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.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to structural building components. More particularly, the invention relates to a structural building component, such as a support column, bracket, trellis, railing, beam or the like having a decorative overmolding, and a molding apparatus and method for fabricating such a component.

2. Description of the Prior Art

In construction of commercial, and even residential, building structures, it is frequently found to be necessary or desirable to substantially enclose or cover all or a portion of structural building components in order to provide a neat, attractive, or up-scaled appearance. Such need or desirability occurs both in the construction of new building structures and in renovation or remodeling of existing building structures. In the past, however, the components and materials required for enclosing or covering all or a portion of a building structure have generally required the attachment of separately fabricated individual overlay components using fasteners, adhesives and the like. The overlay structures of the prior art, while providing some aesthetic improvement to the building component, have been relatively expensive to manufacture, transport, and install, and have frequently lacked a neat and attractive appearance, largely due to visible, unattractive seams and to the necessity for the use of fasteners or other mounting devices that are visible in the finished installation. In addition, such conventional components or materials for such cladding and covering applications have sometimes necessitated the use of relatively expensive, highly-skilled personnel for installation, and have often been unable to conveniently accommodate electrical wiring and other components.

Accordingly, the present invention seeks to overcome the drawbacks, disadvantages and limitations discussed above by providing an overmolding, or an overmolded cladding, and associated overmolding method, adapted for substantially covering all or a portion of structural building components, wherein the overmolded components are relatively inexpensive to manufacture, transport and install, while providing a neat, attractive and up-scaled appearance, devoid of visible seams and fasteners. Furthermore, the present invention incorporates Thermo-Set resins including, Polyaspartic Aliphatic Polyurea, Aromatic Polyurea, Aromatic Polyurethane, Unsaturated Polyester and Epoxy which, in combination with a unique overmolding and finishing method, enable the fabrication of an overmolded layer having exceptional adhesion to the underlying structural building component, and having a decorative surface imparting the authentic appearance and texture of a non-polymeric, naturally occurring wood, stone, metal or other desired finishes.

The overmolding method is particularly suited for automated, high volume, cost-efficient production incorporating relatively inexpensive equipment and materials, and employing minimal components and fabrication steps.

Furthermore, the preferred molding composition and manufacturing method result in an overmolding, or cladding, having excellent structural benefits, dimensional stability, exterior color retention, and environmental durability with no post finishing required.

SUMMARY OF THE INVENTION

The present invention is generally directed to a structural building component, such as a column, bracket, trellis, railing, beam or the like, having an exterior surface substantially covered with a decorative Thermo-Set resin including, Polyaspartic Aliphatic Polyurea, Aromatic Polyurea, Aromatic Polyurethane, Unsaturated Polyester and Epoxy overmolding, and a molding apparatus and method for fabricating such a component. The overmolded components are relatively inexpensive to manufacture, transport and install, while providing a neat, attractive and up-scaled appearance, devoid of visible seams and fasteners. The overmolding is preferably comprised of a unique Polyaspartic Aliphatic Polyurea polymeric composition resulting in an overmolded layer with no post finishing required and the option of using other Thermo-Set resins including, Aromatic Polyurea, Aromatic Polyurethane, Unsaturated Polyester or Epoxy, having exceptional adhesion to the underlying aluminum, metal, steel, iron or structural composite member. The overmolding process used to fabricate the building component incorporates a unique, specially-designed 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.

The overmolding method is particularly well suited for automated, high volume, cost-efficient production requiring relatively inexpensive equipment and materials, and employing minimal components and fabrication steps.

Together, the molding composition and manufacturing method enable production of the preferred overmolding Polyaspartic Aliphatic Polyurea decorative overmolding having excellent structural benefits, dimensional stability, exterior color retention, and environmental durability with no post finishing required.

In one general aspect of the present invention, a structural building component is provided, comprising:

• • an aluminum, metal, steel, iron or a structural composite member having a non-planar geometry and an exterior surface; and a preferred Polyaspartic Aliphatic Polyurea polymer composition directly molded to the exterior surface to form an overmolded layer.

In another aspect of the invention, the structural building component has a aluminum, metal, steel, iron or structural composite member having an exterior surface overmolded with a preferred Thermo-Set Polyaspartic Aliphatic Polyurea Polymer composition.

In another aspect of the invention, the preferred Thermo-Set Polyaspartic Aliphatic Polyurea molding composition is comprised of an Polyaspartic Aliphatic Polyurea having a non wood natural fiber Lignocellulosic material, calcium carbonate and borosilicate hollow glass spheres mixed therein.

