Process for manufacturing plastic siding panels with outdoor weatherable embossed surfaces

Claim 2

A process for making plastic panels with an embossed low gloss decorative surface transfer-laminated to an extruded plastic sheet, comprising: forming a matte release layer on a continuous, thin, flexible, heat-resistant carrier sheet, the matte release layer containing a resinous material hardened at an elevated temperature to form a continuous heat-resistant resinous film permanently bonded to the carrier sheet and having a micro-roughness on a release-coated outer surface thereof; forming a decorative coating on the micro-roughened, release-coated outer surface of the hardened matte release layer to thereby form a thin, flexible transfer laminate; extruding a plastic sheet at an elevated temperature through an extruder die exit opening, the extruded sheet having a heat of extrusion adjacent the extruder die exit opening; overlaying the transfer laminate on the extruded sheet with the decorative coating thereof facing toward the extruded sheet; applying pressure to the transfer laminate and to the extruded sheet from an embossing roll on the side of the transfer laminate opposite from the extruded sheet, said embossing being directed through the matte release-coated carrier sheet and toward the extruded sheet while the temperature of the extruded sheet is maintained near its heat of extrusion, thereby transferring heat to the decorative coating while the mate release layer remains in its heat-resistant condition under the heat from the extrusion to provide a continuous heat transfer barrier between the carrier sheet and the extruded sheet, to thereby continuously transfer the decorative coating from the matte release layer and bond the decorative coating to the extruded sheet under the applied pressure, the transferred decorative coating being maintained in a pliable condition under the heat transferred thereto while the micro-roughness of the hardened matte release layer transfers a low gloss outer surface to the decorative coating, the embossing roll continuously embossing three-dimensional impressions through the matte release-coated carrier sheet and into the outer surface of the pliable decorative coating; and thereafter releasing the carrier sheet and its hardened resinous film from the embossed low gloss decorative coating after the embossed impressions have set permanently through a temperature reduction to thereby form a panel having said embossed low gloss surface.

Claim 3

The process according to claim 1 in which the surface gloss transferred to the decorative coating has a 75° gloss level of less than about 20 gloss units.

Claim 4

The process according to claim 2 in which the 75° gloss level is less than about 12 gloss units.

Claim 5

The process according to claim 1 in which the resinous material in the matte release coat comprises a thermosetting resinous material which is cured at said elevated temperature.

Claim 6

The process according to claim 1 in which the decorative coating includes a weatherable fluoropolymer resin.

Claim 7

The process according to claim 5 in which the fluoropolymer resin is blended with an acrylic resin.

Claim 8

The process according to claim 6 in which the fluoropolymer component comprises PVDF present in an amount greater than about 40% of the solids contained in the decorative coating.

Claim 9

The process according to claim 1 in which the micro-roughness of the resinous film is produced by a fine particulate filler dispersed in the resinous material.

Claim 10

The process according to claim 1 in which the average depth of permanent embossments in the transferred decorative coating is from about 20 microns to about 120 microns.

Claim 11

The process according to claim 1 in which the transfer and embossing steps are carried out at a temperature of at least about 385° F.

Claim 12

The process according to claim 1 in which the matte release layer includes a release agent comprising a dispersed wax.

Claim 13

The process according to claim 11 in which the release agent further includes a dispersed silicone resin.

Claim 14

The process according to claim 1 in which the release agent comprises a wax from about 12% to about 25% and a silicone resin from about 2.5% to about 25% of the solids contained in the matte release coat.

Claim 15

The process according to claim 1 in which the matte release layer includes a release agent having a wax component suspended in the matte release layer at temperatures below the transfer and embossing temperature, and in which the wax component in its suspended form enhances transfer of the low gloss surface to the decorative layer.

Claim 16

The process according to claim 1 in which the decorative coating includes a weatherable outer clear coat, and an underlying color coat containing a dispersed pigment in a level sufficient to retard UV degradation of the underlying extruded sheet.

Claim 17

The process according to claim 15 in which the clear coat and color coat each contain a fluoropolymer resin.

