CA1126025A - Differential gloss release sheet - Google Patents
Differential gloss release sheetInfo
- Publication number
- CA1126025A CA1126025A CA307,458A CA307458A CA1126025A CA 1126025 A CA1126025 A CA 1126025A CA 307458 A CA307458 A CA 307458A CA 1126025 A CA1126025 A CA 1126025A
- Authority
- CA
- Canada
- Prior art keywords
- gloss
- sheet
- release
- producing
- producing layer
- 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
Links
- 239000000463 material Substances 0.000 claims abstract description 42
- 239000002985 plastic film Substances 0.000 claims abstract description 31
- 238000000034 method Methods 0.000 claims abstract description 29
- 238000000576 coating method Methods 0.000 claims description 57
- 239000011248 coating agent Substances 0.000 claims description 54
- 238000003825 pressing Methods 0.000 claims description 23
- 238000005266 casting Methods 0.000 claims description 19
- 229920005989 resin Polymers 0.000 claims description 12
- 239000011347 resin Substances 0.000 claims description 12
- 238000004049 embossing Methods 0.000 claims description 10
- 238000007639 printing Methods 0.000 claims description 9
- 239000010985 leather Substances 0.000 claims description 5
- 239000002023 wood Substances 0.000 claims description 4
- 235000014113 dietary fatty acids Nutrition 0.000 claims description 3
- 239000000194 fatty acid Substances 0.000 claims description 3
- 229930195729 fatty acid Natural products 0.000 claims description 3
- 150000004665 fatty acids Chemical class 0.000 claims description 3
- 229920002732 Polyanhydride Polymers 0.000 claims description 2
- 229940053200 antiepileptics fatty acid derivative Drugs 0.000 claims description 2
- 229960000359 chromic chloride Drugs 0.000 claims description 2
- 235000007831 chromium(III) chloride Nutrition 0.000 claims description 2
- 239000011636 chromium(III) chloride Substances 0.000 claims description 2
- 229920002050 silicone resin Polymers 0.000 claims description 2
- LJAOOBNHPFKCDR-UHFFFAOYSA-K chromium(3+) trichloride hexahydrate Chemical compound O.O.O.O.O.O.[Cl-].[Cl-].[Cl-].[Cr+3] LJAOOBNHPFKCDR-UHFFFAOYSA-K 0.000 claims 1
- 229920006255 plastic film Polymers 0.000 abstract description 6
- 238000004519 manufacturing process Methods 0.000 abstract description 3
- 239000010410 layer Substances 0.000 description 94
- 229920003023 plastic Polymers 0.000 description 12
- 239000004033 plastic Substances 0.000 description 12
- 230000000694 effects Effects 0.000 description 9
- 229920002451 polyvinyl alcohol Polymers 0.000 description 9
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 8
- 239000004372 Polyvinyl alcohol Substances 0.000 description 8
- 239000000049 pigment Substances 0.000 description 8
- 239000000853 adhesive Substances 0.000 description 7
- 230000001070 adhesive effect Effects 0.000 description 7
- 229910000019 calcium carbonate Inorganic materials 0.000 description 7
- 239000004927 clay Substances 0.000 description 6
- 239000000758 substrate Substances 0.000 description 6
- 239000011230 binding agent Substances 0.000 description 5
- 229920000126 latex Polymers 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 229920006395 saturated elastomer Polymers 0.000 description 5
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 4
- 239000011888 foil Substances 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 3
- 229920001944 Plastisol Polymers 0.000 description 3
- 229920002472 Starch Polymers 0.000 description 3
- 239000004999 plastisol Substances 0.000 description 3
- 235000018102 proteins Nutrition 0.000 description 3
- 108090000623 proteins and genes Proteins 0.000 description 3
- 102000004169 proteins and genes Human genes 0.000 description 3
- 235000019698 starch Nutrition 0.000 description 3
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 2
- 229920000742 Cotton Polymers 0.000 description 2
- IMROMDMJAWUWLK-UHFFFAOYSA-N Ethenol Chemical compound OC=C IMROMDMJAWUWLK-UHFFFAOYSA-N 0.000 description 2
- 239000001856 Ethyl cellulose Substances 0.000 description 2
- ZZSNKZQZMQGXPY-UHFFFAOYSA-N Ethyl cellulose Chemical compound CCOCC1OC(OC)C(OCC)C(OCC)C1OC1C(O)C(O)C(OC)C(CO)O1 ZZSNKZQZMQGXPY-UHFFFAOYSA-N 0.000 description 2
- 229920000877 Melamine resin Polymers 0.000 description 2
- 235000021355 Stearic acid Nutrition 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- MTAZNLWOLGHBHU-UHFFFAOYSA-N butadiene-styrene rubber Chemical compound C=CC=C.C=CC1=CC=CC=C1 MTAZNLWOLGHBHU-UHFFFAOYSA-N 0.000 description 2
- 238000003490 calendering Methods 0.000 description 2
- 239000005018 casein Substances 0.000 description 2
- BECPQYXYKAMYBN-UHFFFAOYSA-N casein, tech. Chemical compound NCCCCC(C(O)=O)N=C(O)C(CC(O)=O)N=C(O)C(CCC(O)=N)N=C(O)C(CC(C)C)N=C(O)C(CCC(O)=O)N=C(O)C(CC(O)=O)N=C(O)C(CCC(O)=O)N=C(O)C(C(C)O)N=C(O)C(CCC(O)=N)N=C(O)C(CCC(O)=N)N=C(O)C(CCC(O)=N)N=C(O)C(CCC(O)=O)N=C(O)C(CCC(O)=O)N=C(O)C(COP(O)(O)=O)N=C(O)C(CCC(O)=N)N=C(O)C(N)CC1=CC=CC=C1 BECPQYXYKAMYBN-UHFFFAOYSA-N 0.000 description 2
- 235000021240 caseins Nutrition 0.000 description 2
- QSWDMMVNRMROPK-UHFFFAOYSA-K chromium(3+) trichloride Chemical compound [Cl-].[Cl-].[Cl-].[Cr+3] QSWDMMVNRMROPK-UHFFFAOYSA-K 0.000 description 2
- 229920001249 ethyl cellulose Polymers 0.000 description 2
- 235000019325 ethyl cellulose Nutrition 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 239000006260 foam Substances 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 239000004816 latex Substances 0.000 description 2
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 2
- 229920000609 methyl cellulose Polymers 0.000 description 2
- 239000001923 methylcellulose Substances 0.000 description 2
- 235000010981 methylcellulose Nutrition 0.000 description 2
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 2
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 2
- 230000035515 penetration Effects 0.000 description 2
- 229920001296 polysiloxane Polymers 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000008107 starch Substances 0.000 description 2
- 239000008117 stearic acid Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- WCVOGSZTONGSQY-UHFFFAOYSA-N 2,4,6-trichloroanisole Chemical compound COC1=C(Cl)C=C(Cl)C=C1Cl WCVOGSZTONGSQY-UHFFFAOYSA-N 0.000 description 1
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- GAWIXWVDTYZWAW-UHFFFAOYSA-N C[CH]O Chemical group C[CH]O GAWIXWVDTYZWAW-UHFFFAOYSA-N 0.000 description 1
- 241000736839 Chara Species 0.000 description 1
- 229910021555 Chromium Chloride Inorganic materials 0.000 description 1
- 229920002261 Corn starch Polymers 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 241000628997 Flos Species 0.000 description 1
- BDAGIHXWWSANSR-UHFFFAOYSA-N Formic acid Chemical compound OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 1
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical group OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 1
- 239000005062 Polybutadiene Substances 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 108010073771 Soybean Proteins Proteins 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229920004890 Triton X-100 Polymers 0.000 description 1
- 239000013504 Triton X-100 Substances 0.000 description 1
- 108091093126 WHP Posttrascriptional Response Element Proteins 0.000 description 1
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 230000001464 adherent effect Effects 0.000 description 1
- 238000007754 air knife coating Methods 0.000 description 1
- 125000002877 alkyl aryl group Chemical group 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 238000010420 art technique Methods 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000008120 corn starch Substances 0.000 description 1
- 229940099112 cornstarch Drugs 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 230000000994 depressogenic effect Effects 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 238000007647 flexography Methods 0.000 description 1
- -1 geometric Substances 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 239000001046 green dye Substances 0.000 description 1
- ATADHKWKHYVBTJ-UHFFFAOYSA-N hydron;4-[1-hydroxy-2-(methylamino)ethyl]benzene-1,2-diol;chloride Chemical compound Cl.CNCC(O)C1=CC=C(O)C(O)=C1 ATADHKWKHYVBTJ-UHFFFAOYSA-N 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 239000004579 marble Substances 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 235000010755 mineral Nutrition 0.000 description 1
- 238000007645 offset printing Methods 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 239000011120 plywood Substances 0.000 description 1
- 229920002857 polybutadiene Polymers 0.000 description 1
- 239000011116 polymethylpentene Substances 0.000 description 1
- 229920000306 polymethylpentene Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 229920002545 silicone oil Polymers 0.000 description 1
- 239000010454 slate Substances 0.000 description 1
- 229940001941 soy protein Drugs 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 229920003048 styrene butadiene rubber Polymers 0.000 description 1
- BDHFUVZGWQCTTF-UHFFFAOYSA-M sulfonate Chemical compound [O-]S(=O)=O BDHFUVZGWQCTTF-UHFFFAOYSA-M 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 210000002268 wool Anatomy 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
- B05D5/06—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
- B05D5/06—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects
- B05D5/061—Special surface effect
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44F—SPECIAL DESIGNS OR PICTURES
- B44F9/00—Designs imitating natural patterns
- B44F9/02—Designs imitating natural patterns wood grain effects
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44F—SPECIAL DESIGNS OR PICTURES
- B44F9/00—Designs imitating natural patterns
- B44F9/12—Designs imitating natural patterns of leather
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D1/00—Processes for applying liquids or other fluent materials
- B05D1/28—Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
- B05D1/286—Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers using a temporary backing to which the coating has been applied
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/02—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
- B05D3/0254—After-treatment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/06—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to wood
- B05D7/08—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to wood using synthetic lacquers or varnishes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/50—Multilayers
- B05D7/52—Two layers
- B05D7/53—Base coat plus clear coat type
- B05D7/532—Base coat plus clear coat type the two layers being cured or baked together, i.e. wet on wet
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/50—Multilayers
- B05D7/52—Two layers
- B05D7/53—Base coat plus clear coat type
- B05D7/534—Base coat plus clear coat type the first layer being let to dry at least partially before applying the second layer
-
- 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
- D21H27/001—Release paper
Abstract
ABSTRACT
Disclosed is a release sheet comprising a base sheet, a release surface over the base sheet, and first and second gloss-producing layers permanently secured to the base sheet. The first gloss-producing layer is continuous over the surface of the base sheet and covers the entire sheet. The second gloss-producing layer forms a discontinuous pattern over the first gloss-producing layer and imparts a different gloss level from the first gloss-producing layer, to thereby produce a differential gloss pattern on the release sheet which is transferable to a plastic film or sheet formed on or against the release sheet without transfer of the materials forming the first and second gloss-producing layers.
