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WO2000069630A1 - Feuille decor resistante a l'abrasion - Google Patents

Feuille decor resistante a l'abrasion Download PDF

Info

Publication number
WO2000069630A1
WO2000069630A1 PCT/SE2000/000969 SE0000969W WO0069630A1 WO 2000069630 A1 WO2000069630 A1 WO 2000069630A1 SE 0000969 W SE0000969 W SE 0000969W WO 0069630 A1 WO0069630 A1 WO 0069630A1
Authority
WO
WIPO (PCT)
Prior art keywords
sheet
abrasion
impregnated
paper
decor
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/SE2000/000969
Other languages
English (en)
Inventor
Thomas Hilbert
Jochen Georg Staudt
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Akzo Nobel NV
Casco Products AB
Original Assignee
Akzo Nobel NV
Casco Products AB
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Akzo Nobel NV, Casco Products AB filed Critical Akzo Nobel NV
Priority to AU49670/00A priority Critical patent/AU4967000A/en
Priority to EP00931852A priority patent/EP1187719A1/fr
Publication of WO2000069630A1 publication Critical patent/WO2000069630A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/06—Layered products comprising a layer of paper or cardboard specially treated, e.g. surfaced, parchmentised
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
    • B44C5/0476—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper with abrasion resistant properties
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/18—Paper- or board-based structures for surface covering
    • D21H27/22—Structures being applied on the surface by special manufacturing processes, e.g. in presses
    • D21H27/26—Structures being applied on the surface by special manufacturing processes, e.g. in presses characterised by the overlay sheet or the top layers of the structures
    • D21H27/28—Structures being applied on the surface by special manufacturing processes, e.g. in presses characterised by the overlay sheet or the top layers of the structures treated to obtain specific resistance properties, e.g. against wear or weather
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/028—Paper layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/74—Partially cured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554—Wear resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2451/00—Decorative or ornamental articles

