CA1057599A - Flexible decorative cladding sheet or strip - Google Patents
Flexible decorative cladding sheet or stripInfo
- Publication number
- CA1057599A CA1057599A CA220,816A CA220816A CA1057599A CA 1057599 A CA1057599 A CA 1057599A CA 220816 A CA220816 A CA 220816A CA 1057599 A CA1057599 A CA 1057599A
- Authority
- CA
- Canada
- Prior art keywords
- resin
- web
- impregnated
- coating
- melamine
- 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.)
- Expired
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- Laminated Bodies (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
- Paints Or Removers (AREA)
- Paper (AREA)
Abstract
ABSTRACT
A decorative cladding sheet or strip capable of being bent about a radius of 3 cm at 20°C without cracking ox being permanently deformed, and comprising a decorative paper web impregnated with a thermoset aminoplast resin impregnating composition, the web having on one surface thereof a coating comprising a thermoset aminoplast resin coating composition.
A decorative cladding sheet or strip capable of being bent about a radius of 3 cm at 20°C without cracking ox being permanently deformed, and comprising a decorative paper web impregnated with a thermoset aminoplast resin impregnating composition, the web having on one surface thereof a coating comprising a thermoset aminoplast resin coating composition.
Description
1~57~
THIS I~VENTION relates to a ~lexible sheet or ~trip which may be used to provide a decorative cladding on walls, furniture and the like, and to a proce~s for preparing the flexible sheet or strip.
Decorative cladding materials comprising thermoset synthetic resin compositions and paper web materials are known and include, for example, decorative plastics laminates having a core comprising a plurality of phenol-formaldehyde resin-impregnated paper sheets and a decorative ~urface comprising a decorative paper sheet impregnated with a thermosetting amino-resin (especially a melamine-formaldehyde resin) with or without a further thermosetting amino-resin impregnated overlay paper sheet.
$hese laminates (referred to herein as "standard laminate~") possess many of the properties desired in decorative cladding materials, Mowever, these "standard" laminates do not possess sufficient flexibility to be capable of being bent about small radii without crazing or cracking and to overcome this disadvantage a further type o*
laminate commonly referred to as a "post-forming" laminate has been developed and is known in the art. "Post-forming"
laminates are substantially similar to standard laminates with regard to their production and construction and in the majority of their properties, but, by suitable variation o* the components u~ed in their manufacture and/or in the manufacturing conditions employed, they have the capability of being deformed about small radii after their manufacture, by means of suitable treatments, The decorative cladding materials o* the types exempli~ied ab~ve are customarily produced by di~continuous processes utilising elevated temperatures and high pre3sures in order to cure substantially the resins and consolidate the assembly, Decorative cladding materials should posse~s a number of desirable properties such as to en3ure their satisfactory use in the variety of cladding purposes to which they are commonly put. For example, they ~hould -S a) possess sufficient flexibility to enable them to be used in applications requiring the material to be bent about small radii without special treatmcnt~
b) have adeguate abrasion-resistance so that the cla~
surface has satisfactory wear characteristics;
c) have adequate hardness so as to be satis~actorily resistant to 3cratching and scuffing;
d) be available in forms which enable areas to be clad with a minimum number of joins in the cladding material;
e) exhibit satisfactory dimensional stability;
f) be capable of being handled and worked without suffering damage; and g) be capable o~ being fixed to the substrate easily and cheaply Decorative plastics ~minates, made by discontinuous high pre~sure processes, have found wide acceptance a~
decorative cladding materials but such laminate~ generally lack flexibility and commonly possess properties to a degree in excess of those required for satisfactory performance in a number of cladding operations Further, as such laminates are produced by the use of presses, their sise is necessarily restricted by the maximum size of press-plate that can be accommodated by the presses.
Flexible decorative cladding materials are also known and are available in sheet or strip form. Further such flexible cladding materials are commonly produced, without the application of high pressure, in a continuous manner, when the material comprises at~Qrmoplastic re3in~
.
l(~S~7S9~
, However, such materials are often deficient in properties such as abrasion- and scuff-resistance.
The invention provides flexible decorative cladding sheets or strips having a wear surface comprising a ~lexible thermoset ~ninoplast resin composition, and produced without using a discontinuous high pressure consolidation step.
