Structural building component having a decorative overmolding, apparatus for fabricating such an article and its method of manufacture

Abstract

A structural building component, such as a column, bracket, trellis, railing, beam or the like, has a construction defined by a rigid aluminum, metal, steel, iron or structural composite member having an exterior surface substantially overmolded with a decorative preferred Thermo-Set Polyaspartic Aliphatic Polyurea polymer composition to form an overmolding devoid of visible seams and fasteners with no post finishing required. The overmolding has exceptional adhesion to the underlined aluminum, metal, steel, iron or structural composite member. The overmolding method incorporates a resilient mold apparatus enabling the formation of a cladding layer having a decorative outer surface imparting the authentic appearance and texture of a non-polymeric, naturally occurring wood, stone, metal, or other desired finishes.

1 . A structural building component, comprising:
 an aluminum, metal, steel, iron or structural composite member having a non-planar geometry and an exterior surface; and a preferred Thermo-Set, Polyaspartic Aliphatic Polyurea composition directly molded to said exterior surface to form an overmolded layer.   
   
   
       2 . A structural building component as recited in  claim 1 , wherein said a preferred Thermo-Set, Polyaspartic Aliphatic Polyurea polymer composition further comprises, Aromatic Polyurea, Aromatic Polyurethane, Unsaturated Polyester and Epoxy. 
   
   
       3 . A structural building component as recited in  claim 2 , wherein said further comprises aluminum, metal, steel, iron or structural composite body. 
   
   
       4 . A structural building component as recited in  claim 1 , wherein said overmolded layer imparts a decorative appearance to said structural building component. 
   
   
       5 . A structural building component as recited in  claim 4 , wherein said overmolded layer imparts a decorative appearance authentically replicating a naturally-occurring wood finish, and other natural finishes. 
   
   
       6 . A structural building component as recited in  claim 4 , wherein said overmolded layer imparts a decorative appearance authentically replicating a natural stone finish, and other natural finishes. 
   
   
       7 . A structural building component as recited in  claim 1 , wherein said aluminum, metal, steel, iron or structural composite body further comprises one of a column, bracket, trellis, railing, beam or the like. 
   
   
       8 . A structural building component as recited in  claim 1 , wherein said aluminum, metal, steel, iron or structural composite member further comprises one or more sidewalls defining an open-ended body having an interior space in communication with said open ends. 
   
   
       9 . A structural building component as recited in  claim 2 , wherein said the preferred Thermo-Set, Polyaspartic Aliphatic Polyurea molding composition further comprises: Aromatic Polyurea, Aromatic Polyurethane, Unsaturated Polyester and Epoxy. 
   
   
       10 . A method for manufacturing a structural building component having a decorative overmolding, comprising the steps of:
 providing an aluminum, metal, steel, iron or structural composite member having an exterior surface terminating at an upper end and a lower end;   providing a mold apparatus including a resilient mold having a mold cavity formed therein;   supporting the aluminum, metal, steel, iron or structural composite member within the mold apparatus solely by engagement of the resilient mold with the ends of the aluminum, metal, steel, iron or structural composite member in such a manner that, when the mold apparatus is in a completely closed condition, a molding composition receiving space is defined between the surface of said mold cavity and the exterior surface of the aluminum, metal, steel, iron or structural composite member;   introducing a volume of a molding composition, into the molding composition receiving space until the mold cavity is substantially filled with the molding composition;   at least partially curing the molding composition such that the molding composition forms an overmolded layer chemically bonded to the structural member exterior surface; and removing the overmolded aluminum, metal, steel, iron or structural composite member from said mold apparatus.   
   
   
       11 . A method as recited in  claim 8  wherein the aluminum, metal, steel, iron or structural composite member is comprised of one or more sidewalls defining an open-ended body having an interior space in communication with the open ends, the step of supporting the aluminum, metal, steel, iron or structural composite member within the mold apparatus further comprising engaging the opposite open ends of the structural body with the resilient mold such that the interior space of the structural body is substantially sealed from the molding composition receiving space when the mold is in a completely closed condition. 
   
   
       12 . A method as recited in  claim 8 , further comprising, prior to the step of introducing the preferred Thermo-Set, Polyaspartic Aliphatic Polyurea a volume of molding composition, the step of orienting the molding apparatus to affect a gradient longitudinally along the central axis of the resilient mold cavity. 
   
   
       13 . A method as recited in  claim 12 , wherein the step of introducing further comprises introducing a volume of molding composition into a lower end of said resilient mold cavity. 
   
   
       14 . A method as recited in  claim 13 , wherein the step of introducing a volume of a molding composition further comprises introducing the preferred Thermo-Set Polyaspartic Aliphatic Polyurea-based molding composition into the molding composition receiving space.