Abstract:
Building materials formed from synthetic polymer materials have an appearance which simulates natural woods. The building materials may be used in the construction of fences, sheds, decking materials, indoor/outdoor furniture, railings and numerous other products. The faux wood material is constructed to include reinforcing fibers and voids for weight reduction. The aesthetic appearance of the finished product can be enhanced by applying a color wash which includes a polymer component and a color component adhering to the surface of the material.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of the filing date of the U.S. Provisional Patent Application No. 61/275,191, filed Aug. 26, 2009, entitled “Faux Wood Building Materials,” the disclosure of which is hereby incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates in general to faux wood building materials, and more particularly, to building materials formed from synthetic polymer materials having an appearance which simulate natural woods. 
         [0003]    Natural wood, due to its strength and aesthetic characteristics has been used in the construction of various products for both indoor and outdoor application. For example, wood such as oak, maple and pine have been used for indoor cabinetry, flooring material, furniture products and other items. Cedar and teak have found applications for patio furniture for both indoor and outdoor use. Natural wood is a versatile product that has extensive applications for construction of fences, sheds, decking material, indoor/outdoor furniture, railings and numerous other products. 
         [0004]    Natural wood is a highly desirable building material for various products due to its richness. However, some woods are less suitable for certain products and use in outdoor environments which are subject to wet conditions. For example, teak and cedar are commonly used for outdoor furniture due to their weather resistance characteristics. However, even these wood products are susceptible to discoloration, splitting and other effects caused by the outdoor environment. In addition, woods like teak are expensive and are environmentally protected in certain regions. 
         [0005]    Various synthetic polymers have been extruded or molded into flat boards for use in the construction of outdoor furniture, such as Adirondack chairs, picnic tables, picnic benches and other outdoor products. However, the constructions of these products from synthetic polymer material evidences a synthetic plastic look which is less attractive compared to natural wood materials. 
         [0006]    There is therefore a need for the construction of synthetic plastic material which simulates natural wood to provide the richness and desirable aesthetic characteristics of wood products. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    The present invention describes a synthetic polymer building material which simulates a wood product, yet due to its synthetic nature, is suitable for outdoor use in harsh environments such as sun, rain and snow. 
         [0008]    The material of the present invention can be formed from a number of synthetic polymer materials which can easily be fabricated into various shapes such as elongated boards, as well as other geometric shapes such as oval, polygonal, circular and the like. The materials incorporate reinforcement elements such as fibers to enhance the mechanical strength of the resulting product. To decrease the weight of the materials, a blowing agent is blended with the synthetic material during the manufacturing process. The blowing agent in addition to creating voids within the material, may also have the effect of forming a slightly uneven exterior surface which enhances the natural appearance or wood simulating effect of the material. 
         [0009]    The polymers may include various color components which result in the material having a solid color or other effects such as marble look, striations or the like. In the preferred embodiment, the resulting product is coated with a color wash of suitable synthetic polymer material which bonds to the base material. The wash may be applied uniformly, randomly or selectively to create various aesthetic effects. 
         [0010]    In one embodiment of the present invention there is described an article of furniture comprising a frame comprising a body of synthetic polymer material having reinforcement elements dispersed therein, and a plurality of voids within the body whereby the weight of the frame is reduced; and a seat portion coupled to the frame for supporting an occupant. 
         [0011]    The article of furniture further includes a backrest portion coupled to the frame, wherein at least one of the seat portion or the backrest portion comprises a woven panel from a plurality of synthetic polymer yarns. The article further includes a wash having a polymer component and a color component adhered to at least a portion of a surface of the frame. The plurality of voids reduces the weight of the frame by about 10% or greater. 
         [0012]    In another embodiment of the present invention there is described an article of furniture including recycled scrap synthetic polymer material, comprising a frame in the shape of an article of furniture comprising a body of synthetic polymer material having reinforcement elements dispersed therethrough, a plurality of voids within the body whereby the weight of the frame is reduced; and a portion of the synthetic polymer material made from recycled scrap synthetic polymer material having the reinforced elements dispersed therethrough and the plurality of voids therein. 
