WO2021126094A1 - Textured materials and manufacturing method thereof - Google Patents

Textured materials and manufacturing method thereof Download PDF

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Publication number
WO2021126094A1
WO2021126094A1 PCT/TH2020/000028 TH2020000028W WO2021126094A1 WO 2021126094 A1 WO2021126094 A1 WO 2021126094A1 TH 2020000028 W TH2020000028 W TH 2020000028W WO 2021126094 A1 WO2021126094 A1 WO 2021126094A1
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WO
WIPO (PCT)
Prior art keywords
materials
pattern
textured
protective layer
patterned
Prior art date
Application number
PCT/TH2020/000028
Other languages
French (fr)
Inventor
Phalatt LEOWKIJSIRI
Original Assignee
Leowkijsiri Phalatt
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from TH1901007928A external-priority patent/TH1901007928A/en
Application filed by Leowkijsiri Phalatt filed Critical Leowkijsiri Phalatt
Priority to CN202090001026.7U priority Critical patent/CN220409857U/en
Publication of WO2021126094A1 publication Critical patent/WO2021126094A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/082—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising vinyl resins; comprising acrylic resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/095—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/04—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B25/08—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B32B27/365—Layered products comprising a layer of synthetic resin comprising polyesters comprising polycarbonates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/10—Interconnection of layers at least one layer having inter-reactive properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/05—5 or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/412—Transparent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/75—Printability

Definitions

  • Materials engineering or materials science particularly relates to the textured materials and manufacturing method thereof.
  • the user also desires the decorative purpose and multipurpose of use, for example, the combination of glass with other materials for decoration or the application as thermal insulation with decorative purpose.
  • the glass used for decorative purpose is often found in stained glass or textured or patterned glass which is different from glass in general and has different manufacturing method. For example, if the stained-glass production is desired, it often uses same manufacturing method as the float glass by melting silicon at the temperature more than 1 ,000°C to make silicon a molten glass before casting.
  • one embodiment of manufacturing method is similar to the laminated glass by using materials like fabric or fiber to insert between two glasses in manner of laminating the bonding materials like film. Then, heating to make the bonding materials soft and de-airing between layers. And then, heating and pressurizing to make the bonding materials melt and connecting both glasses together, that is limited only to the substrate which is a clear float glass.
  • creating pattern by blasting material to create pattern such as, EU Patent Publication No. EP3525986A1 titled “Method for patterning a surface, such as a glass surface” mentions the method of creating pattern on glass surface by blasting any materials and coloring the pattern.
  • creating pattern on glass surface and coating with film such as, Korean Patent Publication No. KR2007118840A titled “EXTERIOR PANEL OF FURNITURE OR HOUSEHOLD ELECTRONIC APPLIANCES, WHICH IMPROVES THE VISUAL IMAGE OF FURNITURE AND ELECTRONIC APPLIANCES” mentions the exterior panel of furniture or household electronic appliances comprising base layer, fabric layer, glass layer, and connecting unit, wherein the fabric layer is coated by laminating with the glass layer to create a visual patterned glass.
  • Chinese Patent Publication No. CN102730981A titled “Method for processing two-color pattern glazed glass (Translation from Clarivate Analytics)” mentions the method of creating two- color pattern glazed glass comprising the process of making pattern on the glass by coating and then re-coating throughout the glass with different color from the first layer, baking, and then washing the glass.
  • the glasses are aimed to perform merely structural function, such as, building structure, thermal and light insulation, or glass for decorative function, such as, creating pattern or texture for decoration, etc.
  • the pattern is made by color spraying, sandblasting, using laser beam, or roller press during the float glass manufacturing process that is applicable only to the substrate which is clear float glass, and also it needs to be heated at the temperature higher than 600°C for the materials to adhere to each other.
  • the glass requires the glass to have at least the thickness of at least 6 mm. for the manufacturing process.
  • the glass for the production involving the use of a machine in the manufacturing process, it still requires the glass to have at least the thickness of at least 3 mm. to prevent the potential damages that may occur during the manufacturing process.
  • the present invention has created and develops a textured material to be patterned using low-temperature manufacturing process using the temperature in manufacturing process lower than 600°C and applicable to the uneven substrate or clear float glass. If the textured glass is made according to the method of the present invention, it requires the thickness of at least 2 mm or more. Further, the manufacturing process according to the present invention could be applied to various kinds of substrate, apart from glass. Although the material already has pattern, this manufacturing method could add more patterns on the substrate materials thereof and choose various kinds of substrate for patterning or to being patterned. The obtained textured materials are safe and also provides structural aesthetics.
