ARTICLE AND PROCESS FOR CONSTRUCTING A MELT PROFILE EXTRUSION OF A PLASTICIZED MATERIAL INCORPORATING AT LEAST ONE OF A METALLIC PIGMENT, FLAKE OR LAYER

CROSS REFERENCE TO RELATED APPLICATION This application claims priority of United States Provisional Patent Application Serial

No. 60/955,242 filed August 10, 2007, which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates generally to profile extruded plasticized articles. More specifically, the present invention teaches an elongated and profile extruded item, such as is constructed from a PVC, ABS, olefin or other plasticized resinous material. The extruded article incoφorates one of a metallic pigment, flake or layer for creating such as a faux metallic or stone appearance and which is incorporated into either of structural insert or decorative trim applications. An associated process for making a hot melt profile extrusion is also disclosed, and such as for application in C-channels, slot board inserts and building panel trim (inside, outside, corner and end cap and the like).

Decorative trims have been in existence as long as building materials themselves. They fill a necessary function of hiding seams and covering minor imperfections in the building construction process. More recently, trims have been used to form a seal between various building components for health and cleanliness reasons. Many new trim systems have come into commercialization recently with matching and or interlocking panels, and corner and end cap trim components. These can be made from metal, plastic, wood, etc. Metal trim components have become of particular interest of recent due to the bright work catching the eye of prospective shoppers and being generally sanitary and easy to clean. Natural metals are, however, difficult to keep clean looking, are expensive and do not easily form into all desired shapes. Plastic-metal composite materials have been developed over the last several years with limited success. Prior art configurations for plastic-metal composite materials fall into two camps; one including a layer of actual metal within the composite structure, and the other wherein a layer of metallic film is applied over a polymer structure. Both systems have significant drawbacks. Incorporating a layer of metal in an article has several drawbacks; lack of recycle-ability, higher cost over an "all plastic" construct, easily dents or creases, difficult to cut and trim; hardly any of the drawbacks of a "natural" metal system are obviated. Similarly, a plastic film cap construct has the disadvantages of scratching the color off easily, high cost and design limitations wherein the film can be incorporated are very limited.

What is needed is a metallized trim component and process wherein the metal can be directly incorporated into a plastic melt of desired cost and processed to multiple desired shapes and strengths. A problem in the prior art of achieving this is the lack of reflectivity of the current generation metallic pigments, the general cost of such pigments, along with process compatibility of such. Current state of the art metallic-pigmented plastics further have only a passing resemblance to actual metal. A further limitation of the prior art is the challenge of keeping the polymer component transparent enough to not spoil any visual effect, while still incorporating a mineral or other opaque filler to strengthen the polymer to such a degree that it is mechanically suitable for the application it will be used in. The innovative solution to such a problem and one that breaks from the prior art constructs is a multiple-layered metallic veneer-colored large-size pigment material. Such a material often contains actual metal, in a powder-type size veneer bonded to a large-size "granule". Such granule is the delivery mechanism to both impart the metallic effect to the final article and preserve some phase-alignment of the visible light reflecting back from the metallics contained in the plastic article. Such phase alignment is accomplished by the flatness [of at least one side of] and overall "diameter'Vsize of the granule such that a significant quantity of metallic pigment hits the viewing surface of the final article substantially simultaneously. This provides a heretofore unseen level of optical color-imparting power. Such a system has so great a degree optical density that polymers previously considered too opaque to use now color easily. Such effect is further enhanced when, during melt introduction into the profile or mold or tool that the flow path of the melt be at least four times greater in a dimension substantially parallel to the viewing surface than in a dimension perpendicular to the viewing surface. This will ensure that multiple granules will further align themselves in a parallel fashion, not only to each other, but also to the viewing surface of the article, thereby maximizing the overall metallic effect and final appearance of the article with very little use of actual metal material. This last point ensures that the final article is substantially plastic in composition and retains all the practical functional aspects of a plastic, versus a metal, and its recycle-ability, ease of use, variety of final configuration and process, low cost, and ability to be handled in a pre-compounded melt or concentrate, if desired. Granules are, therefore, optimally sized to have at least one substantially flat surface having a diameter greater than 0.004 inches (") (or 100 micron), and up to a maximum of 0.6". Thinner granules and granules with minimal mass are preferred for the same reason of maximally preserving the overall polymer content. Ideal granule geometry includes a flake-ular

profile having a thickness of less than 0.009" and a planar diameter between 0.004" and 0.2", as described herein above.

