WO2023230401A1

WO2023230401A1 - Process for making curved laminated solar panel having decorative appearance using distortion printing and panel produced thereby

Info

Publication number: WO2023230401A1
Application number: PCT/US2023/066463
Authority: WO
Inventors: Anuj M. THAKKAR
Original assignee: Aptera Motors Corp.
Priority date: 2022-05-01
Filing date: 2023-05-01
Publication date: 2023-11-30

Abstract

The invention relates to an apparatus and method for fixing an image on complex geometric shapes such as a curved solar panel with an undistorted printed design. The solar panel comprises substrate and superstate preforms having at least one design printed on one surface or interface. The method uses distortion printing during preform fabrication. A transformation from a flat state to the curved panel state is determined. The reverse transformation is applied to the desired design thereby producing a pre-distorted design. The pre-distorted design is printed on a surface or interface of a lamination layer prior to flat lamination. After flat lamination the layers are thermoformed into the final preform shape wherein the design is substantially undistorted. Alternatively, the pre-distorted design may be printed on the full flat laminate or may be applied by a back sheet or transfer film. The preforms are then laminated with encapsulated solar cells forming a curved solar panel with an undistorted design.

Description

PROCESS FOR MAKING CURVED LAMINATED SOLAR PANEL HAVING DECORATIVE APPEARANCE USING DISTORTION PRINTING AND PANEL PRODUCED THEREBY

TECHNICAL FIELD

[0001] The present invention relates to forming a decorative appearance on a laminate structure and, more particularly, to a process for making a doubly curved laminated glass solar panel having a decorative appearance using distortion printing.

BACKGROUND

[0002] The forming of a decorative appearance on solar panels presents challenges when adapted to a solar panel having two-axes of curvature, such as, for example, a vehicle or architectural panel having a curved, complex shape. Conventional systems and methods for creating patterns and designs in flat solar panel applications typically employ a transfer sheet, backsheet, or other separately patterned layer. Alternatively, the image may be applied to the solar panel directly. In either case, the pattern may be applied with a suitable printer such as, for example, a gantry-style printing apparatus and available gantry printing techniques. The layer is applied before or after lamination to rigid, flat panels or flexible, planar panels held in a flat state. Imaging on curved surfaces is generally more challenging than flat surfaces because commercially available proximity or contact printers and printing techniques, are not capable of handling curved surfaces. As a result, a need exists for a printer and printing technique(s) have been developed capable of handling curved surfaces and other complex geometies.

[0003] Some printing techniques are available in the packaging industry to apply image(s) to complex surfaces with Illustrative examples being designs or decorations printed thereon. In one approach, consumable products such as glass and/or plastic bottles can be decorated with heat shrink films. In this technique a pattern, such as a logo or text, is printed on a layer of clear, heat-shrinkable polymer, which is then cut, formed into an open-ended cylinder, placed over the bottle, and heat-shrunk until it conforms to the bottle surface. A layer of adhesive may be used to provide additional durability for the label. In another approach, ink or paint is applied to the surface of a mold in the shape of the item, followed by injection or blow molding of the glass or plastic. The molten plastic bonds to the ink or paint layer forming a highly durable and scratch-resistant design on its surface. In another approach used on films such as blister packaging, a design or label is printed on a flat layer of clear packaging, followed by shaping of the layer using the blistering technique, resulting in the label positioned on the blister. In yet another approach, plastic thermoforming may be used with a printed decoration or label sheet, either laminated or adhered to a sheet of the packaging material. The curved surfaces of these products are printed on a glass or plastic film, semi- or otherwise rigid substrate. [0004] Plastic thermoforming is the broad label given to the manufacturing process that heats thermoplastic sheet material (i.e., “thermos”) and then applies pressure, force, or vacuum to form into a 3-dimensional shape (i.e., “forming”). Methods of thermoforming may include pressure forming, vacuum forming, drape forming, and sag forming, and may depend on the material composition of the item to be formed. In pressure forming, the sheet of thermoplastic material is heated until pliable and placed over a mold. Positive pressure is then applied above the heated sheet, pressing the material into the surface of the mold to create the desired 3-dimensional shape. In vacuum forming, sheet thermoplastic material is heated until pliable and placed over a mold. The air between the heated sheet and mold is then evacuated creating a vacuum that pulls the material onto the surface of the mold to create the desired 3- dimensional shape. One significant difference is that pressure forming allows for pressures greater than one atmosphere to draw a plastic sheet into its final configuration, whereby the additional pressure allows for greater detail and texture when such aesthetics are desired. Drape forming, or sag forming, employs mechanical or manual draping over a mold and may be generally distinguishable in that it does not substantially stretch the plastic during the formation of the part.