         [0013]    In another embodiment of the present invention there is described an article of furniture comprising a frame comprising a body of synthetic polymer material having reinforced fibers dispersed therethrough, a plurality of voids within the body whereby the weight of the frame is reduced by about 10% or greater, and a wash having a polymer component and a color component adhered to at least a surface of the frame; a seat portion coupled to the frame for supporting an occupant; and a backseat portion coupled to the frame, at least one of the seat portion or the backrest portion comprising a woven panel from a plurality of synthetic polymer yarns. 
         [0014]    The article of furniture where the color of the frame is different from the color of the color component; and wherein the seat portion and the backrest portion are formed as a bucket seat attached to the frame. 
         [0015]    In another embodiment of the present invention there is described a building material comprising a body of synthetic polymer material having reinforcement fibers disbursed therein; a plurality of voids within the body whereby the weight of the body is reduced by at least 10%; and a wash having a polymer component and a color component adhered to at least a portion of the body. 
     
    
     
       BRIEF DESCRIPTION OF TEE DRAWINGS 
         [0016]    The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of operation, together with features, objects, and advantages thereof may best be understood by reference to the following detailed description when read with the accompanying drawings in which: 
           [0017]      FIG. 1  is a perspective view of a segment of a building material in the nature of simulated wood plank or board constructed in accordance with one embodiment of the present invention. 
           [0018]      FIGS. 2A and 2B  are perspective views of a segment of a building material in the nature of a simulated wood plank or board constructed in accordance with other embodiments of the present invention. 
           [0019]      FIG. 3  is a perspective view of an outdoor storage chest constructed from the materials of the present invention in accordance with one embodiment thereof. 
           [0020]      FIG. 4  is a perspective view of an article of furniture constructed from the materials of the present invention in accordance with one embodiment thereof. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    In describing the preferred embodiments of the invention illustrated in the drawings, specific terminology will be used for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose. 
         [0022]    Referring to the drawings, wherein like reference numerals represents like elements, there is shown in  FIG. 1  a section of an elongated board or plank constructed in accordance with one embodiment of the present invention, and designated generally as reference numeral  100 . The board  100  is formed from synthetic polymer material and mixture thereof which possesses suitable characteristics for its intended use. For example, for various applications such as indoor and outdoor furniture, thermoplastic materials such as polystyrene, polyvinyl chloride, polyethylene and polypropylene are contemplated. The preferred material is polystyrene. The board  100  can be made using conventional die extrusion techniques. It is also contemplated that thermoset polymer materials may be used for creating objects that can be molded into predetermined shapes. Thus, it should be understood that a wide variety of synthetic polymer materials may be used in constructing the materials of the present invention. 
         [0023]    To provide additional mechanical strength, the polymer material may be mixed with reinforcement elements such as fibers  102  as is known in the art of reinforcement of synthetic polymers. The fibers can be constructed as short elongated segments in the nature of fine filaments, or other desirable forms as is known in the reinforcement of synthetic polymers. The fibers can be constructed from a variety of materials, for example, synthetic polymers, fiberglass, carbon, metal and the like. The percentage of loading of the material with the fibers will be dictated by the polymer material composition, as well as the intended application for the finished material, and the load bearing and mechanical strength requirements. 
         [0024]    In manufacturing the board  100 , a blowing agent is also included in order to form voids within the material thereby reducing weight. Blowing agents are commonly used for this purpose as is known in the synthetic polymer processing industry. Suitable blowing agents and their use are known in the polymer arts. The amount of the blowing agent is generally sufficient to reduce the weight of the material by, for example, about 10% or greater. As the amount of voids within the material decreases the mechanical strength, the amount of blowing agent used will be dependent upon the mechanical strength required of the resulting material based on its intended application. 
         [0025]    As shown in  FIG. 1 , the blowing agent forms voids  104  within the cross-section of the material, and potentially small pits  106  randomly dispersed on the exterior surface of the finished board  100 . In addition, it is contemplated that the blowing agent may result in the surface  108  of the board  100  to have a slightly irregular planar surface. It is also contemplated that some of the fibers  102  may be visible randomly across the surface of the board  100 . Thus, depending upon on the loading extent of the fibers  102  and the extent of the blowing agent, fibers  102  and pits  106  may or may not appear on the surface of the board  100 . Likewise, the extent of the unevenness or irregularity of the surface of the board  100  will be dependent upon the extent of the blowing agent used. 