  • the textured materials comprises the lamination of materials at least three layers, including the substrate which is a material sheet supporting the lamination of other materials layers, the film which connects between the substrate and the protective layer by being heated, and the protective layer which is made of materials able to adhere to the film and is a layer for making pattern, wherein the pattern is provided on the protective layer or materials laminated on the protective layer.
  • the cover layer might be provided to help fix the pattern at predetermined position.
  • the lamination of materials might be provided in more than one set in one product, wherein the film is laminated on any one side of the protective layer or any one side of the substrate.
  • the method of manufacturing said textured materials comprises the process of laminating substrate, film, and protective layer according to the predetermined number of set of materials layers, wherein it could further comprise the lamination of pattern on the protective layer; the process of de-airing the materials at the room temperature with the predetermined pressure; and the process of heating to make the film connect the patterned protective layer and the substrate. When finishing the heating process, reducing the temperature.
  • Said invention has the objective to provide the textured materials and the manufacturing method thereof to be able to produce the textured materials, such as, the textured glass, at the low temperature and be able to create predetermined pattern.
  • the obtained product has safety and aesthetic characteristics and prevents heat and UV transmission effectively.
  • the manufacturing method is proceeded at the low temperature which reduces from 600°C to 110-150°C; therefore, it reduces the production cost and increases the variety of use.
  • FIG. 1 it shows the components of the textured materials, wherein a set of product comprises of the lamination of materials at least three layers, including:
  • the substrate 3 functions to support other materials layers and has the characteristics of adhering to the film 2 effectively, wherein the substrate 3 might be either an even surface material, a partially even surface materials, or an uneven surface material.
  • the examples of the substrate 3 used for the manufacturing method of the textured materials include glass, tile, metal, plastic, wood, rubber, or paper at least one or the combination thereof. That is, the present invention does not limit the materials used as the substrate 3.
  • the film 2 functions the connection between the protective layer 1 and the substrate 3 by being arranged between the protective layer 1 and the substrate 3, wherein the connection is occurred when the heat is applied to the materials layer not less than 100°C.
  • the connection of film 2 provides the predetermined textured materials on the surface of the substrate 3, wherein the film 2 could be chosen from polyvinyl butyral film, ethylene vinyl acetate film, thermoplastic polyurethane film, or ionomers film at least one or the combination thereof.
  • the protective layer 1 functions to support the pattern or the occurrence of pattern to obtain a texture product.
  • the protective layer 1 might be the same materials as the substrate 3. Hence, it is a layer to be patterned as predetermined; therefore, the protective layer 1 might be a transparent materials, such as, plastic polymers like polyvinylchloride (PVC), polypropylene (PP), polyethylene terephthalate (PET), polycarbonate (PC), or clear float glass, etc. to allow the pattern to be clearly visible, for example, the lamination of the substrate 3 which is glass, the film 2, and the protective layer 1 which is plastic for supporting the wood carving.
  • the protective layer 1 is provided with the patterned materials thereof directly, for example, the lamination of the substrate 3 which is glass, the film 2, and the protective layer 1 which is fabric materials, etc.
  • FIG. 2 shows the additional components of the textured material comprising the substrate 3, the film 2, and the protective layer 1, and further comprising:
  • the pattern 100 is provided by patterning on the protective layer 1 or the patterned materials laminated on the protective layer 1, wherein the pattern 100 is provided by patterning on the protective layer 1 chosen from color spraying, pattern printing, carving, etching, weaving, embroidering, cutting, drilling, or casting at least one or the combination thereof.
  • the pattern 100 is configured to be a patterned materials chosen from patterned natural materials, patterned synthetic materials, fabric, the lamination of pattern materials, the lamination of more than one patterned materials layers, color spraying, the lamination of patterned materials, pattern mold, reeded material, or low and uneven patterned materials at least one or the combination thereof.
  • the cover layer 200 is configured to laminate the pattern 100 to be at the predetermined position, wherein the pattern 100 might be permanently laminated with the protective layer 1. Or, in case of the desire of the pattern of the pattern 100 without its material adhered to the texture product, removing the pattern 100 from the product along with the cover layer 200 after finishing all manufacturing processes in order to remain only the substrate 3, the film 2, and the protective layer 1.
  • the method of patterning textured materials might be laminated in first embodiment that the substrate 3 is in the lower portion followed by the film 2 and the protective layer 1 or in the second embodiment that the protective layer 1 is in the lower portion followed by the film 2 and the substrate 3 as shown in FIG. 3. If the lamination follows the second embodiment, patterning the lower portion of the protective layer 1 by, for example, laminating the pattern 100 below the protective layer 1 followed by the cover layer 200 and then heating.
  • the texture product according to the present invention does not limit the number of set of the lamination of substrate 3, film 2, and protective layer 1 as shown in FIG. 4 that provides the lamination of more than one set in one product, wherein the lamination of more than one set in one product arranges the film 2 to laminate in any one side of the protective layer 1 or to laminate in any one side of the substrate 3 to function the connection between the protective layer 1 and the pattern 100 for the lamination of more than one set in one product.
  • the lamination of materials next to the first lamination set it could be provided with or without the substrate 3.
  • the lamination of more than one set in one product could be proceeded simultaneously in one time or proceeded the lamination of the first lamination set after finishing the manufacturing process of the first set of the texture product.
  • the obtained texture product it is further provided with color spraying or coloring in the product with the predetermined lamination of materials for aesthetic and variety of use.
  • the manufacturing method of the textured materials comprises the main processes: laminating materials layers, vacuuming materials layers, heating, and reducing temperature, wherein the details of each process is as follows:
  • the vacuum pressure is controlled throughout the process using the vacuum pressure in the range of -1 to -0.5 bars or using the vacuum pressure and the air pressure at the value lower than or equal to 15 bars, wherein there is the increase in temperature by 1 to 5 °C per minute started from the room temperature; and when the temperature reaches 70 to 90°C, remaining the temperature at the range 70 to 90°C for 20 to 90 minutes before increasing to 110 to 150°C; in another embodiment, the temperature is remained at 70°C for 20 to 90 minutes before increasing to 90°C; in another embodiment, the temperature is remained at 90°C for 20 to 90 minutes before increasing to 110 to 150°C;
  • the temperature reducing process is configured to reduce the temperature at the temperature decrease rate between 1 to 20°C per minute when the product is passed the heating process using the vacuum pressure in the range of -1 to -0.5 bars or configured to reduce the temperature at the temperature decrease rate between 1 to 20°C per minute and reduce the pressure by twisting the valve to discharge the pressure when the product is passed the heating process to use the vacuum pressure and the air pressure together in the condition which is lower than or equal to 15 bars;
  • the pattern 100 is further configured that pattern of the pattern 100 remains but the materials thereof is not on the texture product; the pattern 100 is removed from the product along with the cover layer 200 when all manufacturing processes are completed in order that the final product remain only the substrate 3, the film 2, and the protective layer 1.
  • the example of textured materials is configured to have any one side of either the substrate
  • the protective layer 1 as a glass to be patterned by the method according to the present invention and have thickness of 2 mm. If there is a fracture on the textured glass obtained from the method, it is as safe as the laminated glass because it would not break into pieces (referring to TISI No. 1222-2560) because there is the film as the component that is different from patterned float glass in general which requires the temperature higher than 600°C and the obtained product could break into pieces causing harm to the user.
  • the inventor conducts a comparative test between the textured glass obtained from the present invention, the clear float glass, and the patterned float glass to compare the solar heat gain coefficient (SHGC) and the percentage of UV transmission.
  • SHGC solar heat gain coefficient
  • the solar heat gain coefficient (SHGC) of each type of glass are as follows: the clear float glass 0.87, the patterned float glass 0.81, and the textured glass 0.78.
  • SHGC solar heat gain coefficient
  • the percentage of UV transmission of each type of glass are as follows: the clear float glass 70%, the patterned float glass 61 %, and the textured glass 9%.
  • the patterned float glass with thickness of 4 mm When comparing the patterned float glass with thickness of 4 mm to the clear float glass with thickness of 4 mm, it is found that the patterned float glass has less UV transmission than the clear float glass with thickness of 4 mm by 12%.
  • the textured glass with thickness of 4 mm to the clear float glass with thickness of 4 mm it is found that the textured glass could protect UV more than the clear float glass by 87% and more than the patterned float glass by 75% (FIG. 6).

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  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)

Abstract

The textured glass comprises the lamination of at least three materials layers, including a substrate, a film, and a protective layer, wherein the pattern is provided on the protective layer. For the pattern, it is provided on the protective layer or the patterned materials laminated on the protective layer which is further provided with the cover layer laminated on the pattern to fix the pattern at the predetermined position. Moreover, the lamination of the materials layers could be provided more than one set in one product, wherein the film is laminated on any one side of the protective layer or laminated on any one side of the substrate. For the manufacturing method for the textured materials thereof, it comprises the process of taking the laminated materials layers to de-airing at the room temperature and the predetermined pressure, then heating to make the film connect the patterned protective layer and the substrate. After the heating period is finished, reducing the temperature.

Description

TEXTURED MATERIALS AND MANUFACTURING METHOD THEREOF
Field of the invention
Materials engineering or materials science particularly relates to the textured materials and manufacturing method thereof.
Background of the invention
For the use of glass nowadays, apart from clear float glass or safety glass having operational purpose for accommodation partition, thermal insulation, decrease in luminosity of the light from outside or having insulation for high air pressure and temperature, the user also desires the decorative purpose and multipurpose of use, for example, the combination of glass with other materials for decoration or the application as thermal insulation with decorative purpose. The glass used for decorative purpose is often found in stained glass or textured or patterned glass which is different from glass in general and has different manufacturing method. For example, if the stained-glass production is desired, it often uses same manufacturing method as the float glass by melting silicon at the temperature more than 1 ,000°C to make silicon a molten glass before casting. Then, flowing and floating molten glass on molten tin under preferable temperature and pressure, such as, below 1 ,000°C, to make both surfaces of the glass to be parallel and even. The obtained glass would be clear providing a clear image from looking through glass.
Or, if the patterned glass production using other materials or having texture is desired, one embodiment of manufacturing method is similar to the laminated glass by using materials like fabric or fiber to insert between two glasses in manner of laminating the bonding materials like film. Then, heating to make the bonding materials soft and de-airing between layers. And then, heating and pressurizing to make the bonding materials melt and connecting both glasses together, that is limited only to the substrate which is a clear float glass.
According to the search of patents, it is found that there is prior art related to the manufacturing of texture or pattern of glass in different embodiments. For example, Thai Patent Application No. 0501002497 titled “System and method for creating graphics on glass surfaces” and Chinese Patent Publication No. CN1960810A titled “System and method for creating graphics on glass surfaces” mention the method of creating pattern (e.g. stencil) on translucent surface like glass surface and coating with various films. The obtained pattern might change when moving the substrate from the low temperature area to the higher temperature area. Or,
Chinese Patent Publication No. CN106314001 A titled “A surface pattern manufacturing process of glass steel (Translation from Clarivate Analytics)” mentions the method of creating surface patern of metallic glass by placing nonwoven fabric to make a pattern on the glass surface coated with resin and coating again with fiberglass.
Korean Patent Publication No. KR2011093218A titled “The strengthening proposal former glass process of manufacture in which the ceramics inorganic substance pigment pattern is printed. (Translation from Clarivate Analytics)” mentions the method of creating pattern on glass by adhering patterned film to the glass, and heating at 720°C, then cooling down immediately.
Or, creating pattern by blasting material to create pattern, such as, EU Patent Publication No. EP3525986A1 titled “Method for patterning a surface, such as a glass surface” mentions the method of creating pattern on glass surface by blasting any materials and coloring the pattern. Or,
Chinese Patent Publication No. CN 102615035 A titled “Surface treatment color pattern deplating process (PPVD) (Translation from Clarivate Analytics)” mentions the method of creating color pattern with two colors on glass surface by blasting, screening, printing photosensitive ink in vacuum condition using alkaline solvent. Then, baking for 10-30 minutes and coating with UV or PU paint and UV priming paint and cleaning with ultrasonic technology.
Or, creating pattern on glass surface and coating with film, such as, Korean Patent Publication No. KR2007118840A titled “EXTERIOR PANEL OF FURNITURE OR HOUSEHOLD ELECTRONIC APPLIANCES, WHICH IMPROVES THE VISUAL IMAGE OF FURNITURE AND ELECTRONIC APPLIANCES” mentions the exterior panel of furniture or household electronic appliances comprising base layer, fabric layer, glass layer, and connecting unit, wherein the fabric layer is coated by laminating with the glass layer to create a visual patterned glass.
Chinese Patent Publication No. CN102730981A titled “Method for processing two-color pattern glazed glass (Translation from Clarivate Analytics)” mentions the method of creating two- color pattern glazed glass comprising the process of making pattern on the glass by coating and then re-coating throughout the glass with different color from the first layer, baking, and then washing the glass.
