# US 11,027,517 B2 · Decorative laminates including thermoplastic ink layers and related methods

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- Number: US 11,027,517 B2
- Document ID: US11027517B2
- Status: Granted
- Kind: B2
- Application number: 15/284,188
- Filed: 2016-10-03
- Published: 2018-04-05
- Granted: 2021-06-08
- Earliest claimed: 2016-10-03
- Assignees: The Boeing Company
- Applicants: The Boeing Company
- Inventors: Jason W. Drexler; John Christopher Wilde
- Web page: https://patentgrep.com/patent/US11027517B2

## CPC

- B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
- B32B 5/024: {Woven fabric}
- B32B 3/28: characterised by a layer comprising a deformed thin sheet {, i.e. the layer having its entire thickness deformed out of the plane}, e.g. corrugated, crumpled (B32B29/08 takes precedence)
- B32B 5/022: {Non-woven fabric}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 5/32: {at least two} layers being foamed {and next to each other}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 21/047: {of foam}
- B32B 21/10: Next to a fibrous or filamentary layer
- B32B 27/065: {of foam}
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 37/06: characterised by the heating method
- B32B 37/10: characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- B32B 37/12: characterised by using adhesives
- B32B 2255/02: on fibrous or filamentary layer
- B32B 2255/26: Polymeric coating
- B32B 2255/28: Multiple coating on one surface
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/026: Wood layer
- B32B 2260/046: Synthetic resin
- B32B 2262/0269: Aromatic polyamide fibres
- B32B 2262/0276: Polyester fibres
- B32B 2262/062: Cellulose fibres, e.g. cotton
- B32B 2262/065: Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
- B32B 2262/067: Wood fibres
- B32B 2262/101: Glass fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2307/41: Opaque
- B32B 2307/412: Transparent
- B32B 2307/414: Translucent
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2451/00: Decorative or ornamental articles
- B32B 2605/00: Vehicles
- B32B 2605/18: Aircraft
- B60R 13/00: Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR

## Abstract

Decorative laminates including thermoplastic ink layers and related methods are disclosed. An example apparatus includes a reinforcing layer to provide a rigidity to a decorative laminate, thermoplastic ink applied to the reinforcing layer to form a decorative pattern of the decorative laminate, and a film layer coupled to the thermoplastic ink to form the decorative laminate. The film layer is to preserve the decorative pattern. The thermoplastic ink is solidified when the film layer is coupled to the thermoplastic ink.

## Claims

### Claim 1

A method comprising:
applying thermoplastic ink to a reinforcing layer, the reinforcing layer to provide a rigidity to a decorative laminate, the thermoplastic ink to form a decorative pattern of the decorative laminate;
applying heat, via an oven, to partially solidify the thermoplastic ink applied to the reinforcing layer;
coupling a film layer to the thermoplastic ink to form the decorative laminate, the film layer to preserve the decorative pattern of the decorative laminate, the thermoplastic ink to remain partially solidified during coupling of the film layer to the thermoplastic ink;
contacting a heated press to the film layer;
embossing, via the heated press, the decorative laminate to define an embossed shape of the decorative laminate, wherein the decorative laminate is to be heated to a temperature of at least about 300 degrees Fahrenheit by the heated press during the embossing to set the embossed shape of the decorative laminate; and
fully solidifying, via the heated press, the partially solidified thermoplastic ink during the embossing of the decorate laminate.

### Claim 2 (depends on 1)

The method of claim 1, wherein applying the thermoplastic ink to the reinforcing layer includes applying the thermoplastic ink to a roll of the reinforcing layer that is unwound.

### Claim 3 (depends on 2)

The method of claim 2, wherein the roll is unwound prior applying the thermoplastic ink to the reinforcing layer and is rewound upon forming the decorative laminate.

### Claim 4 (depends on 1)

The method of claim 1, wherein applying the thermoplastic ink to the reinforcing layer includes applying a first thermoplastic ink layer to the reinforcing layer and applying a second thermoplastic ink layer to the first thermoplastic ink layer.

### Claim 5 (depends on 4)

The method of claim 4, further including:
winding the reinforcing layer and the first thermoplastic ink layer into a roll upon partially solidifying the first thermoplastic ink layer on the reinforcing layer; and
unwinding the roll of the reinforcing layer and the first thermoplastic ink layer to enable the second thermoplastic ink layer to be applied to the first thermoplastic ink layer.