Claim 18

The process according to claim 1 in which the decorative coating includes a continuous weatherable resinous paint coat containing a dispersed pigment at a level sufficient to retard UV degradation of the underlying extruded sheet.

Claim 19

The process according to claim 1 in which the decorative coating includes one or more print coats formed by an ink containing an organic pigment.

Claim 20

The process according to claim 1 in which the transferred gloss level and embossed impressions resemble a natural woodgrain or painted woodgrain surface.

Claim 21

A process for making plastic panels with an embossed low gloss decorative surface transfer-laminated to an extruded plastic sheet, comprising: forming a matte release layer on a continuous, thin, flexible, heat-resistant carrier sheet, the matte release layer containing a thermosetting resinous material containing a release agent and a fine particulate filler dispersed therein, the resin being hardened at an elevated temperature to permanently bond to the carrier sheet and form a continuous heat-resistant resinous film having a micro-roughness on a release-coated outer surface thereof; forming a decorative coating on the micro-roughened, release-coated outer surface of the hardened matte release layer to thereby form a thin, flexible transfer laminate; extruding a plastic sheet at an elevated temperature through an extruder die exit opening, the extruded sheet having a heat of extrusion adjacent the extruder die exit opening; overlaying the transfer laminate on the extruded sheet with the decorative coating thereof facing toward the extruded sheet; applying pressure to the transfer laminate and to the extruded sheet from an embossing roll on the side of the transfer laminate opposite from the extruded sheet, said embossing being directed through the matte release-coated carrier sheet and toward the extruded sheet while the temperature of the extruded sheet is maintained near its heat of extrusion, thereby transferring heat to the decorative coating while the matte release layer remains in its heat-resistant condition under the transferred heat to provide a continuous heat transfer barrier between the carrier sheet and the extruded sheet, to thereby continuously transfer the decorative coating from the matte release layer and bond the decorative coating to the extruded sheet under the applied pressure, the transferred decorative coating being maintained in a pliable condition under the heat transferred thereto while the micro-roughness of the hardened matte release layer transfers a low glass outer surface to the decorative coating, the embossing roll continuously embossing three-dimensional impressions through the matte release-coated carrier sheet and into the outer surface of the pliable decorative coating; and thereafter releasing the carrier sheet and its hardened resinous film from the embossed low glass decorative coating after the embossed impressions have set permanently through a temperature reduction to thereby form a panel having said embossed low gloss surface.

Claim 22

A process for making plastic panels with an embossed low gloss decorative surface transfer-laminated to an extruded plastic sheet, comprising: forming a matte release layer on a continuous, thin, flexible, heat-resistant carrier sheet, the matte release layer containing a thermosetting resinous material containing a release agent and a fine particulate filler dispersed therein, the resin being hardened at an elevated temperature to permanently bond to the carrier sheet and form a continuous heat-resistant resinous film having a micro-roughness on a release-coated outer surface thereof; forming a decorative coating on the micro-roughened, release-coated outer surface of the hardened matte release layer to thereby form a thin, flexible transfer laminate; extruding a plastic sheet at an elevated temperature through an extruder die exit opening, the extruded sheet having a heat of extrusion adjacent the extruder die exit opening; overlaying the transfer laminate on the extruded sheet with the decorative coating thereof facing toward the extruded sheet; applying pressure to the transfer laminate and to the extruded sheet from an embossing roll on the side of the transfer laminate opposite from the extruded sheet, said embossing being directed through the matte release-coated carrier sheet and toward the extruded sheet while the temperature of the extruded sheet is maintained near its heat of extrusion, thereby transferring heat to the decorative coating while the matte release layer remains in its heat-resistant condition under the transferred heat to provide a continuous heat transfer barrier between the carrier sheet and the extruded sheet, to thereby continuously transfer the decorative coating from the matte release layer and bond the decorative coating to the extruded sheet under the applied pressure, the transferred decorative coating being maintained in a pliable condition under the heat transferred thereto while the micro-roughness of the hardened matte release layer transfers a low glass outer surface to the decorative coating, the embossing roll continuously embossing three-dimensional impressions through the matte release-coated carrier sheet and into the outer surface of the pliable decorative coating; and thereafter releasing the carrier sheet and its hardened resinous film from the embossed low glass decorative coating after the embossed impressions have set permanently through a temperature reduction to thereby form a panel having said embossed low gloss surface.

