Laminated article and process for making same

Claim 2

A decorative laminated article comprising two outer glass layers, a polyvinyl acetal layer disposed therebetween and a porous fibrous layer comprising fibrous material designed in a decorative pattern having interstices, said fibrous material disposed in a decorative pattern extending well within the peripheral edge of said laminated article, encapsulated in said polyvinyl acetal layer, said polyvinyl acetal layer extending through said interstices and constituting a single, continuous, unitary phase.

Claim 3

The laminated article of claim 1 wherein said polyvinyl acetal layer is a polyvinyl butyral layer.

Claim 4

The laminated article of claim 1 wherein said fibrous layer is a woven cloth.

Claim 5

The laminated article of claim 1 wherein said fibrous layer is substantially parallel to said glass layers.

Claim 6

A process for producing a decorative laminated article which comprises (1) maintaining a substantially constant vacuum in the range of about 15 to about 25 inches of mercury in a flexible container containing an assembly comprising (a) a first glass layer, (b) a first polyvinyl acetal layer in contact with said first glass layer, (c) a porous fibrous layer comprising fibrous material designed in a decorative pattern, having interstices therein, in contact with said first polyvinyl acetal layer, and disposed in a decorative pattern extending well within the peripheral edge of said first polyvinyl acetal layer, (d) a second polyvinyl acetal layer in contact with said fibrous layer and (e) a second glass layer in contact with said second polyvinyl acetal layer; (2) applying pressure on said container while increasing the same from about ambient pressure to an elevated pressure level in the range of about 110 to about 200 pounds per square inch gauge and simultaneously increasing the temperature in the contents of said container from about ambient temperature to an elevated temperature level in the range of about 270° to about 300° F. over a period of about 45 minutes to about two hours; (3) maintaining the contents of said container at said elevated pressure and said elevated temperature for about five to about 45 minutes; (4) reducing the temperature on the contents of said container from said elevated temperature level to about ambient temperature over a period of about 15 to about 90 minutes; (5) reducing the pressure on said container from said elevated pressure level to about ambient pressure over a period of about 30 to about 110 minutes; and (6) releasing the vacuum within said container, whereby a decorative laminated article is obtained comprising two outer glass layers, a polyvinyl acetal layer disposed therebetween and a porous fibrous layer comprising fibrous material designed in a decorative pattern, having interstices, said fibrous material disposed in a decorative pattern extending well within the peripheral edge of said laminated article, encapsulated in said polyvinyl acetal layer, said polyvinyl acetal layer extending through said interstices and constituting a single, continuous, unitary phase.

Claim 7

A process for producing a decorative laminated article which comprises (1) maintaining a substantially constant vacuum in the range of about 15 to about 25 inches of mercury in a flexible container containing an assembly comprising (a) a first glass layer, (b) a first polyvinyl acetal layer in contact with said first glass layer, (c) a porous fibrous layer comprising fibrous material designed in a decorative pattern, having interstices therein, in contact with said first polyvinyl acetal layer, and disposed in a decorative pattern extending well within the peripheral edge of said first polyvinyl acetal layer, (d) a second polyvinyl acetal layer in contact with said fibrous layer and (e) a second glass layer in contact with said second polyvinyl acetal layer; (2) applying pressure on said container while increasing the same from about ambient pressure to an elevated pressure level in the range of about 110 to about 200 pounds per square inch gauge and simultaneously increasing the temperature in the contents of said container from about ambient temperature to an elevated temperature level in the range of about 270° to about 300° F. over a period of about 45 minutes to about two hours; (3) maintaining the contents of said container at said elevated pressure and said elevated temperature for about five to about 45 minutes; (4) reducing the temperature on the contents of said container from said elevated temperature level to about ambient temperature over a period of about 15 to about 90 minutes; (5) reducing the pressure on said container from said elevated pressure level to about ambient pressure over a period of about 30 to about 110 minutes; and (6) releasing the vacuum within said container, whereby a decorative laminated article is obtained comprising two outer glass layers, a polyvinyl acetal layer disposed therebetween and a porous fibrous layer comprising fibrous material designed in a decorative pattern, having interstices, said fibrous material disposed in a decorative pattern extending well within the peripheral edge of said laminated article, encapsulated in said polyvinyl acetal layer, said polyvinyl acetal layer extending through said interstices and constituting a single, continuous, unitary phase.

Claim 8

The process of claim 5 wherein said vacuum is in the range of about 22 to about 24 inches of mercury.

Claim 9

The process of claim 5 wherein the surfaces of said glass layers in contact with the surfaces of said polyvinyl acetal layers have been cleaned prior to the formation of said assembly.

Claim 10

The process of claim 7 wherein said cleaning has been carried out using an abrasive.

Claim 11

The process of claim 5 wherein said elevated pressure level is in the range of about 120 to about 160 pounds per square inch gauge.

Claim 12

The process of claim 5 wherein said elevated temperature level is in the range of about 285° to about 295° F.

Claim 13

The process of claim 5 wherein the time required to raise the pressure and temperature from about ambient conditions to said elevated levels is in the range of about 60 to about 110 minutes.

Claim 14

The process of claim 5 wherein the contents of said container are maintained at said elevated pressure and said elevated temperature for about 25 to about 30 minutes.

Claim 15

The process of claim 5 wherein the time required to reduce the temperature from said elevated temperature level to about ambient temperature is in the range of about 60 to about 80 minutes.

Claim 16

The process of claim 5 wherein the time required to reduce the pressure from said elevated pressure level to about ambient pressure is in the range of about 75 to about 95 minutes.

Claim 17

The process of claim 5 wherein said vacuum is released while the pressure on said container is reduced from said elevated pressure level to about ambient pressure.

Claim 18

The process of claim 5 wherein said polyvinyl acetal layer is a polyvinyl butyral layer.

Claim 19

The process of claim 5 wherein said fibrous layer is a woven cloth.