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  Encapsulation of electrically energized articlesThe Patent Description & Claims data below is from USPTO Patent Application 20080085390. Brief Patent Description - Full Patent Description - Patent Application Claims
RELATED APPLICATION DATA [0001]This application claims benefit of provisional application U.S. Ser. No. 60/849,409 filed 4 Oct. 2006, which is fully incorporated by reference. FIELD OF INVENTION [0002]This invention relates to thermoplastic articles comprising electrically energized materials and devices encapsulated between polymer sheet and methods of making the articles. In particular, this invention relates to methods of encapsulation of light emitting materials and devices encapsulated, by lamination, between polymer sheets comprising a polyester, a polycarbonate, a polyacrylate, or a polycarbonate/polyester miscible blend and the articles made therefrom. BACKGROUND OF THE INVENTION [0003]Various methods are known for encapsulation of decorative and functional items between sheet made from polyesters, polycarbonates, polyacrylates or polycarbonate/polyester miscible blends. Electrically energized materials, including devices, have been made by encapsulation with various polymers, but the devices often have poor resistance to weathering, particularly environmental moisture. Attempts of solve this problem have included the use of adhesive layers for sheet lamination, which also helps to prevent moisture penetration between layers and the use of additional moisture-resistant polymer layers in addition to the initial encapsulation layers. One problem with this approach is that adhesives typically have low glass transition temperatures (Tg) and the adhesive bonding of sheets often fails under temperatures approaching the Tg of the adhesive. These solutions increase the cost of the encapsulate devices. These problems are magnified when the electrically energized materials or devices have a large surface area, for example, greater than one square foot. Furthermore, many of the known encapsulation techniques use combinations of times, temperatures and pressures that degrade or destroy the electrically energized devices, particularly when the electrically energized devices have a large surface area. [0004]A need exists for methods to encapsulate temperature and pressure sensitive electrically energized materials and devices with relatively thick protective polymeric layers, particularly those devices having a large surface area. BRIEF SUMMARY OF THE INVENTION [0005]In one aspect the present invention relates to a method of making an encapsulated electrically energized device, the method comprising: [0006](a) providing a first layer and a second layer each independently comprising a copolyester, [0007](b) providing the electrically energized device having a surface area ranging from greater than 1 square foot (0.093 square meters) and less than 120 square feet (11.2 square meters) between the first and second layer [0008](c) thermocompressively fusing the first layer and the second layer to encapsulate the electrically energized device by applying pressure ranging from 5 psig to 350 psig at a temperature ranging from 180 F to 245 F for a period ranging from 5 minutes to 45 minutes to the surface of the first and second layers, [0009]wherein the first and second layer each independently ranges from 15 mil to 375 mil in thickness, [0010]wherein the temperature at an interface of the first and second layers is equal to or greater than Tg of the first layer and the second layer, and [0011]wherein the first layer and the second layer increase in width and/or length less than 5% relative to the initial width or length of the first and second layer. [0012]In another aspect the present invention relates to a method of making an encapsulated electrically energized device, the method comprising: [0013](a) providing a first layer and a second layer each independently comprising a copolyester, [0014](b) providing the electrically energized device having a surface area ranging from greater than 1 square foot (0.93 square meters) and less than 120 square feet (11.2 square meters) between the first and second layer [0015](c) thermocompressively fusing the first layer and the second layer to encapsulate the electrically energized device by applying pressure ranging from 5 psig to 350 psig at a temperature ranging from 180 F to 245 F for a period ranging from 5 minutes to 45 minutes to the surface of the first and second layers, [0016]wherein the first and second layer each independently ranges from 15 mil to 375 mil in thickness, [0017]wherein the temperature at an interface of the first and second layers is equal to or greater than Tg of the first layer and the second layer, and [0018]wherein the polyester layers have a flow during encapsulation less than the flow that induces fractures in the electrically energized device. [0019]In another aspect the present invention relates to a method of making an encapsulated electrically energized device, the method comprising: [0020](a) providing a first layer and a second layer each independently comprising a copolyester, [0021](b) providing the electrically energized device having a surface area ranging from greater than 1 square foot (0.93 square meters) and less than 120 square feet (11.2 square meters) between the first and second layer [0022](c) thermocompressively fusing the first layer and the second layer to encapsulate the electrically energized device by applying pressure ranging from 5 psig to 350 psig at a temperature ranging from 180 F to 245 F for a period ranging from 5 minutes to 45 minutes to the surface of the first and second layers, [0023]wherein the first and second layer each independently ranges from 15 mil to 375 mil in thickness, [0024]wherein the temperature at an interface of the first and second layers is equal to