Extrusion coating of elongated substrates

Abstract

The present disclosure relates to extrusion coating systems, extrusion coated substrates, and processes for making the same. In some aspects, extrusion coating systems as described herein may include an at least partially insulated outlet wall, which may facilitate production of coated substrates exhibiting a very desirable surface texture and appearance. Coated substrates of the present invention may be utilized in a variety of end applications, including, but not limited to, interior and exterior construction materials for homes, buildings, and furniture.

1 . A coated article comprising:
 an elongated substrate; and   a thermoplastic resin coating extrusion coated onto said substrate, wherein said coated article is a water-quenched article that has not been subjected to a post-quench treatment step and has an average Rmax surface roughness of not more than 40;   wherein said coated substrate has a length of at least 5 feet;   wherein said elongated substrate comprises natural wood, wood composites, medium-density fiber board, particle board, oriented strand board, plastic, cellularized PVC, foam, metal, fiberglass, ceramics, cement and combinations thereof; and   wherein said resin coating comprises one or more of polyesters, copolyesters, polycarbonates, acrylics, cellulose esters, polyolefins, nylons, polyvinylchloride, and combinations thereof.   
     
     
         2 . The article of  claim 1 , wherein said coating is applied to the substrate in a molten or melted form. 
     
     
         3 . The article of  claim 1 , wherein the glass transition temperature of the polymers in said coating material is at least 70° C. 
     
     
         4 . The article of  claim 1 , wherein the glass transition temperature of the polymers in said coating material is at least 60° C. 
     
     
         5 . The article of  claim 1 , wherein said substrate comprises a natural or composite wood substrate or PVC. 
     
     
         6 . The article of  claim 1 , wherein the surface of said coated substrate has less than 10 bubbles per 100 feet. 
     
     
         7 . The article of  claim 1 , wherein the surface of said coated substrate has less than 5 bubbles per 100 feet. 
     
     
         8 . The article of  claim 1 , wherein said coated article has an average Rmax surface roughness of not more than 30. 
     
     
         9 . The article of  claim 1 , wherein said resin coating is extrusion coated onto said substrate such that all of the sides of said elongated substrate are completely encapsulated by said resin coating. 
     
     
         10 . The article of  claim 1 , wherein said resin coating has an average thickness of at least 2 mils and not more than 40 mils. 
     
     
         11 . The article of  claim 1 , wherein said resin coating has an average thickness of at least 2 mils. 
     
     
         12 . The article of  claim 1 , wherein said substrate has two or more coating layers. 
     
     
         13 . The article of  claim 12 , wherein each resin coating layer has an average thickness of at least 2 mils. 
     
     
         14 . The article of  claim 1 , wherein said resin coating is adhered directly to at least a portion of the substrate and has an adhesion peel force of at least 0.10 pounds. 
     
     
         15 . The article of  claim 1 , wherein said resin coating is adhered directly to at least a portion of the substrate and has an adhesion peel force of at least 0.40 pounds. 
     
     
         16 . The article of  claim 1 , wherein said substrate has a non-symmetrical lateral cross-sectional shape. 
     
     
         17 . The article of  claim 1 , wherein said substrate has a symmetrical lateral cross-sectional shape.