Definitions

  • the present invention relates to an abrasion-resistant decor sheet, a method of producing the sheet, a decor laminate containing the sheet and a method of producing the laminate.
  • the decor sheet according to the present invention comprises a protective coversheet of at least one layer of a non pre-impregnated sheet.
  • Abrasion-resistant decorative thermosetting laminates are well known in the art and used for instance as surface material for such applications where a high abrasion resistance is required. This is especially the case for flooring laminates, but also to a certain extent for desktop and tabletop laminates.
  • These laminates usually comprise a top surface or overlay consisting of an impregnated paper containing abrasive particles imparting abrasion resistance to the finished product.
  • the abrasive particles used are hard particles having normally an average particle size of about 50 ⁇ m, which is advantageous for the abrasion resistance but not for the press plates used during the lamination stage.
  • the press plates are scratched by the relatively big particles in the surface of the laminate. These plates are very expensive and manufactured of high quality steel. Intermediate layers of aluminium foil are often used to protect these press plates which will affect the production cost.
  • a process for manufacturing an abrasion- and scratch- resistant decorative thermosetting laminate is disclosed, wherein the surface layer of the laminate, consisting of an overlay of a paper web or sheet, is first impregnated with a melamine-formaldehyde resin, then coated on one side with abrasive particles with an average particle size of 30-90 ⁇ m, and whereafter the resin is dried. Then the other side of the sheet, or alternatively another sheet is coated with a melamine-formaldehyde resin containing abrasive particles with an average particle size of 1-15 ⁇ m, whereafter the resin is dried.
  • the surface containing the smaller particles is placed outwards on the top of the laminate, while the larger particles are incorporated in the lower side of the surface sheet, or on the topside of the sheet directly under the surface sheet. This arrangement will give a good abrasion resistance to the finished product.
  • a protective cover sheet of a non pre-impregnated sheet in a decor sheet significantly improves the abrasion resistance of the resulting decor sheet, does not affect transparency and diminishes wear of the press plates.
  • the handling is simplified and the cost reduced, since the protective cover sheet is applied on the impregnated paper in one single step and there is no need of an extra impregnation and drying step.
  • the present invention accordingly provides an abrasive-resistant decor sheet, a method of producing this sheet, a laminate comprising the sheet and a method of producing this laminate, by which the above mentioned problems are overcome.
  • the decor sheet according to the invention comprises a resin-impregnated paper containing abrasion resisting particles and a protective cover sheet comprising at least one layer of a non pre-impregnated sheet.
  • the non pre-impregnated sheet should suitably be thin enough to be able to be applied directly onto the impregnated paper, without needing a separate impregnation route itself. This normally means that the sheet will be quickly wetted by the resin in the impregnated paper without having absorbed too much resin. If the cover sheet absorbs too much resin from the impregnated substrate, there will not be enough left resin to give a satisfactory adhesion between the sheets, with delamination as a result. In addition, another possible problem might be air inclusion giving rise to a poor surface finish.
  • the non pre-impregnated sheet may consist of a paper having a surface weight of up to about 50 g/m 2 , more suitable of up to about 30 g/m 2 , preferably of up to about 20 g/m 2 , and most preferably of up to about 10 g/m 2 .
  • the non pre- impregnated sheet may also consist of a non-woven.
  • non-woven defined according to ISO 9092/EN 29092 can be used.
  • thin paper such as that used in tea bags and absorbing non-woven may be used.
  • tissue paper is used.
  • thermosetting resins such as melamine resins, for example, melamine-formaldehyde, urea resins, for example, urea-formaldehyde, phenolic resins, for example, phenol-formaldehyde, or mixtures thereof.
  • the abrasion resisting particles that are incorporated in the decor sheet according to the invention may consist of many different materials having a hardness of 7 or more on the Moh hardness scale. Such materials as silicon dioxide, aluminium oxide, silicon carbide, ceramic particles, and mixtures thereof may be used. Depending on which material the abrasive particles are based on and the end-use properties desired in the laminates to be manufactured using the decor sheet of this invention, the particle size could range from 10 to150 microns, suitably from 30 to 90 microns and preferably from 40 to 70 microns.
  • the particles incorporated into the decor sheet should be in a sufficient quantity to impart the desired degree of abrasion resistance to the finished product. Suitably 5-70 g/m 2 of particles, preferably 10-50 g/m 2 , and most preferably 20-40 g/m 2 are incorporated into the impregnated paper.
  • the decor sheet according to the present invention is particularly suitable for use where a high abrasion resistance is required, for example, for flooring, desktop, or tabletop laminates.
  • the method according to the present invention is defined in the appended claims and comprises the steps of applying onto the surface of a wet paper impregnated with a curable resin and containing abrasion resisting particles, a protective cover sheet of at least one layer of a non pre-impregnated sheet, whereafter the decor sheet is dried.
  • the substrate used in the method of the invention for making resin impregnated paper though usually paper, may be any type of impregnable substrate, including such as woven and non-woven textiles.
  • the substrate is normally printed, coloured or otherwise decorated, if it is intended for decorative purposes.
  • the paper that is used normally has a weight of about 20 to about 250 g/m 2 , more typically about 60 to about 100 g/m 2 .
  • the substrate can be impregnated with resin by various conventional techniques of applying resin compositions, such as baths, rollers, doctor blades, air knife, metering roll, doctor bars, etc.
  • the resin compositions can be applied in one or more steps with drying and/or partial curing between the application stages.
  • the abrasive particles can be incorporated into the resin impregnating paper by various methods known in the art. The particles can be added to the paper during impregnation of the paper with a curable resin containing the particles, or they can be applied onto the paper after it has been impregnated with a curable resin. It is also possible to incorporate the particles into the paper before it is impregnated with a curable resin.
  • the non pre-impregnated sheet is applied onto the resin-impregnated paper after the impregnation step and before drying the resin. Thereafter, the resin- impregnated paper and the protective cover sheet are put together, for example, by calande ng, banana rolls and/or pressing.
  • the coversheet adheres to the substrate without air inclusions forming a uniform surface.
  • the sheet covered with the non pre-impregnated cover sheet is suitably sequentially dried and the curable resin is at least partially cured.
  • Sheets that are partially cured are usually bonded to a core by laminating under heat and pressure, whereby final curing of the resin takes place.
  • sheets that are completely cured so-called foils. These are normally bonded to a core by gluing with commercially available glues.
  • the core of the laminate may be of any desired type, and such cores as wood, particle-board, fibre-board, plywood and the like can be used, as well as a number of conventional dry prepreg webs or sheets impregnated with resins such as phenol- formaldehyde or phenol-urea-formaldehyde resins.
  • the abrasion-resistant decor sheets obtainable by the method according to the present invention can be used for both high-pressure and low-pressure laminates.
  • the present invention is illustrated by means of a non-limiting example below, showing one embodiment of the present invention.
  • EXAMPLE A paper sheet was impregnated with melamin-formaldehyde resin (MF) and applied with abrasive particles of aluminium oxide. Whereafter a non-impregnated tissue paper with a surface weight of 28 g/m 2 and a Gurley value of less than 1 second, was applied onto the still wet surface of the impregnated paper, on the side containing the abrasive particles. Normal rolls were used to ensure that the tissue paper was properly adhered to the paper web. The combined sheets were subsequently dried, whereby the resin was transformed to the so-called B-stage.
  • MF melamin-formaldehyde resin
  • the pressed products showed the same transparency with or without a protective layer of a tissue paper.
  • the abrasion resistance of the finished decor laminates was measured according to DIN 53798 (1986).
  • the abrasive paper stripes (Taber S-42) were renewed every 200 cycles.