Claim 23

The process according to claim 20 in which the surface gloss transferred to the decorative coating has a 75° gloss level of less than about 20 gloss units.

Claim 24

The process according to claim 20 in which the release agent comprises a combined wax and silicone resin.

Claim 25

The process according to claim 22 in which the wax component comprises a polyethylene wax.

Claim 26

The process according to claim 20 in which the release agent comprises a wax from about 12% to about 25% and a silicone resin from about 2.5% to about 25% of the solids contained in the matte release coat.

Claim 27

The process according to claim 20 in which the decorative coating includes a continuous paint coat containing a pigment at a level sufficient to retard UV degradation of the extruded sheet.

Claim 28

The process according to claim 25 in which the decorative coating includes a weatherable fluoropolymer resin.

Claim 29

The process according to claim 20 in which the extruded plastic sheet comprises a vinyl resinous material extruded at a temperature of at least about 385° F., and in which the carrier sheet is a polyester sheet having a thickness of about one mil or less to enhance embossing the transferred decorative layer through the carrier sheet.

Claim 30

A process for making plastic panels with an embossed low gloss decorative surface transfer-laminated to an extruded plastic sheet, comprising: forming a matte release layer on a continuous, thin, flexible, heat-resistant carrier sheet, the matte release layer containing a resinous material hardened at an elevated temperature to form a continuous heat-resistant resinous film permanently bond to the carrier sheet and having a micro-roughness on a release-coated outer surface thereof; forming a decorative coating on the micro-roughened, release-coated outer surface of the hardened matte release layer to thereby form a thin, flexible transfer laminate; extruding a plastic sheet at an elevated temperature through an extruder die exit opening, the extruded sheet having a heat of extrusion adjacent the extruder die exit opening; overlaying the transfer laminate on the extruded sheet with the decorative coating thereof facing toward the extruded sheet; applying pressure to the transfer laminate and to the extruded sheet from an embossing roll on the side of the transfer laminate opposite from the extruded sheet, said embossing being directed through the matte release-coated carrier sheet and toward the extruded sheet while the temperature of the extruded sheet is maintained near it sheet of extrusion, thereby transferring heat to the decorative coating while the matte release layer remains in its heat-resistant condition under the transferred heat to provide a continuous heat transfer barrier between the carrier sheet and the extruded sheet, to thereby transfer the decorative coating from the matte release layer and bond the decorative coating to the extruded sheet under the applied pressure, the transferred decorative coating being maintained in a pliable condition under the heat transferred thereto while the micro-roughness of the hardened matte release layer transfers a low gloss outer surface to the decorative coating, the embossing roll embossing three-dimensional impressions through the matte release-coated carrier sheet and into the outer surface of the pliable decorative coating, the transferred low gloss surface having a 75° surface gloss level of about 20 gloss units or less; and thereafter releasing the carrier sheet and its hardened resinous film from the embossed low gloss decorative coating after the embossed impressions have set permanently through a temperature reduction to thereby form a panel having said embossed low gloss surface.

