Extruded Polymeric Layers Spirally Wound for Wood Grain Appearance
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Solution Overview
Problem
Existing methods for creating products with a wood grain appearance that can withstand outdoor use effectively are limited, as real wood does not endure well outdoors and alternative materials like coated metals or polymeric materials with injected colors often result in unrealistic or unsightly 'streakers'.
Innovation Solution
A structure and method involving multiple extruded layers of different colors and thicknesses spirally wound or overlapping to create a wood grain appearance, where layers are varied in thickness and position, mimicking the natural appearance of wood grain, and can be formed into cylindrical or cuboid shapes for enhanced realism and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If real wood is used for outdoor furniture, then aesthetic appeal is maintained, but durability and weather resistance deteriorate
Solution Approach 1:
The patent uses a composite structure consisting of a polymeric substrate material combined with overlying polymeric layers that simulate wood grain. This composite approach provides the durability of synthetic materials while achieving the aesthetic appearance of natural wood through carefully designed layer configurations with varying colors, thicknesses, and patterns.
Solution Approach 2:
The patent creates a visual copy of wood grain appearance using multiple polymeric layers with different colors and thicknesses. The layers are configured to mimic the natural variation and pattern of wood grain, providing an aesthetic copy that resembles real wood without using actual wood material.
2Reliability
If a coating with wood grain appearance is applied to metal substrate, then durability improves, but aesthetic realism deteriorates due to visible streakers
Solution Approach 1:
The patent divides the wood grain appearance into multiple discrete polymeric layers, each with specific color, thickness, and positioning characteristics. By segmenting the visual representation into distinct layers rather than using a continuous coating, the patent eliminates streakers and creates a more realistic appearance that closely resembles natural wood grain patterns.
Solution Approach 2:
The patent applies different properties to different regions of the material by varying the color, thickness, and positioning of individual polymeric layers. This local variation in layer characteristics creates realistic wood grain patterns with natural variation, avoiding the uniform appearance and streakers associated with conventional coatings.
3Reliability
If polymeric material with injected color is used, then durability improves, but aesthetic quality deteriorates due to streakers on outer surface
Solution Approach 1:
The patent replaces the conventional approach of injecting color throughout a polymeric material with a segmented structure of multiple discrete polymeric layers. Each layer has its own color and thickness, and they are positioned to create realistic wood grain patterns. This segmentation eliminates the streakers that result from color injection while maintaining the durability of polymeric materials.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution produces dimensionally stable products with a realistic wood grain appearance that extends through the material, overcoming the limitations of previous methods by providing a more natural and durable alternative to traditional wood products.
Implementation Method 1
A plurality of extruded layers having different colors/shades spirally wound about a longitudinal axis
Data Source
AI summary
Structures for use in forming products having a wood grain appearance include, for example, a plurality of extruded layers having different colors/shades spirally wound about a longitudinal axis to an outer surface to define the structure. The plurality of extruded layers include varying thicknesses along a spiral length of the plurality of layers and/or portions of the plurality of extruded layers encircling the longitudinal axis include portions disposed at different distances from the longitudinal axis. In some embodiments, the spirally winding includes forming a cylindrical structure, and pressing the cylindrical structure into a cuboid structure having a square or rectangular cross-section across the longitudinal axis and at least a portion of the plurality of extruded layers defining a square or rectangle pattern across the longitudinal axis. Longitudinal portions may be cut from the structures to form the products having a wood grain appearance.