Stock material or miscellaneous articles – Hollow or container type article – Polymer or resin containing
Reexamination Certificate
2001-01-16
2004-12-07
Morris, Terrel (Department: 1771)
Stock material or miscellaneous articles
Hollow or container type article
Polymer or resin containing
C428S036910, C428S319700, C428S317900, C052S309100, C052S309400
Reexamination Certificate
active
06827995
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention generally relates to composites and more specifically relates to composites useful as fence components, decking components and the like, and methods for producing same.
Traditionally, fences and decks have been made of components fashioned from solid wood. Wood fences and decks are often considered more aesthetically appealing than those made of metal or cement, for example, wire fences or cement block walls or decks. However, construction of a wood fence or a wood deck is labor intensive. Solid wood components are heavy and cumbersome. In addition, maintenance of a wood fence or deck is expensive. After a period of time, solid wood fence and deck components will naturally begin to break down from weather exposure and pest infestations. It is known that this deterioration can be tempered by treating the fence or deck with widely available weather resistant coatings, paints, varnishes, finishes and the like. Unfortunately however, it is often only a matter of time before such treated fences or decks deteriorate requiring partial or complete replacement. Many solid wood materials that are suitable for fencing or decking are costly. In addition, because of natural variations in wood, replacement of individual components may result in an inconsistent, uneven appearance to the fence or deck.
Plastic fence components have been developed as alternatives or supplements to traditional, natural wood fences. For example, Robbins, III, U.S. Pat. No. 5,100,109 describes a method of constructing a fence by providing a flexible, plastic, rollable fence board that can be unrolled and fastened to spaced apart fence posts. The flexible fence board is made with height and width dimensions simulating a standard wooden board and with a length of 350 feet or more. According to this patent, the fence board is formed in a continuous extrusion process of a flexible thermoplastic material.
Collins U.S. Pat. No. 5,404,685, describes a wall or fence made in part of foamed polystyrene plastic components, more specifically, STYROFOAM™ polystyrene plastic columns and panels. Construction of a fence in accordance with the Collins Patent requires multiple steps. For example, wall or fence stability is achieved by pouring a reinforcing filler, such as concrete, into a hollow of the polystyrene plastic columns after the columns have been secured to the ground. A hardened outer surface of the fence is achieved by applying an exterior finish, such as stucco or special exterior paint, to the fence or wall after the fence has been constructed.
There still remains a need in the market today for inexpensive, lightweight fencing and decking components and fence and deck systems that are sturdy, weather resistant, lightweight, and aesthetically appealing, and easy to manufacture using simple manufacturing techniques.
SUMMARY OF THE INVENTION
New composites, for example, useful in fence and deck systems and fence and decking components, such as rails, fence posts, fence slats, decking planks and the like, as well as methods for producing same have been discovered. The composites are easy to manufacture in a variety of configurations using relatively inexpensive materials. In addition, the composites are sturdy, lightweight and have excellent weatherability properties. In addition, the composites have many of the desirable properties of natural wood fences and decks. For example, the composites, in the form of fence and deck systems or fence and decking components, of the invention can be made to have a wood-like look and texture. However, unlike solid wood fences and decks, the composites of the present invention preferably are highly resistant to effects of weathering.
In a broad aspect of the invention, a layered composite is provided, which can be formed, for example, as a fence component or as a decking component.
The present composites, in general, comprise an outer layer comprising present composites a first polymeric material; a core layer, circumscribed by the outer layer and comprising a second polymeric material; and an inner layer, circumscribed by the core layer and comprising a third polymeric material, wherein the inner layer defines a hollow space. Preferably, the composites of the present invention are in the form of a member having a length defined along a longitudinal axis of the member. The hollow space preferably extends along substantially the entire length of the member. The core layer preferably is substantially completely circumscribed by the outer layer along substantially the entire length of the member and/or the inner layer preferably is substantially completely circumscribed by the core layer along substantially the entire length of the member. The member may have any suitable axial cross-section, such as circular, rectangular, oval, an irregularly shaped cross-section and the like. In one useful embodiment, the member has a substantially rectangular, for example, an elongated rectangular or square, axial cross-section, that is perpendicular to the length or longitudinal axis of the member.
In one especially advantageous embodiment of the invention, the composite is structured in the form of a fence building component or a fence component, for example, the composite may be in the form of a fence post or a fence rail or the like. Moreover, in accordance with the present invention, a fencing system is provided including a plurality of fence components, for example, a plurality of fence posts and a plurality of fence rails, wherein each of the fence components, e.g., each of the fence posts and fence rails, comprise a composite described herein.
In another useful embodiment, the composite is structured in the form of a deck building component or a decking component, for example, the composite may be in the form of a decking plank or the like. A deck system or decking system is provided in accordance with the present invention including a plurality of decking components, for example, a plurality of decking planks, wherein each of the decking components, e.g., each of the decking planks, comprise a composite described herein.
Each one of the first, second and third polymeric materials of the composite layers preferably comprises a thermoplastic polymeric material. In one embodiment of the invention, at least two of the first, second and third polymeric materials have different chemical compositions.
Preferably, the outer layer is made of a weatherable, thermoplastic polymeric material. The outer layer advantageously is substantially solid. As used herein, the term “weatherable” refers to the ability or property of a material to effectively withstand the conditions of an out-of-doors environment for a long period of time, for example, at least about five years and preferably at least about seven years or longer. Specific examples of polymers which can be used as the outer layer include, without limitation, polyvinylchloride, acrylonitrile/styrene/acrylic polymeric materials, and the like and mixtures or combinations thereof.
Preferably, the second material comprises a solid thermoplastic polymeric material or a thermoplastic polymeric material foam or combinations thereof, and an effective amount of a filler. Suitable polymeric materials for the core layer include, without limitation, polyvinylchloride, acrylonitrile/styrene/acrylic polymeric materials, acrylonitrile/butadiene/styrene polymeric materials, and the like and mixtures or combinations thereof. Any suitable filler component may be present in any of the layers of the present composites. Such filler component or components preferably are effective to add bulk and/or strength and/or reinforcement and/or stability to the layer and/or composite. Examples of useful filler components include, without limitation, wood, mica, talc, calcium carbonate, graphite or carbon, for example, in the form of particles, such as fibers, and the like and mixtures thereof. A filler component is particularly advantageous in the core layer, while the inner layer and/or outer layer preferably and substantially fr
Cuttle Jack
Fidati Kevin
Hughes Roderick E.
Schiff Joe
Vuduris George
Extrutech International, Inc.
Morris Terrel
Stout, Uxa Buyan & Mullins, LLP
Uxa Frank J.
Vo Hai
LandOfFree
Composites useful as fence and decking components and... does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Composites useful as fence and decking components and..., we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Composites useful as fence and decking components and... will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-3291851