US5894048A
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US
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Synthetic laminate structure and method for making same
Assignee: Hunter Douglas Industries Switzerland GmbH
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Filing: 1996-10-31
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Granted: 1999-04-13
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Expires: 2016-10-31
Abstract
Abstract This invention relates to a synthetic laminate structure and a method for making the synthetic laminate structure. More particularly, the synthetic laminate structure contains an outer layer comprising a substantially transparent copolyester, a printed or colored film layer having opposed surfaces wherein at least one of the surfaces is colored or has an image printed thereon, a backing layer, and a laminating enhancer layer comprising a polyurethane disposed between the outer layer and the film layer, the laminated enhancer layer providing a bond between the outer layer and film layer characterized by a substantial absence of visible air pockets or adhesion discontinuities.
Inventors
- 👤 Michael Dennis Eckart
- 👤 Raymond Lynn Goodson
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 12:04
CPC Classifications
B; B32; B32B; B32B27/00; B32B27/06; B32B27/08; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/26; Y10T428/269; Y10T428/28; Y10T428/2848; Y10T428/31504; Y10T428/31786; Y10T428/3179; Y10T428/31797
Claims Analysis
Total Claims: 23
Claim 1
Independent Claim
113 words
A synthetic laminate structure which comprises: (A) an outer layer comprising a substantially transparent copolyester having an inherent viscosity of from about 0.5 to about 1.2 dL/g; (B) a printed or colored film layer having opposed surfaces wherein at least one of the surfaces is colored or has an image printed thereon; (C) a backing layer disposed adjacent the film layer comprising a polymer selected from the group consisting of polyvinyl chloride and a copolyester; and (D) a laminating enhancer layer comprising a polyurethane disposed between the outer layer and the film layer providing a bond between the layers which is characterized by a substantial absence of visible air pockets or adhesion discontinuities.
Claim 2
Dependent Claim
113 words
A synthetic laminate structure which comprises: (A) an outer layer comprising a substantially transparent copolyester having an inherent viscosity of from about 0.5 to about 1.2 dL/g; (B) a printed or colored film layer having opposed surfaces wherein at least one of the surfaces is colored or has an image printed thereon; (C) a backing layer disposed adjacent the film layer comprising a polymer selected from the group consisting of polyvinyl chloride and a copolyester; and (D) a laminating enhancer layer comprising a polyurethane disposed between the outer layer and the film layer providing a bond between the layers which is characterized by a substantial absence of visible air pockets or adhesion discontinuities.
Claim 3
Dependent Claim
65 words
The synthetic laminate structure of claim 1 wherein the copolyester comprises: (1) a dicarboxylic acid component comprising repeat units from at least 80 mole % of terephthalic acid or dimethylterephthalate; and (2) a diol component comprising repeat units from 98 to 1 mole % ethylene glycol and 2 to 99 mole % cyclohexanedimethanol, based on 100 mole % dicarboxylic acid and 100 mole % diol.
Claim 4
Dependent Claim
34 words
The synthetic laminate structure of claim 2 wherein the diol component of the copolyester comprises repeat units from 67 to 75 mole % of ethylene glycol and 33 to 25 mole % of 1,4-cyclohexanedimethanol.
Claim 5
Dependent Claim
38 words
The synthetic laminate structure of claim 1 wherein a layer of laminating enhancer is disposed between said outer layer and said printed or colored film layer and between said backing layer and said printed or colored film layer.
Claim 6
Dependent Claim
23 words
The synthetic laminate structure of claim 1 wherein the image on the printed or colored film layer is printed with a solvent-based ink.
Claim 7
Dependent Claim
30 words
The synthetic laminate structure of claim 1 wherein the printed or colored film layer is prepared from a polymer selected from the group consisting of polyvinyl chloride and a copolyester.
Claim 8
Dependent Claim
24 words
The synthetic laminate structure of claim 1 wherein the thickness of the outer layer is from about 0.127 mm to about 12.7 mm thick.
Claim 9
Dependent Claim
26 words
The synthetic laminate structure of claim 1 wherein the thickness of the printed or colored film layer is from about 0.025 mm to 0.254 mm thick.
Claim 10
Dependent Claim
24 words
The synthetic laminate structure of claim 1 wherein the thickness of the backing layer is from about 0.127 mm to about 24.1 mm thick.