Also disclosed are the method of making the release sheet, the method of forming the plastic film or sheet on or against the release sheet, and the plastic film or sheet product so formed.
Disclosed is a release sheet comprising a base sheet, a release surface over the base sheet, and first and second gloss-producing layers permanently secured to the base sheet. The first gloss-producing layer is continuous over the surface of the base sheet and covers the entire sheet. The second gloss-producing layer forms a discontinuous pattern over the first gloss-producing layer and imparts a different gloss level from the first gloss-producing layer, to thereby produce a differential gloss pattern on the release sheet which is transferable to a plastic film or sheet formed on or against the release sheet without transfer of the materials forming the first and second gloss-producing layers.
Also disclosed are the method of making the release sheet, the method of forming the plastic film or sheet on or against the release sheet, and the plastic film or sheet product so formed.
Description
-~
DIFFERENTIAL GLOSS RELEASE SHEET
BACRGROUND OF THE INVENTION
?ield of the In~ention The present invention relates to coatings for paper and ther types of ba5e sheets. More specifically, it relates to 05 oatings which are generally classified in the art as release oatings and which are chara~terized by their ability to separate ntact from a surface which is normally adherent.
istorv of the Prior Art ~ _ _ _ _ -A nu~ber of processes exist in which a platic film or sheet s formed on or against a release sheet and then separated from he release sheet after taking steps, such as cooling or cur~ng, o set the film or sheet. Curing, where necessary, may be ~ ~complished by heat or U.V~ radiation or by electron beam ; adiation. The release sheet provides a surface from which the lastic material will readily release and imparts to the surface f the plastic material the quality of finish of the release urface. A textured surface can be provided on the surface of he plastic material by using a release sheet having a textured urface.
; One example of such forming processes is "casting", wherein resino~s material, such as vinyl or urethane resins, in a lowable fo~m and usually a plastisol, is deposited or "cast" on he release sheet surface, heated, cured or cooled to consolidate he plastic material into a continuous self-supporting film, and tripped from the support.
. . : ~
i~ . . .. '.
., ~. .
. . . .
.
Another example of such orming processes is "panel pressingl' f decorative plastic laminatesO In high pressure panel pressing, ecorative laminates are conventionally prepared from an assembly f a plurality of core sheets which are prepared by impregnating 05 web of paper with a resin material, such as phenolic resin.
he core sheets axe superimposed in a stacked relationship and onsolidated with themselves and a decorative sheet under heat nd pressure. The decorative sheet is positioned immediately bove the core sheet assembly and is a resin saturated sheet aving a solid color or a suitable design thereonl Superimposed bove the decorative sheet is generally an overlay sheet which is thin sheet of fine paper impregnated with a noble thermosetting esi~, such as a melamine ~ormaldehyde resin or an unsaturated olyester resin and the like (and is generally the same resin sed to impregnate the decorative sheet). Hig ~ re laminates fter being consolidated are usually further to a tructural substrate, such as particlP board or plywood.
Low pressure panel pressed decorative laminates are made in similar manner to high pressure laminates, but generally nvolve lamination of the decorative sheet directly to particle oard or other structural substrate. Other pressing processes ~here a plastic film or sheet is formed on or against a release ~ heet may not include lamination, but only texturing a moldable ! lastic ~urface which is already laminated. For example, a - ~ ~5 lastic film could be coated directly onto particle board or lywood and then textured by pressing against a release sheet.
When it is desixed to produce a textured surface on the verlay sheet or the decorative sheet of a decorative plastic aminate, various techniques can be used, such as using a textured ¦~r embossed 1 plate or resin stabiliæed board in the pressing ... ~_ r ~, , ., ,, " ",... . .. . . .
r 31 1~6~Z~ I
peration. The desired embossed or textured pattern can also be roduced on the release sheet for transfer to the pressed plastic urface,which is a technique related to the present invention.
Release sheets can be any one of a number of commercially 05 ~vailable materials, such as a non-adherable paper, a non-adherable luminum foil or a polished metal belt. To render them non-dherable, the sheets can be coated, treated, or impregnated with release coating of such materials as polymethylpentene, poly-ropylene, polyfluoro%arbons~ silicone oil, thermoset silicone esins, and others conventional release agents. Texturing can be rovided by any one of a number of conventional techniques, such s emboss~ng by mechanical means.
The use of textured or embossed release sheets for producing ~ textured pattern on a plastic sheet or film is quite useful for `~ 15 oarse patterns, but not totally satisfactory for the production f ~ine patterns. For one reason, the non-uniformity of the aper surface can mask the embossing pattern. Also, in high ressure pressing processes ther is a tendency for the embossed attern to flatten out under pressure and thus create a smooth urface. Furthermore, fine texture patterns formed by relief in he surfàce are generally not highly visible on the formed lastic surface, whether it be cast or pressed. The reason is hat such texture is primarily visible as a result of shading or ;- hadows formed when 'ight falls upon the irregular surfaces, and ery fine texture does not display shadowing or shading very ~ ~ ~rongly. As a result of this deficiency, it is sometimes - ~ esirable to print shading or shadow patterns onto the cas-t or ressed surface to highlight the textured surface by producing a ifferential gloss effect. This can be accomplished by such echniques as printing a dull coating material or ink onto the igh points of the textured release sheet for transfer of the s coating material into the depressed portions of the formed plastic surface. Or in the alternative, a glossy coating material or ink can be printed directly onto the raised portions of the formed plastic surface. Another technique sometimes employed is to polish the raised surace of the ; formed plastic surface to thereby impart a differential gloss effect to the finished product.
The above-described prior art techniques for pro-ducing a textured pattern on a formed piastic surface have <~ 10 a number of disadvantages. For example, fine patterns can , .
be difficult to transfer from an embossed release sheet and, even when they do transfer, are not highly visible ~` on the formed plastic surface. When glossy or dull , materials are printed either directly or indirectly on the ~ -high or low parts of the formed plastic surface to produce a differential gloss effect which highlights the texture other disadvantages occur, such as the tendency for the materials to rub off the plastic surface, the need for an additional finishing step, and in the case of the material being transferred from the release sheet, the inability to reuse the release sheet.
SUMMARY OF THE INVENTION
It is an object of an aspect of the present inven-tion to provide a formed plastic film or sheet having dif-ferential gloss effect, the method of forming it against arelease sheet, the release sheet, and the method of making the release sheet, all in a manner which avoids the above~
described disadvantages of the prior art.
