FORMABLE FUSED POLYMER PANELS CONTAINING LIGHT REFRACTING FILMS
First Claim
1. A dichroic resin panel configured with sufficient aesthetic and structural properties for use as a building material in an architectural design environment, the dichroic resin panel comprising:
- a substantially translucent first resin substrate layer;
a substantially translucent second resin substrate layer that corresponds with the first resin layer; and
one or more light refracting film layers laminated between the first and second resin layers, wherein the one or more light refracting film layers conform to the first and second resin layers without material defect;
wherein the combination is at least partially malleable after a lamination process.
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0 Petitions
Accused Products
Abstract
A dichroic, light refracting resin panel comprises one or more dichroic/refracting films that have been embedded and/or laminated between a plurality of resin substrates, such as copolyester, polycarbonate, and/or acrylic substrates. The dichroic resin panel can be manufactured with a variety of different materials, and with autoclave or hot press methods in a manner that ensures structural and aesthetic integrity. Specifically, a dichroic resin panel in accordance with the present invention can be created in such a way as to avoid delamination despite a variety of end-uses and formations (e.g., curved panel, embossed/textured surfaces). In addition, the dichroic resin panels can be handled, transported, and installed in a variety of exterior or interior applications, even where certain building code requirements may be relatively stringent. The dichroic resin panels can be used in a variety of structural and/or aesthetic applications.
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Citations
20 Claims
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1. A dichroic resin panel configured with sufficient aesthetic and structural properties for use as a building material in an architectural design environment, the dichroic resin panel comprising:
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a substantially translucent first resin substrate layer; a substantially translucent second resin substrate layer that corresponds with the first resin layer; and one or more light refracting film layers laminated between the first and second resin layers, wherein the one or more light refracting film layers conform to the first and second resin layers without material defect; wherein the combination is at least partially malleable after a lamination process. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method of manufacturing a post-formable, dichroic resin panel comprising a light refracting film, wherein the dichroic resin panel can be modified or formed during or after lamination without cracking, wrinkling, or otherwise distorting the refracting film layer during the manufacturing process, the method comprising the steps of:
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preparing a dichroic laminate assembly comprising one or more light refracting films and one or more tie layers interposed between a plurality of resin substrates; heating the dichroic laminate assembly in a lamination apparatus to a temperature of no more than about 250°
F. to about 260°
F., wherein the one or more tie layers soften or melt between the plurality of resin substrates;cooling the dichroic laminate assembly, wherein the dichroic laminate assembly comprises a substantially unitary resin panel; and removing the unitary resin panel from the lamination apparatus. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19)
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20. A dichroic laminate assembly configured so that, when subject to a lamination temperature of up to about 250°
- F. to about 260°
F. in an autoclave or hot press, bonds one or more resin substrates to a dichroic film in a manner that preserve the integrity of the dichroic film and prevents the resulting dichroic resin panel from delamination, comprising;a plurality of resin substrates comprising one of a copolyester material, a polycarbonate material, or a mixture thereof; one or more light refracting films positioned between the plurality of resin substrates in a stack formation; and a plurality of TPU tie layers positioned between the plurality of resin substrates in the stack formation; wherein; each TPU tie layer is positioned against at least one surface of each of the resin substrates; and each of the one or more light refracting films is positioned adjacent two TPU tie layers on opposing sides.
- F. to about 260°
Specification