Laminate structure with polycarbonate sheets and method of making
First Claim
1. A method of making a decorative laminate structure comprising:
- providing a first sheet comprising polycarbonate, the first sheet having a thickness between 0.13 and 12.7 mm;
providing a second sheet comprising polycarbonate, the second sheet having a thickness between 0.13 and 12.7 mm;
providing a decorative image layer between the first and second sheet; and
heating and pressing the first and second sheet with the decorative image layer there-between at a maximum temperature between 193 and 249°
C. and a maximum pressure between 138 and 2069 kPa, wherein the time at maximum temperature and pressure is between 0.1 and 20 minutes.
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Abstract
Disclosed is a decorative laminate structure having at least two sheets of polycarbonate and at least one decorative image layer there-between two sheets of polycarbonate, and a method of making the decorative laminate structure. Through heat and pressure the sheet layers and the decorative image layer are bonded together resulting in a decorative laminate structure of this invention. This product is intended for use primarily to produce decorative articles which include counter tops, table tops, cabinet doors, game boards, toys, panels for shower stalls, hot tubs, markerboards, indoor and outdoor signs, seamless vanity tops including sink, soap dish, back splash, flooring and others.
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Citations
46 Claims
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1. A method of making a decorative laminate structure comprising:
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providing a first sheet comprising polycarbonate, the first sheet having a thickness between 0.13 and 12.7 mm;
providing a second sheet comprising polycarbonate, the second sheet having a thickness between 0.13 and 12.7 mm;
providing a decorative image layer between the first and second sheet; and
heating and pressing the first and second sheet with the decorative image layer there-between at a maximum temperature between 193 and 249°
C. and a maximum pressure between 138 and 2069 kPa, wherein the time at maximum temperature and pressure is between 0.1 and 20 minutes. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 44, 45)
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29. A decorative laminate structure comprising:
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a first sheet comprising polycarbonate, the first sheet having a thickness between 0.13 and 12.7 mm;
a second sheet comprising polycarbonate, the second sheet having a thickness between 0.13 and 12.7 mm; and
at least one a decorative image layer between the first and second sheet. - View Dependent Claims (30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43)
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46. A decorative laminate structure comprising:
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a first sheet comprising polycarbonate, the first sheet having a thickness between 0.13 and 12.7 mm;
a second sheet comprising polycarbonate, the second sheet having a thickness between 0.13 and 12.7 mm;
a third sheet of polycarbonate, the third sheet having a thickness between 0.13 and 12.7 mm;
at least one first decorative image layer between the first and second sheet; and
at least one second decorative image layer between the second and third sheet.
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Specification