CA1137405A - Laminating vinyl film to wood via two adhesive coats - Google Patents
Laminating vinyl film to wood via two adhesive coatsInfo
- Publication number
- CA1137405A CA1137405A CA000317695A CA317695A CA1137405A CA 1137405 A CA1137405 A CA 1137405A CA 000317695 A CA000317695 A CA 000317695A CA 317695 A CA317695 A CA 317695A CA 1137405 A CA1137405 A CA 1137405A
- Authority
- CA
- Canada
- Prior art keywords
- adhesive
- copolymer
- vinyl acetate
- weight
- adhesive coat
- 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)
Abstract
ABSTRACT OF THE DISCLOSURE
A process for laminating vinyl film to a hard surface substrate which comprises, in sequence, the steps of (1) applying a first adhesive coat, (2) drying the first adhesive coat, (3) applying a second adhesive coat, (4) drying the second adhesive coat, and (5) heating the coated substrate to a temperature of about 121°C and hot rolling a vinyl film thereon. The adhesive comprises a vinyl acetate/copolymer emulsion and an acrylic ester homopolymer or copolymer, to which are optionally added poly-methylene, polyphenylisocyanate and/or methyl pyrrolidone.
A process for laminating vinyl film to a hard surface substrate which comprises, in sequence, the steps of (1) applying a first adhesive coat, (2) drying the first adhesive coat, (3) applying a second adhesive coat, (4) drying the second adhesive coat, and (5) heating the coated substrate to a temperature of about 121°C and hot rolling a vinyl film thereon. The adhesive comprises a vinyl acetate/copolymer emulsion and an acrylic ester homopolymer or copolymer, to which are optionally added poly-methylene, polyphenylisocyanate and/or methyl pyrrolidone.
Description
1~37~05 This invention concerns a new process for the lamina-tion of heavy vinyl films to solid substrates such as lauan, hard-board, or particle board. The lamination of heavy vinyl films, i.e., films having a thickness of from about 1 to 10 mils, to such solid substrates has heretofore been done using solvent ad-hesives such as urethane, acrylic, and epoxy adhesive solvent sys-tems. Although generally satisfactory results have been attained~
I have investigated various modifications of the process in order to obtain a more economically attractive process. If a resin ad-hesive system were used in place of the solvent adhesive system, the cost of the adhesive would be reduced by about one-half. How-ever, the replacemeDt of solvent adhesive with a low cost resin system has hereto~ore not yielded satisfactory results.
It has now been discovered that excellent results are obtainable using a low-cost resin by a process in which the resin is applied in two separate coatings and each coating is dried prior to the next step in the process. The use of the instant resin adhesive system has the advantage of reduced costs, re-duced fire hazard ar.d causes less pollution during ~he manufac-turing process.
A vinyl film of thickness of about 1 to 10 miis is lam-inated to a solid substrate in a process comprising the steps of (1) applying a resinous adhesive coat comprising a vinyl acetate/
copolymer (for instance, a vinyl acetate/ethylene) emulsion and acrylic ester homopolymer or copolymer, (2) drying the adhesive coat, (3) applying a second adhesive coat also comprising a vinyl acetate/copolymer (for instance, a vinyl acetate/ethylene) emul-sion and an acrylic ester homopolymer or copolymer, (4) drying the second adhesive coat, and (5) heating the coated substrate to a temperature of about 121C and subjecting the coated sub-strate to pressure to laminate the vinyl film thereon.
.~
~37405 The adhesive coat comprises either (a) from about 80 to about 95 parts by weight of a vinyl acetate/copolymer emulsion and from about 5 to about 20 parts by weight of an acrylic ester homopolymer or copolymer, or (b) about lO0 parts by weight of a vinyl acetate/copolymer emulsion from about 5 to about 20 parts by weight of an acrylic ester homopolymer or copolymer and from about 2 to about lO parts by weight of polymethylene polyphenyl-isocyanate. In either (a) or (b), there may be added from about 3 to about lO percent by weight of methyl pyrrolidone.
The accompanying drawing shows the adhesive coated sub-strate and the method of hot rolling the vinyl film to the coated substrate.
The substrate contemplated for use with the process of the present invention is a solid substance composed of wood or a wood product. The invention is particularly applicable to par-;
ticle board, hardboard, and lauan.