SUMMARY OF THE PRESENT INVENTION

A profile extruded article is provided that includes a body composed of a plasticized base material. A metallic base additive in the form of a flake, particle, or pigment is entrained within at least a portion of the base plasticized material. The resultant article is adapted to be applied to a surface of a substratum material with particular application to decorative trim forming a seal between building components. An extruded article is also provided that includes a body composed of the plasticized base material having an elongated profile with a main segmented body component. First and second end legs extend from the main segmented body component. The first and second end legs each interconnect to opposite ends of the main body by way of elongated notches. The elongated notches have a selected cross-sectional shape and extend within 0.015 inches of a selected surface of the body. A metallic based additive in the form of flake, particle or pigmented form thereof is entrained within the base plasticized material. The resultant extruded article is adapted to be applied to at least one surface of a substratum material.

A profile extruded article is also provided that includes a body composed of a plasticized base material having a wall thickness x, a base dimension y, and a length dimension z. A metallic based additive made up of a plurality of granules is entrained within the base plasticized material. The resultant article has a specified shape and size and a cross-sectional configuration adapted for application to a substratum material. The plurality of granules are aligned within the profile extruded article upon the ratio of y/x of the extruded article being equal or greater than 7, the ratio of z/x being equal or greater than 5, or the mean aspect ratio of the plurality of granules including a maximum planar dimension over thickness of at least 7.

A hot melt process for creating an inventive profiled extruded article includes forming a three-dimensional shaped body from plasticized base material and entraining a metallic based additive within the base plasticized material. The resultant article is then secured to a substratum material.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to the attached drawings, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout the several views, and in which:

Fig. 1 is an environmental illustration of a slat wall construction, such as capable of incorporating a profile extruded resinous material with metallic impregnate according to a preferred structural application of the present invention;

Fig. 2 is an enlarged partial end view illustration of a selected "C" channel associated with a slat wall construction and within which is incorporated a mating profile extrusion insert according to the present invention;

Fig. 3A is a cross-sectional, end-plan view illustration of a segmented and "V" notched extrusion according to a further selected embodiment of the present invention;

Fig. 3B is a succeeding illustration of the profile extruded article shown in Fig. 3A in a folded and pre-inserted position;

Fig. 4 is a partial end view illustration similar to that shown in Fig. 2 of a modified inwardly notched channel for incorporating a profile extruded insert, the channel exhibiting first and second interior hidden and non-parallel upper surfaces relative an exposed surface;

Fig. 4A is a partial end view illustration of a further channel exhibiting an underside recessed "V" notch surface, the same imparting an additional degree of stiffness and improved structural stability to an associated elongated profile extrusion insert;

Fig. 5 is a cross-sectional end view of a modified "T" shaped profile extruded article according to a yet further variant of the present invention;

Fig. 5A is an application view of the "T" shaped profile article illustrated in Fig. 5, and further illustrating an optional thin interior layer of a metallized film (e.g. Mylar, olefin, et seq.) for adding structural rigidity to the profile extruded article;

Fig. 5B is an enlarged partial view of a wall section drawn from the extruded article in

Fig. 5, and further showing the metallic flake or pigment additive, this selected from such as aluminum, mica, copper, organic/inorganic films and flakes, calcium carbonate, talc, etc., and which may further be provided with high aspect ratios in order to align in a parallel fashion in order to maximize an exposed reflective surface area;

Fig. 6A is a sectional cutaway illustration of an inside corner profile extruded trim application according to the present invention;

Fig. 6B is an illustration of an outside corner profile extruded trim application; Fig. 6C is an illustration of an end cap trim piece application;

Fig. 6D is an illustration of a joint piece trim application; Fig. 6E is an illustration of a panel end cap trim application;

Fig. 7 is an illustration of a geometric profile extrusion with preferred dimensional characteristics according to one preferred embodiment of the present invention;

Fig. 7 A is subset illustration of a selected granular dimension corresponding to the profile extruded dimensions of Fig. 7;

Fig. 8 is an illustration similar to Fig. 3 and showing a cross-sectional, end-plan view illustration of a segmented extrusion exhibiting such as a square shape according to one further possible selected variant;

Fig. 9 is an illustration of a portion of a metallized pigment incorporated into an extruded article, and by which random deflection of light rays are evident, resulting from the likewise random and non-aligned manner of the high aspect ratio pigments; and

