Phosphorescent pultrusion

• US 7,476,432 B2
• Filed: 05/28/2004
• Issued: 01/13/2009
• Est. Priority Date: 05/28/2004
• Status: Expired due to Fees

• Current Assignee: Tecton Products Llc
• Original Assignee: Tecton Products Llc
• Inventors: Johnson, Aaron H., Pringle, Todd
• Primary Examiner(s): Ahmed; Sheeba
• Application Number:
  US10/857,640
• Publication Number:
  US 20050266223A1
• Time in Patent Office: 1,691 Days
• Field of Search: None
• US Class Current: 428/76
• CPC Class Codes: B05D 5/061 Special surface effect
• CPC Class Codes: B05D 7/02 to macromolecular substances, e.g. rubber treatment or coating of shaped articles made of macromolecular substances C08J7/00
• CPC Class Codes: B29C 48/07 Flat, e.g. panels
• CPC Class Codes: B29C 48/15 incorporating preformed parts or layers, e.g. extrusion moulding around inserts
• CPC Class Codes: B29C 70/525 Component parts, details or accessories; Auxiliary operations
• CPC Class Codes: B29K 2995/0018 having particular optical properties, e.g. fluorescent or phosphorescent
• CPC Class Codes: B32B 2260/023 Two or more layers
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/0269 Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/422 Luminescent, fluorescent, phosphorescent
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/302 comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/308 comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/38 : comprising epoxy resins
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 27/42 : comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/026 : Knitted fabric
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: Y10T 428/23 : Sheet including cover or casing
• CPC Class Codes: Y10T 428/239 : Complete cover or casing
• CPC Class Codes: Y10T 428/249933 : Fiber embedded in or on the surface of a natural or synthetic rubber matrix
• CPC Class Codes: Y10T 428/25 : Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/26 : Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/261 : In terms of molecular thickness or light wave length
• CPC Class Codes: Y10T 428/263 : Coating layer not in excess of 5 mils thick or equivalent
• CPC Class Codes: Y10T 428/264 : Up to 3 mils
• CPC Class Codes: Y10T 428/265 : 1 mil or less

Abstract

A plastic component includes a fiber-reinforced pultruded profile having an outer surface and a phosphorescent coating located on at least a portion of the surface.

Claims

1. A plastic component, comprising:

a fiber-reinforced pultruded profile having an outer surface; and

a phosphorescent coating layered directly onto at least a portion of the outer surface of the pultruded profile, wherein the phosphorescent coating is a film layer that is exposed as an outer surface of the plastic component and there is no material over the phosphorescent coating film layer.

2. The plastic component of claim 1, wherein the phosphorescent coating includes phosphorescent pigments in a thermoplastic resin.

3. The plastic component of claim 1, wherein the phosphorescent coating follows a contour of the outer surface and does not define a separate profile.

4. The plastic component of claim 1, wherein the pultruded profile is formed of a non-phosphorescent, thermoset material, and the phosphorescent coating includes phosphorescent pigments in a thermoplastic resin, and wherein the phosphorescent coating is applied over the pultruded profile such that the outer surface of the pultruded profile is covered by the phosphorescent coating.

5. The plastic component of claim 1, wherein the phosphorescent coating has a thickness of about 15 mils or less.

6. The plastic coating of claim 1, wherein the phosphorescent coating has a thickness of about 10 mils or less.

7. The plastic coating of claim 1, wherein the phosphorescent coating has a thickness of about 5 mils or less.

8. The plastic component of claim 1, wherein the phosphorescent coating covers less then an entire outer surface of the profile.

