Multivariate color system with texture application

• US 8,268,106 B2
• Filed: 04/12/2012
• Issued: 09/18/2012
• Est. Priority Date: 05/08/2007
• Status: Active Grant

• Current Assignee: 3Form LLC (Armstrong World Industries Incorporated)
• Original Assignee: 3Form (Hunter Douglas N.V.)
• Inventors: Willham, John E. C.
• Primary Examiner(s): SELLS, JAMES D
• Application Number:
  US13/445,573
• Publication Number:
  US 20120193028A1
• Time in Patent Office: 159 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
• 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 about an outside surface of the first colored film, wherein the second colored film is miscible with at least the first colored film, and comprises 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 substantially throughout the resin substrate, regardless of ordering of the first and second colored films on the translucent resin substrate;

wherein the third color is a composite of the colors of the first and second colored films.

2. The method as recited in claim 1, wherein at least the first colored film comprises a texture on the bonding surface that is different from a texture of the 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 a surface of 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.

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

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

the color of one or both of the first or second colored films comprises a printed image; and

a difference in surface roughness between opposing surfaces at a bonding interface between the resin substrate and first colored film, or at a bonding interface between the first and second colored films, allows for evacuation of air while preventing color streaking.

10. The method as recited in claim 1, wherein the second colored film further comprises a texture on an opposing surface that is different from the bonding surface.

11. The method as recited in claim 10, wherein the translucent resin substrate further comprises a textured finish on a non-bonding surface.

12. 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.

13. 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; and

applying a textured finish to a non-bonding surface of the resin substrate.

14. The method as recited in claim 13, further comprising:

providing a textured finish to a non-bonding surface of the colored film;

wherein the textured finish on the non-bonding surfaces of the resin substrate and colored film cooperate to enhance diffusion of light in the laminate resin structure.

15. The method as recited in claim 13, 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.

16. The method as recited in claim 15, 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.

17. The method as recited in claim 13, wherein:

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

18. The method as recited in claim 13, wherein assembly of the positioned resin substrate and the colored film is devoid of a laminating enhancing layer.

19. The method as recited in claim 13, further comprising applying heat and pressure through a lamination press.

20. The method as recited in claim 13, wherein the color of one or both of the first or second colored films comprises a printed image.

21. The method as recited in claim 13, 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.

22. The method as recited in claim 21, 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.

23. The method as recited in claim 21, further comprising providing a textured finish to a non-bonding surface of the one or more additional colored films, wherein the textured finish on the non-bonding surfaces of the resin substrate and the one or more additional colored films cooperate to enhance diffusion of light in the laminate resin structure.

24. The method as recited in claim 13, 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.

25. The method as recited in claim 24, wherein:

the greater surface roughness is greater than 20μ

inches; and

the lesser surface roughness is less than 20μ

inches.

26. The method as recited in claim 25, wherein the greater surface roughness is greater than 50μ

inches.

27. The method as recited in claim 25, wherein the greater surface roughness is greater than 60μ

inches.

28. The method as recited in claim 25, wherein the greater surface roughness is greater than 250μ

inches.

29. 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 about an outside surface of the first colored film, wherein the second colored film is miscible with at least the first colored film, and comprises 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;

wherein;

the resin substrate intermixes with one or both of the first and second colored films to display a third color substantially throughout the resin substrate, regardless of ordering of the first and second colored films on the translucent resin substrate; and

the third color is a composite of the colors of the first and second colored films; and

applying a texture to an outside, non-bonding surface of the resin substrate and colored film combination, wherein a plurality of surfaces in the laminate resin structure comprise a textured finish.

30. The method as recited in claim 29, wherein the resin substrate comprises a thickness that is approximately 6 times the thickness of the first or second colored film.

31. The method as recited in claim 29, wherein the resin substrates comprises material selected from the group consisting of polycarbonate, polyester, PVC, acrylic, and combinations and polymer alloys thereof.

32. The method as recited in claim 29, wherein the first and second colored films comprise the same color, such that fusing the resin substrate and colored films results in the finished resin structure displaying the color at a higher intensity than when created with only one of the first or second colored films.

33. The method as recited in claim 29, further comprising:

positioning a white film layer about the second colored film;

wherein, when fused to the second colored film, the white film layer cooperates with one or more textured surfaces in the laminate resin structure to diffuse light.

34. The method as recited in claim 29, wherein at least the first colored film comprises a texture on the bonding surface that is different from a texture of the bonding surface of the resin substrate.

35. The method as recited in claim 34, wherein the texture of the second colored film comprises a uniform surface roughness that is different from a surface roughness of the first colored film at a bonding interface.