Fig. 10 is an illustration of an extruded article incorporating high aspect ratio pigments arranged in a substantially coplanar alignment with a viewing surface of the article and by which light rays are likewise substantially reflected, thereby providing a stronger color effect.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS As described previously, the present invention relates generally to profile extruded plasticized articles and, more specifically, to an elongated and profile extruded item, such as is constructed from a polyvinyl chloride (PVC), acrylonitrile butadiene styrene (ABS), olefin or other plasticized resinous material. The article may optionally be made via a flat extrusion, featuring one elongated detent, groove or cut to facilitate folding at a particular point, that may be used as a substitute for the detent, the article taking final shape prior to use as a trim or insert. The extruded article incorporates one of a metallic pigment, flake or layer for creating such as a faux metallic appearance and which is incorporated into either of structural insert or decorative trim applications, in substitution for such as prior art aluminum extruded inserts (these also including such as monochrome rigid PVC inserts and extruded aluminum metal or anodized inserts), and which are significantly more expensive to produce. An associated process is also disclosed for making a hot melt profile extrusion, such as in application for C-channels, slot board inserts and wall panel trim (inside, outside, corner and end cap).

Referencing Fig. 1, an environmental illustration is generally shown at 10 of a slot wall construction, such as capable of incorporating a profile extruded resinous material with metallic impregnate, further referenced in reduced length at 12, according to a preferred structural application of the present invention. The slot wall construction is typically known in the commercial art and, while certain unique and inventive interior channel architectures will be subsequently discussed, typically includes a plurality of elongate and horizontal spaced apart channels or recesses within which is installed the profile extruded articles described herein. As is further known in the art, the channels, see as representatively shown at 14, 16, et seq., each can

receive a selected "J" hook or like hanger attachment or shelf support bracket and the like, see further at 18 in Fig. 1, and as is known in the relevant retail and commercial shelving art.

The enlarged end view illustration of Fig. 2 illustrates a selected "C" channel of Fig. 2, and which again is associated with a slat wall construction within which is incorporated a mating profile extrusion insert according to the present invention. The profile extruded article as shown in Fig. 2 illustrates a substantially "C" shaped cross-sectional shape (reference will subsequently be made to the modified "T" shaped channels illustrated in Figs. 5 and 5A), it being understood that the extruded article is capable of adopting any desired cross-sectional shape or configuration according to the desires of one of ordinary skill in the art. As is further referenced in Fig. 2, the surface accessing channel portion of the slat wall construction may further include a notch or taper, see at 19, this assisting in preventing the extruded article 12 from being inadvertently movable relative to the channel and/or to assist in preventing sideways displacement of the extrusion in certain applications.

The profile extruded article or plastic insert is further typically constructed of a resinous of olefin based material, such as typically a polypropylene, thermoplastic polyolefin (TPO) and thermoplastic polyurethane (TPU), or like material having a specified thickness. A feature of the present invention is the entrainment, impregnation or otherwise incorporation into the plasticized/resinous matrix (such as a hot melt operation as will be subsequently described) of a metallic flake, particle or pigment additive (reference to these being further illustrated in subsequent Figs. 3A, 5B, etc.).

The metallic additives may be selected from such as aluminum, mica, copper, silver, organic/inorganic films and flakes, calcium carbonate, talc, etc., and which may further be provided with high aspect ratios (such as on the order of a first given dimension less than 0.009" and greater than a second dimension and the second dimension greater than 0.002"), typically of more than 1.2 and preferably between 1.4 and 10 in order to align in a parallel fashion to maximize an exposed reflective surface area and minimize the optically deleterious effects of the light scattering/dispersing properties of skew-angled particles of the prior art systems to create a desired faux metallic appearance, and provide such enhanced structural/dynamic aspects not possible with plastic alone. The present invention further renders possible the achievement of the faux metallic and like mechanical properties in matrix combination of as little as 1% by weight or less of innovative metallic-color imparting granules, relative to the 99% or greater by weight plastic component.

Advantages associated with profile extruded insert articles incorporating metallic additives include:

1) significantly lowering cost over 100% metal prior art items, e.g. primarily aluminum and aluminum based articles;

2) providing all-through color capability versus prior art articles and/or at least a thicker veneer or color-containing section of profile; 3) easy buffing out or removal of scratches;

4) safer handling and installation of profile extruded plasticized base inserts (these typically exhibiting less sharp edges than associated prior art aluminum extruded inserts) into existing slat wall and panel constructions;

5) more dent-resistant than prior art aluminum metal articles; 6) fully recyclable plasticized based articles;

7) achievement of a faux metallic appearance with large reduction in use metal; and

8) ability to recreate more varied colors/appearances of metal, faux metal, than is possible with prior art articles (e.g. zinc, copper, gold, silver, etc.).