9. The plastic component of claim 1, wherein the pultruded profile includes a constant cross-section.

10. The plastic component of claim 1, wherein the pultruded profile defines a hand railing.

11. The plastic component of claim 1, wherein the pultruded profile defines a guard railing.

12. The plastic component of claim 1, wherein the pultruded profile defines a fence article.

13. The plastic component of claim 1, wherein the pultruded profile defines a base molding.

14. The plastic component of claim 1, wherein the pultruded profile defines a crown molding.

15. The plastic component of claim 1, wherein the pultruded profile defines a door frame.

16. The plastic component of claim 1, wherein the pultruded profile defines a door panel.

17. The plastic component of claim 1, wherein the pultruded profile defines a ceiling tile frame.

18. The plastic component of claim 1, wherein the pultruded profile defines a light reflector.

19. The plastic component of claim 1, wherein the pultruded profile defines a light fixture.

20. The plastic component of claim 1, wherein the pultruded profile defines stair tread.

21. The plastic component of claim 1, wherein the pultruded profile defines a stair over-molding.

22. A plastic component comprising:

a fiber-reinforced thermoset pultruded profile having an outer surface; and

a thermoplastic phosphorescent coating located on at least a portion of the outer surface, wherein the phosphorescent coating is a film layer that is exposed as an outer surface of the plastic component with the phosphorescent coating covering over at least a portion of the outer surface of the pultruded profile and there is no material over the phosphorescent coating film layer.

23. The plastic component of claim 22, wherein the thermoplastic phosphorescent coating includes phosphorescent pigments in a thermoplastic resin.

24. The plastic component of claim 22, wherein the phosphorescent coating follows a contour of the outer surface and does not define a separate profile.

25. The plastic component of claim 22, wherein the pultruded profile is formed of a non-phosphorescent material.

26. The plastic component of claim 22, wherein the phosphorescent coating has a thickness of about 15 mils or less.

27. The plastic component of claim 22, wherein the phosphorescent coating has a thickness of about 10 mils or less.

28. The plastic component of claim 22, wherein the phosphorescent coating has a thickness of about 5 mils or less.

29. A method comprising:

forming a profile by pulling a fibrous material, having been wetted out by a resin, through a first die;

curing said resin; and

applying a thermoplastic, phosphorescent coating to at least a portion of an outer surface of the profile such that the phosphorescent coating is exposed as an outer surface of the plastic component with no material over the phosphorescent coating film layer.

30. The method of claim 29, wherein forming a profile includes forming a profile from a non-phosphorescent thermoset material.

31. The method of claim 29, wherein applying a thermoplastic, phosphorescent coating includes crosshead extruding the coating onto the profile.

32. A method comprising:

forming a fiber-reinforced thermoset pultruded profile having an outer surface; and

applying a thermoplastic, phosphorescent coating over at least a portion of the outer surface such that the phosphorescent coating is a film layer defining an outer surface of the plastic component with no material over the phosphorescent coating film layer.

33. The method of claim 32, wherein forming a profile includes forming a profile from a non-phosphorescent thermoset material.

34. The method of claim 32, wherein applying a thermoplastic, phosphorescent coating includes crosshead extruding the coating onto an outer surface of the profile.

35. A plastic component, comprising:

a fiber-reinforced pultruded profile; and

a thermoplastic phosphorescent coating forming at least part of an outer surface of the plastic component with no material over the phosphorescent coating film layer.

36. The plastic component of claim 35, wherein the pultruded profile is formed of a non-phosphorescent, thermoset material.

37. The plastic component of claim 35, wherein the phosphorescent coating has a thickness of about 15 mils or less.

38. The plastic component of claim 35, wherein the phosphorescent coating has a thickness of about 10 mils or less.

39. The plastic component of claim 35,wherein the phosphorescent coating has a thickness of about 5 mils or less.

40. A plastic component, comprising:

a fiber-reinforced pultruded profile formed of a non-phosphorescent, thermoset material and having a profile surface; and

a phosphorescent coating including phosphorescent pigments in a thermoplastic resin that is layered directly onto at least a portion of the profile surface, wherein the phosphorescent coating is applied over the pultruded profile such that the profile surface of the pultruded profile is covered by the phosphorescent coating such that the phosphorescent coating is a film layer that is exposed as an outer surface of the plastic component, and wherein the phosphorescent coating has a thickness of about 15 mils or less and there is no material over the phosphorescent coating film layer.

41. The plastic component of claim 40, wherein the phosphorescent coating has a thickness of about 10 mils or less.

42. The plastic component of claim 40, wherein the phosphorescent coating has a thickness of about 5 mils or less.