on the polymer structure can simulate, replicate, imitates or mimic an appearance of a texture of another material. In some examples, the polymer structural component can include an aesthetic surface adhered, coupled, or fastened [nailed, screwed, or bolted], or molded to a surface of a polymercomponent.

[0024] The present inventors have recognized, among other things, that a problem to be solved includes providing a polymer structural component that has an appearance of another material such as a material made from wood, stone, brick, cement, or the like. In some examples, even with regular maintenance, including but not limited to staining and finishing, the structural components need to be replaced.

[0025] In certain examples, polymer structural components replace structural components formed from naturally occurring materials. Polymer structural components are, in examples, formed as boards, panels, columns, railings, bollards, balusters, fencing, or the like. In examples, the polymer structural components are assembled into beams such as boards, panels, columns, railings, bollards, balusters, fencing, or the like used in decking, furniture, railings, posts, fencing, or the like. The polymer structural components are optionally formed as a beam with a texture applied to one or more surfaces. For instance, the polymer structural component is formed to include a uniform, or substantially uniform, texture.

[0026] Shrinkage or deformation of a polymer structural component during cooling or setting can be influenced by one or more factors including, but not limited to, polymer composition, processing conditions, and component geometry. The polymer composition can include proportions of materials such as high-density polyethylene [HDPE], polypropylene (PP), fillers, fiberglass, foaming agents, and colorants. Different proportions of these materials can result in varying shrinkage characteristics as the molten polymer transitions from a liquid or semi-liquid state to a substantially solid state [e.g., cooled or set state]. Processing conditions such as mold temperature, fill time, pack time, foaming agent type, and foaming agent amount can affect the rate and extent of cooling and can influence the degree of surface deformation. The geometry and dimensions of the polymer structural component can also influence shrinkage patterns. In an example, polymer structural components including a wider width dimension than posts, bollards, or the like can exhibit greater tendency toward multiple concavity profiles compared to narrower boards.

[0027] The concavity can vary by polymer type and wall thickness. For example, different proportions of materials and processing conditions can result in different amounts and configurations of shrinkage including single concavity profiles, double concavity profiles, or other non-planar surface geometries. Depth of the shrinkage [such as deformation towards interior portions of the polymer structural component] between a surface at corner portions and an apex of a concave profile can vary based on polymer type, wall thickness, and board dimensions. For example, shrinkage in larger posts such as 6 inch by 6 inch [15.25 centimeters by 15.25 centimeter] posts can be approximately 0.1 inches [0.22 centimeters] approximately at the apex of the concave profile.

[0028] Tools can be used to apply a texture characteristic that can account for the dimensional changes that can occur during cooling or setting. For example, a stamp that has a complementary profile to the set polymer structure can be used to form a texture on a polymer structural component. For instance, a stamp can include a convex profile that can matches [e.g., completely matches or at least partially matches], or at least partially mates with, a concave profile of the set polymer structural component. In another example, the stamp includes a concave profile that can match, or at least partially match a convex profile of the set polymer structure or polymer structural component, such as a beam [e.g., an ovular, elliptical, circular profile, or the like], post, railing, or the like.

[0029] A polymer structural component [e.g., beam, board, panel, column, railing, bollard, baluster, posts, or the like], can be formed by an extrusion or molding process. Molding a polymer structural component can include, for instance, a process including introducing molten polymer material into a mold with the mold as a component of an extrusion, injection or pultrusion process that forms the desired polymer structural component. The mold can be designed to form, for example, an elongate polymer structural component. In some instances, the mold can be constructed to accommodate predetermined, specified, or the like, dimensions, and profiles for the elongate polymer structural component. The mold can include aform that can reduce the likelihood of concave or convex features that can be beneficial to address deformations that can occur during cooling.

[0030] However, polymers structural components can have a set [e.g., cooled] configuration that can include one or more faces that can exhibit a concave profile. For instance, at least one side of an elongate polymer structural component can deform or shrink inward such that there is a concave profile between end portions, or corners, of the elongate polymer structural component.

[0031] A texture characteristic can be applied to the polymer structural component [e.g., beam, board, panel, column, railing, bollard, baluster, posts, or the like]. Optionally, the texture characteristic includes features that simulate or mimic a naturally occurring texture or a texture of a building material. The texture characteristic can be applied to the polymer structural component with a stamp, embosser, press, roller, or the like [hereinafter "stamp”].

[0032] Illustrated in Figures 1A and IB are examples of prior art polymer structural components including an elongate polymer structural component system 100, 101, such as polymer support beams. The prior art elongate polymer structural component system 100, 101 are examples of systems including polymer structural components that include a first textured surface 120 [illustrated in Figure 1A], a second textured surface 121a and third textured surface 121b [illustrated in Figure IB].

[0033] Figure 1A illustrates the elongate polymer structural component system 101 that can include the molded polymer structural component 110 [e.g., beam, board, panel, column, railing, bollard, baluster, posts, or the like]. The molded polymer structural component 110 can extend from a polymer structural component distal portion 114 to a polymer structural component proximal portion 112. For instance, the polymer structural component distal portion 114 can be designed to engage or interact with the ground. The polymer structural component proximal portion 112, for example, extends away from the ground and is positioned more vertically away from the ground than the polymer structural component distal portion 114.

