Extrusion-coated structural members having extruded profile members

Abstract

The present disclosure relates to extrusion-coated structural systems including at least one extruded profile member coupled to and extending outwardly from an extrusion-coated structural member, as well as methods of making and using the same. Structural systems of the present invention that include at least one extruded profile member may exhibit enhanced flexibility, functionality, and/or durability. Structural systems according to embodiments of the present invention can be suitable for use in a variety of applications, including in ready-to-assemble furniture or cabinetry applications or as building and construction materials such as wall board, flooring, trim, and the like.

We claim: 
     
         1 . A method of making an extrusion-coated structural system, said method comprising:
 extrusion coating a coating material onto at least a portion of a substrate to form an extrusion-coated structural member,   wherein said extrusion coating forms at least one extruded profile member extending outwardly from said substrate for a maximum distance that is at least two times greater than the average thickness of said coating material coated onto said substrate proximate said extruded profile member,   wherein at least 75 percent of the total volume of said extruded profile member is formed of said coating material, and   wherein said extrusion-coated structural member further comprises a profile recess at least partially defined by said extruded profile member.   
     
     
         2 . The method of  claim 1 , wherein said coating material is applied to said substrate at the same time that said extruded profile member is formed. 
     
     
         3 . The method of  claim 1 , wherein said extruded profile member extends outwardly from said substrate for a maximum distance that is at least five times greater than the average thickness of said coating material coated onto said substrate adjacent said extruded profile member. 
     
     
         4 . The method of  claim 1 , wherein at least about 5 percent of the total weight of said coating material applied during said extrusion coating is used to form said extruded profile member. 
     
     
         5 . The method of  claim 1 , wherein not more than about 10 percent of the total volume of said extruded profile member is occupied by said substrate. 
     
     
         6 . The method of  claim 1 , further comprising, subsequent to said extrusion coating, inserting at least one functional member into said profile recess. 
     
     
         7 . The method of  claim 1 , further comprising, subsequent to said extrusion coating, cooling said extrusion-coated structural member in a quench zone. 
     
     
         8 . The method of  claim 1 , wherein said coating material has a glass transition temperature in the range of from about 60° C. to about 150° C. 
     
     
         9 . The method of  claim 1 , wherein said coating material comprises at least one resin selected from the group consisting of polyesters, copolyesters, polycarbonates, polymethyl methacrylate (PMMA), impact-modified PMMA, poly(acrylonitrile-styrene-acrylate) (ASA), poly(acrylonitrile-butadiene-styrene) (ABS), poly(styrene-acrylonitrile) (SAN), cellulose esters and mixtures thereof. 
     
     
         10 . The method of  claim 1 , wherein said extrusion coating includes applying said coating material continuously to at least three sides of at least one cross-section of said substrate. 
     
     
         11 . The method of  claim 1 , wherein said substrate comprises natural wood, medium-density fiberboard, particle board, oriented strand board, plastic, cellularized PVC, foam, metal, fiberglass-reinforced thermoset or thermoplastic polymers, or combinations thereof. 
     
     
         12 . A method for assembling an extrusion-coated structural system, said method comprising:
 (a) providing a first extrusion-coated structural member comprising a substrate and a coating material extrusion coated onto at least a portion of said substrate,   wherein said first extrusion-coated structural member comprises an extruded profile member formed of said coating material,   wherein said extruded profile member extends outwardly from said substrate for a maximum distance that is at least two times greater than the average thickness of said coating material proximate said extruded profile member,   wherein at least 75 percent of the total volume of said extruded profile member is formed of said coating material, and   (b) providing a second structural element presenting a contact surface; and   (c) contacting at least a portion of said extruded profile member with said contact surface of said second structural element to form at least a portion of said structural system.   
     
     
         13 . The method of  claim 12 , wherein said extruded profile member defines a profile recess, wherein said second structural element is a second extrusion-coated structural member or a second hardware member, wherein said contacting includes inserting a structural protrusion of said second extrusion-coated structural member, when present, into said profile recess or inserting a hardware protrusion of said hardware member, when present, into said profile recess. 
     
     
         14 . The method of  claim 13 , wherein said structural system is a door jamb, a window jamb, wall paneling, floor paneling, or an item of furniture. 
     
     
         15 . The method of  claim 12 , wherein said second structural element is a function member, wherein said contacting includes inserting said functional member into said profile recess and contacting at least a portion of said profile recess with said contact surface, wherein said functional member is selected from the group consisting of piping, electrical or plumbing conduit, wire, cables, lighting fixtures, LED elements, and combinations thereof. 
     
     
         16 . The method of  claim 12 , further comprising, subsequent to said contacting, breaking contact between said extruded profile member and said contact surface of said second structural element to thereby disassemble at least a portion of said structural system and subsequently re-contacting at least a portion of said extruded profile member with said contact surface of said second structural element to thereby reassemble said structural system. 
     
     
         17 . The method of  claim 12 , wherein said first extrusion-coated structural member is a door or drawer and said second structural element is a cabinet box or door frame or door jamb. 
     
     
         18 . The method of  claim 12 , wherein said coating material comprises at least one resin selected from the group consisting of polyesters, copolyesters, polycarbonates, polymethyl methacrylate (PMMA), impact-modified PMMA, poly(acrylonitrile-styrene-acrylate) (ASA), poly(acrylonitrile-butadiene-styrene) (ABS), poly(styrene-acrylonitrile) (SAN), cellulose esters and mixtures thereof. 
     
     
         19 . The method of  claim 12 , wherein said substrate comprises natural wood, medium-density fiberboard, particle board, oriented strand board, plastic, cellularized PVC, foam, metal, fiberglass-reinforced thermoset or thermoplastic polymers, or combinations thereof.