Multivariate color system with texture application

• US 8,157,942 B1
• Filed: 12/27/2011
• Issued: 04/17/2012
• Est. Priority Date: 05/08/2007
• Status: Active Grant

• Current Assignee: 3Form (Hunter Douglas N.V.)
• Original Assignee: 3Form (Hunter Douglas N.V.)
• Inventors: Willham, John E. C.
• Primary Examiner(s): SELLS, JAMES D
• Application Number:
  US13/337,793
• Publication Number:
  US 20120097317A1
• Time in Patent Office: 112 Days
• Field of Search: 156/209, 156/219, 156/228, 156/553, 156/555, 156/580, 156/581, 156/582, 156/583.1
• US Class Current: 156/209
• CPC Class Codes: B32B 2307/402 Coloured
• CPC Class Codes: B32B 2307/4026 within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/414 Translucent
• CPC Class Codes: B32B 2307/538 Roughness
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles wall paper B32B2607/02
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/16 specially treated, e.g. irradiated
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/30 comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 27/365 comprising polycarbonates
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B44F 1/06 produced by transmitted light, e.g. transparencies, imitations of glass paintings
• CPC Class Codes: B44F 1/066 comprising at least two transparent elements, e.g. sheets, layers layered products of glass and synthetic resin containing decorations or patterns B32B17/10247; window units comprising two or more parallel glass panes E06B3/66
• CPC Class Codes: G02B 5/0215 the surface having a regular structure
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1023 Surface deformation only [e.g., embossing]
• CPC Class Codes: Y10T 156/1039 Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 156/1737 : Discontinuous, spaced area, and/or patterned pressing
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24851 : Intermediate layer is discontinuous or differential
• CPC Class Codes: Y10T 428/24868 : Translucent outer layer
• CPC Class Codes: Y10T 428/24942 : including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/31507 : Of polycarbonate
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31855 : Of addition polymer from unsaturated monomers

Abstract

Implementations of the present invention relate to a translucent and/or transparent polymer-based panel system that incorporates multi-colored insert layers that enable manipulation of color, transparency or light transmission of the finished panel system. Implementations of the present invention also relate to the construction of such panels to avoid the capture and retention of air within the panels through the use of textured surfaces at the lamination interfaces. In addition, implementations of the present invention provide a method of quantifying the optical response achieved in a given panel system and describes types of construction that enable the multiplicity of color and optic manipulation. Furthermore, implementations of the present invention provide methods for applying texture in an efficient, uniform manner.

Claims

1. A method of preparing a laminate resin structure having a custom color created from a plurality of colored films, comprising:

providing a translucent resin substrate having opposing first and second bonding surfaces that correspond with opposing first and second viewable surfaces, and a glass transition temperature;

aligning a bonding surface of a first colored film directly against a bonding surface of the resin substrate, wherein the first colored film is miscible with the bonding surface of the resin substrate, and comprises a glass transition temperature;

aligning a second colored film directly against one of another bonding surface of the resin substrate or another bonding surface of the first colored film, wherein the second colored film is miscible with one or both of the resin substrate and the first colored film, and has a glass transition temperature; and

applying heat and pressure to meet or exceed the highest glass transition temperature of the resin substrate, the first colored film, and the second colored film, such that the resin substrate intermixes with one or both of the first and second colored films to display a third color throughout the resin substrate that is a composite of the colors of the first and second colored films.

2. The method as recited in claim 1, wherein the first and second colored film both comprise texture on the bonding surface that has a surface roughness that is different from a texture of a bonding surface of the resin substrate.

3. The method as recited in claim 2, wherein the texture of the first and second colored film comprises a uniform surface roughness that is greater than the surface roughness of the resin substrate.

4. The method as recited in claim 2, wherein:

the texture of the first and second colored film comprises a uniform surface roughness that is greater than 20μ

inches; and

the texture of the resin substrate comprises a uniform surface roughness that is less than 20μ

inches.

5. The method as recited in claim 2, wherein:

the texture of the first and second colored film comprises a uniform surface roughness that is greater than 62μ

inches; and

the texture of the resin substrate comprises a uniform surface roughness that is less than 10μ

inches.

6. The method as recited in claim 1, further comprising:

positioning a white film about a bonding surface of the resin substrate or one of the first or second colored films;

wherein, after the application of heat and pressure, the white film provides a first haze value to the resultant third color.

7. The method as recited in claim 6, further comprising:

positioning a second white film about a bonding surface of the resin substrate or one of the first or second colored films before application of heat and pressure;

wherein, the combination of the first and second white films results in a laminate structure having a second haze value that is greater than the first haze value.

26. The method as recited in claim 1, wherein the translucent resin substrate comprises an extrusion of a material selected from the group consisting of polycarbonate, polyester, PVC, acrylic, and combinations and polymer alloys thereof.

27. The method as recited in claim 1, wherein the color of one or both of the first or second colored thermoplastic film comprises a printed image.

28. The method as recited in claim 1, wherein:

the first colored film is aligned on the first surface of the translucent resin substrate; and

the second colored film is aligned on the second surface of the translucent resin substrate.

