Process for manufacturing plastic siding panels with outdoor weatherable embossed surfaces

• US 5,662,977 A
• Filed: 04/08/1996
• Issued: 09/02/1997
• Est. Priority Date: 10/19/1989
• Status: Expired due to Term

• Current Assignee: Avery Dennison Corporation
• Original Assignee: Avery Dennison Corporation
• Inventors: Truog, Keith Lawson, Spain, Patrick Leon
• Primary Examiner(s): LONEY, DONALD J
• Application Number:
  US08/628,903
• Time in Patent Office: 512 Days
• Field of Search: 428/156, 428/172, 428/40.1, 428/40.5, 428/41.4, 428/41.8, 428/42.1, 428/141, 428/200, 428/202, 428/207, 428/212, 428/421, 428/542.2
• US Class Current: 428/42.1
• CPC Class Codes: B29C 37/0025 Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing moulding on preformed layers as inserts B29C70/68; applying fluent material to surfaces in general B05
• CPC Class Codes: B29C 59/04 using rollers or endless belts
• CPC Class Codes: B29C 59/046 for layered or coated substantially flat surfaces
• CPC Class Codes: B29K 2995/0022 Bright, glossy or shiny surface
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 38/04 Punching, slitting or perforating
• CPC Class Codes: B44C 1/1712 Decalcomanias applied under heat and pressure, e.g. provided with a heat activable adhesive
• CPC Class Codes: B44C 1/24 Pressing or stamping ornamental designs on surfaces
• CPC Class Codes: B44C 5/0446 bearing graphical information
• CPC Class Codes: B44F 9/02 wood grain effects
• CPC Class Codes: Y10T 428/1419 Wax containing
• CPC Class Codes: Y10T 428/1457 Silicon
• CPC Class Codes: Y10T 428/1476 Release layer
• CPC Class Codes: Y10T 428/1486 Ornamental, decorative, pattern, or indicia
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/24364 with transparent or protective coating
• CPC Class Codes: Y10T 428/24372 Particulate matter
• CPC Class Codes: Y10T 428/24479 including variation in thickness
• CPC Class Codes: Y10T 428/2457 Parallel ribs and/or grooves
• CPC Class Codes: Y10T 428/24612 Composite web or sheet
• CPC Class Codes: Y10T 428/2486 : with outer strippable or release layer
• CPC Class Codes: Y10T 428/24901 : including coloring matter
• CPC Class Codes: Y10T 428/24942 : including components having same physical characteristic in differing degree

Abstract

A process for making plastic siding panels, such as outdoor weatherable vinyl panels with an embossed wood grain pattern, comprises extruding a vinyl sheet, and overlaying on the extruded sheet a flexible carrier sheet having coated thereon (a) matte release layer bonded to the carrier sheet, and (b) decorative coating on the matte release layer facing toward the extruded plastic sheet. An embossing roll applies pressure at elevated temperatures to transfer the decorative coating from the matte release layer and bond it to the extruded sheet, while the embossing roll embosses a three-dimensional impression pattern in the laminate transferred to the extruded sheet. The carrier sheet and its matte release layer are then released from the laminate transferred to the vinyl sheet. The matte release layer transfers a low 75° gloss level, preferably in the range of 8 to 12 gloss units, while enabling free release of the carrier from the embossed low gloss surface at elevated temperatures. In one embodiment, a multi-layer wood grain printed acrylic/polyvinylidene fluoride blended decorative coating is simultaneously transferred to a vinyl extrusion and embossed with a three dimensional wood grain texture. A color coat behind wood grain print coats contains pigment at a level that protects the vinyl substrate from UV deterioration. The matte release layer contains a suspended wax which enhances forming the low gloss surface while improving release of the matte release layer from the transferred laminate. A silicone resin in the matte release coat combines with the wax to further enhance release properties.

Claims

1. A transfer sheet for forming a decorative outer surface coat on a substrate panel, the transfer sheet comprising a flexible carrier sheet having coated thereon (a) a matte release layer bonded to the carrier sheet, and (b) a decorative coating on the matte release layer for facing toward the substrate panel, the decorative coating being releasable from the matte release layer under heat and pressure for bonding it to the substrate panel and for applying a low gloss surface to the transferred decorative coating from the matte release layer, the matte release layer comprising (1) a synthetic resinous coating dried to a film thickness and containing therein a thermosetting resinous component bonding the resinous coating to the carrier sheet, (2) a fine particulate filler dispersed in the resinous coating so that when the resinous coating is dried to its film thickness, the dispersed filler transfers a low gloss surface to the surface of the transferred decorative coating, (3) a wax component contained in the synthetic resinous coating for enhancing release of the matte release layer from the transferred decorative coating, and (4) a silicone resin component in the synthetic resinous coating further enhancing release properties.

2. The transfer sheet according to claim 1 in which the surface gloss level transferred to the decorative coating has a 75°

gloss level of less than about 20 gloss units.

3. The transfer sheet according to claim 2 in which gloss the 75°

level is less than about 12 gloss units.

4. The transfer sheet according to claim 1 in which the decorative coating includes a weatherable fluoropolymer resin.

5. The transfer sheet according to claim 1 in which the wax component is a polyethylene wax.

6. The transfer sheet according to claim 1 in which the wax component is in suspended form in the matte release layer at a transfer temperature, for enhancing transfer of said low surface gloss to the decorative layer;

and in which the wax component can be melted at a temperature lower than the transfer temperature to enhance releasing the matte release coat from the transferred low gloss surface.

7. The transfer sheet according to claim 1 in which the decorative coating comprises a continuous paint coat containing a pigment at a level sufficient to retard UV degradation of the extruded sheet.

8. The transfer sheet according to claim 1 in which the decorative sheet contains one or more printing inks in which the pigment component consists essentially of an organic pigment.