Multivariate color system with texture application

• US 9,348,065 B2
• Filed: 07/31/2013
• Issued: 05/24/2016
• 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:
  US13/955,181
• Publication Number:
  US 20130316146A1
• Time in Patent Office: 1,028 Days
• US Class Current: 1/1
• 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 diffused 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, wherein the front or back surface comprises a bonding surface having a first surface roughness, the thickness defining a distance of opposing side wall surfaces that are perpendicular to the opposing front and back surfaces;

a 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 colored film layer has been fused to and intermixed with the bonding surface of the resin substrate; and

a highly uniform texture applied to each surface of the thermoplastic structure;

wherein;

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

the applied texture and intermixing of the translucent colored film layer cooperate to diffuse the color of the translucent colored film layer throughout the thermoplastic structure, such that the thermoplastic structure displays the color of the translucent colored film on all sides of the thermoplastic structure, regardless of the viewing direction.

2. The thermoplastic structure as recited in claim 1, wherein the transparent resin substrate has a thickness of 0.500 inches to 1 inch.

3. The thermoplastic structure as recited in claim 1, wherein the transparent resin substrate and the translucent colored film comprise the same resin material selected from the group consisting of PVC, polyester, acrylic, polycarbonate, and combinations thereof.

4. The thermoplastic structure as recited in claim 1, wherein the transparent resin substrate comprises PETG, and the translucent colored film comprises PVC or PCTG.

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

the translucent colored film is formed from a material selected from the group, consisting of PVC, polyester, acrylic, polycarbonate, and combinations thereof; and

the transparent resin substrate is formed from a different material in the same group, such that the transparent resin substrate material is different from the translucent colored film material selected from the group.

6. The thermoplastic structure as recited in claim 1, wherein both the transparent resin substrate and the translucent colored film comprise a surface roughness having an even distribution of texture granules.

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

the transparent resin substrate and the translucent colored film layer are fused together through application of heat and pressure; and

the heat applied during the fusing process exceeds the glass-transition temperature (Tg) of each of the transparent resin substrate and the translucent colored film layer.

8. The thermoplastic structure as recited in claim 1, wherein the thermoplastic structure is devoid of entrapped air or color streaking.

9. The thermoplastic structure as recited in claim 1, wherein the uniformly applied texture is mechanically applied.

10. The thermoplastic structure as recited in claim 9, wherein the uniformly applied texture is imparted via one or more textured rollers.

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

the transparent resin substrate has a bonding surface having first surface roughness; and

the translucent colored film layer has a bonding surface having a second surface roughness that is different from the first surface roughness.

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

one of the transparent resin substrate or the translucent colored film layer has a bonding surface that is greater than 20μ

inches; and

the other of the transparent resin substrate or the translucent colored film layer has a bonding surface that is less than 20μ

inches.

13. The thermoplastic structure as recited in claim 1, wherein the second surface roughness of the translucent colored film is up to 25 times the first surface roughness of the transparent resin substrate.

14. A decorative, translucent thermoplastic structure prepared from a plurality of dissimilar resin materials to have the appearance of a unitary structure having a color diffused 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 0.236 inches to 1 inch, the transparent resin substrate comprising a first resin material;

a translucent colored film made of a second resin material that is dissimilar to the first resin material, but that is nevertheless miscible with the first resin material, the translucent colored film being fused to and intermixed with the transparent resin substrate; and

a texture having been uniformly applied to all surfaces of a completed panel comprising the fused combination of the resin substrate and colored film layer;

wherein the uniformly applied texture combined with the intermixing of the combined resin substrate and colored film layer cooperate to diffuse the color of the colored film throughout the thermoplastic structure regardless of viewing angle on each viewing surface, and substantially uniformly on the plurality of adjacent edges.

15. The thermoplastic structure as recited in claim 14, wherein the transparent resin substrate has a thickness of 0.500 inches to 1 inch.

16. The thermoplastic structure as recited in claim 14, wherein the transparent resin substrate comprises PETG, and the translucent colored film comprises PVC or PCTG.

17. The thermoplastic structure as recited in claim 14, wherein:

the first resin material is selected from the group consisting of PVC, polyester, acrylic, polycarbonate, and combinations thereof; and

the second resin material comprises a dissimilar resin material selected from the same group, such that the second resin material is dissimilar to the first resin material selected from the group.

