Multivariate color system with texture application

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.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is a divisional of U.S. patent application Ser. No. 12 / 376,156, filed on Feb. 3, 2009, entitled, “Multivariate Color System with Texture Application,” which is a U.S. National Stage Application corresponding to PCT Application No. PCT / US08 / 63124, filed on May 8, 2008, entitled “Multivariate Color System with Texture Application,” which claims the benefit of priority to U.S. Provisional Patent Application No. 60 / 916,803, filed on May 8, 2007, entitled “Multivariate Color System.” The entire content of each of the aforementioned patent applications is incorporated herein by reference.BACKGROUND OF THE INVENTION[0002]1. The Field of the Invention[0003]This invention relates to translucent and / or transparent polymer-based panel assemblies that incorporate colors through applied colored film layers.[0004]2. Background and Relevant Art[0005]Laminated translucent panel systems have achieved a wide utility in designed architectur...

AI Technical Summary

Benefits of technology

"The present invention is related to a translucent and / or transparent polymer-based panel system that incorporates multiple colored layers. These layers enable manipulation of color, transparency, or light transmission of the finished panel system. The invention also addresses deficiencies and limitations in conventional commercial architectural and lighting panel systems. The invention includes a thermoplastic structure with a substantially transparent polymer substrate and one or more colored film layers laminated thereto, which can impart color to the entire structure. The polymer substrate is thicker than the colored film layers, and the colored film layers have a surface roughness that reduces air-entrapment during manufacture. The system also includes one or more textured rollers configured to provide texture to the resin panel assembly. The features and advantages of the invention include improved color control, light transmission, and reduced air-entrapment."

Problems solved by technology

Many of the aforementioned coloring systems introduce aesthetic, performance or manufacturing constraints when combined with the aforementioned polymer-based or glass-based panel systems.

Drawbacks of screen printing include the fact that the ink may be scratched off of the panel surface.

In addition, the ink typically needs to be bonded to the panel with bonding additives that are often solvent-based and often produce undesirable volatile organic compound (VOC) emissions.

Additionally, painting, and more particularly cleanup from painting, also results in undesirable VOC emissions.

Moreover, colors or images applied through screen printing or painting are only correctly viewable from one side of the panel.

Also, panels colored or decorated using these methods tend to require cure times of between four and twelve hours, during o which time the panels require special storage and possibly drying units.

The dye sublimation method, however, requires considerable technical expertise to create the digital master files and an understanding of the interaction of the dye with the substrate.

Dye sublimation is also a capital-intensive operation that tends to require specialized printing equipment.

Although this method is not entirely capable of rendering a predetermined image, the color driven into the surface of the panel in this way does yield a homogeneous color, and is more resilient to surface abrasion than colors applied directly through screen printing or painting.

Unfortunately, this chemical process consumes large amounts of energy.

In addition, the equipment required to employ this method is very costly.

Furthermore, it takes a significant amount of time to change over between one color and the next because the system must undergo a cleaning cycle to flush out each color after use.

Using colored textiles to achieve a uniform panel color, however, presents several challenges.

One challenge is that fabric has a texture of its own that remains visible through the translucent or transparent thermoplastic panel.

In addition, while colored textiles may be used selectively to control the translucency of a panel, they tend to impair the transparency of a panel.

Moreover, thermoplastic panels with textile interlayers are not generally suitable for wet environments without additional fabrication precautions, because the fabric at the exposed edges of the panel will wick moisture into the interior of the panel.

This wicking action through the fabric layer introduces color distortion and staining within the panel.

Also, fabric interlayers interfere with recycling because they can not be easily separated from the resin substrate.

In addition, care must be taken when laying up fabric interlayers because if they are not placed straight and taut, the fabric layer can create the appearance of waves.

Otherwise the panel, once constructed, will bow as it cools, and the bowing is an undesirable characteristic.

Also, fabric layers within panels reduce the ability to thermoform the panels since the fabric will separate or pull away under deep draw conditions due to the physical limitations of the fabric.

A last disadvantage of fabric layers within panels is that the fabric may wick moisture into the body of the laminated panel if edges are exposed to wet environments.

Accordingly, with this technology, there are at least two interfaces where air entrapment can be a problem.

In addition, panels constructed for high-relief surfaces, when incorporated with a fabric or a printed or a colored image, may experience wrinkling of the fabric or unusual distortion of the color or image when captured between a top layer that is heavily textured and a back layer.

Removal of air from the panels is important, since any air pockets that remain in a finished panel can create a notch—or point of weakness—with the laminate matrix that can result in crack propagation and failure in notch-sensitive thermoplastic materials.

Applying a laminating enhancing layer tends to require additional processing steps, and increases material costs and introduces potential for contamination.

Furthermore, the laminating enhancing layer, whether an actual film or a sprayed-on material, is not generally the same material as the substrate.

Similar to fabric interlayers mentioned above, this dissimilarity contributes to the inability of such panels to be reclaimed and recycled because the dissimilar material would be a contaminant in the recycling stream for the panel substrate which constitutes the majority of the panel.

A drawback of using colored films or sheets under the conventional art is that, typically, colored films are produced in large quantities to achieve economies of scale.

Such high-volume purchase requirements can lead to unnecessary expense do to inventory obsolescence.

Incorporating a laminating enhancing layer not only increases the processing steps and materials required, but also, such additional inputs can increase the potential occurrence of manufacturing defects or contamination within the laminate.

Such conventional mechanisms use a backing layer, which can overcome the increased level of defects caused by the additional processing requirements, but, in the process, further increase the processing requirements.

Furthermore, the backing layer may or may not be of optical quality, and could reduce the transparency or translucency, or both, of the resulting panel.

In addition, colored PVB films, while necessary in the laminated glass composition, may contain plasticizers, which may not be compatible with certain thermoplastics such as the copolyester known as PETG, (i.e., polyethylene-co-cyclohexane 1,4-dimethanol terephthalate), polycarbonate, or acrylic (e.g., polymethyl methacrylate, or PMMA).

Furthermore, PVB tends to require special handling and storage conditions including refrigeration.

Such requirements can add expense to the use of PVB in laminations.

Also, plasticizers used in PVB are known to craze polycarbonate when used in laminations with polycarbonate.

Such films are available in a variety of colors from such companies as Sekesui; however, such films are not ideal for use on the surface of panels due to the fact that they attract dirt and debris, making them difficult to use.

The surface tends to be very sticky and has a low surface roughness, which often requires that a vacuum be used to remove air during lamination.

Further, EVA has a limitation if used to construct interior architectural paneling applications due to its o relatively high flammability.

As noted above, an inherent challenge in manufacturing laminate panels is avoidance of the tendency of the panels to retain air between the layers unless preventative measures are taken to remove the air.

Use of laminating enhancing layers and / or vacuum bagging, however, requires additional lay-up and processing steps and materials, all of which increase expense.

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