Referring to Fig. 3 A, a cross-sectional, end-plan view illustration is generally shown at 20 of a segmented and "V" notched extrusion according to a further selected embodiment of the present invention. As with the other disclosed variants, the extrusion exhibits an elongated profile and includes a main segmented body component 22, from which extend end legs 24 and 26, each of which further being interconnected to opposite ends of the main body 22 by "V" notches, see at 28 and 30. As further shown in Fig. 3B, a succeeding illustration of the profile extruded article shown in Fig. 3A is illustrated in a folded and pre-inserted condition, and whereby the notches 28 and 30 facilitate even alignment of the legs 24 and 26 in perpendicular fashion relative to the main portion 22. As is further shown in the illustration of Fig. 3A, a plurality of higher aspect metallic flakes or the like, see at 31, can be provided, and such as which again can include a first dimension less than 0.009", with another corresponding dimension greater than 0.0001" (175 microns).

Fig. 4 illustrates a partial end view, similar to that shown in Fig. 2, of a modified inwardly notched channel for incorporating a profile extruded insert, the channel exhibiting first and second interior hidden and non-parallel upper surfaces, see at 32 and 34, relative an exposed surface 36, and within which a profile extruded/thermoformed insert, see as again shown at 12, can be installed. Of note, the inside upper surfaces 32 and 34 are generally defined as non-parallel and exhibiting a downward opposingly extending component (e.g. width exceeding depth, or x > y). As with the notched configuration 19 shown in Fig. 2, the non-parallel channel

defining surfaces 32 and 34 assist in holding (as well as providing secondary decorative aspects) of the associated profile extruded article.

Referencing further Fig. 4A, a partial end view illustration is shown of a further channel defined recess (in such as a metal or wooden slat wall construction) and which exhibits an underside recessed "V" notch (see angled surfaces 36 and 38), associated with a selected inside upper surface of the channel defining profile, this opposite a conventional and level inner surface 40 also shown in Fig. 4A. In a preferred application, the notches each extend to within 0.01" of a select surface of the profile article.

In contrast to substantially parallel surface and perpendicular side walls, the utilization of a "V" notch profile, such as in substitution for the angled/non-parallel profiles at 32 and 34 in

Fig. 4, imparts an additional degree of stiffness and improved structural stability to an associated elongated profile extrusion insert, see at 40, thereby causing the associated channel interior architecture to improve and enhance both the aesthetic and dynamic characteristics (e.g. imparting more stiffness and improved structural stability) of the profile extruded article. It is also understood that the hidden/interior upper walls (such as again shown at 32 and 34 in Fig. 4 and collectively at 36/38 in Fig. 4A) can include any non-parallel or otherwise shaping which is calculated to improve the holding and restraining aspects of the associated profile extrusion inserted into the slat wall channel.

Referring now to Fig. 5, a cross-sectional end view is shown at 42 of a modified "T" shaped profile extruded article according to a yet further variant of the present invention. As with the "C" shaped channel insert previously illustrated at 12, and can be inserted into an appropriate recessed channel configuration, such as shown in Fig. 5A.

Fig. 5A illustrates a further view of the "T" shaped profile article illustrated in Fig. 5, and showing an optional thin interior layer 44 of a metallized film (e.g. Mylar, olefin, et seq.) for adding structural rigidity to the profile extruded article. Referencing further Fig. 5B, an enlarged partial view is shown of a wall section drawn from the extruded article in Fig. 5, and further showing the metallic flake or pigment additive, see at 46, this selected from such as aluminum, mica, copper, organic/inorganic films and flakes, calcium carbonate, talc, etc., and which may further again be provided as high aspect ratios in order to align in a parallel fashion in order to maximize an exposed reflective surface area. Additional additives may include such other organic or inorganic components as is calculated to add inner strength, and so that the otherwise plastic article provides similar dynamic properties in comparison to prior art aluminum and like inserts.

Referencing Figs. 6A-6E, a collection of profile edging and trim applications are shown and which may define further application uses of the profile edging construction, and in addition to the slat wall insert support and like applications previously described. To reiterate, the present invention renders possible the use of such substantially plasticized profile extruded and faux metallic appearing articles capable of operating in both structural as well as decorative fashion.