Claim 31

A process for making plastic panels with an embossed low gloss decorative surface transfer-laminated to an extruded plastic sheet, comprising: forming a matte release layer on a continuous, thin, flexible, heat-resistant carrier sheet, the matte release layer containing a resinous material hardened at an elevated temperature to form a continuous heat-resistant resinous film permanently bond to the carrier sheet and having a micro-roughness on a release-coated outer surface thereof; forming a decorative coating on the micro-roughened, release-coated outer surface of the hardened matte release layer to thereby form a thin, flexible transfer laminate; extruding a plastic sheet at an elevated temperature through an extruder die exit opening, the extruded sheet having a heat of extrusion adjacent the extruder die exit opening; overlaying the transfer laminate on the extruded sheet with the decorative coating thereof facing toward the extruded sheet; applying pressure to the transfer laminate and to the extruded sheet from an embossing roll on the side of the transfer laminate opposite from the extruded sheet, said embossing being directed through the matte release-coated carrier sheet and toward the extruded sheet while the temperature of the extruded sheet is maintained near it sheet of extrusion, thereby transferring heat to the decorative coating while the matte release layer remains in its heat-resistant condition under the transferred heat to provide a continuous heat transfer barrier between the carrier sheet and the extruded sheet, to thereby transfer the decorative coating from the matte release layer and bond the decorative coating to the extruded sheet under the applied pressure, the transferred decorative coating being maintained in a pliable condition under the heat transferred thereto while the micro-roughness of the hardened matte release layer transfers a low gloss outer surface to the decorative coating, the embossing roll embossing three-dimensional impressions through the matte release-coated carrier sheet and into the outer surface of the pliable decorative coating, the transferred low gloss surface having a 75° surface gloss level of about 20 gloss units or less; and thereafter releasing the carrier sheet and its hardened resinous film from the embossed low gloss decorative coating after the embossed impressions have set permanently through a temperature reduction to thereby form a panel having said embossed low gloss surface.

Claim 32

The process according to claim 21 in which the surface gloss level transferred to the decorative coating has a 75° gloss level of less than about 12 gloss units.

Claim 33

The process according to claim 28 in which the decorative coating includes a weatherable fluoropolymer resin and an acrylic resin.

Claim 34

The process according to claim 28 in which the resinous material in the matte release layer comprises a thermosetting resin cured at said elevated temperature.

Claim 35

The process according to claim 28 in which the decorative coating includes a weatherable outer clear coat, and an underlying color coat containing a dispersed pigment in a level sufficient to retard UV degradation of the underlying extruded sheet.

Claim 36

A process for making vinyl plastic panels with an embossed low gloss decorative surface transfer-laminated to an extruded vinyl plastic sheet, comprising: forming a matte release layer on a continuous, thin, flexible, heat-resistant carrier sheet having a thickness of about one mil or less, the matte release layer containing a resinous material hardened at an elevated temperature to form a continuous heat-resistant resinous film permanently bonded to the carrier sheet and having a micro-roughness on a release-coated outer surface thereof; forming a weatherable decorative coating on the micro-roughened, release-coated outer surface of the hardened matte release layer to thereby form a thin, flexible transfer laminate; extruding a continuous vinyl plastic sheet at a temperature of at least about 385° F. through an extruder die exit opening, the continuous extruded sheet advancing from the extruder die exit opening and having a heat of extrusion adjacent the extruder die exit opening; overlaying the transfer laminate as a continuous sheet on the advancing extruded vinyl sheet, the decorative coating of the overlaid laminate facing toward the extruded sheet; applying pressure to the advancing transfer laminate and extruded vinyl sheet from an embossing roll on the side of the transfer laminate opposite from the extruded sheet, said embossing being directed through the matte release-coated carrier sheet and toward the extruded sheet while the temperature of the extruded sheet is maintained near its heat of extrusion, thereby transferring heat to the decorative coating while the matte release layer remains in its heat-resistant condition under the transferred heat to provide a continuous heat transfer barrier between the carrier sheet and the extruded sheet, to thereby continuously transfer the decorative coating from the matte release layer and bond the decorative coating to the extruded vinyl sheet under the applied pressure, the transferred decorative coating being maintained in a pliable condition under the heat transferred thereto while the micro-roughness of the hardened matte release layer transfers a low gloss outer surface to the decorative coating, the embossing roll continuously embossing three-dimensional impressions through the matte release-coated carrier sheet are into the outer surface of the pliable decorative coating; and thereafter releasing the carrier sheet and its hardened resinous film from the embossed low gloss decorative coating after the embossed impressions have set permanently through a temperature reduction to thereby form a vinyl plastic panel having said embossed low gloss surface.