~-~ -4-~6~5 In accordance with one asFect of this invention there is provided a release sheet for use in casting or panel pressing comprising a base sheet suitable for use in casting or panel pressing, a first gloss-producing layer provided by one of said base sheet and a di.stinct continuous layer over said base sheet; a second gloss-producing layer providing a different gloss level from said first gloss-producing layer and forming a distinct layer of a discontinuous pattern over `~ said first gloss-producing layer; and a release surface ~` 10 provided one of said first gloss-producing layer, said first and second gloss-producing layers, a distinct layer over said first gloss-producing layer and a distinct layer over said first and second gloss-producing layers, said release surface at least including a material selected from the group consisting of casting and panel pressing release material; all of said distinct layers being permanently secured to said base sheet so that they do not transfer - from said release sheet when used for casting or panel press-ing; said release sheet having a differential gloss pattern which is reproducible on a plastic sheet or film cast on or panel pressed against the release sheet, without transfer of the materials forming the first and second gloss~
producing layers.
: In accordance with another aspect of this inven-- 25 tion there is provided a method of producing a release sheet of the type hereinbefore described in which the . first gloss-producing layer is provided by a coating . comprising a relatively high gloss film-forming resin, and the second gloss producing layer is provided by a relatively low gloss pigmented coating, which comprises:
~_5_ (a) providing a base sheet suitable for use in casting or panel pressing with a first gloss-producing layer uniformly overall on the surface; (b) embossing said base sheet to provide an embossed pattern having raised portions;
(c) permanently applying over said first gloss-producing layer in a discontinuous pattern said second gloss-producing layer which provides a gloss level different from said first gloss-producing layer, said second gloss-producing layer being applied by tip printing said raised portions of said embossed pattern; and (d) coating said release sheet overall with a distinct layer of material having release properties after step (a).
In accordance with another aspect of this inven-"':`
tion there is provided a method of producing a release sheet of the type hereinbefore described in which the first gloss-producing layer is provided by a coating comprising a relatively high gloss film-forming resin, and the second gloss producing layer is provided by a relatively low gloss pigmented coating, which comprises:
(a) providing a base sheet suitable for use in casting or panel pressing with a first gloss-produclng layer uniformly overall on the surface; (b~ embossing said base sheet to provide an embossed pattern having raised portions;
and (c) permanently applying over said first gloss-~, 25 producing layer in a discontinuous pattern said second gloss-producing layer which provides a gloss level dif-ferent from said first gloss-producing layer, said second gloss-producing layer being applied by tip printing said raised portions of said embossed pattern; at least one of said ~irst gloss-producing layer and said first and second gloss-producing layers having release properties.
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In accordance with another aspect of this inven-tion there is provided a method of producing a decorative sheet product which comprises casting or panel pressing a `. plastic sheet or film on or against the release sheet referred to hereinabove, setting the plastic sheet or film and then removing it from the release sheet.
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In addition to overcoming the above-stated disadvantages of he prior art, the invention also offers the capability of producin flat ~not having relief) finished product having the appearance f relief, including the appearance of relief formed by difficult 05 atterns to transfer, such as fine leather or wood grain patterns, sing a flat, unembossed, release sheet. Use of a flat release heet provides more ~niform release than embossed release sheets.
lso, the flat surface of the finished product can be cleaned asier than one which is actually embossed. Additionally, the ifferential gloss surface produced on the finished product can ave a more realistic textured appearance than one actually extured.
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DETAILED DESCRIPTION OF THE PREFERRED EMBC)DIMENTS
In practicing the invention the various layers can be applied y several different techniques. The starting material is a base heet which can be provided by paper or other fibrous substrates r such substrates as polished metal belts as metal foils. The rinc;pal requirement for the substrate is that it have a smooth _ urface to resist the penetration of the coating which provides he release surface. Where the base sheet is provided by paper, his rPquirement is typical~y met by pro~iding the paper with a onventional base coating of a mineral pigment, such as clay, xed with an adhesive. The base coating may in some cases be he first gloss-producing layer, and in other cases, may be ~vercoated with the first gloss-producing layex. In some cases 7 he first gloss-producing layer can be provided by the actual ase sheet, particularly where it is made from such materia~ as etal foii or metal belts. If the release she~t is to be embossed, t must be capable of being embossed without cracking.
11~6~Z5 ThP second gloss-producing layer is applied over the first loss-producing layer in a discontinuous (rather than overall) attern to provide the differential gloss effect. The pattern in which the second gloss-producing layer i5 applied can be almost 05 ny of a wide variety, such as wood grain, leather grain, marble-zed, slate, geometric, clouds, artistic designs, or photographic eproductions. It may be applied by tip printing, flexography, . ravure printing, etc. rThe second gloss-producing layer can be rovided by a coating of a wide variety of materials, but they ~ st produce a different gloss level from the first gloss-producing ayer and must be compatible with and ~ anently adhere to the irst gloss-producing layer~ In some cases, the coating material f the second gloss producing layer can be provided by the same aterial as the first gloss-producing layer, bu~ will have a ; 15 ifferent gloss level due to better "hold-up" (lack of penetration ~,~ nto the substrate) than the first gloss-producing layer.
The release surface is preferably provided by a distinct ayer of a release agent coated over tha first and second gloss-roducing layers. The differential gloss effect surprisingly emains and is still transferable even with the release layer $ laced on top. In some cases, the release surface may be provided y the first and second gloss-producing layers themselves where the coating materials chosen for such layers have adequate ~; elease properties. In other cases the release surface may be rovided by a distinct layer coated over only the first gloss-roducing layer and over which tha second gloss-producing layer s applied. In this lakter case, the coating material of the , econd gloss-producing layer must permanently adhere to the ;; elease surface and must ha~e adequate release properties itself, r at least not substantially interfere (because of only a small rea of surface being covered) with the release properties of the elease surface.
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~ ~ r ~LlZ6(~Z5 On~ of the advantages of the invention is the ability to roduce a flat release sheet which will impart the appearance of ~n embossed pattern upon a plastic film formed on or against the elease sheet~ This advantage is particularly valuable where the 05 ifferential gloss pattern is a very fine one, such as found in ~ood grain or leather grain. However, in other instances, par-icularly where the differential gloss pattern is coarssr, the nvention can be employed advantageously with an embossed release heet. In such cases, it is particularly desirable to emboss the elease sheet after applying the first gloss-producing layer and o apply the second gloss-producing layer only on the raised ortions ~f the embossed pattern. This method offers the advan-ages of tip printing the raised portions of the embossed patterns, which can be conveniently carried out by applying the coating aterial of the second gloss-producing layer with a gravure roll r some other offset printing apparatus positioned to lightly ontact the raised portions of the embossed sheet. In such cases he gravure roll would preferably have an overall pattern which rovides the coating material to substantially the entire surface f the gravure roll. One of the advantages of this technique is hat the'second gloss-producing layer can be provided by a low-loss pigmented coating which causes the recessed areas on the lastic film or sheet formed on or against the release sheet to ;-ppear duller than the remaining surface (raised portions) of the lastic film or sheet, thereby accentuating the embossed pattern.
` ~hen practicing this technique the release surface can be provided i . y an ov~rall applied release agen~ after embossing and tip rinting, or in some cases, it can be applied before embossing nd tip printing~
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ll llZ60;~5 In the ~lternative, it may be desirable to print the second loss-producing layer over the first gloss-producing layer prio~
o embossing the release sheet. In such cases, the embossing attern may be identical to and registered with the differential 05 loss pattern to produce the same effect mentionad above. In ther cases the differential gloss pattern may be different from he embossed pattern to provide a particular appearance. In such ases the two patterns ~ not register and there will be the dvantage of no repeat in the combined pattPrns formed by the mbossed pattern and the second gloss-producing pattern.
Although in most cases, the second gloss-producing layer , ill have a lower gloss level than the first gloss-producing ayer, there may be occasions where it is desirable to reverse his.
The first gloss-producing layer can be provided by a variety coating materials~ Where the invention employs a separate, istinct layer for the release surface, the first gloss-producing ayer can be provided by conventional pigment-binder coatings.
~ ical pigments useful in such coatings are silicas, barium sulphate, precipitated ox unprecipitated calcium carbonate, and alcined alumina. Typical binders are the natural glues such as asein, protein, starches, and synthetic binders, such as latices, ;- olyvinyl alcohol, methylcellulose and othersO
Where no separate, distinct layer is employed for the release urface, the irst gloss-producing layer will preferably include mall additions of conventional release agents, such as silicone esins, complexes of fatty acids and chromic chloride or poly-nhydride fatty acid derivatives. The first gloss-producing ayer is applied uniformly overall to the entire base sheet, hich may or may not have been previously base coated with a .
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. _g_ 11,Z61~1Z5 onventional pigment-binder coating, by conventional coating echniques such as blade coating, air knife coating, or gravure oll coating. The amount of coating applied for the first gloss-roducing layer can vary over a wide range as long as overall 05 overage is obtained, from less than 1 pounds per ream to 15 ounds per ream being a suggested range.
The second gloss-producing layer is provided by a coating at~rial which may be any one of the coating materials described for the first gloss-producing layers, although it most likely ould be one different than the particular one chosen for the first gloss-producing layer. But, as previously mentioned, it could be the same material as used for the first gloss-producing layer. It is critical to the invention that the inherent gloss roduced by the second gloss-producing layer be different f_om hat produced by the first gloss-producing layer. It is generally referred for the gloss level of the first gloss-producing layer o be higher than that for the second gloss-producing layer.
owever, in some instances it may be desired to reverse this.
