High Pressure Decorative Laminate and Method for Manufacturing the Same

Abstract

A method and a process for the production of high pressure laminate is disclosed using conventional manufacturing equipment without the use of melamine-formaldehyde resin pre-impregnated decorative print, solid, or overlay papers or combinations thereof. The method and process of making the disclosed laminate product utilize the assembly of a plurality of pre-impregnated Kraft papers independently saturated with melamine-formaldehyde resin, phenol-formaldehyde resin, and/or a bilayer coated construction of Kraft paper simultaneously containing both resins on opposing surfaces. The resulting pre-impregnated Kraft based components are assembled into the core layer and combined with the desired decorative layer assembly composed of untreated decorative print, solid, and/or overlay papers, or combinations thereof, prior to consolidation into a finished laminate using standard heat and pressure commonly known to those skilled in the art.

Claims

1. A process for the production of high pressure laminate using conventional manufacturing equipment absent the use of melamine-formaldehyde resin pre-impregnated decorative print, solid, and overlay papers, including the absence of combinations thereof, and wherein non-treated papers are used to create an assembly of a plurality of pre-impregnated Kraft papers selected from the group of pre-impregnated Kraft papers having been independently saturated with melamine-formaldehyde resin and papers having been independently saturated with phenol-formaldehyde resin.

2. The process of claim 1 also including the addition of at least one of a bilayer coated construction of Kraft paper defined as simultaneously containing melamine-formaldehyde resin and phenol-formaldehyde resin on opposing surfaces.

3. The process of claim 1 wherein the resin content is in the range of 40-70% wt.

4. The process of claim 2 wherein the resin content is in the range of 40-70% wt.

5. The process of claim 1 wherein the resin content is in the range of 47-55% wt.

6. The process of claim 2 wherein the resin content is in the range of 47-55% wt.

7. The process of claim 1 wherein the volatile content is in the range of 8-12% wt.

8. The process of claim 2 wherein the volatile content is in the range of 8-12% wt.

9. The process of claim 1 wherein the volatile content is in the range of 9-10% wt.

10. The process of claim 2 wherein the volatile content is in the range of 9-10% wt.

11. The process of claim 1 wherein the flow content is in the range of 5-10 wt %.

12. The process of claim 2 wherein the flow content is in the range of 5-10 wt %.

13. The process of claim 1 wherein the flow content is in the range of 7-9 wt %.

14. The process of claim 2 wherein the flow content is in the range of 7-9 wt %.

15. The process of claim 1 wherein the basis weight of the melamine-formaldehyde resin impregnated Kraft paper and dry decorative print papers where weight of the print is in the range of 48-154 gsm.

16. The process of claim 15 wherein the basis weight of the melamine-formaldehyde resin impregnated Kraft paper and dry decorative print papers where weight of the print is in the range of 45-90 gsm.

17. The process of claim 2 by utilizing Kraft paper impregnated with melamine-formaldehyde resin on one side and phenol-formaldehyde resin on the other side and dry decorative print papers where the basis weight of the print is in the range of 48-154 gsm, preferably 45-90 gsm.

18. The process of claim 2 utilizing melamine-formaldehyde resin impregnated Kraft paper and dry decorative solid colored papers where the basis weight of the solid is in the range of 48-154 gsm, preferably 73-129 gsm.

19. The process of claim 2 utilizing Kraft paper impregnated with melamine-formaldehyde resin on one side and phenol-formaldehyde resin on the other side and dry decorative solid colored papers where the basis weight of the solid is in the range of 48-154 gsm, preferably 73-129 gsm.

20. The process of claim 2 utilizing melamine-formaldehyde resin impregnated Kraft paper and dry overlay papers where the basis weight of the overlay is in the range of 5-66 gsm, preferably 5-29 gsm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIG. 1 is a schematic view of one preferred configuration order for arranging the paper plies between the release sheet and the steel plate for manufacturing the invention laminate.

[0023] FIG. 2 is a schematic view of a different preferred configuration order for arranging the paper plies between the release sheet and the steel plate for manufacturing the invention laminate.

[0024] FIG. 3 is a schematic view of a different preferred configuration order for arranging the paper plies between the release sheet and the steel plate for manufacturing the invention laminate.

[0025] FIG. 4 is a schematic view of a different preferred configuration order for arranging the paper plies between the release sheet and the steel plate for manufacturing the invention laminate.

[0026] FIG. 5 is a schematic view of a different preferred configuration order for arranging the paper plies between the release sheet and the steel plate for manufacturing the invention laminate.

[0027] FIG. 6 is a schematic view of a different preferred configuration order for arranging the paper plies between the release sheet and the steel plate for manufacturing the invention laminate.

[0028] FIG. 7 is a schematic view of a different preferred configuration order for arranging the paper plies between the release sheet and the steel plate for manufacturing the invention laminate.

[0029] FIG. 8 is a schematic view of a different preferred configuration order for arranging the paper plies between the release sheet and the steel plate for manufacturing the invention laminate.