29. The method as recited in claim 1, wherein one or both of the first or second resin substrates further comprises a texture on an opposing surface that is opposed to its bonding surface.

30. The method as recited in claim 1, wherein the first and second colored films comprise the same color, such that the new third color comprises the color of the first or second colored film at greater intensity.

8. A method of preparing a laminate resin structure devoid of air entrapment or color streaking, comprising:

providing a resin substrate having a uniform texture with a first surface roughness on a bonding surface;

providing a colored film that is miscible with the resin substrate, and that has a uniform texture with a second surface roughness on a bonding surface, wherein the second surface roughness is different from the first surface roughness;

positioning the resin substrate and the colored film so that the textures of the bonding surfaces of the resin substrate and the colored film are in direct contact with each other; and

applying heat and pressure to the positioned resin substrate and colored film so that the resin substrate and colored film intermix;

wherein, during application of heat and pressure, the uniform textures of the in-contact bonding surfaces allow air removal from between the resin substrate and the colored film while preventing color streaking.

9. The method as recited in claim 8, further comprising:

identifying a preferred light diffusion characteristic of the laminate resin structure; and

identifying a number of one or more white film layers needed to create the light diffusion characteristic.

10. The method as recited in claim 9, further comprising positioning the one or more identified white film layers about an assembly comprising the resin substrate and positioned colored film prior to applying heat and pressure.

11. The method as recited in claim 8, wherein:

the surface roughness of the colored film layer is greater than the surface roughness of the resin substrate layer.

12. The method as recited in claim 8, wherein assembly of the positioned resin substrate and the colored film is devoid of a laminating enhancing layer.

13. The method as recited in claim 8, further comprising applying heat and pressure through a heated-plate, open-air lamination press.

14. The method as recited in claim 8, wherein:

one of the resin substrate or the colored film comprises a greater surface roughness on its bonding surface; and

the other of the resin substrate of the colored film comprises a lesser surface roughness.

15. The method as recited in claim 14, wherein:

the greater surface roughness is greater than 20μ

inches; and

the lesser surface roughness is less than 20μ

inches.

16. The method as recited in claim 15, wherein the greater surface roughness is greater than 50μ

inches.

17. The method as recited in claim 15, wherein the greater surface roughness is greater than 60μ

inches.

18. The method as recited in claim 14, wherein the greater surface roughness is greater than 250μ

inches.

31. The method as recited in claim 8, further comprising:

providing one or more additional colored films that are miscible with one or both of the colored film or the resin substrate;

wherein the colored film and the one or more additional colored films are fused to the resin substrate, such that the prepared laminate structure displays a third color throughout the resin substrate that is a composite of the colors of the colored film and the one or more additional colored films.

32. The method as recited in claim 31, the one or more added colored films comprise the same color as the provided colored film, such that the third color comprises the color of the first or second colored film at greater intensity.

19. A method of combining a thermoplastic film and a plurality of resin substrate materials together through heat and pressure to yield a finished and aesthetically pleasing resin structure that displays the aesthetic characteristics of the thermoplastic film throughout the finished resin structure, comprising:

providing a first resin substrate having a bonding surface with a uniform texture having a first surface roughness;

providing a second resin substrate having a bonding surface with a uniform texture having a second surface roughness that is equal to or less than the first surface roughness; and

positioning a colored thermoplastic film between the first and second resin substrates, wherein the colored thermoplastic film is miscible with the first and second resin substrates, and comprises uniform texturing on opposing bonding surfaces;

wherein the surface roughness of the opposing bonding surfaces of the colored thermoplastic film is greater than about 25 times the first surface roughness; and

fusing the first resin substrate, the colored thermoplastic film, and the second resin substrate, such that the highest glass transition temperature of the thermoplastic film or substrates is exceeded.

20. The method as recited in claim 19, wherein the first and second resin substrates comprise a thickness that is approximately 6 times the thickness of the colored thermoplastic film.

21. The method as recited in claim 19, wherein the first and second resin substrates comprise an extrusion of a material selected from the group consisting of polycarbonate, polyester, PVC, acrylic, and combinations and polymer alloys thereof.

22. The method as recited in claim 19, wherein the color of the colored thermoplastic film comprises a printed image.

23. The method as recited in claim 19, further comprising:

adding one or more colored thermoplastic film between the colored thermoplastic film and one of the first or second resin substrates prior to fusing;

wherein;

the one or more added colored thermoplastic films are miscible with the colored thermoplastic film; and

one of the one or more added colored thermoplastic films adjacent the first or second resin substrate comprises a surface roughness that is greater than about 25 times the first surface roughness.

24. The method as recited in claim 23, wherein the colored thermoplastic film and the one or more added colored thermoplastic films comprise the same color, such that the fusing the substrates and thermoplastic films results in the finished resin structure displaying the color at a higher intensity than when created without the added thermoplastic film.

25. The method as recited in claim 23, wherein at least one of the one or more added colored films comprise a white film layer, which, when fused to the first or second resin substrate, reduces light transmission in the finished resin structure.