or greater than Tg of the first layer and the second layer, and [0025]wherein the polyester layers have a flow during encapsulation less than the flow that induces burn-through in the electrically energized device. [0026]In another aspect the present invention relates to a method of making an encapsulated electrically energized device, the method comprising: [0027](a) providing a first layer and a second layer each independently comprising a polyester, a polycarbonate, a polyacrylate, or a polycarbonate/polyester miscible blend, [0028](b) providing the electrically energized device having a surface area ranging from greater than 1 square foot (0.93 square meters) and less than 120 square feet (11.2 square meters) between the first and second layer [0029](c) thermocompressively fusing the first layer and the second layer to encapsulate the electrically energized device by applying pressure ranging from 5 psig to 750 psig at a temperature ranging from 180 F to 425 F for a period ranging from 5 minutes to 45 minutes to a perimeter of the surface of the first and second layers, wherein the perimeter does not overlap the electrically energized device, [0030]wherein the first and second layer each independently ranges from 15 mil to 375 mil in thickness, [0031]wherein the temperature at an interface of the first and second layers is equal to or greater than Tg of the first layer and the second layer, and [0032]wherein the first layer and the second layer increase in width and/or length less than 5% relative to the initial width or length of the first and second layer. [0033]In another aspect the present invention relates to a method of making an encapsulated electrically energized device, the method comprising: [0034](a) providing a first layer and a second layer each independently comprising a copolyester, a polycarbonate, a polyacrylate, polycarbonate/polyester miscible blends, or mixtures thereof, [0035](b) providing the electrically energized device having a surface area ranging from greater than 1 square foot (0.93 square meters) and less than 120 square feet (11.2 square meters) between the first and second layer [0036](c) thermocompressively fusing the first layer and the second layer to encapsulate the electrically energized device by applying pressure ranging from 5 psig to 750 psig at a temperature ranging from 180 F to 425 F for a period ranging from 5 minutes to 45 minutes to a perimeter of the surface of the first and second layers, wherein the perimeter does not overlap the electrically energized device, [0037]wherein the first and second layer each independently ranges from 15 mil to 375 mil in thickness, [0038]wherein the temperature at an interface of the first and second layers is equal to or greater than Tg of the first layer and the second layer, and [0039]wherein the polyester layers have a flow during encapsulation less than the flow that induces fractures in the electrically energized device. [0040]In another aspect the present invention relates to a method of making an encapsulated electrically energized device, the method comprising: [0041](a) providing a first layer and a second layer each independently comprising a copolyester, a polycarbonate, a polyacrylate, polycarbonate/polyester miscible blends, or mixtures thereof, [0042](b) providing the electrically energized device, having a surface area ranging from greater than 1 square foot (0.93 square meters) and less than 120 square feet (11.2 square meters), between the first and second layer [0043](c) thermocompressively fusing the first layer and the second layer to encapsulate the electrically energized device by applying pressure ranging from 5 psig to 750 psig at a temperature ranging from 180 F to 425 F for a period ranging from 5 minutes to 45 minutes to a perimeter of the surface of the first and second layers, wherein the perimeter does not overlap the electrically energized device, [0044]wherein the first and second layer each independently ranges from 15 mil to 375 mil in thickness, [0045]wherein the temperature at an interface of the first and second layers is equal to or greater than Tg of the first layer and the second layer, and [0046]wherein the polyester layers have a flow during encapsulation less than the flow that induces burn-through in the electrically energized device. [0047]In other aspects the present invention relates to an article comprising: [0048]a) a first layer and a second layer comprising a polyester, a polycarbonate, a polyacrylate, or a polycarbonate/polyester miscible blend; [0049]b) an electrically energized device having a surface area ranging from greater than 1 square foot (0.93 square meters) and less than 120 square feet (11.2 square meters) encapsulated between the first and second layer; [0050]wherein the first and second layer are the same or different, [0051]wherein the first and second layers each independently have a thickness ranging from 15 mil to 375 mil, and [0052]wherein the article remains moisture resistant after immersion in water at 25.degree. C. for 500 hours while continuously energized. [0053]In another aspect the present invention relates to a method of making an encapsulated electrically energized device, the method comprising: [0054](a) providing a first layer and a second layer each independently comprising a polyester, a polycarbonate, a polyacrylate, or a polycarbonate/polyester miscible blend, [0055](b) providing the electrically energized device having a surface area ranging from greater than 1 square foot (0.93 square meters) and less than 120 square feet (11.2 square meters) between the first and second layer [0056](c) thermocompressively fusing the first layer and the second layer to encapsulate the electrically energized device by applying pressure ranging from 5 psig to 750 psig at a temperature ranging from 180 F to 425 F for a period ranging from 5 minutes to 45 minutes to a perimeter of