In another aspect of the invention, the overmolded layer is formed having a decorative appearance authentically replicating both the look and texture of a natural wood, stone, metal or other non-polymeric finishes.

In another aspect of the present invention, a structural building component is produced having a preferred decorative Polyaspartic Aliphatic Polyurea overmolding having exceptional structural benefits, dimensional stability, exterior color retention, and environmental durability with no post finishing required.

In another general aspect of the present invention, a method is provided for manufacturing the structural building component of the invention, comprising the steps of: (1) providing an aluminum, metal, steel, iron or structural composite member having an exterior surface terminating at an upper end and a lower end; (2) providing a mold apparatus including a resilient mold having a mold cavity formed therein; (3) 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 body 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 the mold cavity and the exterior surface of the aluminum, metal, steel, iron or structural composite body; (4) introducing a volume of a molding composition into the molding composition receiving space until the mold cavity is substantially filled with the molding composition; (5) at least partially curing the molding composition such that the molding composition forms an overmolded layer chemically bonded to the structural aluminum, metal, steel, iron or structural composite exterior surface; and (6) removing the overmolded aluminum, metal, steel, iron or structural composite body from said mold apparatus.

In another aspect of the method of the present invention, 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 comprises 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. In this manner, ingress of the overmolding into the interior space is precluded.

In another aspect of the method of the present invention, prior to the step of introducing the molding composition into the resilient mold cavity, the mold apparatus is oriented such that a slope, or gradient, results longitudinally between opposite ends of the apparatus and, correspondingly, along the central axis of the resilient mold cavity. Subsequently, the volume of molding composition is introduced into the lower end of the resilient mold cavity. In this manner, mold cavity air is gradually displaced toward the upper end of the resilient mold, for egress through one or more vent holes, minimizing the formation of voids in the overmolded layer.

In a further aspect of the present invention, the method enables exceptionally detailed replication on the overmolded surface of extremely intricate surface features, such as, for example, nooks, crannies, fissures and the like, found on naturally occurring wood surfaces and other natural finishes.

In a yet another aspect of the present invention, significant time and cost savings are achieved using an automated non-labor-intensive process incorporating relatively inexpensive equipment and materials.

These and other aspects, features, and advantages of the present invention will become more readily apparent from the attached drawings and the detailed description of the preferred embodiments, which follow.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the invention, where like designations denote like elements, and in which:

FIG. 1 is a perspective view of a mold assembly used to manufacture the decorative Thermo-Set resins including, Polyaspartic Aliphatic Polyurea, Aromatic Polyurea, Aromatic Polyurethane, Unsaturated Polyester and Epoxy overmolded structural building components of the present invention;

FIG. 2 is a perspective view of one of the mold assembly end caps 50, 50a;

FIG. 3 is a front plan view of the end cap of FIG. 2;

FIG. 4 is a cross-sectional view taken along cutting plane 4-4 of FIG. 3;

FIG. 5 is a cross-sectional view taken along cutting plane 5-5 of FIG. 1;

FIG. 6 is an exploded perspective view of the mold assembly of FIG. 1, with the mold assembly 10 shown flipped end-to-end and with mold cradle assembly 20 opened to expose its interior, with resilient mold upper portion 40 partially cutaway to expose interior surface 30 of mold cradle body 20, and further illustrating the orientation and positioning of the structural building component 80 relative the mold assembly 10 just prior to an overmolding operation;

FIG. 7 is a partial cross-sectional view taken through a single one of the channels 32 extending longitudinally along the interior surface 30 of main mold body upper half 22;

FIG. 8 is an exploded perspective view of the mold assembly, as illustrated in FIG. 6, following the completion of a molding operation to form the decoratively overmolded Thermo-Set resins including, Polyaspartic Aliphatic Polyurea, Aromatic Polyurea, Aromatic Polyurethane, Unsaturated Polyester and Epoxy structural building component 90 of the present invention;

FIG. 9 is a front elevation view of the decoratively overmolded Thermo-Set resins including, Polyaspartic Aliphatic Polyurea, Aromatic Polyurea, Aromatic Polyurethane, Unsaturated Polyester and Epoxy structural building component 90 of the present invention; and

