Multivariate color system with texture application

• US 8,617,695 B2
• Filed: 05/15/2012
• Issued: 12/31/2013
• 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): Khatri, Prashant J
• Application Number:
  US13/472,336
• Publication Number:
  US 20120225265A1
• Time in Patent Office: 595 Days
• Field of Search: None
• US Class Current: 428/212
• 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 decorative, translucent thermoplastic structure formed to have the appearance of a unitary color throughout its composition, the structure comprising:

a substantially translucent resin substrate having opposing front and back surfaces, wherein the front or back surface comprises a bonding surface having a first surface roughness;

a first translucent colored film layer that has a bonding surface with a second surface roughness that is different from the first surface roughness, wherein the bonding surface of the first colored film layer has been fused to and intermixed with the bonding surface of the resin substrate; and

a second translucent colored film layer fused to at least the first colored film layer on the same side of the resin substrate to which the first colored film layer is fused, such that the resin substrate is fused to at least the first colored film;

wherein;

the surface roughness of at least one of the bonding surfaces of the resin substrate or the first colored film comprises an even distribution of texture granules;

the fused first and second colored film layers impart a combined color throughout the thermoplastic structure, such that the combined color of the thermoplastic structure remains the same throughout the thermoplastic structure regardless of the viewing direction; and

the resin substrate is thicker than the first and second colored film layers.

2. The thermoplastic structure as recited in claim 1, wherein the substrate and at least the first colored film comprise the same resin material.

3. The thermoplastic structure as recited in claim 1, wherein the substrate is made from different materials selected from the group consisting of polycarbonate, polyester, PVC, acrylic, and combinations thereof, and the first or second colored films are made from a material that is different from that selected for the resin substrate.

4. The thermoplastic structure as recited in claim 1, wherein:

the contrast in surface roughness between the first colored film and the resin substrate facilitates removal of air during fusion, while the even distribution of granules preserves even color intensity in the thermoplastic structure.

5. The thermoplastic structure as recited in claim 1, wherein the first colored film is formed from a material selected from the group consisting of PVC, polyester, acrylic and polycarbonate.

6. The thermoplastic structure as recited in claim 1, wherein the resin substrate is formed of a material selected from the group consisting of PVC, polyester, acrylic and polycarbonate.

7. The thermoplastic structure as recited in claim 1, further comprising one or more fabric layers laminated to the resin substrate.

8. The thermoplastic structure as recited in claim 7, wherein:

color from the first and second colored films combines with the one or more fabric layers; and

the thermoplastic structure portrays a combination of the one or more fabric layers and the combined color throughout the thermoplastic structure.

9. A laminate assembly configured to have a unitary color throughout its composition regardless of the viewing direction when subjected to a lamination process, the assembly comprising:

one or more translucent resin substrates, each having opposing front and back surfaces; and

a plurality of translucent colored film layers that are miscible with the translucent resin substrates, and fused to at least one of the front and back surfaces of the one or more substrates;

wherein;

each colored film of the plurality of film layers has a surface roughness that reflects evenly distributed texture granules on a surface to be bonded, and that is substantially greater than a surface roughness of the front and back surfaces of the one or more substrates, thereby reducing incidences of color streaking and of air-entrapment between the bonding surfaces of the plurality of film layers and the one or more substrates during manufacture of the structure;

the plurality of colored films are selected in composition to fuse to and intermix with one side of one of the one or more substrates during manufacture to create a translucent resin structure;

the manufactured translucent resin structure displays a new color on all viewing surfaces of the manufactured structure regardless of the viewing direction; and

the new color represents a combination of each color in the plurality of translucent colored films.

10. The laminate assembly as recited in claim 9, wherein the surface roughness of each film of the plurality of film layers is greater than 20 μ

inches.

11. The laminate assembly as recited in claim 9, wherein the surface roughness of the front and back surfaces of the one or more substrates is less than 20 μ

inches.

12. The laminate assembly as recited in claim 9, wherein at least one film of the plurality of film layers has an image printed thereon.

13. The laminate assembly as recited in claim 9, wherein the one or more substrates and the plurality of film layers are fused together through application of heat and pressure.