The mentioned above inventions the glasses are aimed to perform merely structural function, such as, building structure, thermal and light insulation, or glass for decorative function, such as, creating pattern or texture for decoration, etc. Although there is the production of patterned or textured glass, the pattern is made by color spraying, sandblasting, using laser beam, or roller press during the float glass manufacturing process that is applicable only to the substrate which is clear float glass, and also it needs to be heated at the temperature higher than 600°C for the materials to adhere to each other. Further, it requires the glass to have at least the thickness of at least 6 mm. for the manufacturing process. And for the production involving the use of a machine in the manufacturing process, it still requires the glass to have at least the thickness of at least 3 mm. to prevent the potential damages that may occur during the manufacturing process.
Hence, the present invention has created and develops a textured material to be patterned using low-temperature manufacturing process using the temperature in manufacturing process lower than 600°C and applicable to the uneven substrate or clear float glass. If the textured glass is made according to the method of the present invention, it requires the thickness of at least 2 mm or more. Further, the manufacturing process according to the present invention could be applied to various kinds of substrate, apart from glass. Although the material already has pattern, this manufacturing method could add more patterns on the substrate materials thereof and choose various kinds of substrate for patterning or to being patterned. The obtained textured materials are safe and also provides structural aesthetics.
Summary of the invention
The textured materials comprises the lamination of materials at least three layers, including the substrate which is a material sheet supporting the lamination of other materials layers, the film which connects between the substrate and the protective layer by being heated, and the protective layer which is made of materials able to adhere to the film and is a layer for making pattern, wherein the pattern is provided on the protective layer or materials laminated on the protective layer. The cover layer might be provided to help fix the pattern at predetermined position. The lamination of materials might be provided in more than one set in one product, wherein the film is laminated on any one side of the protective layer or any one side of the substrate.
The method of manufacturing said textured materials comprises the process of laminating substrate, film, and protective layer according to the predetermined number of set of materials layers, wherein it could further comprise the lamination of pattern on the protective layer; the process of de-airing the materials at the room temperature with the predetermined pressure; and the process of heating to make the film connect the patterned protective layer and the substrate. When finishing the heating process, reducing the temperature.
Said invention has the objective to provide the textured materials and the manufacturing method thereof to be able to produce the textured materials, such as, the textured glass, at the low temperature and be able to create predetermined pattern. The obtained product has safety and aesthetic characteristics and prevents heat and UV transmission effectively. The manufacturing method is proceeded at the low temperature which reduces from 600°C to 110-150°C; therefore, it reduces the production cost and increases the variety of use. Detailed description of the invention
According to FIG. 1 , it shows the components of the textured materials, wherein a set of product comprises of the lamination of materials at least three layers, including:
The substrate 3 functions to support other materials layers and has the characteristics of adhering to the film 2 effectively, wherein the substrate 3 might be either an even surface material, a partially even surface materials, or an uneven surface material. The examples of the substrate 3 used for the manufacturing method of the textured materials include glass, tile, metal, plastic, wood, rubber, or paper at least one or the combination thereof. That is, the present invention does not limit the materials used as the substrate 3.
The film 2 functions the connection between the protective layer 1 and the substrate 3 by being arranged between the protective layer 1 and the substrate 3, wherein the connection is occurred when the heat is applied to the materials layer not less than 100°C. The connection of film 2 provides the predetermined textured materials on the surface of the substrate 3, wherein the film 2 could be chosen from polyvinyl butyral film, ethylene vinyl acetate film, thermoplastic polyurethane film, or ionomers film at least one or the combination thereof.
The protective layer 1 functions to support the pattern or the occurrence of pattern to obtain a texture product. The protective layer 1 might be the same materials as the substrate 3. Hence, it is a layer to be patterned as predetermined; therefore, the protective layer 1 might be a transparent materials, such as, plastic polymers like polyvinylchloride (PVC), polypropylene (PP), polyethylene terephthalate (PET), polycarbonate (PC), or clear float glass, etc. to allow the pattern to be clearly visible, for example, the lamination of the substrate 3 which is glass, the film 2, and the protective layer 1 which is plastic for supporting the wood carving. However, in case of patterning the patterned material, the protective layer 1 is provided with the patterned materials thereof directly, for example, the lamination of the substrate 3 which is glass, the film 2, and the protective layer 1 which is fabric materials, etc.
