Formable fused polymer panels containing light refracting films

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.

We 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; and 
 one 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; 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 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. 
 
     
     
       2. The dichroic resin panel as recited in  claim 1 , wherein the form of the translucent first and second resin layers is curved. 
     
     
       3. The dichroic resin panel as recited in  claim 2 , wherein each of the one or more tie layers comprise melted or softened TPU between the one or more light refracting film layers and the first and second resin substrate layers. 
     
     
       4. The dichroic resin panel as recited in  claim 2 , wherein each of the one or more tie layers comprise softened or melted ethylene-vinyl acetate, or ethyl-methyl acrylate between the one or more light refracting film layers and the first and second resin substrate layers. 
     
     
       5. The dichroic resin panel as recited in claim  2  1, wherein the one or more tie layers are between about 0.005 and about 0.125 inches thick. 
     
     
       6. The dichroic resin panel as recited in  claim 1 , further comprising one or more tie layers positioned between the first and second resin layers and about each of one or more light refracting film layers. 
     
     
       7. The dichroic resin panel as recited in  claim 1 , wherein one or both of the first or second resin substrate layers is embossed or textured on an outer surface thereof. 
     
     
       8. The dichroic resin panel as recited in  claim 7 , further comprising one or more additional, non-textured or non-embossed resin substrate layers embedded between the first and second substrate layers. 
     
     
       9. The dichroic resin panel as recited in  claim 8 , wherein the one or more additional resin substrates are thinner in dimension than the first and second resin substrates. 
     
     
       10. The dichroic resin panel as recited in  claim 8 , wherein each resin substrate layer in the dichroic resin panel comprises a copolyester material, a polycarbonate material, or combinations thereof. 
     
     
       11. The dichroic resin panel as recited in  claim 8 , wherein each resin substrate layer in the dichroic resin panel comprises a translucent thermoplastic material including one or more of a polycarbonate styrene material, a polyvinyl chloride material, a polyurethane material, or combinations thereof. 
     
     
       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:
 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. 
 
     
     
       13. The method as recited in  claim 12 , wherein the lamination apparatus comprises an autoclave, the method further comprising:
 raising the autoclave to a final temperature of between 210° F. to about 250° F.; and 
 raising the pressure of the autoclave to between about 110 psi to about 170 psi. 
 
     
     
       14. The method as recited in  claim 13 , further comprising the steps for:
 positioning one or more dichroic laminate assemblies in corresponding one or more vacuum bags; and 
 sealing the one or more vacuum bags. 
 
     
     
       15. The method as recited in  claim 14 , further comprising the steps of:
 cooling the unitary resin panel in the autoclave; and 
 forming the unitary resin panel with into one or more curved shapes in the autoclave. 
 
     
     
       16. The method as recited in  claim 12 , wherein the lamination apparatus comprises at least a hot press and a cold press, wherein the step for heating the dichroic laminate assembly is performed in the hot press at a temperature of between about 250° F. to about 260° F. using a pressure of between about 70 psi to about 150 psi. 
     
     
       17. The method as recited in  claim 16 , wherein the step for cooling the dichroic laminate assembly further comprises applying one or more texture or embossing papers to one or more outer surfaces of the dichroic laminate assembly. 
     
     
       18. The method as recited in  claim 12 , wherein at least two of the plurality of resin substrates in the dichroic laminate assembly comprise a textured or embossed surface that faces away from the one or more light refracting dichroic films. 
     
     
       19. The method as recited in  claim 18 , further comprising positioning one or more additional resin substrates between the at least two resin substrates, wherein the one or more additional resin substrates are free of textured or embossed surfaces. 
     
     
       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. 
 
     
     
       21. The dichroic laminate assembly as recited in claim 20, wherein the stack of one or more dichroic films comprise a thermoplastic assembly of non-image bearing light refracting films that together absorbs or transmits one ray of polarized light differently from another ray of polarized light, and are formable after lamination. 
     
     
       22. The dichroic laminate assembly as recited in claim 20, wherein each TPU layer comprises a continuous layer configured to provide contact adhesion with the stack formation on one side and with a resin substrate on an opposing side upon application of heat and pressure. 
     