The vinyl acetate copolymer used in the adhesive sys-tem of the invention is a copolymer of vinyl acetate and any unsaturated monomer copolymerizable therewith, prefera~ly ethyl-ene. The vinyl acetate constitutes from about 20 to about 30% by weight of the copolymers. The vinyl acetate copolymer emulsion as used herein preferably contains about 45% water.
The acrylic ester polymer component can be an acrylic acid ester or methacrylic acid ester homopolymer or a copolymer of either ester, wherein the methacrylic acid or acrylic acid is ester~ied with one or more polyhydric alcohols, such as, for ex-ample, ethylene glycol, diethylene glycol, butylene ~lycol, neo-pentyl glycol or trimethanol propane. Also usable are methya-crylic acid esters or acrylic acid esters of cycloaliphatic mono-hydric alcohols such as, for example, cyclohexanol, tetrahydrol furfuryl alcohol or 1,3-dic:a-~,2-dimethyl-4-methylolcyclopentane.
1~37~10S
In the case of the acrylic acid ester copolymer, the other monomer carl ~e any other monomer copolymerizable therewi~h, such as for example ethylene.
The vinyl acetate copolymer is used in an amount of about 80 to 95 parts by weight to 5 to 20 parts by weight of acrylic ester polymer.
The polymethylene polyphenylisocyanate, which is a~
optional ingredient in the adhesive coating, is a ~nown agent for the acceleration of hardening. The adhesive may additionally contain from about 3 to about 10 percent by weight of methyl pyr-rolidone. The methyl pyrrolidone is used to help control visco-~
ity and as a modifier to improve bond in the case of over-plasti-cized films. -Steps (1) and (3) of this process both involve the ap-plication of an adhesive coat. Both adhesive coats should fall within the limits of the aforementioned description and for con-venience sake, the same adhesive should be used in both steps.
It should be noted that while a single adhesive coat will work in some applications, the utilization of two adhesive coats af-fords a smoother application in terms of total film thickness.
Drying steps (2) and ~4) should take place at a temper-ature between about 38 and 177C. The drying is conveniently accomplished in an oven of from 30 to 40 feet in length through which the coated substrate is passed at a speed of about 120 feet per minute. As an alternative to oven drying, infrared heat may be used. The use of infrared heat is preferable, particularly in the case of particle board in order to reduce grain raise.
After the drying step (4) is completed, the temperature of the adhesive coated substrate is adjusted to about 121C. The substrate and the vinyl film to be adhered are then subjected to pressure and are preferably passed under a rubber roll, according to methods well known in the art, in order to laminate the vinyl film to the adhesive coated substrate~
1~37~05 The invention will be better understood by reference to the accompanying drawing, which illustrates the coated substrate and the hot roll process of this invention.
A solid substrate 10, such as particle board, is coated with adhesive 11 (step 1) and dried (step 2). It is then coated with a second adhesive 12 (step 3), which may be the same adhesive previously used and is dried (step 4). The temperature of the coated substrate 13 is then adjusted to about 121C.
Coated substrate 13 and a vinyl film 14 having a thickness of from about 1 to about 10 mils and are together passed under a rubber roll 15 in order to cause adhesion of the vinyl film 14 to the coated substrate 13. The vinyl film 14 is conveniently obtained from a supply roller, not shown.
The following Example will further illustrate the invention but is in no wise to be construed as limiting the scope thereof.
EXAMPLE
A vinyl film laminate, utilizing Columbus Coated and Firestone's 6 mil vinyl (Flexible Film), is formed by applying to a 1/2" particle board substrate a resin adhesive system consisting of 80 parts by weight of vinyl acetate/ethylene emulsion (Du Pont ELVAX* 1875) and 20 parts by weight of acrylic ester co-polymer (Rohm and Haas Rhoplex* N-495). The first adhesive coat is dried at a temperature from about 38 to about 177C. A second adhesive coat is applied and dried in the foregoing manner to afford the adhesive coated substrate. The surface temperature of the adhesive coated substrate is adjusted to about 121C and the vinyl film is applied by means of a rubber roller. The resulting bond provides peel values of 8-9#/linear inch as opposed to no bond with a single adhesive coat.
*"ELVAX" and "Rhoplex" are trade marks.
1~3'74~S
The adhesive system may additionally contain from about 3 to about 10 percent by weight, preferably 10 parts by weight, of methyl pyrrolidone.