Claim 37

A process for making vinyl plastic panels with an embossed low gloss decorative surface transfer-laminated to an extruded vinyl plastic sheet, comprising: forming a matte release layer on a continuous, thin, flexible, heat-resistant carrier sheet having a thickness of about one mil or less, the matte release layer containing a resinous material hardened at an elevated temperature to form a continuous heat-resistant resinous film permanently bonded to the carrier sheet and having a micro-roughness on a release-coated outer surface thereof; forming a weatherable decorative coating on the micro-roughened, release-coated outer surface of the hardened matte release layer to thereby form a thin, flexible transfer laminate; extruding a continuous vinyl plastic sheet at a temperature of at least about 385° F. through an extruder die exit opening, the continuous extruded sheet advancing from the extruder die exit opening and having a heat of extrusion adjacent the extruder die exit opening; overlaying the transfer laminate as a continuous sheet on the advancing extruded vinyl sheet, the decorative coating of the overlaid laminate facing toward the extruded sheet; applying pressure to the advancing transfer laminate and extruded vinyl sheet from an embossing roll on the side of the transfer laminate opposite from the extruded sheet, said embossing being directed through the matte release-coated carrier sheet and toward the extruded sheet while the temperature of the extruded sheet is maintained near its heat of extrusion, thereby transferring heat to the decorative coating while the matte release layer remains in its heat-resistant condition under the transferred heat to provide a continuous heat transfer barrier between the carrier sheet and the extruded sheet, to thereby continuously transfer the decorative coating from the matte release layer and bond the decorative coating to the extruded vinyl sheet under the applied pressure, the transferred decorative coating being maintained in a pliable condition under the heat transferred thereto while the micro-roughness of the hardened matte release layer transfers a low gloss outer surface to the decorative coating, the embossing roll continuously embossing three-dimensional impressions through the matte release-coated carrier sheet are into the outer surface of the pliable decorative coating; and thereafter releasing the carrier sheet and its hardened resinous film from the embossed low gloss decorative coating after the embossed impressions have set permanently through a temperature reduction to thereby form a vinyl plastic panel having said embossed low gloss surface.

Claim 38

The process according to claim 33 in which the matte release layer contains a release agent comprising a wax component and a silicone resin component dispersed in a thermosetting resinous coating.

Claim 39

The process according to claim 33 in which the decorative coating includes a weatherable outer clear coat and an underlying color coat containing a dispersed pigment visible through the clear coat.

Claim 40

The process according to claim 33 in which the decorative coating includes one or more print coats formed by an ink consisting essentially of an organic pigment.

Claim 41

The process according to claim 33 in which the decorative coating includes a weatherable fluoropolymer resin and an acrylic resin.

Claim 42

The process according to claim 33 in which the decorative layer includes a color coat containing a sufficient amount of pigment to retard UV degradation of the finished vinyl sheet.

Claim 43

The process according to claim 33 in which the transferred surface gloss has a 75° gloss level of 20 gloss units or less.

Claim 44

A process for making vinyl plastic panels with an embossed low gloss decorative surface transfer-laminated to an extruded vinyl plastic sheet, comprising: forming a matte release layer on a continuous, thin, flexible, heat-resistant carrier sheet, the matte release layer containing a resinous material hardened at an elevated temperature to permanently bond to the carrier sheet and form a continuous heat-resistant resinous film having a micro-roughness on a release-coated outer surface thereof; forming a decorative coating on the micro-roughened, release-coated outer surface of the hardened matte release layer to thereby form a thin, flexible transfer laminate, the decorative coating comprising a weatherable polymer top coat and an underlying color coat containing a dispersed pigment, the color coat being visible through the top coat; extruding a plastic sheet containing a vinyl polymer at an elevated temperature of at least about 385° F. through an extruder die exit opening, the extruded vinyl sheet having a heat of extrusion adjacent the extruder die exit opening; overlaying the transfer laminate on the extruded sheet with the decorative coating thereof facing toward the extruded sheet; applying pressure to the transfer laminate and to the extruded sheet from an embossing roll on the side of the transfer laminate opposite from the extruded sheet, said embossing being directed through the matte release-coated carrier sheet and toward the extruded vinyl sheet while the temperature of the extruded sheet is maintained near its heat of extrusion, thereby transferring heat to the decorative coating while the matte release layer remains in the heat-resistant condition under the transferred heat to provide a continuous heat transfer barrier between the carrier sheet and the extruded sheet, to thereby transfer the decorative coating from the matte release layer and bond the decorative coating to the extruded sheet under the applied pressure, the transferred decorative coating being maintained in a pliable condition under the heat transferred thereon while the micro-roughness of the hardened matte release layer transfers a low gloss outer surface to the top coat of the transferred decorative coating, the embossing roll embossing three-dimensional impressions through the matte release-coated carrier sheet and into the outer surface of the pliable decorative coating; and thereafter releasing the carrier sheet and its hardened resinous film from the embossed low gloss decorative coating after the embossed impressions have set permanently through a temperature reduction to thereby form a panel having an embossed low gloss surface, the pigment contained in the transferred color coat being present in an amount sufficient to retard UV degradation of the underlying vinyl plastic panel.