     
       23. The dichroic resin panel as recited in claim 1, further comprising:
 one or more additional light refracting film layers positioned against and bonded to the one or more dichroic films;   wherein:
 the one or more dichroic films and one or more additional light refracting film layers comprise a dichroic film composite; and 
 the dichroic film composite comprises a set of non-image bearing light refracting films configured to absorb or transmit one polarized light ray differently from another polarized light ray. 
   
     
     
       24. The dichroic resin panel as recited in claim 1, further comprising:
 a substantially translucent third resin substrate layer having a thickness of about 0.06 inches to about 2.0 inches;   a substantially translucent fourth resin substrate layer having a thickness of about 0.06 inches to about 2.0 inches;   wherein the first and second resin substrates comprise non-embossed or non-textured substrates, and the third and fourth resin substrate layers comprise embossed or textured substrates.   
     
     
       25. The method as recited in claim 12, further comprising:
 heat treating at least some of the plurality of resin substrates, wherein:
 the dichroic laminate assembly comprises a mixture of embossed or textured and non-embossed or non-textured resin substrates; and 
 each resin substrate immediately adjacent one of the one or more dichroic film layers in non-embossed. 
   
     
     
       26. The dichroic resin panel as recited in claim 1, wherein:
 each of the translucent first and second resin substrates comprises a PETG sheet that has a thickness of 0.06 inches; and   each TPU tie layer comprises a sheet having a thickness of 0.025 inches.   
     
     
       27. The dichroic resin panel as recited in claim 1, wherein:
 each of the translucent first and second resin substrates comprises a PETG sheet that has a thickness of 0.500 inches; and   each TPU tie layer comprises a sheet that has a thickness of 0.025 inches.   
     
     
       28. The dichroic resin panel as recited in claim 1, wherein:
 each of the translucent first and second resin substrates comprises a PETG sheet that has a thickness of 0.125 inches; and   each TPU tie layer comprises a sheet that has a thickness of 0.025 inches.   
     
     
       29. The dichroic resin panel as recited in claim 1, wherein:
 the translucent first resin substrate comprises a PETG sheet that has a thickness of 0.375 inches;   the translucent second resin substrate comprises a PETG sheet that has a thickness of 0.125 inches; and   each TPU tie layer comprises a sheet that has a thickness of 0.025 inches.   
     
     
       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:
 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. 
   
     
     
       31. The dichroic resin panel as recited in claim 30, wherein the form of the translucent first and second resin layers is curved. 
     
     
       32. The dichroic resin panel as recited in claim 30, wherein the one or more tie layers are between about 0.005 and about 0.125 inches thick. 
     
     
       33. The dichroic resin panel as recited in claim 30, further comprising one or more additional, non-textured or non-embossed resin substrate layers embedded between the first and second substrate layers. 
     
     
       34. The dichroic resin panel as recited in claim 33, wherein the one or more additional resin substrates are thinner in dimension than the first and second resin substrates. 
     
     
       35. The dichroic resin panel as recited in claim 33, wherein each resin substrate layer in the dichroic resin panel comprises a copolyester material, a polycarbonate material, or combinations thereof. 
     
     
       36. The dichroic resin panel as recited in claim 33, wherein each resin substrate layer in the dichroic resin panel comprises one or more of a polycarbonate material, a styrene material, a polyvinyl chloride material, a polyurethane material, or combinations thereof. 
     
     
       37. The dichroic resin panel as recited in claim 30, further comprising:
 one or more additional light refracting film layers positioned against and bonded to the one or more dichroic films;   wherein:
 the one or more dichroic films and one or more additional light refracting film layers comprise a dichroic film composite; and 
 the dichroic film composite comprises a set of non-image bearing light refracting films configured to absorb or transmit one polarized light ray differently from another polarized light ray. 
   
     
     
       38. The dichroic resin panel as recited in claim 30, further comprising:
 a substantially translucent third resin substrate layer having a thickness of about 0.06 inches to about 2.0 inches;   a substantially translucent fourth resin substrate layer having a thickness of about 0.06 inches to about 2.0 inches;   wherein each of the first and second resin substrates comprise non-embossed or non-textured substrates on an inside surface thereof, and each of the third and fourth resin substrate layers comprise embossed or textured substrates.