~he gloss level of either gloss-producing layer can be controlled 2a ~y the use of gloss control additives. A lower gloss level can e provided by larger amounts o piyments and/or larger size igments having greater flatting properties Such pigments are lay, calcium carbonate, sand, barium sulfate etc. These pigments re usually combinea with adhesives. Typical adhesives are olyvinyl alcohol, methyl cellulose, starch, protein and styrene-utadiene rubber~ Any of the binders may be used by itself as a loss control additive, and they in general, would tend to raise ,~ ¦¦the gloss of coating.
.',,. , .,, , ~., llZ~11Z5 Gloss may be described as the characteristic of the surface which causes light to reflect at a given angle in excess of the iEfuse reflection at that angle~ There are a number of instru-ents which measure an arbitrary value indicative of the gloss of 05 particular surface. The Gardner 60 gloss meter is one such nstrument which is commonly used. The 60 angle is measured from a line perpendicular to the paper, and is equivalent to a 0 angle from the plane of the paper surface. In practicing the resent invention, it is critical that the gloss level produced !~ 10 y the second gloss-producing layer be different from that roduced by the first gloss-producing layer. It would be difficult o place quantitative limits on this difference, but the difference s such that the differential gloss appearance is quite noticable o any observer.
15 Where a separate, distinct layer is employed for the release urface, the coating material for the release surface may be -ovided by any one o~ a number of conventional release materials~
uch as silicone resins or a complex of a fatty acid and chromic hloride or polyanhydride fat~y acid derivatives. Such a coating ~a~ be applied by a number of techniques used to provide a ontinuous coating layer. One particularly preferred technique or coating an embossed sheet is use of an aix knife.
Having generally described the invention, the following ; ~ xamples are given to further illustrate preferred embodiments of , 25 he invention.
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. EXAMPLE 1 A paper base sheet with a conventional clay and adhesive ase coat (32 lbs./ream total basis weight) was coated overall ith a first gloss-producing layer which was a mixture of the ollowi~g:
.' l ~ s Dry Weight styrenP-butadiene rubber latex (Dow 620 from Dow Chemical Company) 15 parts l soy protein, medium viscosity 15 parts 05 ¦ clay, coating grade 100 parts ¦ water to make 30% solids ¦ he coating mixture was applied by air knife in an amount of 5 I bs./ream, dried, and calendered to smooth the surface. The ¦ heet was then embossed between an etched steel roll and a cotton ¦ atrix backing roll in four different embossing patterns ranging l from fine to medium leather yrain. The-hills of the embossed ¦ sheet were tip printed with a 150 line gravure roll using a ¦ oating mixture of the following:
¦ Dry Weight 15 ¦ Calcium carbonate, ground particles at 50% 250 parts polyvinyl alcohol (DuPont's l Elvanol 71-30 at 10%, fully ¦ hydrolyzed, medium molecular weight, medium viscosity) 75 parts ¦ Triton X-100 (Rohm and Haas welting ¦ agent, a non-ionic alkylaryl I polye~her alcohol sulfonate at _ ¦ 10%) 1.25 part ¦ wool green dye at 1% (for observation purposes) 0.1 aqueous release coating of a complex of a stearic acid and ;- ¦chromium chloride and poly~inyl alcohol was then applied over the ,~ , ¦entire surface and dried.
¦ The gloss levels of the first gloss-providing layer and the ¦second gloss-producing layer of Example 1 were determined by ~- ~ king samples in a slightly varied manner. That is/ the second ~, ¦gloss-producing layer was coated overall on a large enough area to take gloss readings. ~he 60 Gardner gloss readings obtained , - -12-~'' . _ . , , ~ ~ 2 ~ ~ Z 5 ere 19 for the first gloss-producting layer and 3 for the second loss producing layer. These readings were taken after the elease coating was applied, and they probably would have been a ittle different if taken without the release coating, but the 05 ifference in gloss would be essentially the same.
A poly~inyl chloride plastisol was cast on the release urface of the release sheet o Example 1 as a 4 mil wet film.
Over this was applied a 9 mil PVCl foam, and this was then aminated to cotton fabric. This laminate was heated to expand he foam and dried by known techniques. Upon separation of the elease sheet from the cast product the film surface of the cast roduct had the differential gloss effect of the release sheet.
he hills of the surface were glossy while the valleys were dull.
In another casting example a polyurethane was cast on the elease surface of the release sheet of Example 1, and this 1 mil ry layer was bonded to napped and shÇ red fabric using an adhesive or the urethane. Upon separation of the release paper from the rethane surface the same differential gloss effect on the rethane surface was observed as above~ The hills of the surface Pre glossy while the ~alleys were dull.
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~,~ EXAMPLE 2 ;. A paper base sheet with a conventional clay and adhesive ase coa~ (63 lbs./ream total basis weight) was coated overall ith a mixtu of the follow ng:
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~ ~ , ¦ hydroxyethyl cornstarch 16 parts l tA. E. Staley Mfg. Co.) ¦ styrene-butadiene rubber latex 10 parts 05 ¦ (Dow 620 from Dow Chemical Company) l polyvinyl alcohol (Vinol 107 K from ¦ Air Reduction Co.) 5 parts ¦- clay, coating grade 100 parts ~he coating mixture was applied by air knife in an amount of 6 ~b~./ream, dried and calendered to~smooth the sheet. The sheet ~as then gravure printed with two different wood grain patterns ~o form the second gloss-producing layer-. The coating material ~sed for the second gloss-producing layer was the same as that sed for the second gloss-producing layer in Example 1. the heet was then top coated with a release coating of a release gent, a monomeric polyhydric alcoholl and a cross-linkable hermosetting resin o~ the formula set forth in Example 3 of U.S.
atent No. 3,946,135.
The release sheet of Example 2 was used in high pressure anel pressing where it was placed against a melamina saturated ~verlay, which in turn, was against a melamine saturated and rinted decorative sheet, which in turn, was against four phenolic esin saturated core stock sheets.- The laminates were consoli-ated at 1200 p.s.i. and 285 for 17 minutes. The relaase sheet as stripped away from the panel and the panel exhibited gloss ifferential and appeared to have grain structure in its surface ; ven though it was flat.
The release sheet of Example 2 was used in low pressure anel pressing where it was placed against a melamlne saturated nd printed decorative sheet, which in turn, was against a 3/4 ' ,~'' ' ' ` "''''''' . .. . '"~ ' ~ 6~'Z5 nch thick particle board~ The laminates were consolidated at 50 p.s~i. and 300F for ~ minutes. The release sheet was tripped away, and the panel exhibited gloss differential and ppeared to ha~e grain structure in its surface even though it 05 was flatO
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. EXAMPLE 3 -A sheet of aluminum foil 5-8 mils thick, was coated in a attern of a single wide strip from a gravure roll to provide a eco~d gloss-producing layer of a coating like that of Example 1, but with coating grade clay substitutPd fox the calcium carbonate.
o distinct release surface was applied over the seconcl gloss-producing layer. The 60 Gardiner gloss readings for the foil `- (which provided the first gloss-producing layer) was o~ scale (100~) and was 19.0 for the second gloss-producing layer. A
olyvinyl chloride plastisol was cast on the oil ~elease sheet, ried and stripped from the release sheet and displayed the ifferential gloss effert of the release sheet.
Other examples were made like those of Example 1 and 2, but ith different patterns ~such as marble, cloud prints, etc.) used or the gecona gloss-producing layer and with vaxious release oatings~ These examples were used in various casting and panel ressing modes, providing the same observable gloss differential ;- s in Examples 1, 2 and 3.
. '' As an illustration of the ability to vary the gloss level of he first or second floss-producing layers by ~arying the materials n ~he coating, the following examples are given. A conventional lay/adhesive base coated paper was coated in a single strip attern with the coating mixture of the second gloss producing ayer in Example 1 with the noted variations and noted 60 ardiner gloss readings wPre obtained.
