High-impact, transparent, distortion-free polymeric sheet and windshield
First Claim
1. A high-impact, transparent sheet comprising:
- a base sheet of transparent polycarbonate material having a glass transition temperature and a melt temperature, the base sheet having a non-planar shape comprising a first portion and a second portion;
wherein the first portion has a shape created by a non-contact forming operation occurring at a temperature above the glass transition temperature and below the melt temperature of the transparent polycarbonate material; and
wherein the second portion is a peripheral portion, said second portion has a non-planar shape at its outermost edge created by a contact forming operation occurring at a temperature above the glass transition temperature and below the melt temperature of the polycarbonate material, said second portion non-planar outermost edge having a non-planar contour; and
wherein when said sheet rests on a plane, said second non-planar portion contour is spaced away from said plane such that portions of the periphery including said second non-planar portion contour are raised above and not in contact with said plane.
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Accused Products
Abstract
A base sheet of transparent polycarbonate material has a formed shape including a center portion and a peripheral portion. The center portion is formed by a non-contact forming operation occurring at a temperature above the glass transition temperature and below the melt temperature of the transparent polycarbonate material, thereby resulting in the center portion of the base sheet being free of visual distortion. A top coat layer is disposed over the base sheet. The top coat layer has a greater resistance to abrasion than the polycarbonate material and provides UV protection to the base sheet. A primer coating is disposed between the base sheet and the top coat layer to facilitate bonding therebetween. The peripheral portion can have a shape created by a contact forming operation occurring at a temperature above the glass transition temperature and below the melt temperature of the polycarbonate material.
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Citations
11 Claims
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1. A high-impact, transparent sheet comprising:
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a base sheet of transparent polycarbonate material having a glass transition temperature and a melt temperature, the base sheet having a non-planar shape comprising a first portion and a second portion; wherein the first portion has a shape created by a non-contact forming operation occurring at a temperature above the glass transition temperature and below the melt temperature of the transparent polycarbonate material; and wherein the second portion is a peripheral portion, said second portion has a non-planar shape at its outermost edge created by a contact forming operation occurring at a temperature above the glass transition temperature and below the melt temperature of the polycarbonate material, said second portion non-planar outermost edge having a non-planar contour; and wherein when said sheet rests on a plane, said second non-planar portion contour is spaced away from said plane such that portions of the periphery including said second non-planar portion contour are raised above and not in contact with said plane. - View Dependent Claims (2, 3, 4, 5)
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6. A high-impact, transparent windshield comprising:
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a base sheet of transparent polycarbonate material having a glass transition temperature and a melt temperature, the base sheet being a windshield comprising a first portion and a second portion; wherein the first portion has a shape created by a non-contact forming operation occurring at a temperature above the glass transition temperature and below the melt temperature of the transparent polycarbonate material; and wherein the second portion is a peripheral portion, said second portion has a non-planar shape as its outermost edge created by a contact forming operation occurring at a temperature above the glass transition temperature and below the melt temperature of the polycarbonate material, said second portion non-planar outermost edge having a non-planar contour; and wherein when said sheet rests on a plane, said second non-planar portion contour is spaced away from said plane such that portions of the periphery including said second non-planar portion contour are raised above and not in contact with said plane. - View Dependent Claims (7, 8, 9, 10)
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11. A high-impact, transparent windshield comprising:
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a base sheet of transparent polycarbonate material having a glass transition temperature and a melt temperature, the base sheet being a contoured non-planar windshield comprising a first portion and a second portion; wherein the first portion has a shape created by a non-contact forming operation occurring at a temperature above the glass transition temperature and below the melt temperature of the transparent polycarbonate material; wherein the second portion has a shape created by a contact forming operation occurring at a temperature above the glass transition temperature and below the melt temperature of the polycarbonate material; said second peripheral portion has an outermost edge defined by a pair of opposing surfaces and a terminal end surface connecting the pair of opposing surfaces at the outermost edge, and said opposing surfaces are on a non-perpendicular angle with respect to said end surface; and wherein when said sheet rests on a plane, said second non-planar portion contour is spaced away from said plane such that portions of the periphery including said second non-planar portion contour are raised above and not in contact with said plane.
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Specification