FIG. 10 is a cross-sectional view taken along cutting plane 10-10 of FIG. 9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Shown throughout the figures, the present invention is generally directed to a method and apparatus for overmolding the exterior surface of a non-planar structural building component with a preferred highly-durable, Thermo-Set decorative Polyaspartic Aliphatic Polyurea overlay, as well as, Aromatic Polyurea, Aromatic Polyurethane, Unsaturated Polyester and Epoxy as to the resulting overmolded article. The preferred decorative Thermo-Set, Polyaspartic Aliphatic Polyurea overmolding is particularly fabricated to have an exposed surface simulating a non-polymeric material, such as natural wood, stone, metal, to name just a few, wherein the simulated surface has an exceptionally authentic appearance. The method is particularly well suited for use over-molding aluminum, metal, steel, iron or structural composite building components such as columns, brackets, trellises, railings, beams and the like, with a Polyaspartic Aliphatic Polyurea molding composition. However, it will be apparent to those skilled in the art that the method of the present could be employed to over mold other types of structures, such as a conventional mailbox post, park benches and light poles, for example, for both building and non-building related applications, as well.

Significantly, the method incorporates resilient molds enabling exceptionally detailed replication of extremely intricate surface features, such as nooks, crannies, fissures and the like, found on naturally occurring wood surfaces. Considerable time and cost savings are achieved using an automated non-labor-intensive process incorporating relatively inexpensive equipment and materials.

The preferred overmolding of the present invention has been formulated to provide outstanding adhesion to the underlying aluminum, metal, steel, iron or structural composite surface, and has structural benefits, exceptional dimensional stability, exterior color retention, and environmental durability with no post finishing.

Referring initially to FIG. 1, the molding apparatus employed to fabricate the decorative overmolded structural components 90 (FIGS. 8-9) of the present invention, indicated generally by reference numeral 10, is shown in a fully-assembled, closed position. Generally, the mold apparatus 10 is comprised of a mold cradle assembly 20, and a pair of end caps 50, 50a having attachment means 60 for facilitating releasable attachment of the end caps to opposite flanged ends 26, 28 of the closed mold cradle assembly. Preferably, mold cradle assembly 20 has a clamshell-type construction, comprised of hinged 12 cooperating upper and lower mold cradle portions, 22 and 24, respectively. As described in greater detail below, the mold cradle portions, 22 and 24, and end caps, 50 and 50a, support resilient mold portions (not shown in FIG. 1) which, upon closing the molding apparatus, cooperate to form a resilient mold cavity.

Referring now to FIG. 6, mold cradle assembly 20 is shown in an opened state, with end caps 50, 50a detached, revealing an upper resilient mold portion 40 disposed on interior surface 30 of upper mold cradle portion 22 and a corresponding lower resilient mold portion 42, disposed on the interior surface (not shown) of lower mold cradle portion 24. As described in further detail below, the upper and lower resilient mold portions, 40 and 42, are fabricated having detailed features and contours formed in the resilient mold surface 46 which, in combination with the unique molding composition and method of the present invention, enable the production of an overmolding having a surface finish precisely and authentically replicating both the look and feel of the surface of a desired non-polymeric material. In FIG. 6, upper resilient mold portion 40 is shown partially cutaway, to expose underlying longitudinally extending grooves or channels 32 machined into surface 30. Referring briefly to FIG. 7, the grooves 32 have a geometry defined by sidewalls 36 having an outward taper, or draft, of about 10 degrees toward rear wall 34. The grooves 32 assist securing the upper resilient mold portion 40 to the interior surface 30 of upper mold cradle portion 22. Corresponding grooves (not shown) are provided in the interior surface of lower mold cradle portion 24.

The resilient mold portions, 40 and 42, as well as their method of fabrication, comprise a significant aspect of the present invention. The process used to fabricate the upper and lower cradle resilient mold portions, 40 and 42, of the present invention can vary, depending upon the desired simulated surface.

Generally, the resilient molds are fabricated by encapsulating a master form in order to precisely replicate the master form surface contour and texture.

In the present invention, the resilient mold portions 40, 42 are fabricated using the mold cradle assembly 20 during the resilient mold fabrication process, such that the resilient mold portions 40, 42 are formed directly within the interior of the closed mold cradle assembly 20, as opposed to being prefabricated and subsequently introduced into the assembly.

Referring particularly to FIG. 6, an exemplary resilient mold fabrication process will now be described. During fabrication of the resilient mold portions 40, 42, resilient mold surface 46 is formed having desired surface contouring and texturing authentically replicating the surface of a master form.