The sheets or strips of the invention axe sheets or strips capable of being bent about a radiu~ of 3 cm at 20C without cracking or being permanently deformed, and characterised by comprising a decorative paper web irr.pregnated with a thermoset aminoplast re~in impreg~ating com~osition (a~ hereinafter defined) the we~ having on one surface thereof a coating comprising a thermoset arnino~last resin coating composition ~as hereinafter defined).
The process is one for the preparation of a decorati~e cladding sheet or strip capable o~ being bent about a radius of 3 cm at 20~C without cracking or bei,ng per~anently deformed, characterised by a) impregnating a decorative paper web with a varni~h comprising a thermosettabl~ aminopla~t r~sin impregn~tiny composition (as hereinafter defined) and a volatile solvent;
b) providing on the decorative surface of the impregnated paper web a coating of a varnish comprising a thermo-~ettable aminoplast resin coating,composition (a3 herein-after de~ined) and a volatile solvent;
c) heating the coated web to rernove solvent and any other 3n volatile materials and to conver1- the thermosettable com~ositions to the thermoset state.
~ ~'7~ 9 ~
In a preferred process for preparing the cladding ~heet or strip, the paper web i~ i~pregnated with a varnish comprising a thermo~ettable aminoplast resin impregnating composition in a volatile solvent and the impregnated web is then provided, without intermediate drying, on one surface with a coating comprising a thermosettab7e aminopla~t re~in coating compo~ition and a volatile solvent, Thetreated web is then heated to remove the solvent and other volatile materials and convert the thermosettable compositions to the thenmoset state. In a further preferred proce~, the impregnated web is dried both before and after the coating step, The decorative paper web ma~ be any ~uch web suitable for impregnation and coating with aminoplast resin composition~. It is preferred to employ those decorative paper webs known for use a~ the decorative layer in conventional plastics laminates. ~le web may be printed with any de~ired pattern or legend or may be plain-coloured and suitably ha~ a basis weight of 80 to 250, preferably 150 to 210 g/m2.
By the term "thermosettable aminoplast resin impregnating composition" is meant any thermosettable aminoplast resin impregnating composition known for use as an impregnant in a paper web provided that 3uch compositions can be cured to a thermoset resin which when used as an impregnant~ constituting from 3~0 to 4~/O by weight o~ the treated paper, in a decorative paper web having a ba3is weight of 80 to 250 g/m2, gives an impregnated paper web that may be bent a~out a radius of 3 cm at 20~C without exhibiting cracking and/or permanent deformation. The term "a thermo~et aminoplast resin impregnating composition~
refers to the corresponding thermoset composition 1~5'7S~5~
Suitable compositions are known; examples are melamine-, urea-, acetoguanamine- and benzoguanamine-foxmaldehyde resins and mLxtures thereof, optionally in conjunction with a plasticiser. Melamine-formaldehyde or melzmine-urea-formaldehyde resin compositions are preferred;
the plasticiser is preferably a polyethylene glycol composition, suitably used in an amount of 10~ to 35%, especially about 20~, by weight of the resin solids in the impregnating composition.
In the preferred proces~, the impregnation of the paper web with a varnish cornprising a thermosettable aminoplast resin composition may be carried out in any suitable manner employing apparatus known for such use.
It i~ preferred to use a varnish comprising the aminoplast resin composition dissolved or dispersed in an agueous alcohol solvent Irrespective of how it is performed, the impreg-nation is suitably carried out so that after removal of the solvent and other volatile materials, the r2sin content of the impregnated web is 2~/o to 5~/0, preferably 30~ to 4~0, by weight of the dried impregnated web.
By the term "thermosettable aminoplast resin coatin~ composition" is meant any thermosettable aminoplast composition known for use a~ a coating provided that such compositions can be cured to a thermoset resin which will adhere strongly to, or unite with, the flexible aminoplast resin impregnated decorative paper web and possesses adequate flexibility. The flexibility required of the thermoset resin is such that when the cladding material is bent around a small radius no cracking of the coating layer occurs before cracking of the impregnated paper web.
