Formable fused polymer panels containing light refracting films
First Claim
1. A dichroic resin panel configured with sufficient aesthetic and structural properties for use as a building material in an architectural design environment, the dichroic resin panel comprising:
- a substantially translucent first resin substrate layer having a thickness of about 0.06 inches to about 2.0 inches;
a substantially translucent second resin substrate layer having a thickness of about 0.06 inches to about 2.0 inches and that corresponds with the first resin layer, wherein the first and second resin substrate layers are thermoplastic;
andone or more light refracting dichroic film layers laminated between the first and second resin layers, wherein the one or more light refracting dichroic film layers conform to the first and second resin layers without material defect;
andone or more tie layers positioned between the first and second resin layers and about each of one or more dichroic film layers;
wherein;
each of the one or more tie layers comprise melted or softened TPU between the one or more dichroic film layers and the first and second resin substrate layers;
the dichroic resin panel, by virtue of each dichroic film layer embedded therein displays the one or more dichroic film layers such that the dichroic resin panel absorbs or transmits one polarized light ray differently from another polarized light ray; and
wherein the combination is at least partially malleable and formable after a lamination process without delamination.
3 Assignments
0 Petitions
Accused Products
Abstract
A dichroic, light refracting resin panel comprises one or more dichroic/refracting films that have been embedded and/or laminated between a plurality of resin substrates, such as copolyester, polycarbonate, and/or acrylic substrates. The dichroic resin panel can be manufactured with a variety of different materials, and with autoclave or hot press methods in a manner that ensures structural and aesthetic integrity. Specifically, a dichroic resin panel in accordance with the present invention can be created in such a way as to avoid delamination despite a variety of end-uses and formations (e.g., curved panel, embossed/textured surfaces). In addition, the dichroic resin panels can be handled, transported, and installed in a variety of exterior or interior applications, even where certain building code requirements may be relatively stringent. The dichroic resin panels can be used in a variety of structural and/or aesthetic applications.
29 Citations
38 Claims
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1. A dichroic resin panel configured with sufficient aesthetic and structural properties for use as a building material in an architectural design environment, the dichroic resin panel comprising:
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a substantially translucent first resin substrate layer having a thickness of about 0.06 inches to about 2.0 inches; a substantially translucent second resin substrate layer having a thickness of about 0.06 inches to about 2.0 inches and that corresponds with the first resin layer, wherein the first and second resin substrate layers are thermoplastic;
andone or more light refracting dichroic film layers laminated between the first and second resin layers, wherein the one or more light refracting dichroic film layers conform to the first and second resin layers without material defect;
andone or more tie layers positioned between the first and second resin layers and about each of one or more dichroic film layers; wherein; each of the one or more tie layers comprise melted or softened TPU between the one or more dichroic film layers and the first and second resin substrate layers; the dichroic resin panel, by virtue of each dichroic film layer embedded therein displays the one or more dichroic film layers such that the dichroic resin panel absorbs or transmits one polarized light ray differently from another polarized light ray; and wherein the combination is at least partially malleable and formable after a lamination process without delamination. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 23, 24, 26, 27, 28, 29)
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12. A method of manufacturing a post-formable, dichroic resin panel, sufficiently structural for use as a building material in an architectural design environment, comprising a light refracting dichroic film, wherein the dichroic resin panel can be modified or formed during or after lamination without cracking, wrinkling, or otherwise distorting the refracting film layer dichroic film during the manufacturing forming process, the method comprising the steps of:
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preparing a dichroic laminate assembly comprising one or more light refracting dichroic films and one or more tie layers interposed between a plurality of resin substrates, wherein each of the resin substrates has comprises a translucent thermoplastic sheet having a thickness of about 0.06 inches to about 2.0 inches, and the one or more tie layers comprise a thermoplastic sheet consisting essentially of EVA, EMA, PVB, or TPU; heating the dichroic laminate assembly in a lamination apparatus to a temperature of no more than about 250°
F. to about 260°
F., wherein the one or more tie layers soften or melt between the plurality of resin substrates;cooling the dichroic laminate assembly, wherein the dichroic laminate assembly comprises a substantially unitary resin panel; and removing the unitary resin panel from the lamination apparatus; wherein the unitary resin panel comprises a thermoplastic panel that displays the one or more dichroic films, and can be heated and molded after cooling from a planar shape into one or more curved shapes. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 25)
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20. A dichroic laminate assembly configured so that, when subject to a lamination temperature of up to about 250°
- F. to no more than about 260°
F. in an autoclave or hot press, bonds one or more resin substrates to a dichroic film in a manner that preserves the integrity of the dichroic film and prevents the resulting dichroic resin panel from delamination, comprising;a plurality of resin substrates having a total thickness of about 0.12 inches to about 4.0 inches, comprising a translucent thermoplastic sheet consisting of one of a copolyester material, a polycarbonate material, or a mixture thereof; one or more light refracting dichroic films positioned between the plurality of resin substrates in a stack formation; and a plurality of TPU tie layers positioned between the plurality of resin substrates in the stack formation; wherein; each TPU tie layer is positioned against at least one surface of each of the resin substrates; and each of the one or more light refracting dichroic films is positioned adjacent two TPU tie layers on opposing sides; wherein the dichroic laminate assembly displays the one or more dichroic films through the plurality of translucent resin substrates, and the dichroic laminate assembly is formable after a lamination process. - View Dependent Claims (21, 22)
- F. to no more than about 260°
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30. A dichroic resin panel configured with sufficient aesthetic and structural properties for use as a building material in an architectural design environment, the dichroic resin panel comprising:
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a translucent first resin substrate layer having a thickness of about 0.06 inches to about 2.0 inches; a translucent second resin substrate layer having a thickness of about 0.06 inches to about 2.0 inches and that corresponds with the first resin layer, wherein the first and second resin substrate layers are thermoplastic; one or more dichroic film layers laminated between the first and second resin layers, wherein the one or more dichroic film layers conform to the first and second resin layers without material defect; and one or more tie layers positioned between the first and second resin layers and about each of one or more dichroic film layers; wherein; each of the one or more tie layers comprise softened or melted EVA, or EMA between the one or more dichroic film layers and the first and second resin substrate layers; the dichroic resin panel, by virtue of each dichroic film layer embedded therein, absorbs or transmits one polarized light ray differently from another polarized light ray; and the combination is at least partially malleable and formable after a lamination process without delamination and without wrinkling of the one or more dichroic film layers. - View Dependent Claims (31, 32, 33, 34, 35, 36, 37, 38)
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Specification