[0005] These conventional technologies and methods have disadvantages that become apparent when an undistorted image is first printed on a flat sheet and later transforms or otherwise takes the form of a three dimensions (3-D) surface thereby becoming a distorted in 3-D and undesirable for certain applications such as lettering, labels, bar codes, and the like. In order to compensate, the image must be pre-distorted to counteract this effect, whereby this compensated printing technique is called distortion printing.

[0006] In the automotive space, where designs are applied to a variety of vehicles, the most common techniques for applying designs, decorations, or indicia include standard masking and painting, maskless painting (e.g., airbrushing) and adhesive decals. In recent years two other techniques have emerged for applying protective layers and/or designs. In scratch resistance applications, a protective film is applied to the surface of the vehicle commonly known as invisible shield, car scratch protective film, clear mask, bra, etc. Another technique is generally called a car or vinyl wrap comprised of a heavy-duty vinyl sheet having an adhesive backing on one side. Suitable polyvinyl chloride (PVC) formulations strengthen the vinyl material and plasticizers provide flexibility thereby having success as a durable (e.g. between 1 and 5 years) scratch resistant car wrap. Installation of a vinyl wrap to individual body panels and/or an entire vehicle involves applying the film, that may be printed or colored, and applying heat to conform to the vehicle contours and/or by virtue of suitable adhesives. Yellowing (clear bra) or peeling (clear bra, vinyl wrap) of the of the film are common failure mechanisms. In the above bra and vinyl wrap examples, an image or design is printed first on the flat film having some distortion of the image when it takes the form of the body panel. Because the vehicle or panels are subject to harsh environments, safety requirements, and durability -- as the panel ts expected to last for many years - it heretofore has been unsuitable in this application as distortion disadvantages abound when applying undistorted images on complex surfaces of a vehicle and/or panel(s) using known techniques.

[0007] Consequently, there is a need for a method for integrating patterns, labels, and designs with an article of manufacture, panel(s), and/or with a laminated solar body panel of a desired aerodynamic shape having multiple axes of curvature such as, for example, the roof, hood, or trunk of an automobile. In addition, there exists a long-felt need to be able to form a distortion-free, decorative appearance on laminated solar panels, for example, to improve the appearance of the panel.

SUMMARY

[0008] The present invention is directed to an article of manufacture and method for producing a decorative appearance on a curved laminated solar panel using distortion printing, the article of manufacture corresponding to a solar panel produced thereby.

[0009] In one aspect of the present invention, a method for producing a decorative appearance is described wherein patterns, labels, and/or designs may be applied to a one- or two-axis of curvature, laminated solar panel, in a manner that allows said patterns, labels, and/or designs to appear substantially undistorted.

[0010] In another aspect of the present invention, a one- or two-axis of curvature laminated solar panel is produced that is compatible with the requirements of automotive applications, the solar panel having a distortion-free, decorative appearance.

[0011] In another aspect of the present invention, a doubly curved laminated solar panel is produced, the solar panel having a distortion-free, decorative appearance that may be mass produced at low cost. Other desirable features and characteristics will become apparent from the abstract, the detailed description, the drawings, and the claims, when considered in view of this summary.

DESCRIPTION OF THE DRAWINGS

[0012] Non-limiting and non-exhaustive embodiments of the present disclosure are described with reference to the following drawings. In the drawings, like numerals describe like components throughout the several views. [0013] For a better understanding of the present disclosure, reference will be made to the following Detailed Description, which is to be read in association with the accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations, wherein:

[0014] FIG. 1A illustrates a perspective view of a glass-based, doubly curved solar panel with doubly curved solar cells, according to an embodiment of the present invention;

[0015] FIG. 1 B illustrates a detail view of a glass-based, doubly curved solar panel with doubly curved solar cells, according to an embodiment of the present invention;

[0016] FIG. 2 illustrates a flowchart of a distortion printing method for a laminated solar panel, according to an embodiment of the present invention;

[0017] FIG. 3A illustrates an exploded perspective view of exemplary substrate sheets prior to preforming, employing an inversely-distorted image printed thereon, according to an embodiment of the present invention;

[0018] FIG. 3B illustrates a perspective view of exemplary substrate sheets after preforming, employing a distortion-free image, according to an embodiment of the present invention;

[0019] FIG. 4 illustrates an exploded, exemplary lamination stack for a distortion printed, curved laminated solar panel, according to an embodiment of the present invention;

[0020] FIG. 5A illustrates a partially-exploded perspective view of a flanged solar panel and support structure, according to an embodiment of the present invention;

[0021] FIG. 5B illustrates a perspective view of an assembled flanged solar panel and support structure, according to an embodiment of the present invention; and

[0022] FIG. 5C illustrates an enlarged section view taken from FIG. 5B of a flanged solar panel and support structure, according to an embodiment of the present invention.

DETAILED DESCRIPTION

[0023] Non-limiting embodiments of the invention will be described below with reference to the accompanying drawings, wherein like reference numerals represent like elements throughout. While the invention has been described in detail with respect to the preferred embodiments thereof, it will be appreciated that upon reading and understanding of the foregoing, certain variations to the preferred embodiments will become apparent, which variations are nonetheless within the spirit and scope of the invention. The drawings featured in the figures are provided for the purposes of illustrating some embodiments of the invention and are not to be considered as limitation thereto.

[0024] The terms “a” or “an”, as used herein, are defined as one or as more than one. The term “plurality”, as used herein, is defined as two or as more than two. The term “another”, as used herein, is defined as at least a second or more. The terms “including” and/or “having”, as used herein, are defined as comprising (i.e., open language). The term “coupled”, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically.

[0025] Reference throughout this document to “some embodiments”, “one embodiment”, “certain embodiments”, and “an embodiment” or similar terms means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of such phrases or in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments without limitation.

[0026] The term “or” as used herein is to be interpreted as an inclusive or meaning any one or any combination. Therefore, “A, B or C” means any of the following: “A; B; C; A and B; A and C; B and C; A, B and C”. An exception to this definition will occur only when a combination of elements, functions, steps or acts are in some way inherently mutually exclusive.

[0027] The term “means” preceding a present participle of an operation indicates a desired function for which there is one or more embodiments, i.e., one or more methods, devices, or apparatuses for achieving the desired function and that one skilled in the art could select from these or their equivalent in view of the disclosure herein and use of the term “means” is not intended to be limiting.

[0028] In an embodiment illustrated in FIGS. 1A and 1 B, a laminated solar panel 100 comprises a solar cell array 200 encapsulated in a polymer adhesive 112 and disposed between a pair of preformed, thin, strengthened glass layers 120, 130. The solar panel is doubly curved about two axes, X and Y, thereby having two-axes of curvature. The curvature may be of the same sign and/or magnitude, as in the Figures, or of different sign and/or magnitude. Moreover, the panel may be non-uniformly curved, for example, having more curvature in some portions relative to others. A laminated solar panel curved about two axes can be manufactured according to the disclosure of co-pending Non-Provisional Patent Application No. 18/169,576, filed on February 15, 2023, entitled Curved Laminated Solar Panel And Method Of Manufacturing Thereof, which claims priority to Provisional Patent Application No. 63/310,565, filed on February 15, 2022 entitled Curved Laminated Solar Panel and Method of Manufacture Thereof, both of which are incorporated herein by reference in their entirety. The laminate, shown in the detail view of FIG 2B, includes a pair of glass layers which serve a plurality of purposes for the structure and function of the solar panel 100. At the bottom is a substrate 120 comprised of rigid, ultra-thin, chemically strengthened, alkali-aluminosilicate glass, such as Gorilla® glass from Corning, Dragontail® from Asahi, or Xensation® from Schott, that provides mechanical stiffness. At the top is a superstrate 130 comprised of a rigid layer of ultra-thin, thermally or chemically strengthened glass that provides mechanical stiffness, resistance to impact, resistance to abrasion, and a barrier against moisture. In the center may be a core 110 comprising the cells 210 of the solar cell array 200 surrounded by a layer of flow-melt adhesive, such as POE 112. The POE 112 acts as a barrier to water ingress and increases durability and reliability.