### Claim 6 (depends on 1)

The method of claim 1, wherein coupling the film layer includes applying a clear thermoplastic ink layer to the thermoplastic ink applied to the reinforcing layer.

### Claim 7 (depends on 1)

The method of claim 1, wherein the reinforcing layer includes a fiber layer.

### Claim 8 (depends on 7)

The method of claim 7, wherein the fiber layer includes a synthetic fiber.

### Claim 9 (depends on 7)

The method of claim 7, wherein the fiber layer includes a natural fiber.

### Claim 10 (depends on 1)

The method of claim 1, wherein the heated press is to cause the thermoplastic ink to have a non-uniform thickness.

### Claim 11

A method of forming a decorative laminate, the method comprising:
providing a reinforcing layer having a rigid film that defines a first surface and a second surface opposite the first surface;
forming a decorative pattern of the decorative laminate by applying a thermoplastic ink layer to the first surface of the reinforcing layer;
applying heat, via an oven, to partially solidify the thermoplastic ink layer applied to the first surface;
coupling a film layer to the thermoplastic ink layer, the film layer to protect the decorative pattern formed by the thermoplastic ink layer, the thermoplastic ink layer to remain partially solidified during coupling of the film layer to the thermoplastic ink layer;
contacting a heated press to the film layer;
embossing, via the heated press, the decorative laminate-to define an embossed shape of the decorative laminate, wherein the decorative laminate is to be heated by the heated press to a temperature of at least about 300 degrees Fahrenheit to set the embossed shape of the decorative laminate; and
fully solidifying, via the heated press, the partially solidified thermoplastic ink layer during the embossing of the decorate laminate.

### Claim 12 (depends on 11)

The method of claim 11, wherein the providing of the reinforcing layer includes forming the reinforcing layer from woven or unwoven fabric including at least one of polyester, fiberglass, or carbon fiber.

### Claim 13 (depends on 12)

The method of claim 12, wherein the applying the thermoplastic ink layer includes applying a layer of thermoplastic ink to the first surface of the reinforcing layer.

### Claim 14 (depends on 11)

The method of claim 11, wherein the applying the thermoplastic ink layer includes applying a first thermoplastic ink layer on the reinforcement layer in a first pattern and applying a second thermoplastic ink layer on the first thermoplastic ink layer in a second pattern, the first pattern and the second pattern forming the decorative pattern of the decorative laminate.

### Claim 15 (depends on 11)

The method of claim 11, further including bonding the thermoplastic ink layer to the reinforcement layer.

### Claim 16 (depends on 11)

The method of claim 11, wherein coupling the film layer includes applying a clear thermoplastic ink layer to the thermoplastic ink applied to the reinforcing layer.

### Claim 17

A method of forming a decorative laminate, the method comprising:
unwinding a roll of a reinforcing layer;
applying a thermoplastic ink layer to an unwound portion of the reinforcing layer to form a decorative image;
applying heat, via an oven, to partially solidify the thermoplastic ink layer;
coupling a film layer to the thermoplastic ink layer, the thermoplastic ink layer to remain partially solidified during coupling of the film layer to the thermoplastic ink layer;
contacting a heated press to the film layer;
embossing, via the heated press, the decorative laminate to define an embossed shape of the decorative laminate while heating the decorative laminate, via the heated press, to a temperature of at least about 300 degrees Fahrenheit to set the embossed shape of the decorative laminate; and
fully solidifying, via the heated press, the partially solidified thermoplastic ink layer during the embossing of the decorate laminate.

### Claim 18 (depends on 17)

The method of claim 17, wherein the applying of the thermoplastic ink layer includes applying a thermoplastic ink to the reinforcing layer via a silkscreen printing process.

### Claim 19 (depends on 17)

The method of claim 17, wherein applying the thermoplastic ink layer includes applying a first thermoplastic ink layer to the reinforcing layer, and applying a second thermoplastic ink layer to the first thermoplastic ink layer.

### Claim 20 (depends on 17)

The method of claim 17, further including applying a non-thermoplastic ink layer to the thermoplastic ink layer.