Laminate structure with polycarbonate sheets

• US 7,691,470 B2
• Filed: 06/18/2003
• Issued: 04/06/2010
• Est. Priority Date: 03/05/2001
• Status: Expired due to Term

• Current Assignee: 3Form LLC (Armstrong World Industries Incorporated)
• Original Assignee: 3Form (Hunter Douglas N.V.)
• Inventors: Goodson, Boyd Talley, Goodson, Raymond Lynn
• Primary Examiner(s): Sample; David R
• Assistant Examiner(s): Ferguson; Lawrence D
• Application Number:
  US10/465,465
• Publication Number:
  US 20040053040A1
• Time in Patent Office: 2,484 Days
• Field of Search: 428/339, 428/332, 428/327, 428/323, 428/322.2, 428/357, 428/220, 428/212, 428/213, 428/412, 428/542.2, 428/483, 428/13, 428/66.4, 428/66.5, 428/68, 428/195.1, 428/346, 428/354
• US Class Current: 428/212
• CPC Class Codes: B32B 2305/18 Fabrics, textiles
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/414 Translucent
• CPC Class Codes: B32B 2307/584 Scratch resistance
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/04 Time
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 2309/12 Pressure
• CPC Class Codes: B32B 2317/12 Paper, e.g. cardboard
• CPC Class Codes: B32B 2317/16 Wood, e.g. woodboard, fibreboard, woodchips
• CPC Class Codes: B32B 2318/04 Stone
• CPC Class Codes: B32B 2369/00 Polycarbonates
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 37/00 Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
• CPC Class Codes: B32B 37/04 characterised by the partial melting of at least one layer
• CPC Class Codes: B32B 37/08 characterised by the cooling method
• CPC Class Codes: B32B 37/1027 Pressing using at least one press band
• CPC Class Codes: B32B 37/185 : Laminating sheets, panels or inserts between two discrete plastic layers
• CPC Class Codes: B32B 38/06 : Embossing
• CPC Class Codes: B44C 1/105 : comprising an adhesive layer decalcomania B44C1/16; adhesive tapes C09J7/20
• CPC Class Codes: Y10T 428/216 : Ornamental, decorative, pattern, or indicia
• CPC Class Codes: Y10T 428/23 : Sheet including cover or casing
• CPC Class Codes: Y10T 428/24942 : including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/253 : Cellulosic [e.g., wood, paper, cork, rayon, etc.]
• CPC Class Codes: Y10T 428/26 : Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/269 : including synthetic resin or polymer layer or component
• CPC Class Codes: Y10T 428/2813 : Heat or solvent activated or sealable
• CPC Class Codes: Y10T 428/2848 : Three or more layers
• CPC Class Codes: Y10T 428/31797 : Next to addition polymer from unsaturated monomers

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.

Claims

1. A decorative polycarbonate laminate panel structure having a plurality of layers that are thermoformed into a decorative polycarbonate panel, and that display a decorative image layer, comprising:

at least a first layer, a second layer, and a third layer thermoformed together as a decorative polycarbonate laminate panel;

wherein at least one of the first layer, second layer, or third layer includes a polycarbonate sheet, the polycarbonate sheet having a thickness between 0.13 and 12.7 mm, and at least another of the first layer, the second layer or the third layer includes a decorative image layer comprising a fabric embedded in the polycarbonate sheet;

wherein the decorative image layer has been thermoformed into the polycarbonate sheet, whereby the polycarbonate laminate structure displays the decorative image layer.

2. The decorative laminate structure of claim 1, wherein the polycarbonate sheet is transparent, wherein the decorative image layer can be seen through the polycarbonate sheet.

3. The decorative laminate structure of claim 1, wherein the decorative image layer further comprises one or more metallic wires, metallic rods, or metallic bars.

4. The decorative laminate structure of claim 1, wherein the decorative image layer further comprises vegetation.

5. The decorative laminate structure of claim 4, wherein vegetation is selected from the group consisting of wood chips, grasses, thatch, flowers, flower petals, wheat, grains, and natural papers.

6. The decorative laminate structure of claim 1, wherein the decorative image layer comprises crushed glass.

7. The decorative laminate structure of claim 1, wherein the thickness of the first sheet is between 0.74 and 10 mm thick.

8. The decorative laminate structure of claim 1, wherein the thickness of the first sheet is between 1.48 and 6.35 mm thick.

9. The decorative laminate structure of claim 1, wherein the thickness of the first sheet is between 2.22 and 6.35 mm thick.

10. The decorative laminate structure of claim 1, wherein the thickness of the decorative image layer is between 0.0254 and 1.524 mm thick.

11. The decorative laminate structure of claim 1, wherein the thickness of the decorative image layer is between 0.0254 and 0.05 mm thick.