14. The laminate assembly as recited in claim 13, wherein the heat applied during the fusing process exceeds the glass-transition temperature (T_g) of each of the one or more substrates and the plurality of film layers.

15. The laminate assembly as recited in claim 14 wherein the one or more substrates and the plurality of film layers are further fused together through application of adhesives.

16. A decorative, translucent thermoplastic structure formed to have the appearance of a unitary, custom color throughout its composition, the structure comprising:

a translucent, first colored film having a first color;

a translucent, second colored film having a second color; and

a translucent resin substrate fused to one or both of the first or second colored films on one side of the translucent resin substrate, such that the translucent resin substrate is intermixed with at least the first translucent colored film;

wherein;

the translucent resin substrate comprises a unitary resin extrusion of a material selected from the group consisting of polycarbonate, polyester, PVC, acrylic, and combinations thereof;

an interface between one or more of the first colored film, the second colored film and the translucent resin substrate comprises a surface roughness that reflects a uniform distribution of texture granules;

the resin substrate displays a custom third color uniformly throughout opposing front and back surfaces of the panel regardless of viewing direction; and

the custom third color is a combination of at least the first and second colors from the first and second translucent colored films.

17. The decorative thermoplastic structure as recited in claim 16, wherein each of the first colored film, the second colored film and the resin substrate comprises a bonding surface that is fused to an opposed bonding surface of another of the first colored film, the second colored film, or the resin substrate.

18. The decorative thermoplastic structure as recited in claim 17, wherein, prior to fusion of the opposed bonding surfaces, the opposed bonding surfaces comprise a different surface roughness with respect to each other.

19. The decorative thermoplastic structure as recited in claim 17, wherein, prior to fusion of the opposed bonding surfaces, a surface roughness of the first colored film is greater than a surface roughness of the opposed bonding surface of the resin substrate.

20. The decorative thermoplastic structure as recited in claim 17, wherein, prior to fusion of the opposed bonding surfaces, one or both of the opposed bonding surfaces comprises a surface roughness reflective of an even distribution of texture granules.

21. A decorative, translucent thermoplastic structure formed to have the appearance of a unitary color throughout its composition, the structure comprising:

a transparent resin substrate having opposing front and back surfaces separated by a thickness of 0.236 inches to 1 inch;

a first translucent colored film layer bonded to one of the front or back surface of the resin substrate;

at least a second translucent colored film layer fused to and intermixed with at least the first colored film layer; and

a texture applied to the combination of the resin substrate and colored film layers;

wherein;

the fused colored film layers impart a combined custom color throughout the thermoplastic structure that is different from the first or at least second colored films in isolation; and

the combined custom color is diffused and displayed substantially uniformly throughout the thermoplastic structure regardless of viewing direction.

22. The thermoplastic structure as recited in claim 21, wherein:

the resin substrate is miscible with the first colored film; and

the resin substrate is fused to and intermixed with at least the first colored film.

23. The thermoplastic structure as recited in claim 21, further comprising a laminating enhancing layer positioned between the resin substrate and the first colored film layer.

24. The thermoplastic structure as recited in claim 21, further comprising one or more white film layers bonded to the thermoplastic structure.

25. The thermoplastic structure as recited in claim 24, wherein:

the one or more white film layers are further fused to and intermixed with the first or second film layer; and

the one or more white film layers are visibly inseparable from the first or second film layers.

26. The thermoplastic structure as recited in claim 21, wherein the substrate and the film layers are fused together through application of heat and pressure.

27. The thermoplastic structure as recited in claim 26, wherein the heat applied during the fusing process exceeds the glass-transition temperature (T_g) of each of the resin substrate and the film layers.

28. The thermoplastic structure as recited in claim 21, wherein:

the surface of the resin substrate to which the first colored film layer is bonded comprises a first surface roughness comprising an even distribution of texture granules; and

the first colored film layer comprises a second surface roughness adjacent the bonding surface of the resin substrate; and

the second surface roughness is different from the first surface roughness.

29. The thermoplastic structure as recited in claim 21, wherein the first colored film is formed from a material selected from the group consisting of PVC, polyester, acrylic and polycarbonate.

30. The thermoplastic structure as recited in claim 21, wherein the resin substrate is formed of a material selected from the group consisting of PVC, polyester, acrylic and polycarbonate.

31. The thermoplastic structure as recited in claim 21, wherein the resin substrate is at least 0.500 inches thick.

32. The thermoplastic structure as recited in claim 21, wherein the transparent resin substrate comprises a plurality of unitary sheets fused together.

33. A decorative, translucent thermoplastic structure prepared from a plurality of colored film layers to have the appearance of a unitary custom color throughout its composition, the structure comprising:

a transparent resin substrate having opposing viewing surfaces and a plurality of adjacent edges that separate the opposing viewing surfaces by a thickness 0.236 inches to 1 inch;

a plurality of translucent colored films that are fused to and intermixed with each other, the plurality of colored films being bonded to one of the opposed viewing surfaces of the translucent resin substrate; and

a texture applied to the combination of the resin substrate and bonded plurality of colored film layers;

wherein;

the plurality of fused colored film layers impart a combined custom color throughout the translucent thermoplastic structure, the combined custom color being different from the color of any colored film of the plurality of colored films in isolation;

the combined custom color is diffused and displayed uniformly throughout the thermoplastic structure regardless of viewing angle on each viewing surface, and substantially uniformly on the plurality of adjacent edges.

34. The thermoplastic structure as recited in claim 33, wherein:

the surface of the resin substrate to which the plurality of colored films is bonded comprises a first surface roughness comprising an even distribution of texture granules; and

the plurality of colored films comprises a second surface roughness adjacent the bonding surface of the resin substrate; and

the second surface roughness is different from the first surface roughness.

35. The thermoplastic structure as recited in claim 33, wherein the plurality of colored films is formed from a material selected from the group consisting of PVC, polyester, acrylic and polycarbonate.

36. The thermoplastic structure as recited in claim 33, wherein the resin substrate is formed of a material selected from the group consisting of PVC, polyester, acrylic and polycarbonate.

37. The thermoplastic structure as recited in claim 33, further comprising a lamination enhancing layer bonded to the resin substrate and the plurality of colored films.

38. The thermoplastic structure as recited in claim 33, wherein the transparent resin substrate is at least 0.500 inches thick.

39. The thermoplastic structure as recited in claim 33, wherein the transparent resin substrate comprises a plurality of unitary sheets fused together.

40. A decorative, translucent thermoplastic structure prepared from a plurality of colored film layers to have the appearance of a unitary custom color throughout its composition even though the plurality of colored film layer are laminated to only one side of a resin substrate, the translucent thermoplastic structure comprising:

a transparent resin substrate comprising a unitary sheet, or a plurality of unitary sheets fused together, the translucent resin substrate having opposing viewing surfaces and a plurality of adjacent edge surfaces that separate the opposing viewing surfaces by a thickness of 0.236 inches to 1 inch;

a plurality of translucent colored films that are fused to and intermixed with each other, the plurality of colored films being further fused to and intermixed with one of the opposed viewing surfaces of the translucent resin substrate; and

a texture applied to multiple surfaces of the resin substrate, including one or more of the opposing viewing surfaces, and one or more of the adjacent edge surfaces;

wherein;

the plurality of fused colored film layers impart a combined custom color that is diffused and displayed substantially uniformly throughout each textured surface of the translucent thermoplastic structure; and

the combined custom color is different from the color of any colored film of the plurality of colored films in isolation.

41. The thermoplastic structure as recited in claim 40, wherein:

the surface of the resin substrate to which the plurality of colored films is bonded comprises a first surface roughness comprising an even distribution of texture granules; and

the plurality of colored films comprises a second surface roughness adjacent the bonding surface of the resin substrate; and

the second surface roughness is different from the first surface roughness.

42. The thermoplastic structure as recited in claim 40, wherein the plurality of colored films is formed from a material selected from the group consisting of PVC, polyester, acrylic and polycarbonate.

43. The thermoplastic structure as recited in claim 40, wherein the resin substrate is formed of a material selected from the group consisting of PVC, polyester, acrylic and polycarbonate.

44. The thermoplastic structure as recited in claim 40, further comprising a lamination enhancing layer bonded to the plurality of colored films.

45. The thermoplastic structure as recited in claim 40, wherein the transparent resin substrate is at least 0.500 inches thick.