18. The thermoplastic structure as recited in claim 14, wherein both the transparent resin substrate and the translucent colored film comprise a surface roughness having an even distribution of texture granules.

19. The thermoplastic structure as recited in claim 14, wherein:

the transparent resin substrate and the translucent colored film layer are fused together through application of heat and pressure; and

the heat applied during the fusing process exceeds the glass-transition temperature (Tg) of each of the transparent resin substrate and the translucent colored film layer.

20. The thermoplastic structure as recited in claim 14, wherein the thermoplastic structure is devoid of entrapped air or color streaking.

21. The thermoplastic structure as recited in claim 14, wherein the uniformly applied texture is mechanically applied.

22. The thermoplastic structure as recited in claim 21, wherein the uniformly applied texture is imparted via one or more textured rollers.

23. The thermoplastic structure as recited in claim 14, wherein:

the transparent resin substrate has a bonding surface having first surface roughness; and

the translucent colored film layer has a bonding surface having a second surface roughness that is different from the first surface roughness.

24. The thermoplastic structure as recited in claim 23, wherein:

one of the first surface roughness or the second surface roughness is greater than 20μ

inches; and

the other of the first or second surface roughness is less than 20μ

inches.

25. The thermoplastic structure as recited in claim 23, wherein the second surface roughness is up to 25 times that of the first surface roughness.

26. A decorative, translucent thermoplastic structure prepared from a plurality of dissimilar resin materials to have the appearance of a unitary structure having a color diffused throughout its composition, the structure comprising:

a transparent resin substrate having opposing front and back surfaces and a plurality of adjacent edges that separate the opposing viewing surfaces by 0.500 inches to 1 inch, the transparent resin substrate comprising a first resin material, wherein the front or back surface comprises a bonding surface having a first surface roughness;

a translucent colored film made of a second resin material that is dissimilar to the first resin material, but that is nevertheless miscible with the first resin material, the translucent colored film having a bonding surface with a second surface roughness that is different from the first surface roughness, the bonding surface of the translucent colored film being fused to and intermixed with the bonding surface of the transparent resin substrate without any air pockets being trapped therein; and

a texture having been uniformly applied to all surfaces of a completed panel comprising the fused combination of the resin substrate and colored film layer;

wherein the uniformly applied texture combined with the intermixing of the combined resin substrate and colored film layer cooperate to diffuse the color of the colored film throughout the thermoplastic structure regardless of viewing angle on each viewing surface, and substantially uniformly on the plurality of adjacent edges.

27. The thermoplastic structure as recited in claim 26, wherein the transparent resin substrate comprises PETG, and the translucent colored film comprises PVC or PCTG.

28. The thermoplastic structure as recited in claim 26, wherein:

the first resin material is selected from the group consisting of PVC, polyester, acrylic, polycarbonate, and combinations thereof; and

the second resin material is a dissimilar resin material selected from the same group, such that the second resin material is dissimilar to the first resin material selected from the group.

29. The thermoplastic structure as recited in claim 26, wherein both the transparent resin substrate and the translucent colored film comprise a surface roughness having an even distribution of texture granules.

30. The thermoplastic structure as recited in claim 26, wherein:

the transparent resin substrate and the translucent colored film layer are fused together through application of heat and pressure; and

the heat applied during the fusing process exceeds the glass-transition temperature (Tg) of each of the transparent resin substrate and the translucent colored film layer.

31. The thermoplastic structure as recited in claim 26, wherein the thermoplastic structure is devoid of entrapped air or color streaking.

32. The thermoplastic structure as recited in claim 26, wherein the uniformly applied texture is mechanically applied.

33. The thermoplastic structure as recited in claim 32, wherein the uniformly applied texture is imparted via one or more textured rollers.

34. The thermoplastic structure as recited in claim 26, wherein:

one of the first surface roughness or the second surface roughness is greater than 20μ

inches; and

the other of the first or second surface roughness is less than 20μ

inches.

35. The thermoplastic structure as recited in claim 26, wherein the second surface roughness is up to 25 times that of the first surface roughness.