Fig. 6A is a sectional cutaway illustration of a profile extruded trim application, see at 48, and which is capable of supporting perpendicularly arrayed edges of sheets 50 and 52 associated with an inside corner 54 of a substratum material. Fig. 6B is an illustration of a corresponding outside extruded trim application, see at 56, for again supporting perpendicularly arrayed edges of sheets 58 and 60 associated with an outside corner profile 62 of a substratum material. Additional applications include the end cap trim piece application 64 of Fig. 6C, the joint piece 66 trim application of Fig. 6D and the panel end cap 68 illustrated in Fig. 6E.

A further application of the present invention discloses profile extruding the article utilizing a hot melt process, again utilizing such as a metallic or metallized polymer (again polypropylene, ABS, PVC, olefin, acrylic or like resinous/plastic material (exhibiting a suitable portion of the innovative granule material). The article thus created by the hot melt extruded process is capable of being incorporated into a "C", modified "T" or other channel insert or trim piece application (including again the decorative trim articles summarized in Figs. 6A-6E).

Additional applications include provision of veneer pigmented metallic granules or surface film/olefin based applications.

Yet additional features include the additives further exhibiting at least granules (generally understood to include a solid version or type of particle or flake or even to reference a type of pigment in solidified form), of which at least 5% by surface area is visible across an exposed viewing surface of the article and aligning in substantially parallel fashion relative the viewing surface. Yet additional features include the granules being surface pigmented or exhibiting a mean granule planar size greater than 175 microns. A liquid-applied clear coat may also be adhered to at least one surface of the article/body.

Referencing now Fig. 7, an illustration is shown at 70 of a geometric profile extrusion with preferred dimensional characteristics according to one preferred embodiment of the present invention. An example of a modified "T" shaped extrusion is again shown, it being understood that a "C" shaped or other suitable shaped extrusion can be employed in the arrangement of Fig. 7. In particular, Fig. 7 illustrates a preferred architecture of profile extruded dimensions, whereby provision of high aspect ratio granules (see as shown at 72 in Fig. 7A) provides for

optimal alignment of the granules as progressively fed into the profile extruded article (see as further generally represented at 74).

As illustrated, desired alignment of the high aspect ratio granules (greatest planar dimension versus thickness) within the profile extruded article occurs upon: 1) a ratio of y/x of the extruded article is equal or greater than approximately a factor of

7;

2) a ratio of z/x being equal or greater than approximately a factor of 1 1 ; and

3) the ratio of maximum granular planar dimension (D) over thickness (A) being greater than 7. The rearrangement of structural orientation and dimensions is also contemplated and in order to achieve different alignment characteristics for granules exhibiting differing aspect ratios, and in use with other desired profile extruded shapes.

Fig. 8 is an illustration at 76 similar in regards to that previously shown in Fig. 3, and again showing a cross-sectional, end-plan view illustration of a segmented extrusion exhibiting such as a square shape according to one further possible selected variant. As with the variant 20 of Fig. 3A, the extrusion may exhibit an elongated profile with a main segmented body, at 78, from which extend legs 80 and 82 inter-connected to opposite ends of the main body 78.

The square shaped profile notches, respectively shown at 84 and 86, can also be redefined in any of semicircular, modified "V", "U", molded-in (extruded) shapes during the formation of the profile article. Alternatively, the desired notch shapes can be cut (i.e. mechanically post- formed in flat pre-extruded stocks of material).

Fig. 9 illustrates at 88 a representation of a portion of a metallized pigment incorporated into an extruded article, the pigment being represented by a plurality of substantially non- coplanar and randomly positioned pigment (see at 90) arranged within the extruded article. Owing to the random, non-aligned nature of the pigment, resultant light rays (see at 92, 94 and 96) which impact the surface of the article are randomly deflected (see at 98, 100 and 102, respectively), this resulting from the likewise random and non-aligned manner of the high aspect ratio pigments relative to the (partially/semi/substantially translucent or transparent) polymer matrix within which the metallic pigments are entrained. Contrasting finally Fig. 10, an illustration 104 is shown of an extruded article incoφorating high aspect ratio pigments 106 arranged in a substantially coplanar alignment relative to a viewing surface of the profile extruded article. In this fashion, impacting light rays 108, 1 10 and 1 12 are likewise substantially reflected, see respectively at 1 14, 1 16 and 1 18, thereby providing a stronger color illuminating effect.

Having described my invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains, and without deviating from the scope of the appended claims. I claim: