Formable fused polymer panels containing light refracting films

A method of manufacturing a post-formable, dichroic resin panel, sufficiently structural for use as a building material in an architectural design environment, comprising a light refracting dichroic film, wherein the dichroic resin panel can be modified or formed during or after lamination without cracking, wrinkling, or otherwise distorting the refracting film layer dichroic film during the manufacturing forming process, the method comprising the steps of:

• preparing a dichroic laminate assembly comprising one or more light refracting dichroic films and one or more tie layers interposed between a plurality of resin substrates, wherein each of the resin substrates has comprises a translucent thermoplastic sheet having a thickness of about 0.06 inches to about 2.0 inches, and the one or more tie layers comprise a thermoplastic sheet consisting essentially of EVA, EMA, PVB, or TPU;
• heating the dichroic laminate assembly in a lamination apparatus to a temperature of no more than about 250° F. to about 260° F., wherein the one or more tie layers soften or melt between the plurality of resin substrates;
• cooling the dichroic laminate assembly, wherein the dichroic laminate assembly comprises a substantially unitary resin panel;
• and
• removing the unitary resin panel from the lamination apparatus;
• wherein the unitary resin panel comprises a thermoplastic panel that displays the one or more dichroic films, and can be heated and molded after cooling from a planar shape into one or more curved shapes.

A dichroic laminate assembly configured so that, when subject to a lamination temperature of up to about 250° F. to no more than about 260° F. in an autoclave or hot press, bonds one or more resin substrates to a dichroic film in a manner that preserves the integrity of the dichroic film and prevents the resulting dichroic resin panel from delamination, comprising:

• a plurality of resin substrates having a total thickness of about 0.12 inches to about 4.0 inches, comprising a translucent thermoplastic sheet consisting of one of a copolyester material, a polycarbonate material, or a mixture thereof;
• one or more light refracting dichroic films positioned between the plurality of resin substrates in a stack formation;
• and
• a plurality of TPU tie layers positioned between the plurality of resin substrates in the stack formation;
• wherein:
• each TPU tie layer is positioned against at least one surface of each of the resin substrates;
• and
• each of the one or more light refracting dichroic films is positioned adjacent two TPU tie layers on opposing sides;
• wherein the dichroic laminate assembly displays the one or more dichroic films through the plurality of translucent resin substrates, and the dichroic laminate assembly is formable after a lamination process.

A dichroic resin panel configured with sufficient aesthetic and structural properties for use as a building material in an architectural design environment, the dichroic resin panel comprising:

• a translucent first resin substrate layer having a thickness of about 0.06 inches to about 2.0 inches;
• a translucent second resin substrate layer having a thickness of about 0.06 inches to about 2.0 inches and that corresponds with the first resin layer, wherein the first and second resin substrate layers are thermoplastic;
• one or more dichroic film layers laminated between the first and second resin layers, wherein the one or more dichroic film layers conform to the first and second resin layers without material defect;
• and
• one or more tie layers positioned between the first and second resin layers and about each of one or more dichroic film layers;
• wherein:
• each of the one or more tie layers comprise softened or melted EVA, or EMA between the one or more dichroic film layers and the first and second resin substrate layers;
• the dichroic resin panel, by virtue of each dichroic film layer embedded therein, absorbs or transmits one polarized light ray differently from another polarized light ray;
• and
• the combination is at least partially malleable and formable after a lamination process without delamination and without wrinkling of the one or more dichroic film layers.