According to FIG. 2, it shows the additional components of the textured material comprising the substrate 3, the film 2, and the protective layer 1, and further comprising:
The pattern 100 is provided by patterning on the protective layer 1 or the patterned materials laminated on the protective layer 1, wherein the pattern 100 is provided by patterning on the protective layer 1 chosen from color spraying, pattern printing, carving, etching, weaving, embroidering, cutting, drilling, or casting at least one or the combination thereof. Or, the pattern 100 is configured to be a patterned materials chosen from patterned natural materials, patterned synthetic materials, fabric, the lamination of pattern materials, the lamination of more than one patterned materials layers, color spraying, the lamination of patterned materials, pattern mold, reeded material, or low and uneven patterned materials at least one or the combination thereof.
The cover layer 200 is configured to laminate the pattern 100 to be at the predetermined position, wherein the pattern 100 might be permanently laminated with the protective layer 1. Or, in case of the desire of the pattern of the pattern 100 without its material adhered to the texture product, removing the pattern 100 from the product along with the cover layer 200 after finishing all manufacturing processes in order to remain only the substrate 3, the film 2, and the protective layer 1.
Thus, the method of patterning textured materials might be laminated in first embodiment that the substrate 3 is in the lower portion followed by the film 2 and the protective layer 1 or in the second embodiment that the protective layer 1 is in the lower portion followed by the film 2 and the substrate 3 as shown in FIG. 3. If the lamination follows the second embodiment, patterning the lower portion of the protective layer 1 by, for example, laminating the pattern 100 below the protective layer 1 followed by the cover layer 200 and then heating.
And, the texture product according to the present invention does not limit the number of set of the lamination of substrate 3, film 2, and protective layer 1 as shown in FIG. 4 that provides the lamination of more than one set in one product, wherein the lamination of more than one set in one product arranges the film 2 to laminate in any one side of the protective layer 1 or to laminate in any one side of the substrate 3 to function the connection between the protective layer 1 and the pattern 100 for the lamination of more than one set in one product. For the lamination of materials next to the first lamination set, it could be provided with or without the substrate 3. The lamination of more than one set in one product could be proceeded simultaneously in one time or proceeded the lamination of the first lamination set after finishing the manufacturing process of the first set of the texture product.
For the obtained texture product, it is further provided with color spraying or coloring in the product with the predetermined lamination of materials for aesthetic and variety of use.
The manufacturing method of the textured materials comprises the main processes: laminating materials layers, vacuuming materials layers, heating, and reducing temperature, wherein the details of each process is as follows:
Laminating materials layers
A. laminating at least three materials layers, including the substrate 3, the film 2, and the protective layer 1 corresponding to the number of predetermined materials layers, wherein the lamination might be as in the first embodiment that the substrate 3 is in the lower portion followed by the film 2 and the protective layer 1 or the second embodiment that the protective layer 1 is in the lower portion followed by the film 2 and the substrate 3, or if the lamination follows the second embodiment, the pattern is provided below the protective layer 1 ;
B. laminating the pattern 100 on the protective layer 1 in order to pattern on the protective layer 1, wherein the lamination of the pattern 100 might be further included the cover layer 200 to laminate the pattern 100 in order to fix the pattern 100 in the predetermined position;
De-airing materials layers
C. taking materials from B. to be vacuuming at the room temperature with vacuum pressure in the range of -1 to -0.5 bars for not less than 10 minutes;
Heating
D. taking product from C. to be heated at the temperature between 110 to 150°C for 30 to 240 minutes in order to allow the film 2 to connect to the protective layer 1 having pattern 100 and the substrate 3; for the heating process, the vacuum pressure is controlled throughout the process using the vacuum pressure in the range of -1 to -0.5 bars or using the vacuum pressure and the air pressure at the value lower than or equal to 15 bars, wherein there is the increase in temperature by 1 to 5 °C per minute started from the room temperature; and when the temperature reaches 70 to 90°C, remaining the temperature at the range 70 to 90°C for 20 to 90 minutes before increasing to 110 to 150°C; in another embodiment, the temperature is remained at 70°C for 20 to 90 minutes before increasing to 90°C; in another embodiment, the temperature is remained at 90°C for 20 to 90 minutes before increasing to 110 to 150°C;
Reducing temperature
E. when finishing the heating period, reducing the temperature to below 50°C, wherein the temperature reducing process is configured to reduce the temperature at the temperature decrease rate between 1 to 20°C per minute when the product is passed the heating process using the vacuum pressure in the range of -1 to -0.5 bars or configured to reduce the temperature at the temperature decrease rate between 1 to 20°C per minute and reduce the pressure by twisting the valve to discharge the pressure when the product is passed the heating process to use the vacuum pressure and the air pressure together in the condition which is lower than or equal to 15 bars; when the manufacturing method of textured materials is finished, the pattern 100 is further configured that pattern of the pattern 100 remains but the materials thereof is not on the texture product; the pattern 100 is removed from the product along with the cover layer 200 when all manufacturing processes are completed in order that the final product remain only the substrate 3, the film 2, and the protective layer 1.