[0034] At times, the molded polymer structural component 110 includes an accessory coupling portion 130. For example, the accessory coupling portion 130 can include a recess extending at least partially within the molded polymer structural component 110. For example, a rope, bar, rail, sign, or other accessory can be coupled with the molded polymer structural component 110 via the accessory coupling portion 130.

[0035] Illustrated in Figure IB is an example of another prior art elongate polymer structural component system 101. The elongate polymer structural component system 101 includes an elongate polymer structural component 111 [e.g., board, panel, column, railing, bollard, baluster, posts, or the like]. The elongate polymer structural component 111 can extend as an upright elongate polymer structural component. The elongate polymer structural component 111 can extend, for example from an elongate polymer structural component proximal portion 113 to an elongate polymer structural component distal portion 115. A decorative cap 141 can be coupled to the elongate polymer structural component proximal portion 113.

[0036] A textured characteristic can be applied to the face 116 of the molded polymer structural component 110 or the face 119 of the elongate polymer structural component 111. The texture characteristic can be applied to the molded polymer structural component 110 or the elongate polymer structural component 111 with a stamp having a substantially linear profile. For example, the stamp can include a cylindrical form or profile.

[0037] The molded polymer structural component 110 and the elongate polymer structural component 111 are examples of molded polymer beams that include an area along a surface where shrinkage occurred during setting. For instance, shrinkage can have a concave profile occurring along a face 116, 119 of the molded polymer structural component 110 or the elongate polymer structural component 111 . For example, a first untextured surface 122 [illustrated in Figure 1A], second untextured surface 123a and third untextured surface 123b [illustrated in Figure IB] can extend at least partially along one of the face 116 or the face 119.

[0038] As illustrated in Figure 1A, the face 116 can include a concave profile, or an area where shrinkage or deformation occurred during setting or cooling. The concave profile of the face 116 can include an apex 118 area. The area around the apex 118 can include areas of the face 116 where the texture characteristic was not applied because a cylindrically formed stamp cannot reach or continuously contact the complete surface [e.g., greater than 80% of the surface, greater than 90% of the surface, greater than 95% of the surface] of the concave profile of the face 116. In the example of Figure 1A, the areas of the face 116 surrounding the apex 118 of the concave profile can be untextured while areas of the face 116 closer to corner portions 124 of the molded polymer structural component 110 can include a textured surface 120.

[0039] Figure IB illustrates the elongate polymer structural component 111 including a concave profile formed in the face 119. The concave profile of the face 119 can include an apex or lowest form of the concave provide. In areas of the face 119 including the apex 117 the one or more texture characteristics was not applied. The areas of the face 119 surrounding the apex 117 can include fewer texture characteristics or is substantially untextured relative to outer portions of the face 119 proximate to corner areas of the face 119. while areas of the face 119 closer to corner portions 127 of the molded polymer structural component 110 include a textured surface 120. In the example of IB, the concave profile of the face 119 extends a longer distance of the face 119 than the face 116 of the molded polymer structural component 110. In this example, the second textured surface 121a occupies less space of the face 119 than the second untextured surface 123a.

[0040] The elongate polymer structural component system 101 can include an at least partially textured elongate polymer structural component 111 and a partially textured decorative cap 141. The decorative cap 141 includes, for instance, the third textured surface 121b. The decorative cap 141 includes a concave profile including an apex 129 of the concave profile of the decorative cap 141. Areas surrounding the apex 129include the third untextured surface 123b and the areas closer to corner portions 127b include the third textured surface 121b.

[0041] The first untextured surface 122, the second untextured surface 123a, and the third untextured surface 123b are the result of the concave profile of each of the molded polymer structural component 110, elongate polymer structural component 111 and the decorative cap 141. For each of these, a stamp [e.g., roller, embosser, press or the like] was unable to contact the face 116, 119 and apply the texture characteristic during processing or forming the [no text] 100 or the elongate polymer structural component system 101.

[0042] In some polymer structural components, such as those with larger cross-sections or greater widths, multiple concave regions can form. For instance, some polymer structural components can include concave and convex profiles or other deformations that can occur during cooling, such as a double concavity presenting a W-shaped profile across a face.Conventional flat or cylindrical stamps cannot accommodate such complex surface geometries. The inability to consistently apply texture characteristics across the entire surface of polymer structural components, including concave regions, can represent a technical challenge in producing polymer structural components with uniform aesthetic appearances that convincingly simulate naturally occurring or traditional building materials.

[0043] Figure 2A is an example of a polymer structural component 200. For example, the polymer structural component 200 includes a polymer support body 210 [e.g., board, panel, column, railing, bollard, baluster, posts, or the like]. The polymer support body 210 can include a polymer support beam. The polymer support body 210 includes, for instance, one or more faces 216 along an outer perimeter of the polymer support body 210. The one or more faces 216 are, for instance, faces of a polygon support body such as a prism [e.g., rectangular prism] or a cylinder. Areas where two of the one or more faces 216 meet includes at least one corner portion 218. Each of the one or more faces 216 extends laterally from at least one corner portion 218 to another at least one corner portion 218. The one or more faces 216 extends longitudinally from a polymer structural componentproximate portion 212 to a polymer structural component distal portion 214.