The term "thermoset aminoplast resin coating composition"
refers to the oorresponding thermoset composition `` 1~5759'3 The preferred aminoplast resin coating composition comprise tho~e commercially available compositions known generally as aminoplast stoving finishe~; examples are condensates of an alkylated urea and/or alkylated melamine and/or alkylated acetoguanamine and/or alkylated benzoguanamine with formaldehyde in conjunction with at least one alkyd resin, polyester resin, epoxy resin or poly (unsaturated monomer) resin. More preferably, there are used the aminoplast compositions generally identified as alkyd modified aminoplast compositions and more especially such compositions w~erein the ~mino-plast component comprises an alkylated melamine-formaldehyde and/or an al~lated urea-formaldehyde resin~ Such compositions are commercially available in forms that in the cured (stoved) state, exhibit surfaces de-cribed by the terms "gloss", "se~i-matt" and "matt". Thus for any product prepared by the invention the composition is so chosen that the finished surface exhibits tnat degree of gloss desired, In the preferred p.rocess, the coating of the ~mpregnated paper web may be performed in any suitable manner, for example spray coating, curtain coating or roller coating; it is preferred to employ a reverse-roll coating technique and to apply th~ coatin~ cornpo~ition so as to provide afte~ drying a coating weight o~ 20 to 60, preferably 25 t~ 50 9 g/m , After applying the coating composition, the treated ~eb is heated by any suitahle means so that the solvent and other volatile materials present are substantially completely removed and the aminoplast re3in composition~ are con~erted to the thermoset state ~e prefer to carry out this heating by passing t'ne treated we~ through an oven, operating at such a tem~erature, and the passage therethrough beiny at such a rate, that the desired evapora~ion and conversion occur.
~5~ 9 ~he coated and impregnated web after the heat treatment is co~led by any suitable means and is then collected suitably ky roll take-up means.
Suitable cooling means include, for example, an air blast or chill rollers If it is desired to impart a non-planar sur~ace to the product, it i~ preferred to employ chill-rollers and to pass the hot web emerging from the heat treatment between chill rollers, at least one of which ha~ a sur~ace complementary to that to be provided on the surface of the cladding material.
The invention i5 illustrated by the following Examples, wherein all parts and percentages are by weight, A web (1.2 m. wide) of standard laminate decorative paper having a basis weight of 150 g/m and printed with a w~odgrain pattern was passed through an impregnating bath containing a melamine-~ormaldehyde resin camposition varnish. The composition of the varnish was:-i) 10 parts of a thermosettable melamine-fonmaldehyde resin having a melamine:form-aldehyde ratio of 2.25 : 1 ii) 10 parts of a ~olvent comprising a water and industrial methylated spirit mixture in a ratio of 4 iii) 1 part of polyethylene ylycol plasticiser, having a molecular weight o~ about 1000.
(The impregnation process was adjusted so that the impregnated web had a resin content of 3~/o after dryingO) The impregnated web was then (without intermediate drying) coated with a colourless commercially available alkyd-modified melamine-fonmaldehyde resin, by means of a reverse roll technique, the coating process being so adjusted a~ to provide a dry coating weight of about 40 g/m2.
1~517~9~
( me resin employed was supplied ~y ICI Limited under the designation K105/2030 and was mixed with an activator, K275~77, in accordance with the manufacturerls instruction , prior to use), S The impregnated and coated web was then heated by passage through a hot air oven at an air temperature of 135-145C so that the solven~ and volatile material were driven off and the thermosettable resin compositions con~erted to the thermoset ~tate. The product emerging from the oven was cooled ~y an air bla~t and wound upon a reel, The product thus produced exhibited sati~factory abrasion- and scuff-resistance and could be bent about a radius of less than 3 cm at 20~C without cracking or permanent deformation.
A web (1,2 m, wide) of standard laminate plain white decorative paper having a basi~ weight of 165 g/m2 was passed through an impregnating bath containing a thermosettable melamine-~ormaldehyde resin composition varnish. The composition of the varnish wa~:-i) 10 parts of a thermo~ettable melamine-~ormaldehyde resin having a melamine:
formaldehyde ratio of 2,0 1 ii) 10 parts of a solvent comprising a water and indu~trial methylated spirit mixture in a ratio of ll : 1 (The impregnation process was adjusted ~o that the impregnated web had a re~inoo~tent of 35~ after drying), The impregnated web was then (without intermediate drying) coated with the colourles~ commercially available alkyd-modified melamine-formaldehyde resin used in Example 1, by mean~ of a reverse-roll technique, The coating _ g _ 7S9~
proces~ was so adjusted as to provide a dry coating weight of about 35 g/m2.