[0030] FIG. 9 is a schematic view of a different preferred configuration order for arranging the paper plies between the release sheet and the steel plate for manufacturing the invention laminate.

[0031] FIG. 10 is a schematic view of a different preferred configuration order for arranging the paper plies between the release sheet and the steel plate for manufacturing the invention laminate.

DISCLOSURE OF PREFERRED CONDITIONS

[0032] Kraft paper of 245 gsm basis weight is impregnated with melamine-formaldehyde resin and dried in an oven heated to about 165 C. The resin content is approximately 55 wt % with a volatile content of approximately 10 wt % and a flow content of approximately 8 wt % and a resin solids content of approximately 60%. The resin wt % may range from 40 wt % to 70 wt %, the volatile wt % may range from 8 wt % to 12 wt %, the flow wt % may range from 5 wt % to 10 wt % and the resin solids may range is 20% to 70% depending on basis weight of decorative or overlay papers or combinations thereof used in laminate assembly. Examples of various assembly configurations, but not limited to those assemblies, are summarized in FIGS. 1-5. The melamine-formaldehyde resin may be catalyzed or un-catalyzed with catalysts common to those skilled in the art to achieve desired b- and c-staging of the components required for manufacturing as well as the finished product performance required for a particular application. The Kraft paper basis weight may range from 154 gsm to 380 gsm depending on the basis weights of the decorative, overlay or combinations thereof used in the laminate assembly. One key objective to this invention is the impregnated Kraft paper must contain a sufficient amount of melamine-formaldehyde resin or the like to penetrate and saturate the dry decorative print, solid overlay papers or combinations thereof used on the laminate surface. The wt % resin, volatiles and flow content for each layer mentioned are also key to this successful application of this invention for developing the requisite rheological potential during the high pressure and temperature assembly consolidation process. Using conventional laminate processing conditions, these components are assembled into the desired structure and consolidated using the temperature and pressure profiles familiar to those skilled in the art of laminate manufacturing. As discussed previously, the resin, volatile and flow contents described herein are sufficient to create the rheological potential required to force the melamine-formaldehyde resin into the dry decorative layer, wetting out the fiber contained within the decorative print, solid, or overlay papers or combinations thereof, sufficient to consolidate the decorative layer and Kraft core layer into a unitary structure with a completely contiguous surface layer of c-staged melamine-formaldehyde resin; the entirety of which is commonly referred to as high pressure decorative laminate with the unexpected benefits described above.

Example

[0033] A laminate prepared according to the invention disclosure was tested per the National Electrical Manufactures Association (NEMA).

Test Method Parameters and Conditions:

Nema Test Method 3.5High Temperature Water Resistance

[0034] The oil is heated to 100 C-110 C and placed on the surface of the laminate for 20 min.

Nema Test Method 3.13Wear Resistance

[0035] 180 grit sand paper is utilized and 375-425 laminate surface wear cycles is achieved

Nema Test Method 3.1Formability

[0036] The Radiant heat bar is set at a temperature of 135 C-190 C and the laminate postforms to a face bend radius of - and a hack bend radius of -

Nema Test Method 3.15Blister Resistance

[0037] The Radiant heat bar is set at a temperature of 149 C-205 C and the laminate blister time is 40-55 sec.

*Note

[0038] All test samples are conditioned for 48 hours at a temperature of 23 C and 50% relative humidity.

TABLE-US-00001 TABLE National Electrical Manufacturers Association (NEMA) Laminate Testing Performance Properties Specifications Grade General Purpose Post-Forming Property Units HGL VGS IIGP VGP LD 3 Nominal mm 1.0 0.7 1.0 0.7 Test Thickness (inch) 0.039 0.028 0.039 0.028 Method 3.6 High Temp Rating* Slight Slight Slight Slight Water Min effect effect effect effect Resistance 3.13 Wear Cycles 400 400 400 400 Resistance 3.14 Formability mm 16 () 13 () (inch) Radius 3.15 Blister Sec 55 40 55 40 Resistance

[0039] The test performance properties and specifications in the table were set by NEMA for high pressure laminate. Laminate produced using the described invention herein met or exceeded NEMA properties for high pressure laminate.