Claim 45

A process for making vinyl plastic panels with an embossed low gloss decorative surface transfer-laminated to an extruded vinyl plastic sheet, comprising: forming a matte release layer on a continuous, thin, flexible, heat-resistant carrier sheet, the matte release layer containing a resinous material hardened at an elevated temperature to permanently bond to the carrier sheet and form a continuous heat-resistant resinous film having a micro-roughness on a release-coated outer surface thereof; forming a decorative coating on the micro-roughened, release-coated outer surface of the hardened matte release layer to thereby form a thin, flexible transfer laminate, the decorative coating comprising a weatherable polymer top coat and an underlying color coat containing a dispersed pigment, the color coat being visible through the top coat; extruding a plastic sheet containing a vinyl polymer at an elevated temperature of at least about 385° F. through an extruder die exit opening, the extruded vinyl sheet having a heat of extrusion adjacent the extruder die exit opening; overlaying the transfer laminate on the extruded sheet with the decorative coating thereof facing toward the extruded sheet; applying pressure to the transfer laminate and to the extruded sheet from an embossing roll on the side of the transfer laminate opposite from the extruded sheet, said embossing being directed through the matte release-coated carrier sheet and toward the extruded vinyl sheet while the temperature of the extruded sheet is maintained near its heat of extrusion, thereby transferring heat to the decorative coating while the matte release layer remains in the heat-resistant condition under the transferred heat to provide a continuous heat transfer barrier between the carrier sheet and the extruded sheet, to thereby transfer the decorative coating from the matte release layer and bond the decorative coating to the extruded sheet under the applied pressure, the transferred decorative coating being maintained in a pliable condition under the heat transferred thereon while the micro-roughness of the hardened matte release layer transfers a low gloss outer surface to the top coat of the transferred decorative coating, the embossing roll embossing three-dimensional impressions through the matte release-coated carrier sheet and into the outer surface of the pliable decorative coating; and thereafter releasing the carrier sheet and its hardened resinous film from the embossed low gloss decorative coating after the embossed impressions have set permanently through a temperature reduction to thereby form a panel having an embossed low gloss surface, the pigment contained in the transferred color coat being present in an amount sufficient to retard UV degradation of the underlying vinyl plastic panel.

Claim 46

The process according to claim 40 in which the decorative layer contains one or more printing inks in which a pigment component thereof includes an organic pigment.

Claim 47

The process according to claim 40 in which the transferred surface gloss has a 75° gloss level of about 20 gloss units or less.

Claim 48

The process according to claim 40 in which the top coat contains a fluoropolymer resin and an acrylic resin.