[0044] The polymer structural component 200 in an example includes a polymer support body 210 [e.g., polymer beam] that is an upright polymer support body 210 [e.g., board, panel, column, railing, bollard, baluster, posts, or the like]. In other examples, the polymer structural component 200 is a component of a multi-component system such as a railing, fencing, item of furniture or the like. In yet other examples, the polymer support body 210 includes beams, planks, boards, slats, or the like, that extend between upright structures. While illustrated as a singular polymer structural component 200 in the Figures it is contemplated for the concepts discussed herein to be applied to multi-component polymer structural component systems such as at least two polymer structural components coupled, joined, or arranged together. While the concepts discussed herein are described related to a post-like polymer structural component, similar methods are contemplated for use on other polymer structural components, or other polymer forms.

[0045] The polymer support body 210 is, in some instances, formed from a molded and set polymer. For example, the polymer support body 210 is formed from a polymer that is formed with a molding process. A molding process includes, for instance, extrusion, pultrusion, injection, blow molding, or the like a molten polymer through subsequent molds, cavities, or the like. A molten polymer is, in one introduced into a mold through an extrusion process. The molten polymer is then allowed to set [e.g., cool]. The set polymer then substantially retains the shape of the mold.

[0046] In some instances, as the molten polymer transitions through the setting process from a molten [e.g., liquid, semi-liquid] state to a substantially solid [e.g., completely solid, greater than 90% solid, hardened to the touch] state, deformations in the molded and set polymer can occur. For example, the one or more faces 216 shrinks inward [e.g., arches inward, concaves, or the like]. This shrinkage forms a surface that is not planar. Instead, the one or more faces 216 has a concave profile 217.

[0047] Figure 2B illustrates an example of lateral cross section of the polymer structural component 200. At least one or more faces 216 has a concave profile 217 that occurred due to, for example, the setting [e.g., cooling] process. In other examples, the concave profile 217 is formed from other malformation actions, such as irregularities in the mold. In another example, the concave profile can be formed during the molding process as at least a portion of the specified design of the one or more faces 216.

[0048] In the example illustrated, the one or more faces 216 curves inward from at least one corner portion 218 toward another, opposing, at least corner portion 218. In other examples, there are multiple concave portions of the one or more faces 216. The concave profile 217 includes an apex 225 and a surrounding region 227 of the apex 225. The apex 225 includes, for instance, the portion having the greatest amplitude of the curve of the concave profile 217. In some instances, the curve of the concave profile 217 is substantially symmetrical about the apex 225. In other examples, the apex 225 is closer to at least one corner portion 218 than an opposing at least one corner portion 218. In some examples, each of the one or more faces 216 can have a similar concave profile 217. In other examples, each of the one or more faces 216 can have a different concave profile 217.

[0049] In some examples, the one or more faces 216 of the polymer structural component 200 formed from molding sometimes can have an unattractive appearance, such as a planar character or a texture that fails to meet aesthetic specifications of builders, customers, or the like. For instance, the polymer structural component 200 can include an untextured configuration. The untextured configuration can include the one or more faces 216 that can include an undisturbed surface. The undisturbed face can include surfaces where no further actions or processes were applied to the one or more faces 216 after the molding process finished.

[0050] In some instances, the polymer structural component 200 includes textures to enhance the appearance. For example, the polymer structural component includes textures that mimic a wood texture, stone, brick, concrete, or the like. The enhanced appearance, for example,simulates a naturally occurring structural component, such as a plank of lumber, a brick, concrete form, or the like.

[0051] In an example, the polymer structural component 200 including a simulated texture [e.g., virtual texture or virtual image] can be designed to be used in as an interior or exterior structural component. The polymer structural component 200 can include a polymer support body 210 having one or more texture characteristics 222 that can simulate or mimic a different material such as a naturally existing material [e.g., wood, stone] or other building materials [e.g., brick, cement]. In an example, the texture characteristics that simulates the different material are applied to the one or more faces 216 of the polymer support body 210. For instance, the one or more texture characteristics 222 can be applied with a stamping process to at least one of the one or more faces 216 of the polymer support body 210. The one or more texture characteristics 222, for example, can extend along a length of the polymer support body 210. The one or more texture characteristics 222 can extend continuously along a the one or more faces 216.

[0052] The texture characteristic can be applied to extend longitudinally along the elongate polymer support. For example, the texture characteristic can extend from a first end portion of the elongate polymer support to a second end portion of the elongate polymer support. The first end portion can be the polymer structural component proximate portion 212. The second end portion can be the polymer structural component distal portion 214. The texture characteristic can be applied continuously from the first end portion to the second end portion.

[0053] The texture characteristic can be applied to extend laterally across at least one of the one or more faces 216 of the polymer support 210, such as an elongate polymer support. For example, the one or more texture characteristics 222 can extend from a first edge portion 219a of the at least one corner portion 218 to a second edge portion 219b of the at least one corner portion 218 of the elongate polymer support 210. The first edge portion 219a can be located at or near a first corner portion 218. The second edge portion 219b can be located at or near an opposing cornerportion 218. The one or more texture characteristics 222 can be applied continuously from the first edge portion 219a to the second edge portion 219b. The continuous application of the one or more texture characteristics 222 from the first edge portion 219a to the second edge portion 219b can include application across the concave profile 217 including areas surrounding the apex 225.