The impregnated and coated web was then heated-by pas~age through a hot air oven at an air temperature of 135C-145C xo that the qolvent and volatile material was driven off and the thermosettable resin compo~itions converted to the thermoset ~tate. The product emerging from the oven was cooled and embossed by passage between a pair of chill rollers, the roller in contact with the coated surface bearing a non-planar pattern whereby a complementary linen texture finish was imparted to the product ~hQ cooled embossed material was then wound upon a reel, The decorative cladding strip or sheet may be satisfactorily adhered to substrates using, for example, techniques and adhe~ives known for cladding such substrates with standard laminates. For example, a decorative faced chip~oard may be prepared, by adhering the strip or sheet to the substrate using a commercial urea-formaldehyde adhe~ive employing a contact pressure of 3.5 kg/cm2 ~or 5 minutes at 160F.
The strip or sheet also finds utility as an edging strip; quch edging strips are commonly employed to cover the side edges of substrates wllose major surfaces have been clad with sheets of standard laminates or other decorative cladding materials. The edging strip may be prepared by impregnating and coating the paper web with a thermo3ettable aminoplast compo~ition and ~en subsequently ~litting same to the deqired width either before or a~ter conversion of the composition to the thermoset state.
If desired thicker products than can conveniently be prepared from ~ingle paper webs may be produced by laminating to the paper web, preferably in a continuous manner and ~ ~ 5~5 ~
prior to the application of the coating layer, a second flexible web of any suitable material. Clearly the nature of such a second we~ must be such as not to render a material comprising sæme incapable of being bent about a radius of 3 cm at 20C, Suitable webs include paper, glass fibre and textile webs, optionally impregnated and/or coated with flexible thermoplastic or thermoset resin~.
If a second paper web is to be laminated to the decorative paper web then this second web may be impregnated with a similar resincomposition to that used for the decorative web. Clearly when a second paper web i~ en~loyed such i5 not necessarily a decorative paper web.
THIS I~VENTION relates to a ~lexible sheet or ~trip which may be used to provide a decorative cladding on walls, furniture and the like, and to a proce~s for preparing the flexible sheet or strip.
Decorative cladding materials comprising thermoset synthetic resin compositions and paper web materials are known and include, for example, decorative plastics laminates having a core comprising a plurality of phenol-formaldehyde resin-impregnated paper sheets and a decorative ~urface comprising a decorative paper sheet impregnated with a thermosetting amino-resin (especially a melamine-formaldehyde resin) with or without a further thermosetting amino-resin impregnated overlay paper sheet.
$hese laminates (referred to herein as "standard laminate~") possess many of the properties desired in decorative cladding materials, Mowever, these "standard" laminates do not possess sufficient flexibility to be capable of being bent about small radii without crazing or cracking and to overcome this disadvantage a further type o*
laminate commonly referred to as a "post-forming" laminate has been developed and is known in the art. "Post-forming"
laminates are substantially similar to standard laminates with regard to their production and construction and in the majority of their properties, but, by suitable variation o* the components u~ed in their manufacture and/or in the manufacturing conditions employed, they have the capability of being deformed about small radii after their manufacture, by means of suitable treatments, The decorative cladding materials o* the types exempli~ied ab~ve are customarily produced by di~continuous processes utilising elevated temperatures and high pre3sures in order to cure substantially the resins and consolidate the assembly, Decorative cladding materials should posse~s a number of desirable properties such as to en3ure their satisfactory use in the variety of cladding purposes to which they are commonly put. For example, they ~hould -S a) possess sufficient flexibility to enable them to be used in applications requiring the material to be bent about small radii without special treatmcnt~
b) have adeguate abrasion-resistance so that the cla~
surface has satisfactory wear characteristics;
c) have adequate hardness so as to be satis~actorily resistant to 3cratching and scuffing;
d) be available in forms which enable areas to be clad with a minimum number of joins in the cladding material;
e) exhibit satisfactory dimensional stability;
f) be capable of being handled and worked without suffering damage; and g) be capable o~ being fixed to the substrate easily and cheaply Decorative plastics ~minates, made by discontinuous high pre~sure processes, have found wide acceptance a~
decorative cladding materials but such laminate~ generally lack flexibility and commonly possess properties to a degree in excess of those required for satisfactory performance in a number of cladding operations Further, as such laminates are produced by the use of presses, their sise is necessarily restricted by the maximum size of press-plate that can be accommodated by the presses.