Claim 49

A process for making outdoor weatherable vinyl plastic siding panels having a low gloss decorative surface transfer-laminated to an extruded vinyl plastic sheet, comprising: forming a matte release layer on a continuous, thin, flexible, heat-resistant carrier sheet, the matte release layer containing a resinous material hardened at an elevated temperature to form a continuous heat-resistant resinous film permanently bonded to the carrier sheet and having a micro-roughness on a release-coated outer surface thereof; forming a decorative coating on the micro-roughened, release-coated outer surface of the hardened matte release layer to thereby form a thin, flexible transfer laminate; extruding a vinyl plastic sheet at a temperature of at least about 385° F. through an extruder die exit opening, the extruded vinyl sheet having a heat of extrusion adjacent the extruder die exit opening; overlaying the transfer laminate on the extruded sheet with the decorative coating thereof facing toward the extruded sheet; applying pressure to the transfer laminate and to the extruded vinyl sheet from a pressure roll on the side of the transfer laminate opposite from the extruded sheet, said pressure being applied to the matte release-coated carrier sheet while the temperature of the extruded sheet is maintained near said heat of extrusion, thereby transferring heat to the decorative coating while the matte release layer remains in tis heat-resistant condition under the transferred heat to provide a continuous heat transfer barrier between the carrier sheet and the extruded vinyl sheet, to thereby continuously transfer the decorative coating from the matte release layer and bond the decorative coating to the extruded vinyl sheet under the applied pressure, the transferred decorative coating being maintained in a pliable condition under the heat transferred thereto while the micro-roughness of the hardened matte release layer transfers a continuous low gloss surface to an outer surface of the decorative coating being transferred from the carrier to the extruded vinyl sheet; and thereafter releasing the carrier sheet and its hardened resinous film from the transferred low gloss decorative coating to thereby form a vinyl siding panel having said low gloss surface.

Claim 50

A process for making outdoor weatherable vinyl plastic siding panels having a low gloss decorative surface transfer-laminated to an extruded vinyl plastic sheet, comprising: forming a matte release layer on a continuous, thin, flexible, heat-resistant carrier sheet, the matte release layer containing a resinous material hardened at an elevated temperature to form a continuous heat-resistant resinous film permanently bonded to the carrier sheet and having a micro-roughness on a release-coated outer surface thereof; forming a decorative coating on the micro-roughened, release-coated outer surface of the hardened matte release layer to thereby form a thin, flexible transfer laminate; extruding a vinyl plastic sheet at a temperature of at least about 385° F. through an extruder die exit opening, the extruded vinyl sheet having a heat of extrusion adjacent the extruder die exit opening; overlaying the transfer laminate on the extruded sheet with the decorative coating thereof facing toward the extruded sheet; applying pressure to the transfer laminate and to the extruded vinyl sheet from a pressure roll on the side of the transfer laminate opposite from the extruded sheet, said pressure being applied to the matte release-coated carrier sheet while the temperature of the extruded sheet is maintained near said heat of extrusion, thereby transferring heat to the decorative coating while the matte release layer remains in tis heat-resistant condition under the transferred heat to provide a continuous heat transfer barrier between the carrier sheet and the extruded vinyl sheet, to thereby continuously transfer the decorative coating from the matte release layer and bond the decorative coating to the extruded vinyl sheet under the applied pressure, the transferred decorative coating being maintained in a pliable condition under the heat transferred thereto while the micro-roughness of the hardened matte release layer transfers a continuous low gloss surface to an outer surface of the decorative coating being transferred from the carrier to the extruded vinyl sheet; and thereafter releasing the carrier sheet and its hardened resinous film from the transferred low gloss decorative coating to thereby form a vinyl siding panel having said low gloss surface.

Claim 51

The process according to claim 44 in which the surface gloss transferred to the decorative coating has a 75° gloss level of less than about 20 gloss units.

Claim 52

The process according to claim 44 in which the decorative coating includes a weatherable outer clear coat, and an underlying color coat containing a dispersed pigment in a level sufficient to retard UV degradation of the underlying extruded sheet.

Claim 53

The process according to claim 44 in which the decorative coating includes one or more print coats formed by an ink containing an organic pigment.

Claim 54

The process according to claim 44 in which the resin in the matte release layer contains a release agent which includes a silicone resin and a wax component.

Claim 55

The process according to claim 44 in which the weatherable decorative coating contains a fluoropolymer resin and an acrylic resin.

