Process for manufacturing plastic siding panels with outdoor weatherable embossed surfaces

A process for making plastic panels with an embossed low gloss decorative surface transfer-laminated to an extruded plastic sheet, comprising:

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

A process for making plastic panels with an embossed low gloss decorative surface transfer-laminated to an extruded plastic sheet, comprising:

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

A process for making vinyl plastic panels with an embossed low gloss decorative surface transfer-laminated to an extruded vinyl plastic sheet, comprising:

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

A process for making vinyl plastic panels with an embossed low gloss decorative surface transfer-laminated to an extruded vinyl plastic sheet, comprising:

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

A process for making outdoor weatherable vinyl plastic siding panels having a low gloss decorative surface transfer-laminated to an extruded vinyl plastic sheet, comprising:

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

A process for making plastic panels having a low gloss decorative surface transfer-laminated to an extruded plastic sheet, comprising:

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