Wood-grained polymer substrate
A wood-grained polymer substrate includes a plurality of layers of different colors. The substrate is formed into elongated boards and used in the production of various end products similar to natural wood. Methods for producing the wood-grained polymer substrate are also provided.
1 . A polymer substrate that simulates natural wood extending along a first direction, the polymer substrate having a first side and a second side spaced apart from the first side along a second direction different than the first direction, the first and the second sides defining a width of the substrate, the first and the second sides extending along the first direction, the substrate comprising:
a first set of polymer layers extending along the first direction and containing a first colorant, a plurality of the first set of polymer layers being substantially continuous along the first direction;
a second set of polymer layers extending along the first direction and containing a second colorant different than the first colorant, a plurality of the second set of polymer layers being substantially continuous along the first direction;
the substrate extending between the first and the second sides and along the first direction, the substrate comprising a wood-grained pattern formed of the first set of polymer layers and the second set of polymer layers, wherein individual layers of the first and the second set of polymer layers are interspersed within the substrate to form the wood-grained pattern, wherein a plurality of individual layers of at least one of the first and the second sets of polymer layers extend along a substantially curvilinear path in the second direction originating proximate the first side and terminating proximate the second side; and
a cross-section of the substrate exposing the wood-grained pattern.
2 . The polymer substrate of claim 1 , wherein the wood-grained pattern extends uninterrupted between the first end and the second end.
3 . The polymer substrate of claim 1 , wherein the wood-grained pattern includes a plurality of grains oriented in different directions such that individual grains of the plurality of grains vary in thickness with respect to a third direction that is perpendicular to the first direction and the second direction.
4 . The polymer substrate of claim 1 , wherein the plurality of individual layers of the first set of polymer layers extend along an uninterrupted curvilinear path in the second direction originating proximate the first side and terminating proximate the second side.
5 . The polymer substrate of claim 1 , wherein the substrate comprises texturized exterior surfaces.
6 . The polymer substrate of claim 1 , wherein the first and the second set of polymer layers are one of homopolymers, copolymers, virgin homopolymers, virgin copolymers, recycled homopolymers, and recycled copolymers.
7 . The polymer substrate of claim 1 , wherein the exposed portions of the wood-grained pattern form a burled grain pattern.
8 . The polymer substrate of claim 1 , wherein the first set of polymer layers are thinner than the layers of the second set of polymer layers.
9 . The polymer substrate of claim 1 , wherein the first and the second set of polymer layers include at least one of a UV inhibitor and a foaming agent.
10 . A polymer substrate that simulates natural wood extending along a first direction, the polymer substrate having a first side and a second side spaced apart from the first side along a second direction different than the first direction, the first and the second sides defining a width of the substrate, the first and the second sides extending along the first direction, the substrate comprising:
a first set of polymer layers extending along the first direction and containing a first colorant, a plurality of the first set of polymer layers being substantially continuous along the first direction;
a second set of polymer layers extending along the first direction and containing a second colorant different than the first colorant, a plurality of the second set of polymer layers being substantially continuous along the first direction;
the substrate extending between the first and the second sides and along the first direction, the substrate comprising a wood-grained pattern formed of the first set of polymer layers and the second set of polymer layers, wherein individual layers of the first and the second set of polymer layers are interspersed within the substrate to form the wood-grained pattern, wherein a plurality of individual layers of both the first and the second sets of polymer layers extend along a substantially curvilinear path in the second direction originating proximate the first side and terminating proximate the second side; and
a cross-section of the substrate exposing the wood-grained pattern.
11 . The polymer substrate of claim 10 , wherein the wood-grained pattern extends uninterrupted between the first end and the second end.
12 . The polymer substrate of claim 10 , wherein the wood-grained pattern includes a plurality of grains oriented in different directions such that individual grains of the plurality of grains vary in thickness with respect to a third direction that is perpendicular to the first direction and the second direction.
13 . The polymer substrate of claim 10 , wherein the plurality of individual layers of the first set of polymer layers extend along an uninterrupted curvilinear path in the second direction originating proximate the first side and terminating proximate the second side.
14 . The polymer substrate of claim 10 , wherein the substrate comprises texturized exterior surfaces.
15 . The polymer substrate of claim 10 , wherein the first and the second set of polymer layers are one of homopolymers, copolymers, virgin homopolymers, virgin copolymers, recycled homopolymers, and recycled copolymers.
16 . The polymer substrate of claim 10 , wherein the exposed portions of the wood-grained pattern form a burled grain pattern.
17 . The polymer substrate of claim 10 , wherein the first set of polymer layers are thinner than the layers of the second set of polymer layers.
18 . The polymer substrate of claim 10 , wherein the first and the second set of polymer layers include at least one of a UV inhibitor and a foaming agent.
19 . A simulated natural wood-grained polymer board extending along a first direction, having a first side and a second side spaced apart from the first side along a second direction different than the first direction, the first and the second sides defining a width of the board, the first and the second sides extending along the first direction, the board comprising:
a first set of polymer layers extending along the first direction and containing a first colorant;
a second set of polymer layers extending along the first direction and containing a second colorant different than the first colorant;
the board extending between the first and the second sides and along the first direction, the board comprising a wood-grained pattern formed of the first set of polymer layers and the second set of polymer layers, wherein individual layers of the first and the second set of polymer layers are interspersed within the board to form the wood-grained pattern, wherein a plurality of individual layers of the first set of polymer layers extend along a substantially curvilinear path in the second direction originating proximate the first side and terminating proximate the second side; and
a cross-section of the board exposing the wood-grained pattern.
20 . The polymer substrate of claim 19 , wherein at least one of the first and the second set of polymer layers are formed from high density polyethylene.