[0054] The polymer structural component 200 of Figure 2A and 2B can include a textured configuration. The textured configuration can include the one or more texture characteristics 222 substantially continuously applied to the one or more faces 216. The one or more texture characteristics 222 can include, for example, a naturally occurring texture such as wood, stone, brick, concrete, or the like. The one or more texture characteristics 222 applied to the one or more faces 216 can include a surface on the one or more faces 216 that is textured. Textured can include physical surface variations such as ridges, troughs, protrusions, recesses, or indentations that simulate, mimic, or replicate the appearance or tactile properties of naturally occurring materials or building materials.

[0055] The textured surface 224, for example, tactilely simulates the texture of a naturally occurring material such as wood, stone, brick, concrete, or the like. The textured surface 224 also, in some instances, simulates an appearance of a naturally occurring material such as wood, stone, brick, concrete or the like. In examples, the polymer support body 210 both substantially appears and substantially feels like a naturally occurring material such as wood, stone, brick, concrete, or the like. The polymer support body 210 can include the one or more texture characteristics 222 applied continuously to the one or more faces 216 to simulate or mimic at least one of feel and appearance of a naturally occurring material such as wood, stone, brick, concrete, or the like. The one or more texture characteristics 222 can be applied to a surface on the one or more faces 216 that includes a roughened [e.g., ridged, bumpy, uneven] texture compared to the undisturbed molded surface. The one or more texture characteristics 222 can be applied to the one or more faces 216 forms a textured surface 224 on the polymer support body 210.

[0056] The one or more texture characteristics 222 can be applied from at least one corner portion 218 to an opposing at least one corner portion 218, from polymer structural component proximate portion 212 to the polymer structural component distal portion 214, or to substantially all of the one or more faces 216 [e.g., covers 100 percent, greater than 95 percent, greater than 90 percent or the like]. The one or more texture characteristics 222 can be applied to the concave profile 217 to continuously extend along the one or more faces 216 including the surrounding region 27 of the apex 225. Applying the one or more texture characteristics 222 to substantially all of the concave profile 217 can avoid areas where there is an undisturbed surface such as a portion of the one or more faces 216 without the textured surface 224.

[0057] Avoiding areas having an undisturbed surface of the one or more faces 216 can increase the appearance of a polymer structural component 200 formed from a different material. The textured surface 224 can be applied to substantially all [e.g., 100 percent, greater than 95 percent, greater than 90 percent or the like] of the surfaces of the polymer structural component 200. The textured surface 224 can extend, for example, along the concave profile 217 of the polymer support body 210. For instance, the polymer structural component 200 is a bollard including a textured surface 224 that includes a simulated appearance of wood. In another example, the polymer structural component 200 is a bollard including a textured surface 224 that includes a simulated appearance of concrete. In other examples, the polymer structural component 200 includes the polymer support body 210 with the textured surface 224 occurring on all of the one or more faces 216.

[0058] In some examples, as illustrated in Figure 3, the polymer structural component 200 is formed to include accessories such as a post cap 340, one or more attachment accessories 333, or the like. In other examples, the polymer structural component 200 is formed to include one or more attachment recesses 230. The one or more attachment recesses 230, for instance extends from a surface of the one or more faces 216 inward towards a center portion of the polymer support body 210. The oneor more attachment recesses 230 is optionally formed to receive the one or more attachment accessories 333.

[0059] In examples, the post cap 340 or the one or more attachment recesses 230 can be formed to continue the appearance of the textured surface 224. The same or similar one or more texture characteristics 222 can be applied to the post cap 340 as the polymer support body 210, or the post cap 340 can include a different one or more texture characteristics 222. Similar to the polymer support body 210, the post cap 340 can include a concave profile 317, and the one or more texture characteristics 222 can be applied to the post cap 340 including the concave profile 317 such that the one or more faces 316 includes the textured surface 224.

[0060] Figure 4A illustrates an example of an imprint apparatus 400. The imprint apparatus 400 can include a mechanism that is designed to apply a texture characteristic to a surface of the polymer structural component. The one or more texture characteristics 222 can be applied to the polymer structural component 200, such as the polymer support body 210, with the imprint apparatus 400. The imprint apparatus 400 can include a stamp 450. The stamp 450 can include an embosser, a press, or the like. In examples, the stamp 450 can be a dynamic mechanism such as a roller or a static mechanism.

[0061] The stamp 450 can be a heated stamp with surfaces heated externally or internally. Internally heated structures can radiate heat towards one or more external surfaces of the stamp 450. When the one or more heated external surfaces of the stamp 450 contact the polymer support body 210, the heated surfaces can at least partially melt the one or more faces 216 and transfer the texture characteristic onto the polymer support body 210. In some examples, the stamp 450 can include a hollow structure with the one or more texture characteristics 456 extending along an outer surface 455 of a perimeter wall that surrounds a tunnel extending within the stamp 450. The tunnel can receive a heated fluid, such as heated oil, that transfers heat to the perimeter wall. The heated fluid can be supplied to the tunnel within the stamp 450 with a heat pump and can continuously transfer heat to the perimeter wall when the stamp is in use.

[0062] The imprint apparatus 400 can include a receiving pathway 402. The receiving pathway 402, for example, includes a cavity or an opening that can extend at least partially within or through the imprint apparatus 400. The receiving pathway 402 can be formed to receive a polymer structural component [e.g., board, panel, column, railing, bollard, baluster, posts, or the like]. The receiving pathway 402 can be formed to permit the polymer structural component to be exposed to the stamp 450. For instance, the receiving pathway 402 extends a desired distance within the imprint apparatus 400 to permit sufficient space for the polymer structural component to be exposed to the stamp 450.