Flexible decorative cladding materials are also known and are available in sheet or strip form. Further such flexible cladding materials are commonly produced, without the application of high pressure, in a continuous manner, when the material comprises at~Qrmoplastic re3in~
.
l(~S~7S9~
, However, such materials are often deficient in properties such as abrasion- and scuff-resistance.
The invention provides flexible decorative cladding sheets or strips having a wear surface comprising a ~lexible thermoset ~ninoplast resin composition, and produced without using a discontinuous high pressure consolidation step.
The sheets or strips of the invention axe sheets or strips capable of being bent about a radiu~ of 3 cm at 20C without cracking or being permanently deformed, and characterised by comprising a decorative paper web irr.pregnated with a thermoset aminoplast re~in impreg~ating com~osition (a~ hereinafter defined) the we~ having on one surface thereof a coating comprising a thermoset arnino~last resin coating composition ~as hereinafter defined).
The process is one for the preparation of a decorati~e cladding sheet or strip capable o~ being bent about a radius of 3 cm at 20~C without cracking or bei,ng per~anently deformed, characterised by a) impregnating a decorative paper web with a varni~h comprising a thermosettabl~ aminopla~t r~sin impregn~tiny composition (as hereinafter defined) and a volatile solvent;
b) providing on the decorative surface of the impregnated paper web a coating of a varnish comprising a thermo-~ettable aminoplast resin coating,composition (a3 herein-after de~ined) and a volatile solvent;
c) heating the coated web to rernove solvent and any other 3n volatile materials and to conver1- the thermosettable com~ositions to the thermoset state.
~ ~'7~ 9 ~
In a preferred process for preparing the cladding ~heet or strip, the paper web i~ i~pregnated with a varnish comprising a thermo~ettable aminoplast resin impregnating composition in a volatile solvent and the impregnated web is then provided, without intermediate drying, on one surface with a coating comprising a thermosettab7e aminopla~t re~in coating compo~ition and a volatile solvent, Thetreated web is then heated to remove the solvent and other volatile materials and convert the thermosettable compositions to the thenmoset state. In a further preferred proce~, the impregnated web is dried both before and after the coating step, The decorative paper web ma~ be any ~uch web suitable for impregnation and coating with aminoplast resin composition~. It is preferred to employ those decorative paper webs known for use a~ the decorative layer in conventional plastics laminates. ~le web may be printed with any de~ired pattern or legend or may be plain-coloured and suitably ha~ a basis weight of 80 to 250, preferably 150 to 210 g/m2.
By the term "thermosettable aminoplast resin impregnating composition" is meant any thermosettable aminoplast resin impregnating composition known for use as an impregnant in a paper web provided that 3uch compositions can be cured to a thermoset resin which when used as an impregnant~ constituting from 3~0 to 4~/O by weight o~ the treated paper, in a decorative paper web having a ba3is weight of 80 to 250 g/m2, gives an impregnated paper web that may be bent a~out a radius of 3 cm at 20~C without exhibiting cracking and/or permanent deformation. The term "a thermo~et aminoplast resin impregnating composition~
refers to the corresponding thermoset composition 1~5'7S~5~
Suitable compositions are known; examples are melamine-, urea-, acetoguanamine- and benzoguanamine-foxmaldehyde resins and mLxtures thereof, optionally in conjunction with a plasticiser. Melamine-formaldehyde or melzmine-urea-formaldehyde resin compositions are preferred;
the plasticiser is preferably a polyethylene glycol composition, suitably used in an amount of 10~ to 35%, especially about 20~, by weight of the resin solids in the impregnating composition.