[0029] As described herein and with respect to any of the embodiments of the disclosure, distortion printing may refer to disposing, or otherwise imparting, a design on or proximate to one or more layers of a lamination stack of which the solar panel is comprised. In this context a design may include an image, label, logo, lettering, or any other indicia. Such designs may be decorative or aesthetically pleasing or be purposed for masking components from view. A design may comprise a pigment, ink, dye, or other coloring. The design may be disposed on one or more layers of the lamination stack. Where a design is disposed on two or more layers, the design may form a 3D image characterized as having depth or other visual components thereof. In a preferred embodiment, the design may be disposed below the solar cells, in this case on the bottom surface or at the interface of the substrate 120. For disposing a design in or on the lamination stack, the design may be printed or transferred thereto. In the transferring process, there may be a disposable layer that conveys the design from the printer or location or origin to the layer to be disposed thereto.

[0030] FIG. 2 illustrates a flowchart of a preferred method for distortion printing 180 on a glass layer of a laminated solar panel 100 to create the represented printed design when formed. The method 180 may include the following steps. In a first step 182, calculating or measuring the distortion created in a forming process for a design on a solar panel 100 or other component. In a second step 184, calculating the inverse of said distortion and applying it to the desired image to be printed on a flat sheet. In this context, these steps may be achieved in part by a computational solver that renders a curved surface into a discrete mesh defining discretized points; distortion is measured or calculated for each point. The inverse of that distortion is then calculated to determine the flattened image. Such computational or numerical solvers are useful to solve translation to the flat surface and/or sheet, and are available as commercial software packages known to one skilled in the art; however, other distortion adjustments can occur due to translations of the image that are not solved thereby such as a group of adjustments for material stretching, thermal flow, properties of the preforms and/or laminate stack, and other process factors of temperature, pressure, time, heat, curing and/or fixing the image. In a third step 186 the inversely distorted image is either printed (e.g., inks, pigments, etc.) or applied (image sheet, transfer sheet) on the as-drawn flat sheet glass 166. In a fourth step 168, the flat glass is formed to the final panel shape resulting in the desired image appearing on the surface of the glass in the desired proportions. In a fifth step, the glass preforms are chemically or thermally strengthened. In a sixth step 170, the preforms are trimmed to the final panel dimensions. The preforms 120, 130 thusly prepared comprise input components to the solar panel lamination process.

[0031] FIGS. 3A and 3B describe the process of distortion printing on glass preforms. Referring to FIG. 3A, in a first step the glass 128 is distortion printed 129a in a flat state with an organic or ceramic ink. A screen printer or a digital printer may be used, for example. For glass, ceramic inks may be considered the most durable, but their colors are limited. On the other hand, organic inks may be used in certain applications for glass preforms. However, due to the relatively low temperature of the organic ink curing process, the high temperature needed to form the glass tends to cause discoloration or adverse effects of organic inks, whites and yellows in particular. Ceramic inks generally comprise three parts: the colored frit that melts into, i.e., chemically bonds to, the glass; a binder, such as a resin, that holds the frit in place prior to the firing process; and a liquid medium, such as a solvent that allows the ink to be applied.

[0032] Drying occurs immediately after the ink is printed. Drying may generally be considered as removing the solvent from the mixture without blistering, cracking, or otherwise over-drying. Generally, passive drying takes too long to be economical. Therefore, active methods of drying coatings, paints, inks, and the like, can be accomplished with convection heating, infrared energy, a combination of convection and infrared, UV energy, and/or forced-air drying. With convection, the air is heated, transferring energy to the coating. Infrared and UV drying provides highly-efficient electromagnetic energy directly from the heat source to the coating without heating the air therebetween. With forced-air drying, air is passed over the coating and convection occurs. In the context of printing multiple layers directly on top of one another, the presence of binder in the initially-disposed ink may facilitate the adhesion or acceptance of the subsequently-disposed layer. The drying process generally enables a subsequent printing of additional layers.

