Surface appearance simulation systems and methods

Abstract

A structural member includes a simulated surface appearance. The structural member includes a substrate, plural intermediate layers, and a top coat. The plural intermediate layers are applied over at least one surface of the substrate, with at least some of the plural intermediate layers configured to cooperate with each other to provide a simulated appearance for the structural member. The top coat is applied outward of the plural intermediate layers. The top coat is relatively thin and is configured for use with exterior applications. The top coat includes a base configured for UV resistance and an additive configured to provide abrasion resistance.

What is claimed is: 
     
         1 . A structural member having a simulated surface appearance, the structural member comprising:
 a substrate;   plural intermediate layers applied over at least one surface of the substrate, two or more of the plural intermediate layers configured to cooperate with each other to provide a simulated appearance for the structural member; and   a top coat applied outward of the plural intermediate layers, wherein the plural intermediate layers are interposed between the substrate and the top coat, the top coat being relatively thin and configured for use with exterior applications, the top coat comprising a base configured for ultraviolet (UV) resistance and including an additive configured to provide abrasion resistance.   
     
     
         2 . The structural member of  claim 1 , wherein the base of the top coat comprises a fluoropolymer and the additive comprises plural inorganic particles, the inorganic particles having a size and distribution within the base configured for a particular application. 
     
     
         3 . The structural member of  claim 2 , wherein the fluoropolymer comprises Polyvinylidene Fluoride (PVDF) and the inorganic particles comprise an Aluminum Oxide (Al 2 O 3 ). 
     
     
         4 . The structural member of  claim 1 , wherein the plural intermediate layers include a primer layer, a ground coat layer, a print undertone layer, and a print layer. 
     
     
         5 . The structural member of  claim 1 , wherein the plural intermediate layers are configured to provide an appearance corresponding to a wood grain. 
     
     
         6 . The structural member of  claim 1 , wherein at least some of the intermediate layers are arranged in a foil configured for substantially simultaneous application of the at least some of the intermediate layers to the substrate. 
     
     
         7 . The structural member of  claim 1 , wherein the plural intermediate layers are configured for thermal application and wherein the top coat is configured for spray application. 
     
     
         8 . The structural member of  claim 1 , wherein the additive includes particles having a size, and wherein the thickness of the top coat and the size of the particles are configured to provide a texture. 
     
     
         9 . A structural member coating system comprising:
 at least one intermediate coating station configured to apply plural intermediate layers over a substrate, at least some of the plural intermediate layers configured to cooperate with each other to provide a simulated appearance for the structural member;   a top coat application station configured to apply a top coat outward of the plural intermediate layers, the top coat being relatively thin and configured for use with exterior applications, the top coat comprising a base configured for ultraviolet (UV) resistance and an additive configured to provide abrasion resistance; and   a curing station configured for curing of the top coat after the top coat has been applied, wherein the curing is configured to lock in a positioning of the additive with the base.   
     
     
         10 . The coating system of  claim 9 , wherein the at least one intermediate coating station comprises a foil application station, the foil application station configured to apply a foil to the substrate, the foil comprising the plural intermediate layers. 
     
     
         11 . The coating system of  claim 9 , wherein the at least one intermediate layer station is configured to thermally apply the plural intermediate layers, and wherein the top coat application station is configured to at least one of spray or curtain coat the top coat over an exterior of the plural intermediate layers. 
     
     
         12 . The coating system of  claim 9 , wherein the additive includes particles having a size, wherein the top coat application system is configured to apply a thickness of the top coat configured to provide a texture based on the size of the particles. 
     
     
         13 . The coating system of  claim 9 , wherein the base of the top coat comprises a fluoropolymer and the additive comprises plural inorganic particles, the inorganic particles having a size and distribution in the base configured for a particular application.