12. The decorative laminate structure of claim 1, wherein the thickness of the decorative image layer is about 0.04 mm.

13. The decorative laminate structure of claim 1, wherein the thickness of the second layer is between 0.74 and 10 mm thick.

14. The decorative laminate structure of claim 1, wherein the thickness of the second layer is between 1.48 and 6.35 mm thick.

15. The decorative laminate structure of claim 1, wherein the thickness of the second layer is between 2.22 and 6.35 mm thick.

16. The decorative laminate structure of claim 1, further comprising an embossing paper removably bonded to an outer layer of the first or second sheets.

17. The decorative laminate structure of claim 1, wherein the at least one decorative image layer further comprises a printed or colored image layer having opposed first and second surfaces.

18. The decorative laminate structure of claim 17, wherein, an image is printed on one of the first and second surfaces, and wherein the decorative image layer further comprises coloration.

19. The decorative laminate structure of claim 18, wherein the decorative image layer comprises a polyvinyl chloride (PVC) or copolyester material.

20. The decorative laminate structure of claim 2, further comprising a protective layer consisting of a bilayer film.

21. The decorative laminate structure of claim 1, further comprising a protective layer, wherein the protective layer is applied on at least one surface of the first sheet, the protective layer being selected from the group consisting of UV-cured or electron-beam-cured crosslinked acrylic, vacuum-cured or UV-cured urethane, UV-cured or electron-beam-cured silicon with acrylic or heat cured urethane or plastisol, and combinations thereof.

22. The decorative laminate structure of claim 1, wherein the fabric of the decorative image layer is woven.

23. The decorative laminate structure of claim 1, wherein at least the polycarbonate sheet is thermally fused through the at least one decorative image layer.

24. The decorative laminate structure of claim 1, wherein the at least one decorative image layers further comprises a photographic image.

25. The decorative laminate structure as recited in claim 23, wherein at least two of the first, second, or third layers comprise a polycarbonate sheet.

26. A rigid, impact resistant, decorative polycarbonate laminate panel structure with a thickness from at least ⅛

inch to about 1 inch, comprising;

at least a first layer, a second layer, and a third layer thermoformed together in a decorative polycarbonate laminate panel structure;

wherein;

at least one of the first layer, second layer, or third layer includes a polycarbonate sheet, the polycarbonate sheet having a thickness between about 1.48 mm and 12.7 mm;

at least another of the first layer, the second layer or the third layer includes a decorative image layer that is thermoformed adjacent the polycarbonate sheet such that the decorative image layer is embedded in the polycarbonate sheet, wherein the polycarbonate laminate structure displays the decorative image layer; and

two of the first layer, second layer, and the third layer are thermally compatible.

27. The polycarbonate laminate structure as recited in claim 26, wherein the decorative image layer comprises a woven fabric.

28. The polycarbonate laminate structure as recited in claim 27, wherein the polycarbonate sheet is thermally fused around and through the decorative image layer.

29. The polycarbonate laminate structure as recited in claim 28, wherein the decorative image layer comprises vegetation.

30. A rigid, impact resistant, decorative polycarbonate laminate panel structure with a thickness from at least ⅛

inch to about 1 inch, comprising;

at least a first layer, a second layer, and a third layer thermoformed together in a decorative polycarbonate laminate panel structure;

wherein;

at least one of the first layer, second layer, or third layer includes a polycarbonate sheet, the polycarbonate sheet having a thickness between about 1.48 mm and 12.7 mm;

at least another of the first layer, the second layer or the third layer includes a decorative image layer that is thermoformed adjacent the polycarbonate sheet such that the decorative image layer is embedded in the polycarbonate sheet, wherein the polycarbonate laminate structure displays the decorative image layer; and

the decorative image layer is intermittently opaque in the decorative polycarbonate laminate panel structure.

31. A decorative polycarbonate laminate panel structure having a plurality of layers that are thermoformed into a decorative polycarbonate panel that displays a decorative image layer, comprising:

at least a first layer, a second layer, and a third layer thermoformed together as a decorative polycarbonate laminate panel;

wherein at least one of the first layer, second layer, or third layer includes a polycarbonate sheet, the polycarbonate sheet having a thickness between 0.13 and 12.7 mm, and at least another of the first layer, the second layer or the third layer includes a decorative image layer embedded in the polycarbonate sheet consisting of a non-synthetic or non-melting material, wherein the non-synthetic or non-melting material is selected from the group consisting of a fabric, metallic wire, rod, bar, papers, photographic images, crushed glass, and vegetation;

wherein the decorative image layer has been thermoformed into the polycarbonate sheet such that the decorative image layer is embedded therein, whereby the polycarbonate laminate structure displays the decorative image layer.