[0033] After drying, a firing may be used, which may generally be considered as removing the binder from the mixture, at which point the frit bonds with or adheres to the glass. In one embodiment, firing may occur with the glass in a flat state. The flat glass with adhered frit may then be subjected to preforming 168 and strengthening 169, as described in FIG. 2. Alternatively, the firing may occur during the thermoforming process 168. In this way, the glass may then be formed into the desired shape via pressure forming, sag forming, or other known method, as shown in FIG. 3B. In FIG. 3B the substrate 120 has been thermoformed and the image 129b has been reshaped to the desired proportions. Here, the desired proportions include, for example, a substantially straight appearance of the arms and crossmember forming the letter “A”. Subsequently, the glass may be strengthened, such as by chemical or tempering methods 169.

[0034] FIG. 4 illustrates the subsequent arrangement of exemplary layers, via an exploded perspective view, that may comprise the laminated solar panel 100. At the bottom is the preformed substrate 120 which may include the distortion-free image 129b. A first encapsulant 112a may be disposed on the substrate 120 followed by placement of the solar cell array 200. A second encapsulant 112b may then be disposed on the solar cell array 200. Then, a preformed superstrate 130, which may be similar in materials and/or construction to the substrate preform 120, may be disposed on the second encapsulant 112b. The lamination stack may then be placed into a laminator and laminated. Note that, with the exception of the solar cell array 200, all of the layers may be fully or partially transparent. Thus, printed surfaces or interfaces above the solar cells may be visible, as well as any printed surfaces or interfaces below and beyond the bounds of the solar cells. If surfaces or interfaces on the superstrate 130 are printed, then to avoid reducing or blocking the light to the cells printing is restricted to in between and/or outside the extents of the cells. Precision alignment between the superstrate 130 and solar cell array 200 may then be relied upon on to avoid overlapping the pattern with the cells.

[0035] In an alternative embodiment, other layers in the lamination stack may be printed as desired. For example, one or more laminate layers may be combined to create multi-dimensional images to the laminated solar panel 100 by the lamination process. Graphical effects may be accomplished by using the spatial relationship of the multiple layers such as, for example, depth of view, electroluminescent coatings (i.e., layers that can glow or create illuminated lettering), or other graphical layer combinations. Also, printing on layers above the solar cells 200 can be done for various purposes. For example, it can be used to mask defects, it can be used to mask solar cells 200 from view, or it can be used to create a three-dimensional effect.

[0036] In an alternate embodiment, a laminated solar panel 100 may include a structural flange 140 comprising all or a portion of the laminated layers. A laminated solar panel 100 including a flange 140 can be manufactured according to the disclosure of co-pending Non-Provisional Patent Application No. 18/169,576, filed on February 15, 2023, entitled Curved Laminated Solar Panel And Method Of Manufacturing Thereof, which claims priority to Provisional Patent Application No. 63/310,565, filed on February 15, 2022 entitled Curved Laminated Solar Panel and Method of Manufacture Thereof, both of which are incorporated herein by reference in their entirety. The flange 140 may serve several functions, as exemplified in FIGS. 5A - 5C herein. In a first function, illustrated in FIG. 5A, the vertical flange 140 may be used as an alignment feature for ease of assembly to the vertical surface 262a of a support structure 260, such as the frame of an automobile. In FIG. 5B the panel 100 has been mated to the frame 260 through a vertical motion. FIG. 5C illustrates the mated interface which provides a small gap between the flange 140 and frame datum 262a suitable for containing a structural adhesive. Alternative ways of attachment are possible, such as a notch 262b in the frame 260 which accepts the panel edging 142, thereby providing a snap fit retainment feature. Also, the flange 140 may be used to partially protect the edge of the laminated panel by positioning it toward the interior of the supporting structure 260, in this case a vehicle, and away from exposure to the elements. The panel edging 142, which is the primary way of protecting the panel edge, may comprise a layer of sealant/adhesive, or a rubber or metal seal, or any combination thereof. The flange may also serve aesthetic purposes, such as hiding the edge of the panel from view and thus hiding any edge sealing elements from the viewable surface. Furthermore, the panel edge termination (outer fillet of the flange) used to form an aesthetic seam with the frame 260 as by, for example, forming a fillet-to-fillet joint along an extension of the panel contour 264.