-lS-~ 25 ¦ Stearic Acid and l Substituted Mo ReleaseSilicone type Chromic Chloriae : I Material Coat Release Coat Release Coat ~ydroxyethyl corn- ~
05 ¦starch for PVA 3.0 6.0 3.0 . Isoy protein for PVA3.0-6.0 7.0-9.0 4.0 ~ethyl cellulose ¦ for PVA . 5,0 9.0~9.5 5.0 . ~actic casein for ¦ PVA 2.5-3.0 7.0-9.0 ---~yrene butadine ¦ rubber latex ¦ for PVA 2.5 8.5-10.0 3.0 ~and ~or CaC03 --- 7.5 4.0-5.0 ~inex, anhydrous ¦(Na, K) aluminum silicate for ¦ CaC03 4-0 5.5-6.0 4.0 ~lass beads for ¦ _ 3 24~0-25,0 19.0 22.0-24.0 play for CaC03 --- 14 . O .8 . O
: po pigment --- 20.0 29.O
. . ~tyrene butadiene : I rubber latex 25 ¦ for PVA and no pigment 48.0-52.0 37.0-39.0 45.0-47.0 : ethyl cellulose for PVA and no -. ` pigment 15.0 22.0-24.0 1600 i 30 actic casein for :~ P~A and no pigment 27.0-28.0 26.0 2~tO-26.0 ontrol (same as ; Ex. 1) - - 4.0 2.0 ase coated paper 32.0-35.0 20.0 18.0-20.0 Having described the invention generally and also in its ~ referred embodiments, variations within the scope of the inven-.~ . ion will be obvious to -onè skilled in the art. For example, the ¦First gloss-p ducing layer is described as completely covering ,~, ,, . .~. .. ,.v _.. , .. ., _ ,, . -11~Z6~3Z~ I
the surace of the base sheet, and this is highly préferred for he convenience of coating and necessary where the second gloss-roducing layer is in a fine pattern.
However, it is readily apparent that the first gloss-producing 05 layer does not have to cover the base sheet immediately beneath . he second gloss-producing layer, and it can be absent in those areas where the second gloss~producing layer is in a very coarse . . attern. ~his variation is believed to be a functional equivalent ~f the prese invention in i=s broade~e form.
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DIFFERENTIAL GLOSS RELEASE SHEET
BACRGROUND OF THE INVENTION
?ield of the In~ention The present invention relates to coatings for paper and ther types of ba5e sheets. More specifically, it relates to 05 oatings which are generally classified in the art as release oatings and which are chara~terized by their ability to separate ntact from a surface which is normally adherent.
istorv of the Prior Art ~ _ _ _ _ -A nu~ber of processes exist in which a platic film or sheet s formed on or against a release sheet and then separated from he release sheet after taking steps, such as cooling or cur~ng, o set the film or sheet. Curing, where necessary, may be ~ ~complished by heat or U.V~ radiation or by electron beam ; adiation. The release sheet provides a surface from which the lastic material will readily release and imparts to the surface f the plastic material the quality of finish of the release urface. A textured surface can be provided on the surface of he plastic material by using a release sheet having a textured urface.
; One example of such forming processes is "casting", wherein resino~s material, such as vinyl or urethane resins, in a lowable fo~m and usually a plastisol, is deposited or "cast" on he release sheet surface, heated, cured or cooled to consolidate he plastic material into a continuous self-supporting film, and tripped from the support.
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Another example of such orming processes is "panel pressingl' f decorative plastic laminatesO In high pressure panel pressing, ecorative laminates are conventionally prepared from an assembly f a plurality of core sheets which are prepared by impregnating 05 web of paper with a resin material, such as phenolic resin.
he core sheets axe superimposed in a stacked relationship and onsolidated with themselves and a decorative sheet under heat nd pressure. The decorative sheet is positioned immediately bove the core sheet assembly and is a resin saturated sheet aving a solid color or a suitable design thereonl Superimposed bove the decorative sheet is generally an overlay sheet which is thin sheet of fine paper impregnated with a noble thermosetting esi~, such as a melamine ~ormaldehyde resin or an unsaturated olyester resin and the like (and is generally the same resin sed to impregnate the decorative sheet). Hig ~ re laminates fter being consolidated are usually further to a tructural substrate, such as particlP board or plywood.
Low pressure panel pressed decorative laminates are made in similar manner to high pressure laminates, but generally nvolve lamination of the decorative sheet directly to particle oard or other structural substrate. Other pressing processes ~here a plastic film or sheet is formed on or against a release ~ heet may not include lamination, but only texturing a moldable ! lastic ~urface which is already laminated. For example, a - ~ ~5 lastic film could be coated directly onto particle board or lywood and then textured by pressing against a release sheet.
When it is desixed to produce a textured surface on the verlay sheet or the decorative sheet of a decorative plastic aminate, various techniques can be used, such as using a textured ¦~r embossed 1 plate or resin stabiliæed board in the pressing ... ~_ r ~, , ., ,, " ",... . .. . . .
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peration. The desired embossed or textured pattern can also be roduced on the release sheet for transfer to the pressed plastic urface,which is a technique related to the present invention.
Release sheets can be any one of a number of commercially 05 ~vailable materials, such as a non-adherable paper, a non-adherable luminum foil or a polished metal belt. To render them non-dherable, the sheets can be coated, treated, or impregnated with release coating of such materials as polymethylpentene, poly-ropylene, polyfluoro%arbons~ silicone oil, thermoset silicone esins, and others conventional release agents. Texturing can be rovided by any one of a number of conventional techniques, such s emboss~ng by mechanical means.
The use of textured or embossed release sheets for producing ~ textured pattern on a plastic sheet or film is quite useful for `~ 15 oarse patterns, but not totally satisfactory for the production f ~ine patterns. For one reason, the non-uniformity of the aper surface can mask the embossing pattern. Also, in high ressure pressing processes ther is a tendency for the embossed attern to flatten out under pressure and thus create a smooth urface. Furthermore, fine texture patterns formed by relief in he surfàce are generally not highly visible on the formed lastic surface, whether it be cast or pressed. The reason is hat such texture is primarily visible as a result of shading or ;- hadows formed when 'ight falls upon the irregular surfaces, and ery fine texture does not display shadowing or shading very ~ ~ ~rongly. As a result of this deficiency, it is sometimes - ~ esirable to print shading or shadow patterns onto the cas-t or ressed surface to highlight the textured surface by producing a ifferential gloss effect. This can be accomplished by such echniques as printing a dull coating material or ink onto the igh points of the textured release sheet for transfer of the s coating material into the depressed portions of the formed plastic surface. Or in the alternative, a glossy coating material or ink can be printed directly onto the raised portions of the formed plastic surface. Another technique sometimes employed is to polish the raised surace of the ; formed plastic surface to thereby impart a differential gloss effect to the finished product.
The above-described prior art techniques for pro-ducing a textured pattern on a formed piastic surface have <~ 10 a number of disadvantages. For example, fine patterns can , .
be difficult to transfer from an embossed release sheet and, even when they do transfer, are not highly visible ~` on the formed plastic surface. When glossy or dull , materials are printed either directly or indirectly on the ~ -high or low parts of the formed plastic surface to produce a differential gloss effect which highlights the texture other disadvantages occur, such as the tendency for the materials to rub off the plastic surface, the need for an additional finishing step, and in the case of the material being transferred from the release sheet, the inability to reuse the release sheet.
SUMMARY OF THE INVENTION
It is an object of an aspect of the present inven-tion to provide a formed plastic film or sheet having dif-ferential gloss effect, the method of forming it against arelease sheet, the release sheet, and the method of making the release sheet, all in a manner which avoids the above~
described disadvantages of the prior art.
~-~ -4-~6~5 In accordance with one asFect of this invention there is provided a release sheet for use in casting or panel pressing comprising a base sheet suitable for use in casting or panel pressing, a first gloss-producing layer provided by one of said base sheet and a di.stinct continuous layer over said base sheet; a second gloss-producing layer providing a different gloss level from said first gloss-producing layer and forming a distinct layer of a discontinuous pattern over `~ said first gloss-producing layer; and a release surface ~` 10 provided one of said first gloss-producing layer, said first and second gloss-producing layers, a distinct layer over said first gloss-producing layer and a distinct layer over said first and second gloss-producing layers, said release surface at least including a material selected from the group consisting of casting and panel pressing release material; all of said distinct layers being permanently secured to said base sheet so that they do not transfer - from said release sheet when used for casting or panel press-ing; said release sheet having a differential gloss pattern which is reproducible on a plastic sheet or film cast on or panel pressed against the release sheet, without transfer of the materials forming the first and second gloss~
producing layers.
: In accordance with another aspect of this inven-- 25 tion there is provided a method of producing a release sheet of the type hereinbefore described in which the . first gloss-producing layer is provided by a coating . comprising a relatively high gloss film-forming resin, and the second gloss producing layer is provided by a relatively low gloss pigmented coating, which comprises:
~_5_ (a) providing a base sheet suitable for use in casting or panel pressing with a first gloss-producing layer uniformly overall on the surface; (b) embossing said base sheet to provide an embossed pattern having raised portions;
(c) permanently applying over said first gloss-producing layer in a discontinuous pattern said second gloss-producing layer which provides a gloss level different from said first gloss-producing layer, said second gloss-producing layer being applied by tip printing said raised portions of said embossed pattern; and (d) coating said release sheet overall with a distinct layer of material having release properties after step (a).