Landscapes

  • Laminated Bodies (AREA)

Abstract

L'invention concerne une feuille décor résistante à l'abrasion comprenant un papier imprégné de résine contenant des particules résistantes à l'abrasion et un revêtement de protection comportant au moins une couche d'une feuille non pré-imprégnée. L'invention concerne également un procédé de production de la feuille décor, un laminé décor comprenant la feuille décor et un procédé de production du laminé décor.
PCT/SE2000/000969 1999-05-19 2000-05-16 Feuille decor resistante a l'abrasion Ceased WO2000069630A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU49670/00A AU4967000A (en) 1999-05-19 2000-05-16 Abrasion-resistant decor sheet
EP00931852A EP1187719A1 (fr) 1999-05-19 2000-05-16 Feuille decor resistante a l'abrasion

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US13484599P 1999-05-19 1999-05-19
US60/134,845 1999-05-19
EP99850087.0 1999-05-19
EP99850087 1999-05-19

Publications (1)

Publication Number Publication Date
WO2000069630A1 true WO2000069630A1 (fr) 2000-11-23

Family

ID=56290023

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/SE2000/000969 Ceased WO2000069630A1 (fr) 1999-05-19 2000-05-16 Feuille decor resistante a l'abrasion

Country Status (3)

Country Link
EP (1) EP1187719A1 (fr)
AU (1) AU4967000A (fr)
WO (1) WO2000069630A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002066265A1 (fr) * 2001-02-20 2002-08-29 Kronospan Technical Company Ltd. Papier decoratif et procede pour impregner un papier decoratif
CN103343494A (zh) * 2013-06-15 2013-10-09 昆山三达包装有限公司 一种防水防破损瓦楞纸板
CN110499673A (zh) * 2019-08-27 2019-11-26 江苏美新建材科技有限公司 一种可压弯的装饰用复合贴面板

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1921008A1 (de) * 1968-04-24 1969-11-06 Formica Corp Dekorativer Schichtstoff mit einer Oberflaeche aus einer gepressten Schicht aus Papier aus fibrillierten Acrylfasern
US4140837A (en) * 1977-10-25 1979-02-20 Formica Corporation Decorative article having a bondable surface and method of manufacture
EP0329154A1 (fr) * 1988-02-18 1989-08-23 Perstorp Ab Procédé pour la production de stratifié décoratif et thermodurcissable
WO1997000172A1 (fr) * 1995-06-19 1997-01-03 Perstorp Ab Procede de fabrication d'un stratifie plastique decoratif thermodurcissable
WO1997026410A1 (fr) * 1996-01-15 1997-07-24 Arjo Wiggins S.A. Feuille papetiere et stratifies resistants a l'abrasion
WO1999012736A1 (fr) * 1997-09-11 1999-03-18 Perstorp Ab Procede de production d'un stratifie thermodurcissable

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1921008A1 (de) * 1968-04-24 1969-11-06 Formica Corp Dekorativer Schichtstoff mit einer Oberflaeche aus einer gepressten Schicht aus Papier aus fibrillierten Acrylfasern
US4140837A (en) * 1977-10-25 1979-02-20 Formica Corporation Decorative article having a bondable surface and method of manufacture
EP0329154A1 (fr) * 1988-02-18 1989-08-23 Perstorp Ab Procédé pour la production de stratifié décoratif et thermodurcissable
WO1997000172A1 (fr) * 1995-06-19 1997-01-03 Perstorp Ab Procede de fabrication d'un stratifie plastique decoratif thermodurcissable
WO1997026410A1 (fr) * 1996-01-15 1997-07-24 Arjo Wiggins S.A. Feuille papetiere et stratifies resistants a l'abrasion
WO1999012736A1 (fr) * 1997-09-11 1999-03-18 Perstorp Ab Procede de production d'un stratifie thermodurcissable

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2002066265A1 (fr) * 2001-02-20 2002-08-29 Kronospan Technical Company Ltd. Papier decoratif et procede pour impregner un papier decoratif
EP1274594B2 (fr) † 2001-02-20 2017-09-20 Kronoplus Technical AG Papier decoratif et procede pour impregner un papier decoratif
CN103343494A (zh) * 2013-06-15 2013-10-09 昆山三达包装有限公司 一种防水防破损瓦楞纸板
CN110499673A (zh) * 2019-08-27 2019-11-26 江苏美新建材科技有限公司 一种可压弯的装饰用复合贴面板

Also Published As

Publication number Publication date
EP1187719A1 (fr) 2002-03-20
AU4967000A (en) 2000-12-05

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