[0063] The stamp 450 can be retained by the imprint apparatus 400 in a location specified by the purpose. For instance, the stamp 450 can be positioned in an upper portion of the imprint apparatus 400. The stamp 450, in other examples, can be positioned relative to a lateral side of the imprint apparatus 400. In another example, the stamp 450 can be positioned proximate to a lower portion of the imprint apparatus 400. Optionally, there can be more than one stamp 450 positioned within the imprint apparatus 400.

[0064] The imprint apparatus 400 optionally can include one or more alignment posts 408. The one or more alignment posts 408 can be positioned relative to the receiving pathway 402 to assist in proper alignment or positioning of the polymer structural component as the polymer structural component is subjected to the stamp 450. For instance, the one or more alignment posts 408 can retain the polymer structural component within the one or more alignment posts 408 during application of the stamp 450 to the polymer structural component.

[0065] The imprint apparatus 400 can include a feed roller 406. The feed roller 406 can allow the polymer structural component to pass through the receiving pathway 402 during application of the stamp 450 to the one or more surfaces of the polymer structural component. In an example, the one or more alignment posts 408 and the feed roller 406 can assist in ensuring the stamp 450 is properly engaged with the polymer structural component.

[0066] Illustrated in Figure 4B is a close-up view of the stamp 450. The stamp 450 can include a convex profile 452. The convex profile 452 can include an apex 425 at a point of greatest amplitude. For instance, the apex 425 is positioned relative to a lateral plane 451. The lateral plane extends through the apex 425 and can be substantially equidistant from each lateral side of the stamp 450. For instance, a convex angle 454 can be formed between the lateral plane 451 and a relative line extending along the convex curve of the convex profile 452. In an example, the convex angle 454 is similar on both lateral sides of the apex 425. For instance, the convex profile 452 can be substantially symmetrical about the apex 425. In other instances, the convex profile 452 is asymmetric.

[0067] The convex profile 452 can include a shape or profile that is complementary to the concave profile 217 of the polymer support body 210 or the concave profile 317 of the post cap 340, or the like. The convex profile 452 can be formed to substantially match with the concave profile [as discussed relative to Figure 2A, 2B or Figure 3] when the stamp 450 comes into contact with the polymer structural component [as discussed relative to Figure 2A, 2B or Figure 3].

[0068] The stamp 450 can include a textured surface 458. The textured surface 458 can include one or more texture characteristics 456 that can form a simulation of a feel or appearance of a naturally occurring material or building material on the polymer structural component. The textured surface 458 can include ridges, undulations, knurls, or the like. The stamp 450 can be curved to, for example, apply the one or more texture characteristics 456 to the polymer structural component [as discussed relative to Figure 2A, 2B or Figure 3]. In examples, the stamp 450 can be curved, or has a convex profile, that can be complementary to a concave profile of the polymer structural component. For instance, the textured surface 458 contacts the polymer structural component and can imprint the one or more texture characteristics 456 on one or more faces of the polymer structural component 200.

[0069] Illustrated in Figure 5A-C are schematics of a process for forming a texture on a polymer structural component 510 [e.g., board, panel,column, railing, bollard, baluster, posts, or the like). Illustrated in Figure 5A is an example of a molded the polymer structural component 510 as an elongate polymer support. The polymer structural component 510 can be molded to include one or more faces 516. Each of the one or more faces 516 can include a surface 520. The polymer structural component 510, when molded can include a flat, planar, or the like one or more faces 516. As the polymer structural component 510 sets [e.g., cools) each of the one or more faces 516 can shrink inward.

[0070] In examples, the set polymer structural component 510 can include one or more faces 516 that have a concave profile 517. For example, a polymer structural component lateral plane 515 can extend through corner portions 518 on opposite sides of each of the one or more faces 516. For instance, the concave profile 517 can extend away from the polymer structural component lateral plane 515 towards a central portion of the polymer structural component 510. The concave profile 517 can include an apex 525. The apex 525 can be the portion of the concave profile having the greatest amplitude relative to the polymer structural component lateral plane 515.

[0071] The polymer structural component 510 can be exposed to a stamp 550 and can include a convex profile 552. The convex profile 552 is, for instance, complementary to the concave profile 517 of the polymer structural component 510, as illustrated in Figure 5B. The stamp 550 can include a textured surface 558 including one or more texture characteristics 554. The textured surface 558, and the stamp 550, can be arranged to face the one or more faces 516 of the polymer structural component 510.

[0072] Illustrated in Figure 5C is a step in the process for forming a textured polymer structural component. The stamp 550 can be brought into engagement with one or more faces 516 of the polymer structural component 510, such as at a stamping zone 530. The complementary convex profile 552 of the stamp 550 can match [e.g., matches 100 percent, greater than 95 percent, greater than 90 percent or the like) the concave profile 517. The complementary convex profile 552 of the stamp 550 can bebrought into contact with the concave profile 517 of the polymer structural component 510.

[0073] For instance, the one or more texture characteristics 554 of the stamp 550 can be applied to the concave surface 521 of the polymer structural component 510. The stamp 550 can apply the one or more texture characteristics 554 by one of rotating the stamp, dynamically pressing the stamp, or moving the polymer structural component 510 against a statically held stamp. In examples, the textured surface 558 including the one or more texture characteristics 554 is pressed into the concave profile 517. The textured surface 558 can form one or more texture characteristics 522 in surfaces of the concave profile 517 of the polymer structural component 510. For instance, the textured surface 558 of the stamp 550 can contact and apply the texture characteristic 556 along a length of the polymer structural component 510.