In the preferred proces~, the impregnation of the paper web with a varnish cornprising a thermosettable aminoplast resin composition may be carried out in any suitable manner employing apparatus known for such use.
It i~ preferred to use a varnish comprising the aminoplast resin composition dissolved or dispersed in an agueous alcohol solvent Irrespective of how it is performed, the impreg-nation is suitably carried out so that after removal of the solvent and other volatile materials, the r2sin content of the impregnated web is 2~/o to 5~/0, preferably 30~ to 4~0, by weight of the dried impregnated web.
By the term "thermosettable aminoplast resin coatin~ composition" is meant any thermosettable aminoplast composition known for use a~ a coating provided that such compositions can be cured to a thermoset resin which will adhere strongly to, or unite with, the flexible aminoplast resin impregnated decorative paper web and possesses adequate flexibility. The flexibility required of the thermoset resin is such that when the cladding material is bent around a small radius no cracking of the coating layer occurs before cracking of the impregnated paper web.
The term "thermoset aminoplast resin coating composition"
refers to the oorresponding thermoset composition `` 1~5759'3 The preferred aminoplast resin coating composition comprise tho~e commercially available compositions known generally as aminoplast stoving finishe~; examples are condensates of an alkylated urea and/or alkylated melamine and/or alkylated acetoguanamine and/or alkylated benzoguanamine with formaldehyde in conjunction with at least one alkyd resin, polyester resin, epoxy resin or poly (unsaturated monomer) resin. More preferably, there are used the aminoplast compositions generally identified as alkyd modified aminoplast compositions and more especially such compositions w~erein the ~mino-plast component comprises an alkylated melamine-formaldehyde and/or an al~lated urea-formaldehyde resin~ Such compositions are commercially available in forms that in the cured (stoved) state, exhibit surfaces de-cribed by the terms "gloss", "se~i-matt" and "matt". Thus for any product prepared by the invention the composition is so chosen that the finished surface exhibits tnat degree of gloss desired, In the preferred p.rocess, the coating of the ~mpregnated paper web may be performed in any suitable manner, for example spray coating, curtain coating or roller coating; it is preferred to employ a reverse-roll coating technique and to apply th~ coatin~ cornpo~ition so as to provide afte~ drying a coating weight o~ 20 to 60, preferably 25 t~ 50 9 g/m , After applying the coating composition, the treated ~eb is heated by any suitahle means so that the solvent and other volatile materials present are substantially completely removed and the aminoplast re3in composition~ are con~erted to the thermoset state ~e prefer to carry out this heating by passing t'ne treated we~ through an oven, operating at such a tem~erature, and the passage therethrough beiny at such a rate, that the desired evapora~ion and conversion occur.
~5~ 9 ~he coated and impregnated web after the heat treatment is co~led by any suitable means and is then collected suitably ky roll take-up means.
Suitable cooling means include, for example, an air blast or chill rollers If it is desired to impart a non-planar sur~ace to the product, it i~ preferred to employ chill-rollers and to pass the hot web emerging from the heat treatment between chill rollers, at least one of which ha~ a sur~ace complementary to that to be provided on the surface of the cladding material.
The invention i5 illustrated by the following Examples, wherein all parts and percentages are by weight, A web (1.2 m. wide) of standard laminate decorative paper having a basis weight of 150 g/m and printed with a w~odgrain pattern was passed through an impregnating bath containing a melamine-~ormaldehyde resin camposition varnish. The composition of the varnish was:-i) 10 parts of a thermosettable melamine-fonmaldehyde resin having a melamine:form-aldehyde ratio of 2.25 : 1 ii) 10 parts of a ~olvent comprising a water and industrial methylated spirit mixture in a ratio of 4 iii) 1 part of polyethylene ylycol plasticiser, having a molecular weight o~ about 1000.
(The impregnation process was adjusted so that the impregnated web had a resin content of 3~/o after dryingO) The impregnated web was then (without intermediate drying) coated with a colourless commercially available alkyd-modified melamine-fonmaldehyde resin, by means of a reverse roll technique, the coating process being so adjusted a~ to provide a dry coating weight of about 40 g/m2.