In accordance with another aspect of this inven-"':`
tion there is provided a method of producing a release sheet of the type hereinbefore described in which the first gloss-producing layer is provided by a coating comprising a relatively high gloss film-forming resin, and the second gloss producing layer is provided by a relatively low gloss pigmented coating, which comprises:
(a) providing a base sheet suitable for use in casting or panel pressing with a first gloss-produclng layer uniformly overall on the surface; (b~ embossing said base sheet to provide an embossed pattern having raised portions;
and (c) permanently applying over said first gloss-~, 25 producing layer in a discontinuous pattern said second gloss-producing layer which provides a gloss level dif-ferent from said first gloss-producing layer, said second gloss-producing layer being applied by tip printing said raised portions of said embossed pattern; at least one of said ~irst gloss-producing layer and said first and second gloss-producing layers having release properties.
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In accordance with another aspect of this inven-tion there is provided a method of producing a decorative sheet product which comprises casting or panel pressing a `. plastic sheet or film on or against the release sheet referred to hereinabove, setting the plastic sheet or film and then removing it from the release sheet.
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In addition to overcoming the above-stated disadvantages of he prior art, the invention also offers the capability of producin flat ~not having relief) finished product having the appearance f relief, including the appearance of relief formed by difficult 05 atterns to transfer, such as fine leather or wood grain patterns, sing a flat, unembossed, release sheet. Use of a flat release heet provides more ~niform release than embossed release sheets.
lso, the flat surface of the finished product can be cleaned asier than one which is actually embossed. Additionally, the ifferential gloss surface produced on the finished product can ave a more realistic textured appearance than one actually extured.
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DETAILED DESCRIPTION OF THE PREFERRED EMBC)DIMENTS
In practicing the invention the various layers can be applied y several different techniques. The starting material is a base heet which can be provided by paper or other fibrous substrates r such substrates as polished metal belts as metal foils. The rinc;pal requirement for the substrate is that it have a smooth _ urface to resist the penetration of the coating which provides he release surface. Where the base sheet is provided by paper, his rPquirement is typical~y met by pro~iding the paper with a onventional base coating of a mineral pigment, such as clay, xed with an adhesive. The base coating may in some cases be he first gloss-producing layer, and in other cases, may be ~vercoated with the first gloss-producing layex. In some cases 7 he first gloss-producing layer can be provided by the actual ase sheet, particularly where it is made from such materia~ as etal foii or metal belts. If the release she~t is to be embossed, t must be capable of being embossed without cracking.
11~6~Z5 ThP second gloss-producing layer is applied over the first loss-producing layer in a discontinuous (rather than overall) attern to provide the differential gloss effect. The pattern in which the second gloss-producing layer i5 applied can be almost 05 ny of a wide variety, such as wood grain, leather grain, marble-zed, slate, geometric, clouds, artistic designs, or photographic eproductions. It may be applied by tip printing, flexography, . ravure printing, etc. rThe second gloss-producing layer can be rovided by a coating of a wide variety of materials, but they ~ st produce a different gloss level from the first gloss-producing ayer and must be compatible with and ~ anently adhere to the irst gloss-producing layer~ In some cases, the coating material f the second gloss producing layer can be provided by the same aterial as the first gloss-producing layer, bu~ will have a ; 15 ifferent gloss level due to better "hold-up" (lack of penetration ~,~ nto the substrate) than the first gloss-producing layer.
The release surface is preferably provided by a distinct ayer of a release agent coated over tha first and second gloss-roducing layers. The differential gloss effect surprisingly emains and is still transferable even with the release layer $ laced on top. In some cases, the release surface may be provided y the first and second gloss-producing layers themselves where the coating materials chosen for such layers have adequate ~; elease properties. In other cases the release surface may be rovided by a distinct layer coated over only the first gloss-roducing layer and over which tha second gloss-producing layer s applied. In this lakter case, the coating material of the , econd gloss-producing layer must permanently adhere to the ;; elease surface and must ha~e adequate release properties itself, r at least not substantially interfere (because of only a small rea of surface being covered) with the release properties of the elease surface.
.~
; _ ~ ~7~
~ ~ r ~LlZ6(~Z5 On~ of the advantages of the invention is the ability to roduce a flat release sheet which will impart the appearance of ~n embossed pattern upon a plastic film formed on or against the elease sheet~ This advantage is particularly valuable where the 05 ifferential gloss pattern is a very fine one, such as found in ~ood grain or leather grain. However, in other instances, par-icularly where the differential gloss pattern is coarssr, the nvention can be employed advantageously with an embossed release heet. In such cases, it is particularly desirable to emboss the elease sheet after applying the first gloss-producing layer and o apply the second gloss-producing layer only on the raised ortions ~f the embossed pattern. This method offers the advan-ages of tip printing the raised portions of the embossed patterns, which can be conveniently carried out by applying the coating aterial of the second gloss-producing layer with a gravure roll r some other offset printing apparatus positioned to lightly ontact the raised portions of the embossed sheet. In such cases he gravure roll would preferably have an overall pattern which rovides the coating material to substantially the entire surface f the gravure roll. One of the advantages of this technique is hat the'second gloss-producing layer can be provided by a low-loss pigmented coating which causes the recessed areas on the lastic film or sheet formed on or against the release sheet to ;-ppear duller than the remaining surface (raised portions) of the lastic film or sheet, thereby accentuating the embossed pattern.
` ~hen practicing this technique the release surface can be provided i . y an ov~rall applied release agen~ after embossing and tip rinting, or in some cases, it can be applied before embossing nd tip printing~
.,", , .
.
....,..- ..~ ,..,, ,, .. .,, ~, . . . ...
ll llZ60;~5 In the ~lternative, it may be desirable to print the second loss-producing layer over the first gloss-producing layer prio~
o embossing the release sheet. In such cases, the embossing attern may be identical to and registered with the differential 05 loss pattern to produce the same effect mentionad above. In ther cases the differential gloss pattern may be different from he embossed pattern to provide a particular appearance. In such ases the two patterns ~ not register and there will be the dvantage of no repeat in the combined pattPrns formed by the mbossed pattern and the second gloss-producing pattern.
Although in most cases, the second gloss-producing layer , ill have a lower gloss level than the first gloss-producing ayer, there may be occasions where it is desirable to reverse his.
The first gloss-producing layer can be provided by a variety coating materials~ Where the invention employs a separate, istinct layer for the release surface, the first gloss-producing ayer can be provided by conventional pigment-binder coatings.
~ ical pigments useful in such coatings are silicas, barium sulphate, precipitated ox unprecipitated calcium carbonate, and alcined alumina. Typical binders are the natural glues such as asein, protein, starches, and synthetic binders, such as latices, ;- olyvinyl alcohol, methylcellulose and othersO
Where no separate, distinct layer is employed for the release urface, the irst gloss-producing layer will preferably include mall additions of conventional release agents, such as silicone esins, complexes of fatty acids and chromic chloride or poly-nhydride fatty acid derivatives. The first gloss-producing ayer is applied uniformly overall to the entire base sheet, hich may or may not have been previously base coated with a .
,':
. _g_ 11,Z61~1Z5 onventional pigment-binder coating, by conventional coating echniques such as blade coating, air knife coating, or gravure oll coating. The amount of coating applied for the first gloss-roducing layer can vary over a wide range as long as overall 05 overage is obtained, from less than 1 pounds per ream to 15 ounds per ream being a suggested range.
The second gloss-producing layer is provided by a coating at~rial which may be any one of the coating materials described for the first gloss-producing layers, although it most likely ould be one different than the particular one chosen for the first gloss-producing layer. But, as previously mentioned, it could be the same material as used for the first gloss-producing layer. It is critical to the invention that the inherent gloss roduced by the second gloss-producing layer be different f_om hat produced by the first gloss-producing layer. It is generally referred for the gloss level of the first gloss-producing layer o be higher than that for the second gloss-producing layer.
owever, in some instances it may be desired to reverse this.
~he gloss level of either gloss-producing layer can be controlled 2a ~y the use of gloss control additives. A lower gloss level can e provided by larger amounts o piyments and/or larger size igments having greater flatting properties Such pigments are lay, calcium carbonate, sand, barium sulfate etc. These pigments re usually combinea with adhesives. Typical adhesives are olyvinyl alcohol, methyl cellulose, starch, protein and styrene-utadiene rubber~ Any of the binders may be used by itself as a loss control additive, and they in general, would tend to raise ,~ ¦¦the gloss of coating.
.',,. , .,, , ~., llZ~11Z5 Gloss may be described as the characteristic of the surface which causes light to reflect at a given angle in excess of the iEfuse reflection at that angle~ There are a number of instru-ents which measure an arbitrary value indicative of the gloss of 05 particular surface. The Gardner 60 gloss meter is one such nstrument which is commonly used. The 60 angle is measured from a line perpendicular to the paper, and is equivalent to a 0 angle from the plane of the paper surface. In practicing the resent invention, it is critical that the gloss level produced !~ 10 y the second gloss-producing layer be different from that roduced by the first gloss-producing layer. It would be difficult o place quantitative limits on this difference, but the difference s such that the differential gloss appearance is quite noticable o any observer.