Claim 11
Dependent Claim
18 words
The synthetic laminate structure of claim 1 further comprising a hard coat disposed on the outer surface layer.
Claim 12
Dependent Claim
15 words
The synthetic laminate structure of claim 10 wherein the hard coat is a bilayer film.
Claim 13
Dependent Claim
41 words
The synthetic laminate structure of claim 10 wherein the hard coat 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, heat cured urethane or plastisol, and combinations thereof.
Claim 14
Dependent Claim
22 words
The synthetic laminate structure of claim 1 wherein the printed or colored film layer has an image of a natural building material.
Claim 15
Dependent Claim
14 words
The synthetic laminate structure of claim 13 wherein the natural building material is wood.
Claim 16
Dependent Claim
14 words
The synthetic laminate structure of claim 13 wherein the natural building material is stone.
Claim 17
Independent Claim
197 words
A method for making a synthetic laminate structure which comprises: I. disposing a laminating enhancer comprising a polyurethane in a random or uniform pattern between a first surface of an outer layer comprising a substantially transparent copolyester having an inherent viscosity of from about 0.5 to about 1.2 dL/g and a first surface of a printed or colored film layer so that a substantially discontinuous layer of the laminating enhancer is sandwiched between the first surface of the outer layer and the first surface of the film layer; II. disposing a backing layer comprising a polymer selected from the group consisting of a copolyester and polyvinyl chloride adjacent a second surface of the film layer so that the outer layer and film layer with the laminating enhancer sandwiched therebetween and the backing layer are in superposed relation; and III. applying sufficient heat and pressure to the superposed outer layer, film layer and backing layer to cause the laminating enhancer to flow and spread between the outer layer and film layer into a substantially continuous layer providing a bond between the outer layer and film layer characterized by a substantial absence of visible air pockets or adhesion discontinuities.
Claim 18
Independent Claim
197 words
A method for making a synthetic laminate structure which comprises: I. disposing a laminating enhancer comprising a polyurethane in a random or uniform pattern between a first surface of an outer layer comprising a substantially transparent copolyester having an inherent viscosity of from about 0.5 to about 1.2 dL/g and a first surface of a printed or colored film layer so that a substantially discontinuous layer of the laminating enhancer is sandwiched between the first surface of the outer layer and the first surface of the film layer; II. disposing a backing layer comprising a polymer selected from the group consisting of a copolyester and polyvinyl chloride adjacent a second surface of the film layer so that the outer layer and film layer with the laminating enhancer sandwiched therebetween and the backing layer are in superposed relation; and III. applying sufficient heat and pressure to the superposed outer layer, film layer and backing layer to cause the laminating enhancer to flow and spread between the outer layer and film layer into a substantially continuous layer providing a bond between the outer layer and film layer characterized by a substantial absence of visible air pockets or adhesion discontinuities.
Claim 19
Dependent Claim
13 words
The method of claim 16 wherein the laminating enhancer is disposed by spraying.
Claim 20
Dependent Claim
14 words
The method of claim 16 wherein the laminating enhancer is disposed by sputter coating.
Claim 21
Dependent Claim
22 words
The method of claim 16 further comprising a laminating enhancer between the backing layer and the second surface of the film layer.
Claim 22
Dependent Claim
76 words
The method of claim 16 wherein Step (III) is carried out by hot press bonding followed by cold press bonding wherein hot press bonding is conducted at a temperature of about 250° F. to about 340° F. and a pressure of about 70 psi to about 110 psi and cold press bonding is conducted at a temperature of about 70° F. to about 340° F. and a pressure of about 13 psi to about 500 psi.
Claim 23
Dependent Claim
52 words
The method of claim 20 wherein hot press bonding is conducted at a temperature of 270° F. to 295° F. and a pressure of 90 to 100 psi and cold press bonding is conducted at a temperature of 100° F. to 130° F, and a pressure of 100 psi to 300 psi.
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| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 2002-04-12 | 2002-10-12 | 2003-04-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2006-04-12 | 2006-10-12 | 2007-04-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2010-04-12 | 2010-10-12 | 2011-04-13 | $7700.00 | Window Closed / Lapsed |