1~517~9~
( me resin employed was supplied ~y ICI Limited under the designation K105/2030 and was mixed with an activator, K275~77, in accordance with the manufacturerls instruction , prior to use), S The impregnated and coated web was then heated by passage through a hot air oven at an air temperature of 135-145C so that the solven~ and volatile material were driven off and the thermosettable resin compositions con~erted to the thermoset ~tate. The product emerging from the oven was cooled ~y an air bla~t and wound upon a reel, The product thus produced exhibited sati~factory abrasion- and scuff-resistance and could be bent about a radius of less than 3 cm at 20~C without cracking or permanent deformation.
A web (1,2 m, wide) of standard laminate plain white decorative paper having a basi~ weight of 165 g/m2 was passed through an impregnating bath containing a thermosettable melamine-~ormaldehyde resin composition varnish. The composition of the varnish wa~:-i) 10 parts of a thermo~ettable melamine-~ormaldehyde resin having a melamine:
formaldehyde ratio of 2,0 1 ii) 10 parts of a solvent comprising a water and indu~trial methylated spirit mixture in a ratio of ll : 1 (The impregnation process was adjusted ~o that the impregnated web had a re~inoo~tent of 35~ after drying), The impregnated web was then (without intermediate drying) coated with the colourles~ commercially available alkyd-modified melamine-formaldehyde resin used in Example 1, by mean~ of a reverse-roll technique, The coating _ g _ 7S9~
proces~ was so adjusted as to provide a dry coating weight of about 35 g/m2.
The impregnated and coated web was then heated-by pas~age through a hot air oven at an air temperature of 135C-145C xo that the qolvent and volatile material was driven off and the thermosettable resin compo~itions converted to the thermoset ~tate. The product emerging from the oven was cooled and embossed by passage between a pair of chill rollers, the roller in contact with the coated surface bearing a non-planar pattern whereby a complementary linen texture finish was imparted to the product ~hQ cooled embossed material was then wound upon a reel, The decorative cladding strip or sheet may be satisfactorily adhered to substrates using, for example, techniques and adhe~ives known for cladding such substrates with standard laminates. For example, a decorative faced chip~oard may be prepared, by adhering the strip or sheet to the substrate using a commercial urea-formaldehyde adhe~ive employing a contact pressure of 3.5 kg/cm2 ~or 5 minutes at 160F.
The strip or sheet also finds utility as an edging strip; quch edging strips are commonly employed to cover the side edges of substrates wllose major surfaces have been clad with sheets of standard laminates or other decorative cladding materials. The edging strip may be prepared by impregnating and coating the paper web with a thermo3ettable aminoplast compo~ition and ~en subsequently ~litting same to the deqired width either before or a~ter conversion of the composition to the thermoset state.
If desired thicker products than can conveniently be prepared from ~ingle paper webs may be produced by laminating to the paper web, preferably in a continuous manner and ~ ~ 5~5 ~
prior to the application of the coating layer, a second flexible web of any suitable material. Clearly the nature of such a second we~ must be such as not to render a material comprising sæme incapable of being bent about a radius of 3 cm at 20C, Suitable webs include paper, glass fibre and textile webs, optionally impregnated and/or coated with flexible thermoplastic or thermoset resin~.
If a second paper web is to be laminated to the decorative paper web then this second web may be impregnated with a similar resincomposition to that used for the decorative web. Clearly when a second paper web i~ en~loyed such i5 not necessarily a decorative paper web.
Claims (12)
1. A decorative cladding sheet or strip capable of being bent about a radius of 3 cm at 20°C without cracking or being permanently deformed, and comprising a decorative paper web impregnated with an impregnating composition containing at least one thermoset aminoplast resin selected from melamine-, urea-, acetoguanamine- and benzoguanamine-formaldehyde resins, the web having on one surface thereof a coating of a coating composition comprising at least one thermoset alkylated aminoplast resin which is an alkylated condensate of at least one of urea, melamine, acetoguanamine and benzoguanamine with formaldehyde, and at least one alkyd resin, polyester resin, epoxy resin or poly(unsat-urated monomer) resin.
2. A sheet or strip according to claim 1, wherein the paper web is a printed or plain-coloured web having a basis weight of 80 to 250 g/m2.