[0074] As illustrated in Figures 6A and 6B, an imprint apparatus can include a stamp 650 having a concave profile 652. The concave profile 652 can include a texture characteristic 656. The texture characteristic can simulate the texture of a naturally occurring material such as wood, stone, brick, or concrete. The stamp 650 can include a textured surface 658 including ridges, undulations, bumps, or the like that provide the texture characteristic 656.

[0075] In examples, the concave profile 652 can match a convex profile 617 of a polymer structural component 610. The convex profile 617 can result from molding specifications during the molding process of the polymer structural component 610. The convex profile 617 can be a portion of a polymer structural component such as an elongate polymer support including one of a board, panel, column, railing, bollard, baluster, or post. The concave profile 652 of the stamp 650 can include a complementary profile to the convex profile 617 of the polymer structural component 610. The complementary profile can match the convex profile 617 at 100 percent, greater than 95 percent, greater than 90 percent, or the like.Similar to the arrangement of the polymer structural component 510 relative to the stamp 550 of Figures 5A-5C, the concave profile 652 of thestamp 650 can conform to and contact the convex profile 617 of the polymer structural component 610.

[0076] The convex profile 617 can include a molded surface 620 that is undisturbed. The undisturbed molded surface 620 can be a surface that has not received a texture characteristic. As illustrated in Figure 6B, when the polymer structural component 610 and the undisturbed molded surface 620 are brought into engagement with the stamp 650 at a stamping zone 630, the textured surface 658 of the stamp 650 can be applied to the undisturbed molded surface 620. The concave profile 652 of the stamp 650 can contact substantially all areas of the convex profile 617. The stamp 650 can contact areas around and including the apex regions to continuously apply the texture characteristic 656 along the molded surface 620. The resulting product can be a polymer structural component such as a bollard, baluster, post, or railing having a textured surface that simulates a naturally occurring material.

[0077] The complementary concave profile 652 of the stamp 650 can enable uniform pressure distribution across the convex profile 617 during texture application. Conventional stamps having flat or cylindrical profiles cannot adequately conform to convex surfaces and can result in inconsistent texture application with excessive pressure at apex regions and insufficient contact at edge or corner portions. The concave profile 652 can conform to the geometry of the convex profile 617 such that the textured surface 658 maintains consistent contact pressure from corner portions to apex regions of the polymer structural component 610. This consistent contact can enable the texture characteristic 656 to be continuously applied without untextured gaps or regions of incomplete texture transfer. The resulting textured surface can extend continuously along the molded surface 620 to provide a uniform aesthetic appearance that simulates naturally occurring materials such as wood grain, stone texture, brick patterns, or concrete finishes across the entire face of the polymer structural component 610.

[0078] Figure 7 illustrates a polymer structural component 710 can include a molded and set elongate polymer support having one or more faces 716 that exhibit multiple concave profiles 721 along a single face. Themultiple concave profiles 721 can result from cooling or setting conditions. In an example, the dimensions of the polymer structural component 710 can influence the formation of multiple concave profiles 721. For example, a polymer structural component 710 such as a board including a face of the one or more faces 716 with a multiple concave profile 721 including a double concavity profile. The double concavity profile can include a first concave region 721a and a second concave region 721b separated by an intermediate region 721c. Each concave region 721a, 721b can include an apex 725a, 725b representing the point of greatest inward curvature or shrinkage.

[0079] The multiple concave profiles 721 can present challenges for applying one or more texture characteristics 756 using conventional stamps having substantially flat profiles [e.g., relative to a stamp including a convex or concave outer profile]. A stamp including a convex profile configured to match a single concave profile [such as that discussed related to Figures 5A-5C] cannot adequately contact all regions of a double concavity profile. Areas between the first concave region 721a and the second concave region 721b, including the intermediate region 721c, can remain untextured when stamps including only one concave profile are applied.

[0080] A stamp 750 can include a profile 752 formed to match the multiple concavity profile of the polymer structural component 710. The stamp 750 having a profile complementary to a specific multiple concavity of a polymer structural component can apply a texture characteristic continuously along the face including areas surrounding the apexes of each of the multiple concavity profiles. The stamp 750 includes a profile that corresponds or is complementary to the profile of the polymer structural component 710 to reduce the likelihood of untextured regions and can provide a uniform aesthetic appearance that can simulate naturally occurring materials or other building materials. The stamp 750 can include a textured outer surface 758. The textured outer surface 758 can include one or more one or more texture characteristics 756. For example, the stamp 750 can include a first convex region 752a corresponding to the first concave region 721a, a second convex region 752b corresponding to thesecond concave region 721b, and an intermediate concave region 752c corresponding to the intermediate region 721c between the multiple concave profiles 721. The complementary profile of the stamp 750 can enable continuous application of the one or more texture characteristics 756 across substantially all areas of the face 716 including each of the multiple concave profiles 721 and the intermediate region 721c (including more than one intermediate region).ASPECTS

[0081] Aspect 1 can include subject matter such as a polymer structural component comprising: a molded and set polymer structure including: one or more faces, each face of the one or more faces including a molded surface; wherein at least one face of the one or more faces includes one of a convex profile or a concave profile; and the molded and set polymer structure includes an untextured configuration and a textured configuration; wherein, in the untextured configuration, at least one face of the one or more faces includes an undisturbed molded surface; and wherein, in the textured configuration, at least one texture of each face of the one or more faces includes at least one texture characteristic extending along the undisturbed molded surface of the at least one face of the one or more faces.

