Textured structure and method of making a textured structure

Abstract

The present application is directed to textured surfaces and methods for forming textured surfaces. The textured surfaces of the present application comprise a conformable film, which conforms to a texture pattern. In certain embodiments, the texture pattern comprises inks having a desired thickness. The methods of the present application may be used to form textured surfaces for a variety of applications, including, for example, aircraft having at least one interior panel with a textured surface.

What is claimed is: 
     
         1 . A method of forming a laminate having a textured surface, wherein the laminate includes a conformable film having a first major surface and an opposing second major surface, the method comprising:
 depositing a texture pattern, comprising an ink having a first thickness, on the first major surface of the conformable film;   bonding the first major surface of the conformable film to a substrate; and   subjecting the conformable film to a temperature and pressure sufficient to cause the conformable film to deform around the texture pattern to form the textured surface comprising raised surface portions and lower surface portions of the opposing second major surface of the conformable film.   
     
     
         2 . The method of  claim 1 , wherein the depositing the texture pattern on the first major surface of the conformable film comprises depositing the ink on the first major surface of the conformable film using a printing process. 
     
     
         3 . The method of  claim 2 , wherein the printing process comprises a digital printing process or a silk screening process. 
     
     
         4 . The method of  claim 1  wherein the subjecting the conformable film to the temperature and the pressure is performed during the bonding of the first major surface of the conformable film to the substrate. 
     
     
         5 . The method of  claim 5 , wherein the bonding the first major surface of the conformable film to the substrate comprises subjecting the laminate to a bonding temperature while employing a vacuum to cause the laminate to bond to the substrate. 
     
     
         6 . The method of  claim 6 , wherein the bonding temperature ranges from about 70° F. to about 400° F., and the pressure ranges from about 8 inches Hg to about 25 inches Hg. 
     
     
         7 . The method of  claim 1 , wherein the substrate comprises an aircraft panel. 
     
     
         8 . The method of  claim 1 , further comprising forming a colored texture pattern using the ink, the textured pattern showing through the conformable film so as to be at least partially visible to a naked eye. 
     
     
         9 . The method of  claim 1 , wherein the depositing the texture pattern on the first major surface of the conformable film comprises depositing the ink, with the first thickness of the ink being at least 0.8 mil, on the first major surface of the conformable film. 
     
     
         10 . The method of  claim 1 , wherein the method of forming the laminate having the textured surface consists of: depositing the texture pattern on the first major surface of the conformable film; bonding the first major surface of the conformable film to the substrate; and subjecting the conformable film to the temperature and the pressure sufficient to cause the conformable film to deform around the texture pattern to form the textured surface comprising the raised surface portions and the lower surface portions of the opposing second major surface of the conformable film. 
     
     
         11 . A method of forming a laminate having a textured surface comprising:
 depositing a texture pattern, comprising a material having a first thickness, on a first major surface of a conformable film;   bonding the first major surface of the conformable film to a substrate; and   subjecting the conformable film to a temperature and pressure sufficient to cause the conformable film to deform around the texture pattern to form a textured surface comprising raised surface portions and lower surface portions of an opposing second major surface of the conformable film.   
     
     
         12 . The method of  claim 11 , wherein the depositing the texture pattern on the first major surface of the conformable film comprises depositing ink on the first major surface of the conformable film using a printing process. 
     
     
         13 . The method of  claim 12 , wherein the printing process comprises a digital printing process. 
     
     
         14 . The method of  claim 12 , wherein the printing process comprises a silk screening process. 
     
     
         15 . The method of  claim 11  wherein the subjecting the conformable film to the temperature and the pressure sufficient to cause the conformable film to deform around the texture pattern to form the textured surface is done during the bonding of the first major surface of the conformable film to the substrate. 
     
     
         16 . The method of  claim 15 , wherein the bonding the first major surface of the conformable film to the substrate comprises subjecting them to a bonding temperature while employing a vacuum to cause the bonding. 
     
     
         17 . The method of  claim 16 , wherein the bonding temperature ranges from about 70° F. to about 400° F., and the pressure ranges from about 8 inches Hg to about 25 inches Hg. 
     
     
         18 . The method of  claim 11 , wherein the substrate comprises an aircraft panel. 
     
     
         19 . The method of  claim 11 , further comprising the material forming a colored texture pattern which shows through the conformable film so as to be at least partially visible to a naked eye. 
     
     
         20 . The method of  claim 11 , wherein the method of forming the laminate having the textured surface consists of: depositing the texture pattern on the first major surface of the conformable film; bonding the first major surface of the conformable film to the substrate; and subjecting the conformable film to the temperature and the pressure sufficient to cause the conformable film to deform around the texture pattern to form the textured surface comprising the raised surface portions and the lower surface portions of the opposing second major surface of the conformable film