The example of textured materials is configured to have any one side of either the substrate
3 or the protective layer 1 as a glass to be patterned by the method according to the present invention and have thickness of 2 mm. If there is a fracture on the textured glass obtained from the method, it is as safe as the laminated glass because it would not break into pieces (referring to TISI No. 1222-2560) because there is the film as the component that is different from patterned float glass in general which requires the temperature higher than 600°C and the obtained product could break into pieces causing harm to the user.
Hence, the inventor conducts a comparative test between the textured glass obtained from the present invention, the clear float glass, and the patterned float glass to compare the solar heat gain coefficient (SHGC) and the percentage of UV transmission. The results are as follows.
The solar heat gain coefficient (SHGC) of each type of glass are as follows: the clear float glass 0.87, the patterned float glass 0.81, and the textured glass 0.78. When comparing the patterned float glass with thickness of 4 mm to the clear float glass with thickness of 4 mm, it is found that the patterned float glass has less thermal resistance than the clear float glass with thickness of 4 mm by 7%. However, when comparing the textured glass with thickness of 4 mm to the clear float glass with thickness of 4 mm. it is found that the textured glass has more thermal resistance than the clear float glass by 10% and could protect heat better than the patterned float glass by 3% (FIG. 5).
The percentage of UV transmission of each type of glass are as follows: the clear float glass 70%, the patterned float glass 61 %, and the textured glass 9%. When comparing the patterned float glass with thickness of 4 mm to the clear float glass with thickness of 4 mm, it is found that the patterned float glass has less UV transmission than the clear float glass with thickness of 4 mm by 12%. However, when comparing the textured glass with thickness of 4 mm to the clear float glass with thickness of 4 mm, it is found that the textured glass could protect UV more than the clear float glass by 87% and more than the patterned float glass by 75% (FIG. 6).
Any modifications could be clearly comprehensible and done by the person skilled in the related art under the scope and the intention of the present invention according to the attached claims.
Best mode of the invention
As mentioned in detailed description of the invention.

Claims

Claims
1. The textured materials of which one product comprises the lamination of at least three materials layers, including: a substrate (3) provided as the materials sheet supporting other materials layers; a film (2) provided to connect between the substrate and the protective layer by being supplied with heat; a protective layer (1) provided as the materials which is able to be adhered to the film (2) and to be patterned.
2. The textured materials according to claim 1, wherein further comprising: a pattern (100) provided to be patterned on the protective layer (1) or the patterned materials laminated on the protective layer (1); a cover layer (200) provided to laminate on the pattern (100) to fix the pattern (100) at the predetermined position.
3. The textured materials according to claim 1 , wherein the substrate (3), the film (2), and the productive layer (1) are laminated more than one set in one product.
4. The textured materials according to claim 1 or 3, wherein the film (2) is laminated on one side of the protective layer (1) or laminated on one side of the substrate (3).
5. The textured materials according to claim 1 or 3, wherein the lamination of the materials in the next set might be provided with or without the substrate (3).
6. The textured materials according to claim 1, wherein the substrate (3) is either a patterned material, a partially patterned materials, or a non-pattern materials.
7. The textured materials according to claim 1, wherein the substrate (3) could be chosen from glass, tile, metal, plastic, wood, rubber, or paper at least one or a combination thereof.
8. The textured materials according to claim 1, wherein the substrate (3) is preferably configured as a glass.
9. The textured materials according to claim 1, wherein the film (2) could be chosen from polyvinyl butyral film, ethylene vinyl acetate film, thermoplastic polyurethane film, or ionomers film at least one or the combination thereof.
10. The textured materials according to claim 1, wherein the protective layer (1) could be chosen from polymers, fabric, or glass at least one or the combination thereof.
11. The textured materials according to claim 10, wherein the polymer could be chosen from polyvinylchloride, polypropylene, polyethylene terephthalate, or polycarbonate at least one or the combination thereof.