For the purpose of this example, we'll assume that it is desired to fabricate a resilient mold particularly configured for producing an overmolding authentically replicating a natural wood finish upon exterior surface 82 of a hollow square structural member 80. The resilient mold is generally produced in the following manner:

(1) Initially, a master form (not shown), such as an actual piece of wood, having a geometry substantially complementary to member 80, but nominally larger, is stood on end upon a substrate such as a wood panel (not shown); (2) nominally larger aluminum mold cradle assembly 20 is closed and positioned over/around the master form, also supported on one of its ends, 26 or 28, atop the substrate, to define a space, or gap, between mold cradle surface 30 and the exterior surface of the master form; (3) a liquid silicone material (e.g., HS-2 High Strength Silicone Rubber, manufactured by Dow Corning, Inc. of Corning, N.Y.) is poured, or otherwise introduced, into the aforementioned space/gap; substantially filling the gap and, thereby, encapsulating the sidewalls of the master form; (4) the liquid silicone material is cured, forming a unitary resilient body; (5) the unitary resilient body is separated into upper and lower resilient mold portions, 40 and 42, respectively, via precise cuts, or incisions, introduced longitudinally along opposite corner edges 44, 44a of the resilient body; and (5) the mold cradle assembly 20 is opened, disengaging the upper and lower aluminum mold cradle portions, 22 and 24, from each other, and separating corresponding upper and lower resilient mold portions, 40 and 42, from the master form, leaving behind resilient mold surface impressions precisely replicating the surface of the master wood form.

Significantly, during encapsulation of the master form, the RTV silicone molding compound material seeps into and fills virtually each and every nook and cranny on the wood surface. In some instances, the nooks and crannies define pockets undercutting the wood surface. By way of example, this is common when using master forms created from natural wood grained characteristics. Upon curing, the silicone material that has seeped into these pockets forms mold surface projections, also referred to in the art as nipples, which become captivated within the pockets.

However, the resiliency of the silicone mold material enables these nipples to temporarily deform during removal from the pockets, thereby facilitating complete separation of the cured mold from the master form while leaving the nipples completely intact.

Similarly, mold nipples enveloped by cured molding resin following a molding operation temporarily deform during removal of the molded article, such that the molded article contains a perfect impression of the master form surface while the resilient mold, including the nipples, is left completely intact.

Referring now particularly to FIGS. 2-4, mold apparatus 10 incorporates end caps 50, 50a particularly configured for releasable attachment to opposite ends of the mold cradle assembly 20. The following description of the structure of the end caps is made with particular reference to left end cap 50 (which is the rightmost end cap in FIGS. 6 and 8, where the mold assembly 10 has been flipped end-to-end), it being understood that corresponding right end cap 50a has a substantially identical construction.

End cap 50 preferably has an aluminum housing, in this case comprised of rear wall 54 and sidewalls 52, defining an interior space. A resilient mold portion 70 is provided substantially filling the interior space of the end cap 50.

The resilient mold portion 70 has an upper surface 72 including a lip portion 76 extending outwardly over end cap flange 56. Resilient mold lip 76 functions as a gasket, enhancing sealing between end cap flange 56 and mold cradle flange 28 upon attachment of the end cap 50 to the end of the mold cradle assembly 20.

A contiguous channel 74 formed in upper surface 72 of resilient mold portion 70 extends peripherally adjacent to end cap sidewalls 52.

An aperture 78, coextensive with a corresponding aperture 58 in end cap rear wall 54, extends completely through resilient mold portion 70. The function of the channel 74 and aperture 78 are described in more detail below. End cap 50 is provided having a conventional latch structure 60, including latch mechanism 62 and bail 64, which cooperate with mold cradle catches 38 on the exterior of mold cradle assembly 20, to facilitate releasable sealing attachment of the end cap 50 to the mold cradle assembly 20.

Referring now to FIGS. 1-10, and particularly to FIGS. 6-10, a preferred molding composition and method for fabricating the decorative Thermo-Set Polyaspartic Aliphatic Polyurea overmolded structural component 90 of the present invention will now be described.

As best shown in FIG. 6, initially, a structural member, shown generally as reference numeral 80, is provided. In this exemplary application, structural member is comprised of a hollow square column defined by a plurality of sidewalls 81 extending between opposite open ends, 86 and 88, in communication with an interior space 89. Structural member 80 includes an exterior surface 82, to be overmolded, and an interior surface 84.

However, as will be appreciated by those skilled in the art, the mold apparatus and method of the present invention has an inherent flexibility to be adapted for overmolding structural members, either solid or hollow, having a virtually endless variety of geometries and configurations.