the surface of the first and second layers, wherein the perimeter does not substantially overlap the electrically energized device, [0057]wherein the first and second layer each independently ranges from 15 mil to 375 mil in thickness, [0058]wherein the temperature at an interface of the first and second layers is equal to or greater than Tg of the first layer and the second layer, and [0059]wherein the first layer and the second layer increase in width and/or length less than 5% relative to the initial width or length of the first and second layer. [0060]In another aspect the present invention relates to a method of making an encapsulated electrically energized device, the method comprising: [0061](a) providing a first layer and a second layer each independently comprising a copolyester, a polycarbonate, a polyacrylate, polycarbonate/polyester miscible blends, or mixtures thereof, [0062](b) providing the electrically energized device having a surface area ranging from greater than 1 square foot (0.93 square meters) and less than 120 square feet (11.2 square meters) between the first and second layer [0063](c) thermocompressively fusing the first layer and the second layer to encapsulate the electrically energized device by applying pressure ranging from 5 psig to 750 psig at a temperature ranging from 180 F to 425 F for a period ranging from 5 minutes to 45 minutes to a perimeter of the surface of the first and second layers, wherein the perimeter does not substantially overlap the electrically energized device, [0064]wherein the first and second layer each independently ranges from 15 mil to 375 mil in thickness, [0065]wherein the temperature at an interface of the first and second layers is equal to or greater than Tg of the first layer and the second layer, and [0066]wherein the polyester layers have a flow during encapsulation less than the flow that induces fractures in the electrically energized device. [0067]In another aspect the present invention relates to a method of making an encapsulated electrically energized device, the method comprising: [0068](a) providing a first layer and a second layer each independently comprising a copolyester, a polycarbonate, a polyacrylate, polycarbonate/polyester miscible blends, or mixtures thereof, [0069](b) providing the electrically energized device, having a surface area ranging from greater than 1 square foot (0.93 square meters) and less than 120 square feet (11.2 square meters), between the first and second layer [0070](c) thermocompressively fusing the first layer and the second layer to encapsulate the electrically energized device by applying pressure ranging from 5 psig to 750 psig at a temperature ranging from 180 F to 425 F for a period ranging from 5 minutes to 45 minutes to a perimeter of the surface of the first and second layers, wherein the perimeter does not substantially overlap the electrically energized device, [0071]wherein the first and second layer each independently ranges from 15 mil to 375 mil in thickness, [0072]wherein the temperature at an interface of the first and second layers is equal to or greater than Tg of the first layer and the second layer, and [0073]wherein the polyester layers have a flow during encapsulation less than the flow that induces burn-through in the electrically energized device. [0074]In another aspect the invention relates to an article comprising: [0075]a) a first layer and a second layer comprising a polyester, polycarbonate, polyacrylate or polycarbonate/polyester miscible blends; [0076]b) an electrically energized device having a surface area ranging from greater than about 1 square foot (0.93 square meters) and less than about 120 square feet (11.2 square meters) encapsulated between the first and second layer; [0077]wherein the first and second layer are the same or different, [0078]wherein the first and second layers each independently have a thickness ranging from 15 mil to 375 mil, and [0079]wherein the article remains moisture resistant after immersion in water at 25.degree. C. for 500 hours while continuously energized. [0080]In one aspect the processes of the present invention provide articles that are moisture resistant after immersion in water at 25 C for 500 hours while continuously energized. "Immersion" refers to the encapsulated electrically energized device, but not the electrical connector or plug. In certain embodiments, the electrical connector or plug may be partially embedded in the laminate structure. [0081]In another aspect the processes of the present invention provide articles that function after ten cycles in an environmental chamber cycling through a relative humidity ranging from 3% to 100% during a 320 hour period. [0082]In another aspect the processes of the present invention provide articles that function after ten cycles in an environmental chamber cycling through a temperature ranging from minus 20 F to 130 F during a 320 hour period. [0083]In another aspect the processes of the present invention provide articles that function after ten cycles in an environmental chamber cycling through a relative humidity ranging from 3% to 100% during a 320 hour period and that function after ten cycles in an environmental chamber cycling through a temperature ranging from minus 20 F to 130 F during a 320 hour period. [0084]In one aspect the energized electrical devices have a surface area ranging from 1 square foot to 120 square feet, or 5 square feet to 120 square feet, or square feet to 120 square feet, or 25 square feet to 120 square feet, or 50 square feet to 120 square feet, or 75 square feet to 120 square feet or 100 square feet to 150 square feet. In another aspect, the energized electrical devices have a surface area ranging from 1 square foot to 6 square feet, or 1 square foot to 12 square feet, or 1 square foot to 32 square feet. Continue reading... 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