         [0026]    Referring to  FIG. 2A , there is illustrated a board  108  constructed in accordance with another embodiment of the present invention. The board  108  differs from the board  100  by the inclusion of a wash  110  over the exterior surfaces of the board to provide a more faux wood appearance. The wash  110  is in the nature of a coating or paint composition which adheres or bonds to the surface of the material forming the board  108 . The wash composition typically will include a polymer film forming component, a solvent, and a color component. A variety of colors may be used. The solvent typically will be suitable for dissolving the polymer component, as well as being a solvent for the material forming the board  100 . In a preferred embodiment, the polymer component will also be the same polymer used for constructing the board  100 . In this manner, the wash will adhere strongly to the surface of the board  100 . Examples of suitable wash compositions and methods of applying same to a synthetic polymer material are disclosed in U.S. Pat. No. 7,472,961, the disclosure of which is incorporated herein by reference, and a copy of which is attached hereto. 
         [0027]    As shown in  FIG. 2A , the wash is bonded over only a portion of the surface of the board  108 , allowing underlying portions of the board to be exposed. The wash  110  may be applied over the entire surface of the board  108 , and selected and/or random portions removed using a suitable solvent and optionally a rag for removing the wash. In such case, the pits  106  will be filled with the wash composition, becoming filled pits  109  taking on the color of the wash. It is also contemplated that the wash  110  may applied randomly on the surface of the board  108  using any suitable technique desired. In the embodiment shown in  FIG. 2A , the wash is not uniformly applied to the board  108 , creating a random painted effect with the imperfections such as pits  109  and fibers  102  being partially visible on the non-coated areas. 
         [0028]    Referring to  FIG. 2B , there is shown a board  108 ′ where the wash  100  is applied over the entire surface of the board to form a more uniform coating. 
         [0029]    The boards  100 ,  108 ,  108 ′ can be constructed in a variety of sizes and shapes. For example, the boards may be rectangular, octagonal, triangular, square, or circular or in other shapes, and continuously extruded in a variety of lengths. The boards may be thick, or thin, depending upon their application. In addition, sheets of the aforementioned material may be formed, and various shapes cut from the sheets as desired. The scrap material by virtue of using thermoplastic material can be recycled. The boards, as previously noted, can be used in a variety of applications, for example, for construction of fences, barns, sheds, indoor and outdoor furniture, patio furniture, frame for chairs, and the like. The surface of the boards in addition to including a wash  110 , may also be machine finished such as having a hammer finish, or using other tooling and engraving machines to create various irregularities or patterns in the surface. 
         [0030]    Turning to  FIG. 3 , there is illustrated a storage chest  112  constructed from any one of or combination of the boards  100 ,  108 ,  108 ′ as previously described. The boards are used as conventional wood boards. In this regard, the boards  100 ,  108 ,  108 ′ can be cut using conventional sawing techniques, and drilled with holes as may be required. The boards may be attached together using screws intended for plastic materials. In addition, it is also contemplated that adhesives may be used to join the boards together. 
         [0031]    Turning now to  FIG. 4 , there is illustrated an article of furniture in the nature of a chair  120  having a frame  122  constructed from the faux wood building materials in accordance with the present invention. By way of illustration only, the frame  122  forms a plurality of legs  124  for supporting the article on an underlying surface. The frame  122  further includes cross braces  126  and, optionally, sidearms  128 . In the illustrative embodiment, the sidearms  128  are formed as an extension of the front legs  124 . A plurality of cross members  130  delineates a seat portion  132  and backrest portion  134 . The seat and/or backrest portions may be formed from a woven panel constructed from a plurality of woven synthetic polymer yarns such as disclosed in, for example, U.S. Pat. No. 7,472,961. The woven panels may be attached directly to portions of the frame  122  or through additional structure which may be attached to the frame  122 . For example, the seat and backrest portions  132 ,  134  may be constructed as a bucket seat which is separately manufactured and assembled to a frame  122  previously assembled using the faux wood building materials disclosed pursuant to the present invention. 
         [0032]    Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. For example, it is not required that the boards have a faux wood appearance. Rather, the wash may be applied to provide any other appearance that may be desired. In addition, the boards may be used without a wash. In another aspect of the present invention, scrap or unused material left over when making articles may be recycled with virgin material for making articles therefrom. The ability to recycle the scrap material results in the generation of little waste material. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.