Initially, the mold assembly end caps 50, 50a are mounted upon opposite ends, 86 and 88, of structural member 80. More particularly, structural member end 86 is snugly received with channel 74a of resilient mold portion 70a of end cap 50a, with opposite structural member end 88 mounted in similar fashion into end cap 50.

Subsequently, structural member 80, having end caps 50a, 50 securely engaged to opposite ends 86 and 88, respectively, is positioned within opened mold cradle assembly 20. Then, upper and lower mold cradle assembly portions 22 and 24 are brought together about structural member 80, and the respective end caps are securely attached, via latch assemblies 60, to mold cradle portion 20.

With the mold cradle assembly 20 closed, and end caps 50, 50a securely fastened thereto, a mold composition receiving space or gap (not shown) is defined between the exterior surface 82 of structural member 80 and the interior surface 46 of the mold cradle resilient mold portions 40, 42.

Significantly, the sealing engagement of structural member end 86 within end cap resilient mold channel 74, and corresponding engagement of structural member end 88 and end cap 50a, seal the interior space 89 of structural member 80 from the aforementioned mold receiving space.

In this manner, the overmolding is restricted to exterior surface 82 of structural member 80.

With the structural member 80 mounted within mold assembly 10, and fully supported by the end caps 50, 50a, a volume of decorative molding composition is injected, or otherwise introduced through aperture 58 in rear wall 54 of end cap 50, and through coextensive aperture 78 in resilient mold portion 70, into the aforementioned space, or gap, between exterior surface 82 of structural member 80 and surface 46 of upper and lower resilient mold portions 40 and 42. An aperture (not shown) in right end cap 50a, corresponding to aperture 58 in left end cap 50, functions as a means for venting mold cavity air displaced by the injected decorative molding composition.

Preferably, the molding apparatus 10 is positioned, or otherwise oriented, to create a slight upward gradient from the left, mold composition-receiving, end of the apparatus toward the opposite vented end. In this mariner, the creation of void-forming air pockets in the overmolding is substantially minimized.

For some applications, it may be desirable to manufacture Class-1 Fire Resistant products that meet ASTM-E84 flame spread and smoke density criteria.

The use of Melamine Formaldehyde surface treated Ammonium Polyphosphate, and Expandable Graphite can be added to the present formula to achieve this criteria.

The applicant has also found that there are several options for post finishing the surface of the decorative overmolding Thermo-Set Polyaspartic Aliphatic Polyurea, Aromatic Polyurea, Aromatic Polyurethane, Unsaturated Polyester, and Epoxy overmolding can be post finished with Polyaspartic Aliphatic Polyurea, Fluoro Polymer Polyurethane, Moisture Cure Aliphatic Polyurethane, Aliphatic Polyurethane, transparent, semi transparent, or opaque top coats for exterior surface protection. Also, the decorative overmolding can be post finished utilizing a novel hydrographic transcription finishing method also known as, water transfer printing. This process provides the decorative overmolding a digitally processed water soluble printed film, which produces a true and realistic three dimensional emulation of wood, stone, and other natural materials to the surface of the decorative overmolding.

Also, the decorative overmolding can be post finished with a Non Woven, Decorative, Polyester Fibre Vail, that can be produced in wood, stone, and other natural finishes. The Non Woven, Decorative, Polyester Fibre Vail, is applied to the surface of the Decorative overmolding with a clear Moisture Cure Aliphatic Polyurethane that is saturated to the film and bonded in place to the surface of the decorative overmolding.

As best shown in FIGS. 8-10, upon curing, a semi-rigid overmolding layer 92, having an ornate surface 94 substantially identical to the master form used to create mold cavity surface 46, substantially covers exterior surface 82 of structural member 80.

With respect to comparable decorative cladding methods of the prior art, the overmolding method of the present invention enables the direct formation of a decorative overmolding upon a structural building component, wherein the resulting overmolding has exceptional adhesion to the underlying structural member, and a decorative surface imparting the authentic appearance and texture of a naturally occurring wood or other desired finish.

The method is particularly suited for automated, high volume, cost-efficient production, incorporates relatively inexpensive equipment and materials, and employs minimal components and fabrication steps. Furthermore, the combination of the unique preferred Thermo-Set Polyaspartic Aliphatic Polyurea molding composition and manufacturing method results in an overmolding having superior dimensional stability, color retention and environmental durability with no post finishing required.

Since many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalence.

Claims

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.