Laminate structure with polycarbonate sheets and method of making

Abstract

Disclosed is a decorative laminate structure having at least two sheets of polycarbonate and at least one decorative image layer there-between two sheets of polycarbonate, and a method of making the decorative laminate structure. Through heat and pressure the sheet layers and the decorative image layer are bonded together resulting in a decorative laminate structure of this invention. This product is intended for use primarily to produce decorative articles which include counter tops, table tops, cabinet doors, game boards, toys, panels for shower stalls, hot tubs, markerboards, indoor and outdoor signs, seamless vanity tops including sink, soap dish, back splash, flooring and others.

1 . A method of making a decorative laminate structure comprising: 
 providing a first sheet comprising polycarbonate, the first sheet having a thickness between 0.13 and 12.7 mm;    providing a second sheet comprising polycarbonate, the second sheet having a thickness between 0.13 and 12.7 mm;    providing a decorative image layer between the first and second sheet; and    heating and pressing the first and second sheet with the decorative image layer there-between at a maximum temperature between 193 and 249.degree. C. and a maximum pressure between 138 and 2069 kPa, wherein the time at maximum temperature and pressure is between 0.1 and 20 minutes.    
     
     
         2 . The method of  claim 1 , wherein heating and pressing of the first and second sheet with the decorative image layer there-between occur at a maximum temperature between 210 and 227.degree. C. and a maximum pressure between 448 and 662 kPa, wherein the time at the maximum temperature and pressure is 0.1 to 5 minutes.  
     
     
         3 . The method of  claim 1 , wherein heating and pressing of the first and second sheet with the decorative image layer there-between occur at a maximum temperature between 210 and 227.degree. C. and a maximum pressure of 634 kPa (92 psi), wherein the time at the maximum temperature and pressure is about 0.17 minute.  
     
     
         4 . The method of  claim 1 , wherein the decorative image layer is selected from the group consisting of fabric, metallic wire, rod, bar, wood, stone, paper, and photographic images.  
     
     
         5 . The method of  claim 1 , wherein the decorative image layer comprises vegetation.  
     
     
         6 . The method of  claim 5 , wherein vegetation is selected from the group consisting of wood chips, grasses, thatch, flowers, flower petals, wheat, grains, and natural papers.  
     
     
         7 . The method of  claim 1 , wherein the decorative image layer comprises crushed glass.  
     
     
         8 . The method of  claim 1 , wherein the thickness of the first sheet is between 0.74 and 10 mm thick.  
     
     
         9 . The method of  claim 1 , wherein the thickness of the first sheet is between 1.48 and 6.35 mm thick.  
     
     
         10 . The method of  claim 1 , wherein the thickness of the first sheet is between 2.22 and 6.35 mm thick.  
     
     
         11 . The method of  claim 1 , wherein the thickness of the decorative image layer is between 0.0254 and 1.524 mm thick.  
     
     
         12 . The method of  claim 1 , wherein the thickness of the decorative image layer is between 0.0254 and 0.05 mm thick.  
     
     
         13 . The method of  claim 1 , wherein the thickness of the decorative image layer is about 0.04 mm.  
     
     
         14 . The method of  claim 1 , wherein the thickness of the second layer is between 0.74 and 10 mm thick.  
     
     
         15 . The method of  claim 1 , wherein the thickness of the second layer is between 1.48 and 6.35 mm thick.  
     
     
         16 . The method of  claim 1 , wherein the thickness of the second sheet is between 2.22 and 6.35 mm thick.  
     
     
         17 . The method of  claim 1 , further comprising removing air by vacuum prior to heating and pressing.  
     
     
         18 . The method of  claim 1 , further comprising cooling the first and second sheet with the decorative image layer there-between at a temperature between 10 to 149.degree. C. and pressure between 7 and 2069 kPa.  
     
     
         19 . The method of  claim 18 , wherein cooling the first and second sheet with the decorative image layer there-between is at a temperature between 21.1 to 32.2.degree. C. and pressure between 448 and 662 kPa.  
     
     
         20 . The method of  claim 19 , wherein cooling the first and second sheet with the decorative layer there-between is at pressure between 552 to 662 kPa.  
     
     
         21 . The method of  claim 19 , wherein cooling the first and second sheet with the decorative layer there-between is at pressure of 634 kPa.  
     
     
         22 . The method of  claim 1 , further comprising providing a protective layer, wherein the protective layer is applied on at least one surface of the first sheet.  
     
     
         23 . The method of  claim 22 , wherein the protective layer is a bilayer film.  
     
     
         24 . The method of  claim 22 , wherein the protective layer is selected from the group consisting of UV-cured or electron-beam-cured crosslinked acrylic, vacuum-cured or UV-cured urethane, UV-cured or electron-beam-cured silicon with acrylic or heat cured urethane or plastisol, and combinations thereof.  
     
     
         25 . The method of  claim 22 , wherein the protective layer is UV-cured or electron-beam-cured silicon.  
     
     
         26 . The method of  claim 1 , further comprising providing cast paper or embossing paper.  
     
     
         27 . The method of  claim 26 , wherein cast paper or embossing paper is selected from the group consisting of patent paper, patina, matte, stucco, ostrich, reptilian, glitter, topaz, grid, and allegro.  
     
     
         28 . The method of  claim 26 , wherein the cast paper or embossing paper is disposed between a metal plate and an exterior surface of the first sheet or protective layer.