3. A sheet or strip according to claim 1 wherein the impregnating composition comprises a melamine-formaldehyde resin or a melamine-urea-formaldehyde resin and a plasticiser.
4. A sheet or strip according to claim 1 wherein the coating composition comprises an alkyd modified alkylated aminoplast resin selected from alkylated melamine-formaldehyde resin and alkylated urea-formaldehyde resin.
5. A process for preparing a sheet or strip as claimed in claim 1, the process comprising:
(a) impregnating the decorative paper web with a varnish of an impregnating composition containing at least one thermosettable aminoplast resin selected from melamine-, urea-, acetoguanamine- and benzoguanamine-formaldehyde resins in a volatile solvent:
(b) providing on the decorative surface of the impregnated paper web a coating of a varnish of a coating composition comprising at least one thermosettable alkylated aminoplast resin which is an alkylated condensate of at least one of urea, melamine, acetoguanamine and benzoguanamine with formaldehyde, and at least one alkyd resin, polyester resin, epoxy resin or poly(unsaturated monomer) resin in a volatile solvent; and (c) heating the coated web to remove solvent and any other volatile materials and to convert the thermosettable resins to the thermoset state.
(a) impregnating the decorative paper web with a varnish of an impregnating composition containing at least one thermosettable aminoplast resin selected from melamine-, urea-, acetoguanamine- and benzoguanamine-formaldehyde resins in a volatile solvent:
(b) providing on the decorative surface of the impregnated paper web a coating of a varnish of a coating composition comprising at least one thermosettable alkylated aminoplast resin which is an alkylated condensate of at least one of urea, melamine, acetoguanamine and benzoguanamine with formaldehyde, and at least one alkyd resin, polyester resin, epoxy resin or poly(unsaturated monomer) resin in a volatile solvent; and (c) heating the coated web to remove solvent and any other volatile materials and to convert the thermosettable resins to the thermoset state.
6. A process according to claim 5 wherein the impregnated web is dried before providing the coating therein.
7. A process according to claim 5 wherein the heated, impregnated and coated web is cooled by passage between co-operating chill-rollers.
8. A process according to claim 7 wherein the chill-roller co-operating with the coated surface of the heated, impregnated and coated web has a non-planar surface whereby the coated surface is cooled and embossed.
9. A process according to claim 5 wherein prior to the provision of the coating, a flexible web is laminated to the surface of the impregnated web not to be provided with the coating.
10. A process according to claim 9 wherein the flexible web is a paper web.
11. A process according to claim 10 wherein the paper web is impregnated with a thermosettable resin composition prior to lamination.
12. A process according to claim 5 wherein the impregnated and coated decorative paper web is slit to the desired width to give an edging strip.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB887674 | 1974-02-27 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1057599A true CA1057599A (en) | 1979-07-03 |
Family
ID=9860995
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA220,816A Expired CA1057599A (en) | 1974-02-27 | 1975-02-26 | Flexible decorative cladding sheet or strip |
Country Status (4)
| Country | Link |
|---|---|
| AR (1) | AR217036A1 (en) |
| BR (1) | BR7501151A (en) |
| CA (1) | CA1057599A (en) |
| ES (1) | ES425226A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2019220354A1 (en) * | 2018-05-17 | 2019-11-21 | Unilin, Bvba | Wrapping foil, method of manufacture thereof and finishing profile |
-
1974
- 1974-04-10 ES ES425226A patent/ES425226A1/en not_active Expired
-
1975
- 1975-02-26 CA CA220,816A patent/CA1057599A/en not_active Expired
- 1975-02-26 BR BR7501151A patent/BR7501151A/en unknown
- 1975-02-27 AR AR25779475A patent/AR217036A1/en active
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2019220354A1 (en) * | 2018-05-17 | 2019-11-21 | Unilin, Bvba | Wrapping foil, method of manufacture thereof and finishing profile |
| BE1026287B1 (en) * | 2018-05-17 | 2019-12-17 | Unilin Bvba | Sheathing film, method of manufacturing it and finishing profile |
Also Published As
| Publication number | Publication date |
|---|---|
| ES425226A1 (en) | 1976-05-16 |
| BR7501151A (en) | 1975-12-02 |
| AR217036A1 (en) | 1980-02-29 |
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