[0040] In addition to the above disclosed invention process and product, the following objectives are also envisioned: [0041] (1) A high pressure decorative laminate produced by utilizing Kraft paper impregnated with melamine-formaldehyde resin on one side and phenol-formaldehyde resin on the other side and dry overlay papers where the basis weight of the overlay is in the range of 5 66 gsm, preferably 5-29 gsm, [0042] (2) A high pressure decorative laminate produced by utilizing melamine-formaldehyde resin impregnated Kraft paper and dry print decorative, dry solid decorative and dry overlay papers or combinations thereof; [0043] (3) A high pressure decorative laminate produced by utilizing melamine-formaldehyde resin pre-impregnated Kraft paper as the only resin carrier; [0044] (4) A high pressure decorative laminate produced to improve release characteristics of the high pressure laminate surface from metal plates by using melamine-formaldehyde impregnated Kraft as the resin carrier; [0045] (5) A high pressure decorative laminate produced to improve optical clarity of the laminate by using melamine-formaldehyde impregnated Kraft as the resin carrier; [0046] (6) A high pressure decorative laminate produced to improve laminate surface abrasion characteristics by using melamine-formaldehyde impregnated Kraft as the resin carrier; [0047] (7) A high pressure decorative laminate process to produce high pressure, low pressure, continuous pressure decorative laminates using melamine-formaldehyde impregnated Kraft as the resin carrier; [0048] (8) A process to produce decorative laminate by utilizing melamine-formaldehyde resin impregnated Kraft paper and melamine-formaldehyde resin pre-impregnated overlay papers where the basis weight of the overlay is in the range of 5-66 gsm, preferably 5-29 gsm and the resin content is in the range of 10-70 wt %, preferably 20-35 wt % and the volatile content is 4-6 wt %, preferably 4.5-5.5 wt %; [0049] (9) A process to produce decorative laminate by utilizing Kraft paper impregnated with melamine-formaldehyde resin on one side and phenol-formaldehyde resin on the other side and melamine-formaldehyde resin pre-impregnated overlay papers where the basis weight of the overlay is in the range of 5-66 gsm, preferably 5-29 gsm and the resin content is in the range of 10-70 wt %, preferably 20-35 wt % and the volatile content is 4-6 wt %, preferably 4.5-5.5 wt %; [0050] (10) A process to produce decorative laminate by utilizing melamine-formaldehyde resin impregnated Kraft paper and melamine-formaldehyde resin pre-impregnated solid color decorative paper where the basis weight of the solid color decorative paper is in the range of 48-158 gsm, preferably 48-100 gsm and the resin content is in the range of 10-70 wt %, preferably 20-35 wt % and the volatile content is 4-6 wt %, preferably 4.5-5.5 wt %; [0051] (11) A process to produce decorative laminate by utilizing Kraft paper impregnated with melamine-formaldehyde resin on one side and phenol-formaldehyde resin on the other side and melamine-formaldehyde resin pre-impregnated solid color decorative paper where the basis weight of the solid color decorative paper is in the range of 48-158 gsm, preferably 48-100 gsm and the resin content is in the range of 10-70 wt %, preferably 20-35 wt % and the volatile content is 4-6 wt %, preferably 4.5-5.5 wt %; [0052] (12) A process to produce decorative laminate by utilizing melamine-formaldehyde resin impregnated Kraft paper and melamine-formaldehyde resin pre-impregnated decorative print paper where the basis weight of the decorative print paper is in the range of 48-158 gsm, preferably 48-100 gsm and the resin content is in the range of 10-70 wt %, preferably 20-35 wt % and the volatile content is 4-6 wt %, preferably 4.5-5.5 wt %; [0053] (13) A process to produce decorative laminate by utilizing Kraft paper impregnated with melamine-formaldehyde resin on one side and phenol-formaldehyde resin on the other side and melamine-formaldehyde resin pre-impregnated decorative print paper where the basis weight of the decorative print paper is in the range of 48-158 gsm, preferably 48-100 gsm and the resin content is in the range of 10-70 wt %, preferably 20-35 wt % and the volatile content is 4-6 wt %, preferably 4.5-5.5 wt %; [0054] (14) A process to produce decorative laminate where abrasive particles, including but not limited to aluminum oxide, are added to the overlay during the impregnation process; [0055] (15) A process to produce decorative laminate where abrasive particles, including but not limited to aluminum oxide, are added to the solid color decorative paper during the impregnation process; [0056] (16) A process to produce decorative laminate where abrasive particles, including but not limited to aluminum oxide, are added to the decorative print paper during the impregnation process; [0057] (17) A process to produce decorative laminate where abrasive particles, including but not limited to aluminum oxide, are distributed into melamine-formaldehyde resin and Kraft paper pre-impregnated with such resin; and [0058] (18) A process to produce decorative laminate where a plurality of abrasive particle sizes are utilized.

[0059] While the present general inventive concept has been illustrated by description of some embodiments, and while the illustrative embodiments have been described in detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant's general inventive concept.

[0060] It is also noted that numerous variations, modifications, and additional embodiments are possible, and, accordingly, all such variations, modifications, and embodiments are to be regarded as being within the spirit and scope of the present general inventive concept. For example, regardless of the content of any portion of this application, unless clearly specified to the contrary, there is no requirement for the inclusion in any claim herein or of any application claiming priority hereto of any particular described or illustrated activity or element, any particular sequence of such activities, or any particular interrelationship of such elements. Moreover, any activity can be repeated, any activity can be performed by multiple entities, and/or any element can be duplicated. Accordingly, while the present general inventive concept has been illustrated by description of several embodiments, it is not the intention of the applicant to restrict or in any way limit the scope of the inventive concept to such descriptions and illustrations. Instead, the descriptions, drawings, and claims herein are to be regarded as illustrative in nature, and not as restrictive, and additional embodiments will readily appear to those skilled in the art upon reading the above description and drawings.