[0037] While certain configurations of structures have been illustrated for the purposes of presenting the basic structures of the present invention, one of ordinary skill in the art will appreciate that other variations are possible which would still fall within the scope of the appended claims. Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.

Claims

CLAIMS What is claimed is:

1. A vehicle comprising: a solar panel having one or more axes of curvature, the solar panel comprising: a substrate and a superstrate each comprising a layer of glass, said substrate and superstrate being preformed in a complementary shape when said solar panel is in an assembled configuration, said substrate characterized by upper and lower substrate surfaces, said superstrate characterized by upper and lower superstrate surfaces; a core disposed therebetween, said core comprising a solar cell array including at least one solar cell, said solar cell array being encapsulated by one or more encapsulant layers; a design disposed proximate one or more of said upper and lower substrate surfaces, and/or proximate said upper and lower superstrate surfaces, said design being formed by a distortion printing process, wherein when said solar panel is in said assembled configuration, said core is integrally formed with said substrate and said superstrate, and said solar panel is characterized by a perimeter; and a support structure adapted to couple to said solar panel about at least a portion of said perimeter.

2. The vehicle according to claim 1 wherein said perimeter comprises a flange adapted to form an aesthetic seam with said support structure.

3. The vehicle according to claim 1 , wherein said design is selected from the group consisting of: an image, a label, a logo, lettering, and/or indicia.

4. The vehicle according to claim 1 , wherein said distortion printing process comprises disposing said design in a flat, distorted orientation prior to preforming said superstrate and/or said substrate, and after preforming, said design appears undistorted and exhibits two axes of curvature.

5. The vehicle according to claim 1 , wherein said design is disposed proximate two or more of said upper and lower substrate surfaces, and/or said upper and lower superstrate surfaces, forming a 3D effect.

6. The vehicle according to claim 1 , wherein said one or more preformed layers of said substrate and said superstrate comprise preformed and thermally or chemically strengthened glass.

7. The vehicle according to claim 1 , wherein in said assembled configuration, said core is integrally formed with said substrate and said superstrate such that said at least one solar cell of said solar cell array is doubly curved.

8. A method of manufacturing a vehicle panel comprising: determining a transformation required to go from a flat state to a doubly curved state of a solar panel; applying the reverse of said transformation to form a design characterized by pre-distortion; disposing said pre-distorted design proximate one or more of an upper and a lower substrate surface and/or proximate one or more of an upper and a lower superstrate surface; preforming said substrate and said superstrate so that said substrate and said superstrate are each characterized by said doubly curved state, and so that said substrate and said superstrate form a complementary shape when said solar panel is in an assembled configuration; disposing a core between said substrate and said superstrate to form a lamination stack, said core comprising a solar cell array including at least one solar cell, said solar cell array being encapsulated by one or more encapsulant layers; laminating said lamination stack to form said doubly curved solar panel wherein said design appears undistorted; and coupling said doubly curved solar panel to a support structure thereby forming a vehicle panel.

9. The method according to claim 7, wherein said disposing said pre-distorted design is a step selected from the group consisting of printing and transferring.

10. The method according to claim 7, wherein said design is selected from the group consisting of: an image, a label, a logo, lettering, and/or indicia.

11 . The method according to claim 7, wherein said design is disposed on two or more of said upper and lower substrate surfaces, and/or said upper and lower superstrate surfaces, forming a 3D effect.

12. The method according to claim 7, wherein said one or more preformed layers of said substrate and said superstrate comprise preformed and thermally or chemically strengthened glass.

13. The method according to claim 7, wherein in said assembled configuration, said core is integrally formed with said substrate and said superstrate such that said at least one solar cell of said solar cell array is doubly curved.

14. The method according to claim 7, further comprising the step of providing a transfer sheet, wherein said design is conveyed proximate said one or more of said lower substrate surface and/or proximate said upper superstrate surface, said transfer sheet being removed before said preforming process.

15. The method according to claim 7, wherein said disposing said pre-distorted design is a step consisting of printing and transferring other distortion adjustments and/or translations of the image selected from the group adjustments for material stretching, thermal flow, properties of the preforms and/or laminate stack, and other process factors of temperature, pressure, time, heat, curing and/or fixing the image.