[0082] Aspect 2 can include, or can optionally be combined with the subject matter of Aspect 1, to optionally include in the textured configuration, the at least one texture characteristic continuously extends from a first end portion of the polymer structure to a second end portion of the polymer structure; and wherein in the textured configuration the at least one texture characteristic extends from a first edge portion of the polymer structure to a second edge portion of the polymer structure.

[0083] Aspect 3 can include, or can optionally be combined with the subject matter of Aspect 1 or 2, to optionally include at least one texture characteristic continuously extends along the molded surface; and wherein the at least one texture characteristic extends along areas of the moldedsurface including an apex of at least one of the convex or the concave profile.

[0084] Aspect 4 can include, or can optionally be combined with the subject matter of Aspect 1 to 3, to optionally include a post cap coupled to a proximal portion of the polymer structure; wherein the post cap includes the at least one texture characteristic.

[0085] Aspect 5 can include, or can optionally be combined with the subject matter of Aspect 1 to 4, to optionally include the polymer structure includes an upright elongate polymer support.

[0086] Aspect 6 can include, or can optionally be combined with the subject matter of Aspect 5, to optionally include the elongate polymer includes one of a bollard, baluster, post, or railing.

[0087] Aspect 7 can include, or can optionally be combined with the subject matter of Aspect 1 to 6, to optionally include the at least one texture characteristic includes a simulated naturally occurring texture.

[0088] Aspect 8 can include, or can optionally be combined with the subject matter of Aspect 1 to 7, to optionally include the at least one texture characteristic extends continuously from a first edge portion of the polymer structure to a second edge portion of the polymer structure.

[0089] Aspect 9 can include, or can optionally be combined with the subject matter of Aspect 1 to 8, to optionally include the texture of the polymer structure includes a patterned texture characteristic.

[0090] Aspect 10 can include subject matter such as a system for forming at least one texture characteristic along an elongate polymer structural component, the system comprising: an imprint apparatus, including: a receiving pathway extending within the imprint apparatus; and a stamp positioned and supported by the imprint apparatus, relative to the receiving pathway, the stamp including: at least one of a stamp concave profile or a stamp convex profile; and a stamp textured surface including the at least one texture characteristic; and a molded, elongate polymer support including one or more faces, each face including a face profile including at least one of a polymer support concave profile or a polymer support convex profile; wherein at least one of the stamp concave profile orthe stamp convex profile is a complementary profile to the face profile; and wherein at least one of the convex stamp profile or the concave stamp profile is configured to imprint the texture characteristic on at least one of the one or more faces.

[0091] Aspect 11 can include, or can optionally be combined with the subject matter of Aspect 10, to optionally include at least one of the convex stamp or the concave stamp continuously imprints the texture characteristic along at least one face of the one or more faces.

[0092] Aspect 12 can include, or can optionally be combined with the subject matter of Aspect 10 or 11, to optionally include at least one of the convex stamp or concave stamp imprints the at least one texture characteristic along an apex of the polymer support concave profile or an apex of the polymer support convex profile of the at least one of the one or more faces.

[0093] Aspect 13 can include, or can optionally be combined with the subject matter of Aspect 10 to 12, to optionally include the at least one texture characteristic is a simulation of a natural material.

[0094] Aspect 14 can include, or can optionally be combined with the subject matter of Aspect 10 to 13, to optionally include wherein the stamp includes a roller, the stamp configured to imprint the one or more texture characteristics.

[0095] Aspect 15 can include, or can optionally be combined with the subject matter of Aspect 10 to 14, to optionally include the molded elongate polymer support includes one of a bollard, baluster, post, or railing.

[0096] Aspect 16 can include subject matter such as a method for forming a polymer structural component including at least one texture comprising: introducing a molten polymer into a mold and forming the polymer structural component including at least one face; setting the polymer structural component; wherein the at least one face of the set polymer structural component includes at least one of a concave profile or convex profile; exposing the at least one face of the set polymer structural component to a stamp; wherein the stamp includes a complementary profile to at least one of the concave profile or the convex profile; andwherein the stamp includes a textured surface with at least one texture characteristic; and applying the at least one texture characteristic with the stamp to the at least one face of the set polymer structural component.

[0097] Aspect 17 can include, or can optionally be combined with the subject matter of Aspect 16, to optionally include applying the at least one texture characteristic along a length of the polymer structural component.

[0098] Aspect 18 can include, or can optionally be combined with the subject matter of Aspect 17, to optionally include applying the at least one texture characteristic includes contacting areas including an apex of at least one of the convex profile or the concave profile of the polymer structural component.

[0099] Aspect 19 can include, or can optionally be combined with the subject matter of Aspect 16 to 18, to optionally include the stamp includes one of a concave profile or a convex profile.

[0100] Aspect 20 can include, or can optionally be combined with the subject matter of Aspect 16 to 19, to optionally include the at least one texture characteristic simulates a naturally occurring material texture.

[0101] Aspect 21 can include, or can optionally be combined with the subject matter of Aspect 16 to 20, to optionally include the at least one texture characteristic includes a knurl or patterned texture.