36. A method of preparing a laminate resin structure having a custom color created from a plurality of colored films, wherein the custom color of the plurality of films is diffused substantially throughout the laminate resin structure, regardless of viewing direction, 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 about a bonding surface of the resin substrate, wherein the first colored film comprises opposing bonding surfaces, a uniform texture on at least one of the bonding surfaces of the first colored film, and a glass transition temperature;

aligning a bonding surface of a second colored film about a bonding surface of the first colored film, wherein the second colored film is miscible at least with the first colored film, and comprises opposing bonding surfaces, a uniform texture on at least one of the bonding surfaces of the second colored film, and a glass transition temperature;

applying heat and pressure to meet or exceed the highest glass transition temperature of at least the first colored film and the second colored film; and

applying a textured finish to the aligned resin substrate and colored film combination, wherein a plurality of outside surfaces in the laminate resin structure comprise a textured finish;

wherein the first and second colored films intermix to create a substantially uniform third color that, in cooperation with each texture of the non-bonding and bonding surfaces, is diffused substantially throughout the resulting laminate resin structure regardless of viewing direction.

37. The method as recited in claim 36, wherein the textured finish on the plurality of outside surfaces of the laminate resin structure comprises a uniform distribution of texture granules.

38. The method as recited in claim 36, wherein the texture of the second colored film is different from a texture of the first colored film at a bonding interface between the first and second colored films.

39. The method as recited in claim 36, wherein a texture of the first colored film is different from a texture of the translucent resin substrate at a bonding interface between the first colored film and the translucent resin substrate.

40. The method as recited in claim 36, wherein the translucent resin substrate comprises a material selected from the group consisting of polycarbonate, polyester, PVC, acrylic, and combinations and polymer alloys thereof.

41. The method as recited in claim 40, wherein the translucent resin substrate is miscible with at least the first colored film.

42. The method as recited in claim 36, further comprising providing a lamination enhancer layer between the resin substrate and the first colored film.

43. The method as recited in claim 42, wherein the translucent resin substrate and at least the first colored film comprise heterogeneous materials.

44. The method as recited in claim 43, wherein:

the translucent resin substrate comprises one of PETG, a copolyester, polycarbonate, or acrylic; and

the first and second colored films are co-miscible with each other, but are heterogeneous with the translucent resin substrate.

45. A method of preparing a laminate resin structure having a custom color created from a plurality of colored films, wherein the custom color of the plurality of films is diffused substantially throughout the laminate resin structure, regardless of viewing direction, comprising:

providing a translucent resin substrate having a glass transition temperature;

providing a first colored film having a glass transition temperature about the translucent resin substrate;

providing one or more additional colored films about the first colored film, each of the one or more additional colored films comprising a glass transition temperature, wherein each of the one or more additional colored films is miscible with an adjacent colored film, or the first colored film;

wherein each interface between the resin substrate and first colored film, and between the first colored film and a next one of the one or more additional colored films, in succession, comprises opposing bonding surfaces having a texture of uniform surface roughness on each opposed bonding surface;

wherein the texture of the bonding surface of the resin substrate is different in surface roughness from that of the texture of the bonding surface of the first colored film;

applying heat and pressure to meet or exceed the highest glass transition temperature of each of the first colored film and one or more additional colored films, such that each of the first colored film and one or more additional colored films intermix to create a uniform new color; and

applying a textured finish to one or more outer surfaces of the resin substrate and colored film combination, wherein the textured finish of the one or more outer surfaces and one or more bonding surfaces cooperate to diffuse the uniform new color in the finished panel, such that the uniform new color is displayed substantially the same throughout the finished panel regardless of viewing direction or ordering of films.

46. The method as recited in claim 45, wherein the translucent resin substrate is miscible with at least the first colored film.

47. The method as recited in claim 46, wherein:

the translucent resin substrate comprises a uniform surface roughness on its bonding surface opposed to a bonding surface of the first colored film; and

the opposed bonding surface of the first colored film comprises a uniform surface roughness that is different from the surface roughness of the surface roughness of the resin substrate.

48. The method as recited in claim 46, wherein the surface roughness of the translucent resin substrate or of the first colored film is less than 20μ

inches, while the other opposed surface roughness is greater than 20μ

inches.

49. The method as recited in claim 45, further comprising providing a lamination enhancer layer between the resin substrate and the first colored film.

50. The method as recited in claim 49, wherein the translucent resin substrate and at least the first colored film comprise heterogeneous materials.

51. The method as recited in claim 45, wherein the translucent resin substrate comprises a material selected from the group consisting of polycarbonate, polyester, PVC, acrylic, and combinations and polymer alloys thereof.

52. The method as recited in claim 45, wherein applying heat and pressure further comprises:

meeting or exceeding the highest glass transition temperature of the translucent resin substrate;

wherein the translucent resin substrate intermixes at least with the first colored film.

53. The method as recited in claim 45, wherein a plurality of outside surfaces of the finished panel comprises a textured finish having a uniform distribution of texture granules.

54. The method as recited in claim 45, further comprising:

positioning one or more white film layers in or about the resin substrate and colored film combination;

wherein the one or more white film layers enhance diffusion of light in the finished panel.