15 Where a separate, distinct layer is employed for the release urface, the coating material for the release surface may be -ovided by any one o~ a number of conventional release materials~
uch as silicone resins or a complex of a fatty acid and chromic hloride or polyanhydride fat~y acid derivatives. Such a coating ~a~ be applied by a number of techniques used to provide a ontinuous coating layer. One particularly preferred technique or coating an embossed sheet is use of an aix knife.
Having generally described the invention, the following ; ~ xamples are given to further illustrate preferred embodiments of , 25 he invention.
'' . 'Q.
. EXAMPLE 1 A paper base sheet with a conventional clay and adhesive ase coat (32 lbs./ream total basis weight) was coated overall ith a first gloss-producing layer which was a mixture of the ollowi~g:
.' l ~ s Dry Weight styrenP-butadiene rubber latex (Dow 620 from Dow Chemical Company) 15 parts l soy protein, medium viscosity 15 parts 05 ¦ clay, coating grade 100 parts ¦ water to make 30% solids ¦ he coating mixture was applied by air knife in an amount of 5 I bs./ream, dried, and calendered to smooth the surface. The ¦ heet was then embossed between an etched steel roll and a cotton ¦ atrix backing roll in four different embossing patterns ranging l from fine to medium leather yrain. The-hills of the embossed ¦ sheet were tip printed with a 150 line gravure roll using a ¦ oating mixture of the following:
¦ Dry Weight 15 ¦ Calcium carbonate, ground particles at 50% 250 parts polyvinyl alcohol (DuPont's l Elvanol 71-30 at 10%, fully ¦ hydrolyzed, medium molecular weight, medium viscosity) 75 parts ¦ Triton X-100 (Rohm and Haas welting ¦ agent, a non-ionic alkylaryl I polye~her alcohol sulfonate at _ ¦ 10%) 1.25 part ¦ wool green dye at 1% (for observation purposes) 0.1 aqueous release coating of a complex of a stearic acid and ;- ¦chromium chloride and poly~inyl alcohol was then applied over the ,~ , ¦entire surface and dried.
¦ The gloss levels of the first gloss-providing layer and the ¦second gloss-producing layer of Example 1 were determined by ~- ~ king samples in a slightly varied manner. That is/ the second ~, ¦gloss-producing layer was coated overall on a large enough area to take gloss readings. ~he 60 Gardner gloss readings obtained , - -12-~'' . _ . , , ~ ~ 2 ~ ~ Z 5 ere 19 for the first gloss-producting layer and 3 for the second loss producing layer. These readings were taken after the elease coating was applied, and they probably would have been a ittle different if taken without the release coating, but the 05 ifference in gloss would be essentially the same.
A poly~inyl chloride plastisol was cast on the release urface of the release sheet o Example 1 as a 4 mil wet film.
Over this was applied a 9 mil PVCl foam, and this was then aminated to cotton fabric. This laminate was heated to expand he foam and dried by known techniques. Upon separation of the elease sheet from the cast product the film surface of the cast roduct had the differential gloss effect of the release sheet.
he hills of the surface were glossy while the valleys were dull.
In another casting example a polyurethane was cast on the elease surface of the release sheet of Example 1, and this 1 mil ry layer was bonded to napped and shÇ red fabric using an adhesive or the urethane. Upon separation of the release paper from the rethane surface the same differential gloss effect on the rethane surface was observed as above~ The hills of the surface Pre glossy while the ~alleys were dull.
~ ~ ~ . .
~,~ EXAMPLE 2 ;. A paper base sheet with a conventional clay and adhesive ase coa~ (63 lbs./ream total basis weight) was coated overall ith a mixtu of the follow ng:
~ , .
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'., I .
, . ~ 6~Z~
~ ~ , ¦ hydroxyethyl cornstarch 16 parts l tA. E. Staley Mfg. Co.) ¦ styrene-butadiene rubber latex 10 parts 05 ¦ (Dow 620 from Dow Chemical Company) l polyvinyl alcohol (Vinol 107 K from ¦ Air Reduction Co.) 5 parts ¦- clay, coating grade 100 parts ~he coating mixture was applied by air knife in an amount of 6 ~b~./ream, dried and calendered to~smooth the sheet. The sheet ~as then gravure printed with two different wood grain patterns ~o form the second gloss-producing layer-. The coating material ~sed for the second gloss-producing layer was the same as that sed for the second gloss-producing layer in Example 1. the heet was then top coated with a release coating of a release gent, a monomeric polyhydric alcoholl and a cross-linkable hermosetting resin o~ the formula set forth in Example 3 of U.S.
atent No. 3,946,135.
The release sheet of Example 2 was used in high pressure anel pressing where it was placed against a melamina saturated ~verlay, which in turn, was against a melamine saturated and rinted decorative sheet, which in turn, was against four phenolic esin saturated core stock sheets.- The laminates were consoli-ated at 1200 p.s.i. and 285 for 17 minutes. The relaase sheet as stripped away from the panel and the panel exhibited gloss ifferential and appeared to have grain structure in its surface ; ven though it was flat.
The release sheet of Example 2 was used in low pressure anel pressing where it was placed against a melamlne saturated nd printed decorative sheet, which in turn, was against a 3/4 ' ,~'' ' ' ` "''''''' . .. . '"~ ' ~ 6~'Z5 nch thick particle board~ The laminates were consolidated at 50 p.s~i. and 300F for ~ minutes. The release sheet was tripped away, and the panel exhibited gloss differential and ppeared to ha~e grain structure in its surface even though it 05 was flatO
. ,', .
. EXAMPLE 3 -A sheet of aluminum foil 5-8 mils thick, was coated in a attern of a single wide strip from a gravure roll to provide a eco~d gloss-producing layer of a coating like that of Example 1, but with coating grade clay substitutPd fox the calcium carbonate.
o distinct release surface was applied over the seconcl gloss-producing layer. The 60 Gardiner gloss readings for the foil `- (which provided the first gloss-producing layer) was o~ scale (100~) and was 19.0 for the second gloss-producing layer. A
olyvinyl chloride plastisol was cast on the oil ~elease sheet, ried and stripped from the release sheet and displayed the ifferential gloss effert of the release sheet.
Other examples were made like those of Example 1 and 2, but ith different patterns ~such as marble, cloud prints, etc.) used or the gecona gloss-producing layer and with vaxious release oatings~ These examples were used in various casting and panel ressing modes, providing the same observable gloss differential ;- s in Examples 1, 2 and 3.
. '' As an illustration of the ability to vary the gloss level of he first or second floss-producing layers by ~arying the materials n ~he coating, the following examples are given. A conventional lay/adhesive base coated paper was coated in a single strip attern with the coating mixture of the second gloss producing ayer in Example 1 with the noted variations and noted 60 ardiner gloss readings wPre obtained.
-lS-~ 25 ¦ Stearic Acid and l Substituted Mo ReleaseSilicone type Chromic Chloriae : I Material Coat Release Coat Release Coat ~ydroxyethyl corn- ~
05 ¦starch for PVA 3.0 6.0 3.0 . Isoy protein for PVA3.0-6.0 7.0-9.0 4.0 ~ethyl cellulose ¦ for PVA . 5,0 9.0~9.5 5.0 . ~actic casein for ¦ PVA 2.5-3.0 7.0-9.0 ---~yrene butadine ¦ rubber latex ¦ for PVA 2.5 8.5-10.0 3.0 ~and ~or CaC03 --- 7.5 4.0-5.0 ~inex, anhydrous ¦(Na, K) aluminum silicate for ¦ CaC03 4-0 5.5-6.0 4.0 ~lass beads for ¦ _ 3 24~0-25,0 19.0 22.0-24.0 play for CaC03 --- 14 . O .8 . O
: po pigment --- 20.0 29.O
. . ~tyrene butadiene : I rubber latex 25 ¦ for PVA and no pigment 48.0-52.0 37.0-39.0 45.0-47.0 : ethyl cellulose for PVA and no -. ` pigment 15.0 22.0-24.0 1600 i 30 actic casein for :~ P~A and no pigment 27.0-28.0 26.0 2~tO-26.0 ontrol (same as ; Ex. 1) - - 4.0 2.0 ase coated paper 32.0-35.0 20.0 18.0-20.0 Having described the invention generally and also in its ~ referred embodiments, variations within the scope of the inven-.~ . ion will be obvious to -onè skilled in the art. For example, the ¦First gloss-p ducing layer is described as completely covering ,~, ,, . .~. .. ,.v _.. , .. ., _ ,, . -11~Z6~3Z~ I
the surace of the base sheet, and this is highly préferred for he convenience of coating and necessary where the second gloss-roducing layer is in a fine pattern.
However, it is readily apparent that the first gloss-producing 05 layer does not have to cover the base sheet immediately beneath . he second gloss-producing layer, and it can be absent in those areas where the second gloss~producing layer is in a very coarse . . attern. ~his variation is believed to be a functional equivalent ~f the prese invention in i=s broade~e form.
~' ~ ~
. .
. .' ~ ' , ,~' .
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, I' ~~ ~, .~ - ',. r ~, . . . '',".