Claim 56

A process for making plastic panels having a low gloss decorative surface transfer-laminated to an extruded plastic sheet, comprising: forming a matte release layer on a continuous, thin, flexible, heat-resistant carrier sheet, the matte release layer containing a resinous material hardened at an elevated temperature to form a continuous heat-resistant resinous film permanently bond to the carrier sheet and having a micro-roughness on a release-coated outer surface thereof; forming a decorative coating on the micro-roughened, release-coated outer surface of the hardened matte release layer to thereby form a thin, flexible transfer laminate; extruding a continuous plastic sheet through an extruder die exit opening, the extruded sheet advancing from the extruder die exit opening and having a heat of extrusion adjacent the extruder die exit opening; overlaying the transfer laminate as a continuous sheet on the advancing extruded sheet with the decorative coating thereof facing toward the extruded sheet; applying pressure to the advancing transfer laminate and to the extruded plastic sheet from a pressure roll on the side of the laminate opposite from the extruded sheet, said pressure being applied to the matte release-coated carrier sheet while the temperature of the extruded sheet is maintained near said heat of extrusion thereby transferring heat to the decorative coating while the matte release layer remains in its heat-resistant condition under the heat transferred from the extrusion to provide a continuous heat transfer barrier between the carrier sheet and the extruded sheet, to continuously transfer the decorative coating from the matte release layer and bond the decorative coating to the extruded sheet under the applied pressure, the transferred decorative coating being maintained in a pliable condition under the heat transferred thereto while the micro-roughness of the hardened resinous coating transfers a continuous low gloss surface to an outer surface of the decorative coating; and thereafter continuously releasing the carrier sheet and its hardened resinous film from the transferred decorative coating of the advancing plastic sheet to thereby form a plastic panel having said low gloss surface.

Claim 57

A process for making plastic panels having a low gloss decorative surface transfer-laminated to an extruded plastic sheet, comprising: forming a matte release layer on a continuous, thin, flexible, heat-resistant carrier sheet, the matte release layer containing a resinous material hardened at an elevated temperature to form a continuous heat-resistant resinous film permanently bond to the carrier sheet and having a micro-roughness on a release-coated outer surface thereof; forming a decorative coating on the micro-roughened, release-coated outer surface of the hardened matte release layer to thereby form a thin, flexible transfer laminate; extruding a continuous plastic sheet through an extruder die exit opening, the extruded sheet advancing from the extruder die exit opening and having a heat of extrusion adjacent the extruder die exit opening; overlaying the transfer laminate as a continuous sheet on the advancing extruded sheet with the decorative coating thereof facing toward the extruded sheet; applying pressure to the advancing transfer laminate and to the extruded plastic sheet from a pressure roll on the side of the laminate opposite from the extruded sheet, said pressure being applied to the matte release-coated carrier sheet while the temperature of the extruded sheet is maintained near said heat of extrusion thereby transferring heat to the decorative coating while the matte release layer remains in its heat-resistant condition under the heat transferred from the extrusion to provide a continuous heat transfer barrier between the carrier sheet and the extruded sheet, to continuously transfer the decorative coating from the matte release layer and bond the decorative coating to the extruded sheet under the applied pressure, the transferred decorative coating being maintained in a pliable condition under the heat transferred thereto while the micro-roughness of the hardened resinous coating transfers a continuous low gloss surface to an outer surface of the decorative coating; and thereafter continuously releasing the carrier sheet and its hardened resinous film from the transferred decorative coating of the advancing plastic sheet to thereby form a plastic panel having said low gloss surface.

Claim 58

The process according to claim 50 in which the surface gloss transferred to the decorative coating has a 75° gloss level of less than about 20 gloss units.

Claim 59

The process according to claim 50 in which the resinous material in the matte release layer comprises a thermosetting resinous material.

Claim 60

The process according to claim 50 in which the matte release layer includes a release agent comprising a wax component from about 12% to about 25% and a silicone resin component from about 2.5% to about 25% of the solids contained in the matte release layer.