Fence And Deck Post Cap

Abstract

A post cap is provided that is formed of a material having increased durability from the prior art post cap formed of plastics. The material includes some plastic components but also includes other compounds that provide the increased weight and durability to the post cap. The material includes a plastic, a solidifying agent, an accelerating agent, and a filler, optionally in conjunction with other ingredients, such as a color and one or more fillers. The material forming the post cap is formed in a mold in a suitable molding process, such as a casting process.

1 . A post cap comprising:
 a) a base adapted to be positioned over a deck or fence post; and   b) a cover connected to and extending over the base to define an interior within the cap, where the base and cover are formed from a material including:
 i. a plastic resin; 
 ii. a solidifying agent; and 
 iii. an accelerating agent. 
   
     
     
         2 . The post cap of  claim 1  wherein the material includes a filler selected from the group consisting of calcium carbonate, powdered stone, and combinations thereof. 
     
     
         3 . The post cap of  claim 1  wherein the material consists of a polyester resin, calcium carbonate powder, a solidifying agent and an accelerating agent. 
     
     
         4 . The post cap of  claim 3  wherein the solidifying agent is methyl ethyl ketone peroxide. 
     
     
         5 . The post cap of  claim 3  wherein the accelerating agent is cobalt octonoate. 
     
     
         6 . The post cap of  claim 3  wherein the material consists of:
 a) 40-60% w/w polyester resin; 
 b) 35-55% w/w calcium carbonate powder; 
 c) 1.0-3.0% w/w solidifying agent; and 
 d) 0.5-2.0% w/w accelerating agent. 
 
     
     
         7 . The post cap of  claim 3  wherein the material consists of:
 a) 52% w/w polyester resin; 
 b) 43% w/w calcium carbonate powder; 
 c) 1.5% w/w solidifying agent; and 
 d) 1.0% w/w accelerating agent. 
 
     
     
         8 . The post cap of  claim 1  wherein the interior includes at least one shoulder therein. 
     
     
         9 . The post cap of  claim 8  wherein the shoulder divides the interior into a wide lower section and a narrow upper section. 
     
     
         10 . A method of forming a post cap adapted to be positioned of a fence or deck post, the method comprising the steps of:
 a) providing a material including a plastic resin, a solidifying agent and an accelerating agent;   b) placing the material into a mold;   c) casting the material within the mold to form the cap; and removing the cap from the mold.   
     
     
         11 . The method of  claim 3  wherein the mold is formed of a resilient material and wherein the step of removing the cap from the mold comprises deflecting the mold from around the cap. 
     
     
         12 . The method of  claim 1  wherein the step of providing the material comprises providing the material of  claim 3 . 
     
     
         13 . The method of  claim 1  wherein the step of providing the material comprises providing the material of  claim 4 . 
     
     
         14 . The method of  claim 1  wherein the step of providing the material comprises providing the material of  claim 5 . 
     
     
         15 . The method of  claim 1  wherein the step of providing the material comprises providing the material of  claim 6 . 
     
     
         16 . The method of  claim 1  wherein the step of providing the material comprises providing the material of  claim 7 .