. . . -17~
,, 11 , .
Claims (19)
1. A release sheet for use in casting or panel pressing comprising a base sheet suitable for use in casting or panel pressing, a first gloss-producing layer provided by one of said base sheet and a distinct continuous layer over said base sheet; a second gloss-producing layer providing a different gloss level from said first gloss-producing layer and forming a distinct layer of a discontinuous pattern over said first gloss-producing layer; and a release surface provided one of said first gloss-producing layer, said first and second gloss-producing layers, a distinct layer over said first gloss-producing layer and a distinct layer over said first and second gloss-producing layers, said release surface at least including a material selected from the group consisting of casting and panel pressing release material; all of said distinct layers being permanently secured to said base sheet so that they do not transfer from said release sheet when used for casting or panel press-ing; said release sheet having a differential gloss pattern which is reproducible on a plastic sheet or film cast on or panel pressed against the release sheet, without transfer of the materials forming the first and second gloss-producing layers.
2. A release sheet according to claim 1 wherein said release surface is of a material selected from the group consisting of casting and panel pressing material.
3. A release sheet according to claim 1 wherein said release surface contains a material selected from the group consisting of casting and panel pressing material.
4. A release sheet as claimed in claim 1 wherein said release material comprises a material selected from silicone resins, a complex of a fatty acid and chromic chloride, and polyanhydride fatty acid derivatives.
5. A release sheet as claimed in any of claims 1, 2 or 3 wherein said base sheet is paper coated with a base coating.
6. A release sheet as claimed in any of claims 1, 2 or 3 wherein said first gloss-producing layer is provided by a coating comprising a relatively high gloss film-forming resin, and said second gloss-producing layer is provided by a relatively low gloss pigmented coating.
7. A release sheet as claimed in any of claims 1, 2 or 3 wherein said release sheet is flat.
8. A release sheet as claimed in any of claims 1, 2 or 3 wherein said release sheet is embossed in a pattern and said second gloss-producing layer is only on the raised portions of the embossed pattern to form a dis-continuous pattern over said first gloss-producing layer.
9. A release sheet as claimed in any of claims 1, 2 or 3 wherein said discontinuous pattern of said second gloss-producing layer is in a pattern of leather grain.
10. A release sheet as claimed in any of claims 1, 2 or 3 wherein said discontinuous pattern of said second gloss-producing layer is in a pattern of wood grain.
11. A method of producing a release sheet as claimed in claim 1 and wherein said first gloss-producing layer is provided by a coating comprising a relatively high gloss film-forming resin, and said second gloss-producing layer is provided by a relatively low gloss pigmented coating, which comprises (a) providing a base sheet suitable for use in casting or panel pressing with a first gloss-producing layer uniformly overall on the surface; (b) embossing said base sheet to provide an embossed pattern having raised portions; (c) permanently applying over said first gloss-producing layer in a discontinuous pattern said second gloss-producing layer which provides a gloss level different from said first gloss-producing layer, said second gloss-producing layer being applied by tip printing said raised portions of said embossed pattern; and (d) coating said release sheet overall with a distinct layer of material having release properties after step (a).
12. A method according to claim 11 wherein step (d) is carried out before step (c).
13. A method according to claim 11 wherein step (d) is carried out after step (c).
14. A method of producing a release sheet as claimed in claim 1 and wherein said first gloss-producing layer is provided by a coating comprising a relatively high gloss film-forming resin, and said second gloss-producing layer is provided by a relatively low gloss pigmented coating, which comprises (a) providing a base sheet suitable for use in casting or panel pressing with a first gloss-producing layer uniformly overall on the surface; (b) embossing said base sheet to provide an embossed pattern having raised portions; and (c) permanently applying over said first gloss-producing layer in a discontinuous pattern said second gloss-producing layer which provides a gloss level different from said first gloss-producing layer, said second gloss-producing layer being applied by tip printing said raised portions of said embossed pattern; at least one of said first gloss-producing layer and said first and second gloss-producing layers having release properties.
15. A method as claimed in claim 11 wherein step (a) comprises applying a coating uniformly overall to said base sheet to form said first gloss-producing layer.
16. A method of producing a decorative sheet product which comprises casting or panel pressing a plastic sheet or film on or against said release sheet of claim 1, setting said plastic sheet or film and then removing it from said release sheet.
17. A method as claimed in claim 16 wherein said plastic sheet or film is cast on said release sheet, cured, and then removed.
18. A method as claimed in claim 16 wherein said plastic sheet or film is cast on said release sheet, cooled, and then removed.
19. A method as claimed in claim 16 wherein said plastic sheet or film is panel pressed under heat and pressure along with at least one laminate against said release sheet, cooled and removed.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US82078677A | 1977-08-01 | 1977-08-01 | |
| US820,786 | 1977-08-01 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1126025A true CA1126025A (en) | 1982-06-22 |
Family
ID=25231722
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA307,458A Expired CA1126025A (en) | 1977-08-01 | 1978-07-14 | Differential gloss release sheet |
Country Status (9)
| Country | Link |
|---|---|
| JP (1) | JPS602989B2 (en) |
| BE (1) | BE869249A (en) |
| BR (1) | BR7804803A (en) |
| CA (1) | CA1126025A (en) |
| DE (1) | DE2833066C2 (en) |
| FR (1) | FR2399320A1 (en) |
| GB (1) | GB2002260B (en) |
| IT (1) | IT1108691B (en) |
| PL (1) | PL208774A1 (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3311407C1 (en) * | 1983-03-29 | 1984-10-31 | Bernhard Schmolke "Die neue Linie", 8501 Ezeldorf | Process for the production of medals |
| GB9524502D0 (en) * | 1995-11-30 | 1996-01-31 | Elfglade Ltd | Transfer printing method and apparatus |
| ATE294242T1 (en) * | 1999-11-01 | 2005-05-15 | Max India Ltd | MATTE TRANSFER ELEMENT TO GIVE A LEATHER FINISH |
| ATE277201T1 (en) * | 1999-11-01 | 2004-10-15 | Max India Ltd | SPRAY ITEMS FOR REFINING REFINED LEATHER |
| RU2379198C2 (en) * | 2004-12-16 | 2010-01-20 | Флоринг Индастриз Лтд. | Flooring board and method of manufacturing thereof |
| BE1016347A3 (en) * | 2004-12-16 | 2006-08-01 | Flooring Ind Ltd | Floor panel used for forming floating floor covering has zones of different gloss degrees extending over upper surface of floor panel in function of imitated global wood pattern |
| BE1016399A3 (en) * | 2005-01-06 | 2006-10-03 | Flooring Ind Ltd | Floor panel e.g. laminate panel, has multipartite substrate, decor, top layer and upper side that includes impressed zones, where impressed zones are extended along part of one upper edge is provided with mechanical coupling unit |
| CN113355637A (en) * | 2020-03-06 | 2021-09-07 | 西铁城时计株式会社 | Decorative member, method for manufacturing decorative member, and timepiece including decorative member |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3816155A (en) * | 1969-09-02 | 1974-06-11 | E Iverson | Decorative wood graining method and articles |
| DE2140150A1 (en) * | 1971-08-11 | 1973-02-22 | John R Morrison | PROCESS FOR DESIGN OR DECORATION OF SURFACES |
| US3666516A (en) * | 1971-10-12 | 1972-05-30 | Richard E Dunning | Hot stamp tape |
| US4053669A (en) * | 1974-04-11 | 1977-10-11 | Pandel-Bradford, Inc. | Imitation sheet material with surface grain appearance |
-
1978
- 1978-05-25 JP JP53062839A patent/JPS602989B2/en not_active Expired
- 1978-07-14 CA CA307,458A patent/CA1126025A/en not_active Expired
- 1978-07-24 IT IT68753/78A patent/IT1108691B/en active
- 1978-07-25 BE BE189485A patent/BE869249A/en not_active IP Right Cessation
- 1978-07-26 BR BR7804803A patent/BR7804803A/en unknown
- 1978-07-27 DE DE2833066A patent/DE2833066C2/en not_active Expired
- 1978-07-31 GB GB7831713A patent/GB2002260B/en not_active Expired
- 1978-07-31 FR FR7822655A patent/FR2399320A1/en active Granted
- 1978-08-01 PL PL20877478A patent/PL208774A1/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| GB2002260A (en) | 1979-02-21 |
| BE869249A (en) | 1978-11-16 |
| FR2399320B1 (en) | 1983-10-07 |
| GB2002260B (en) | 1982-07-14 |
| PL208774A1 (en) | 1979-06-04 |
| FR2399320A1 (en) | 1979-03-02 |
| JPS5426877A (en) | 1979-02-28 |
| BR7804803A (en) | 1979-04-24 |
| IT1108691B (en) | 1985-12-09 |
| IT7868753A0 (en) | 1978-07-24 |
| DE2833066A1 (en) | 1979-02-15 |
| JPS602989B2 (en) | 1985-01-25 |
| DE2833066C2 (en) | 1982-12-23 |
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