[0102] Aspect 22 can include, or can optionally be combined with the subject matter ofAspect l6to 21, to optionally include the polymer structural component includes at least one of a bollard, baluster, post, or railing.

[0103] Aspect 23 can include, or can optionally be combined with the subject matter of Aspect 16 to 22, to optionally include the stamp includes one of a rotating stamp, dynamic stamp, or static stamp.

[0104] 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 inaddition 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 contemplates aspects 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.

[0105] In the event of inconsistent usages between this document and any documents so incorporated by reference, the usage in this document controls.

[0106] 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.

[0107] 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.

[0108] 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 upon reviewing 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:a molded and set polymer structure including:one or more faces, each face of the one or more faces including a molded surface;wherein at least one face of the one or more faces includes one of a convex profile or a concave profile; andthe molded and set polymer structure includes an untextured configuration and a textured configuration;wherein, in the untextured configuration, at least one face of the one or more faces includes an undisturbed molded surface; andwherein, in the textured configuration, at least one texture of each face of the one or more faces includes at least one texture characteristic extending along the undisturbed molded surface of the at least one face of the one or more faces.

2. The polymer structural component of claim 1, wherein in the textured configuration, the at least one texture characteristic continuously extends from a first end portion of the polymer structure to a second end portion of the polymer structure; andwherein in the textured configuration the at least one texture characteristic extends from a first edge portion of the polymer structure to a second edge portion of the polymer structure.

3. The polymer structural component of claim 1, wherein at least one texture characteristic continuously extends along the molded surface; andwherein the at least one texture characteristic extends along areas of the molded surface including an apex of at least one of the convex or the concave profile.

4. The polymer structural component of claim 1, including a post cap coupled to a proximal portion of the polymer structure;wherein the post cap includes the at least one texture characteristic.

5. The polymer structural component of claim 1, wherein the polymer structure includes an upright elongate polymer support.

6. The polymer structural component of claim 5, wherein the elongate polymer includes one of a bollard, baluster, post, or railing.

7. The polymer structural component of claim 1, wherein the at least one texture characteristic includes a simulated naturally occurring texture.

8. The polymer structural component of claim 1, wherein the at least one texture characteristic extends continuously from a first edge portion of the polymer structure to a second edge portion of the polymer structure.

9. The polymer structural component of claim 1, wherein the texture of the polymer structure includes a patterned texture characteristic.

10. A system for forming at least one texture characteristic along an elongate polymer structural component, the system comprising:an imprint apparatus, including:a receiving pathway extending within the imprint apparatus; anda stamp positioned and supported by the imprint apparatus, relative to the receiving pathway, the stamp including:at least one of a stamp concave profile or a stamp convex profile; anda stamp textured surface including the at least one texture characteristic; anda molded, elongate polymer support including one or more faces, each face including a face profile including at least one of a polymer support concave profile or a polymer support convex profile;wherein at least one of the stamp concave profile or the stamp convex profile is a complementary profile to the face profile; and wherein at least one of the convex stamp profile or the concave stamp profile is configured to imprint the texture characteristic on at least one of the one or more faces.

11. The system of claim 10, wherein at least one of the convex stamp or the concave stamp continuously imprints the texture characteristic along at least one face of the one or more faces.

12. The system of claim 10, wherein at least one of the convex stamp or concave stamp imprints the at least one texture characteristic along an apex of the polymer support concave profile or an apex of the polymer support convex profile of the at least one of the one or more faces.

13. The system of claim 10, wherein the at least one texture characteristic is a simulation of a natural material.

14. The system of claim 10, wherein the stamp includes a roller, the stamp configured to apply imprint the one or more texture characteristics to the .

15. The system of claim 10, wherein the molded elongate polymer support includes one of a bollard, baluster, post, or railing.

16. A method for forming a polymer structural component including at least one texture comprising:introducing a molten polymer into a mold and forming the polymer structural component including at least one face;setting the polymer structural component;wherein the at least one face of the set polymer structural component includes at least one of a concave profile or convex profile;exposing the at least one face of the set polymer structural component to a stamp;wherein the stamp includes a complementary profile to at least one of the concave profile or the convex profile; and wherein the stamp includes a textured surface with at least one texture characteristic; andapplying the at least one texture characteristic with the stamp to the at least one face of the set polymer structural component.

17. The method for forming the polymer structural component including at least one texture of claim 16, includes applying the at least one texture characteristic along a length of the polymer structural component.

18. The method for forming the polymer structural component including at least one texture of claim 17, wherein applying the at least one texture characteristic includes contacting areas including an apex of at least one of the convex profile or the concave profile of the polymer structural component.

19. The method for forming the polymer structural component including at least one texture of claim 16, wherein the stamp includes one of a concave profile or a convex profile.

20. The method for forming the polymer structural component including at least one texture of claim 16, wherein the at least one texture characteristic simulates a naturally occurring material texture.

21. The method for forming the polymer structural component including at least one texture of claim 16, wherein the at least one texture characteristic includes a knurl or patterned texture.

22. The method for forming the polymer structural component including at least one texture of claim 16, wherein the polymer structural component includes at least one of a bollard, baluster, post, or railing.

23. The method for forming the polymer structural component including at least one texture of claim 16, wherein the stamp includes one of a rotating stamp, dynamic stamp, or static stamp.

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