Method, article and assembly for applying a multi-layer film to an elongate extruded article
A process and related assembly for creating an extrusion molded article with a chemically applied outer film. An extruded base material is formed during a first extrusion operation, following which a multi-layer film is bonded to the base material while the base material still at an above ambient temperature. The multi-layer film further includes successive layers of each of a polypropylene (PP), an adhesive, a polyethylene terephthalate (PET), a coating and s subsequent surface PET. The step of bonding of the film further occurs during an intermediate step between the first extrusion operation for forming the base material according to a given profile section and a subsequent extrusion operation for applying additional material along an edge of the film, the additional material including profile wings as required for a given design.
1. A process for creating an extrusion molded article incorporating an outer film, comprising the steps of:
forming an extruded base material during a first extrusion operation;
applying a coating layer in a second extrusion operation; and
bonding a multi-layer film over the coating layer and to the base material while the base material is at an above ambient temperature.
2. The process of claim 1 , further comprising providing the multi-layer film, in succession, with each of a polypropylene (PP) layer, an adhesive, a first polyethylene terephthalate (PET) layer, a coating and a second surface PET layer.
3. The process of claim 1 , further comprising a third extrusion operation for applying wing portions in partially overlapping fashion and along an edge of the film.
4. The process of claim 3 , further comprising utilizing a cross head die with each of the extrusion operations.
5. The process of claim 3 , further comprising a pressing operation following the third extrusion operation for sectioning the molded article into lengths.
6. The process of claim 5 , further comprising pulling the extrusion molded article following each of the first and third extrusion operations.
7. An extrusion molded article, comprising:
an extrusion formed rigid polymer;
an extruded coating applied over the rigid polymer;
a multi-layer film applied over said coating and to said rigid polymer, said multi-layer film including each of a first polypropylene layer, an adhesive binder layer, at least one polyethylene terephthalate (PET) layer, and a coating layer; and
a third stage extrusion formed profile wing configured along an edge of said second stage multi-layer film.
8. The extrusion article of claim 7 , said at least one PET layer of said multi-layer film further comprising a first subset PET layer applied over said adhesive binder and a second subset PET layer applied over said coating layer.
9. The extrusion article of claim 8 , said rigid polymer further comprising a polypropylene material.
10. The extrusion article of claim 9 , said polypropylene material further comprising a thickness of at least 75 μm.
11. The extrusion article of claim 7 , said adhesive binder of said multi-layer film further comprising a thickness of at least 12 μm.
12. The extrusion article of claim 8 , said first subset PET layer of said multi-layer film further comprising a thickness of at least 50 μm.
13. The extrusion article of claim 8 , said second subset PET layer of said multi-layer film further comprising a thickness of at least 75 μm.
14. The extrusion article of claim 7 , said coating layer of said multi-layer film further comprising an ultraviolet protective layer.
15. The extrusion article of claim 14 , said coating layer further comprising a thickness of at least 12 μm.
16. An extrusion process for creating an extrusion molded article with a chemically applied outer film, comprising the steps of:
forming an extruded base material of a rigid polymer during a first extrusion operation;
bonding a multi-layer film to the base material while the base material is at an above ambient temperature; and
forming at least one wing portion along an edge of said base material during a succeeding extrusion operation and in order to overlap at least a portion of said film.
17. The process of claim 16 , the step of bonding the multi-layer film further comprising bonding, in succession, each of a polypropylene (PP) layer, an adhesive, a first polyethylene terephthalate (PET) layer, a coating and a second surface PET layer.
18. The process of claim 16 , further comprising utilizing a cross head die with each of the extrusion operations.
19. The process of claim 16 , further comprising a pressing operation following the succeeding extrusion operation for sectioning the molded article into lengths.
20. The process of claim 16 , further comprising pulling the extrusion molded article following each of the extrusion operations.