12. The textured materials according to claim 1, wherein the pattern (100) is configured to be patterned on the protective layer (1) chosen from color spraying, pattern printing, carving, etching, weaving, embroidering, cutting, drilling, or casting at least one or the combination thereof.
13. The textured materials according to claim 1, wherein the pattern (100) is configured to be a patterned materials chosen from patterned natural materials, patterned synthetic materials, fabric, the lamination of patterned materials, the lamination of more than one patterned materials layers, color spraying and lamination of patterned materials, pattern mold, reeded material, or low and uneven patterned materials at least one or the combination thereof.
14. The textured materials according to claim 1, wherein further comprising the method of color spraying or coloring in the product obtained from the lamination of the predetermined materials layers.
15. The method of manufacturing the textured materials comprises the processes as follows:
A. laminating the substrate (3), the film (2), and the protective layer (1) according to the number of predetermined materials layers;
B. taking the pattern (100) to laminate on the protective layer (1) to pattern the protective layer (1);
C. taking the materials from B. to De-airing by vacuum at the room temperature using the vacuum pressure in the range of -1 to -0.5 bars for not less than 10 minutes;
D. taking the materials from C. to be heated at the temperature of 110 to 150°C for 30 to 240 minutes in order to allow the film (2) to connect the protective layer ( 1 ) with the pattern (100) and the substrate (3), wherein the vacuum pressure is controlled throughout the process;
E. when the heating period is finished, reducing the temperature below 50°C.
16. The method of manufacturing the textured materials according to claim 15, wherein further comprises the cover layer (200) laminated on the pattern (100) in order to fix the pattern (100) at the predetermined position.
17. The method of manufacturing the textured materials according to claim 15, wherein the vacuum pressure is controlled to use the vacuum pressure in the range of -1 to -0.5 bars or to use the vacuum pressure and the air pressure in the condition that is below or equal to 15 bars.
18. The method of manufacturing the textured materials according to claim 15, wherein the heating process is configured to have the temperature increase rate of 1 to 5°C per minute.
19. The method of manufacturing the textured materials according to claim 15, wherein the heating process is further included the temperature maintenance at the temperature range of 70 to 90°C for 20 to 90 minutes before increasing the temperature to 110 to 150°C.
20. The method of manufacturing the textured materials according to claim 15, wherein the heating process is further included the temperature maintenance at the temperature of 70°C for 20 to 90 minutes before increasing the temperature to 90°C.
21. The method of manufacturing the textured materials according to claim 15, wherein the heating process is further included the temperature maintenance at the temperature 90°C for 20 to 90 minutes before increasing the temperature to 110 to 150°C.
22. The method of manufacturing the textured materials according to claim 15, wherein the temperature reducing process is configured to have the temperature decrease rate of 1 to 20°C per minute or to have the temperature decrease rate of 1 to 20°C and reduce the pressure by twisting the valve to discharge the pressure.
PCT/TH2020/000028 2019-12-20 2020-04-30 Textured materials and manufacturing method thereof WO2021126094A1 (en)

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CN101554740A (en) * 2008-04-10 2009-10-14 施义安 Log glass and manufacturing process thereof
CN102825939A (en) * 2012-08-16 2012-12-19 郑州玉海玻璃技术有限公司 Manufacturing method of ultra-large plate glass pattern and processing equipment thereof
CN104291016A (en) * 2013-07-16 2015-01-21 丰新科技股份有限公司 Membrane body and use method thereof
WO2016178169A1 (en) * 2015-05-05 2016-11-10 Testa Elisabetta Manufacturing process of a laminated polymeric product
CN107443816A (en) * 2016-05-31 2017-12-08 鸿富锦精密工业（深圳）有限公司 Artistic glass and preparation method thereof

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101554740A (en) * 2008-04-10 2009-10-14 施义安 Log glass and manufacturing process thereof
CN102825939A (en) * 2012-08-16 2012-12-19 郑州玉海玻璃技术有限公司 Manufacturing method of ultra-large plate glass pattern and processing equipment thereof
CN104291016A (en) * 2013-07-16 2015-01-21 丰新科技股份有限公司 Membrane body and use method thereof
WO2016178169A1 (en) * 2015-05-05 2016-11-10 Testa Elisabetta Manufacturing process of a laminated polymeric product
CN107443816A (en) * 2016-05-31 2017-12-08 鸿富锦精密工业（深圳）有限公司 Artistic glass and preparation method thereof

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