- 5a -B
,
I have investigated various modifications of the process in order to obtain a more economically attractive process. If a resin ad-hesive system were used in place of the solvent adhesive system, the cost of the adhesive would be reduced by about one-half. How-ever, the replacemeDt of solvent adhesive with a low cost resin system has hereto~ore not yielded satisfactory results.
It has now been discovered that excellent results are obtainable using a low-cost resin by a process in which the resin is applied in two separate coatings and each coating is dried prior to the next step in the process. The use of the instant resin adhesive system has the advantage of reduced costs, re-duced fire hazard ar.d causes less pollution during ~he manufac-turing process.
A vinyl film of thickness of about 1 to 10 miis is lam-inated to a solid substrate in a process comprising the steps of (1) applying a resinous adhesive coat comprising a vinyl acetate/
copolymer (for instance, a vinyl acetate/ethylene) emulsion and acrylic ester homopolymer or copolymer, (2) drying the adhesive coat, (3) applying a second adhesive coat also comprising a vinyl acetate/copolymer (for instance, a vinyl acetate/ethylene) emul-sion and an acrylic ester homopolymer or copolymer, (4) drying the second adhesive coat, and (5) heating the coated substrate to a temperature of about 121C and subjecting the coated sub-strate to pressure to laminate the vinyl film thereon.
.~
~37405 The adhesive coat comprises either (a) from about 80 to about 95 parts by weight of a vinyl acetate/copolymer emulsion and from about 5 to about 20 parts by weight of an acrylic ester homopolymer or copolymer, or (b) about lO0 parts by weight of a vinyl acetate/copolymer emulsion from about 5 to about 20 parts by weight of an acrylic ester homopolymer or copolymer and from about 2 to about lO parts by weight of polymethylene polyphenyl-isocyanate. In either (a) or (b), there may be added from about 3 to about lO percent by weight of methyl pyrrolidone.
The accompanying drawing shows the adhesive coated sub-strate and the method of hot rolling the vinyl film to the coated substrate.
The substrate contemplated for use with the process of the present invention is a solid substance composed of wood or a wood product. The invention is particularly applicable to par-;
ticle board, hardboard, and lauan.
The vinyl acetate copolymer used in the adhesive sys-tem of the invention is a copolymer of vinyl acetate and any unsaturated monomer copolymerizable therewith, prefera~ly ethyl-ene. The vinyl acetate constitutes from about 20 to about 30% by weight of the copolymers. The vinyl acetate copolymer emulsion as used herein preferably contains about 45% water.
The acrylic ester polymer component can be an acrylic acid ester or methacrylic acid ester homopolymer or a copolymer of either ester, wherein the methacrylic acid or acrylic acid is ester~ied with one or more polyhydric alcohols, such as, for ex-ample, ethylene glycol, diethylene glycol, butylene ~lycol, neo-pentyl glycol or trimethanol propane. Also usable are methya-crylic acid esters or acrylic acid esters of cycloaliphatic mono-hydric alcohols such as, for example, cyclohexanol, tetrahydrol furfuryl alcohol or 1,3-dic:a-~,2-dimethyl-4-methylolcyclopentane.
1~37~10S
In the case of the acrylic acid ester copolymer, the other monomer carl ~e any other monomer copolymerizable therewi~h, such as for example ethylene.
The vinyl acetate copolymer is used in an amount of about 80 to 95 parts by weight to 5 to 20 parts by weight of acrylic ester polymer.
The polymethylene polyphenylisocyanate, which is a~
optional ingredient in the adhesive coating, is a ~nown agent for the acceleration of hardening. The adhesive may additionally contain from about 3 to about 10 percent by weight of methyl pyr-rolidone. The methyl pyrrolidone is used to help control visco-~
ity and as a modifier to improve bond in the case of over-plasti-cized films. -Steps (1) and (3) of this process both involve the ap-plication of an adhesive coat. Both adhesive coats should fall within the limits of the aforementioned description and for con-venience sake, the same adhesive should be used in both steps.
It should be noted that while a single adhesive coat will work in some applications, the utilization of two adhesive coats af-fords a smoother application in terms of total film thickness.
Drying steps (2) and ~4) should take place at a temper-ature between about 38 and 177C. The drying is conveniently accomplished in an oven of from 30 to 40 feet in length through which the coated substrate is passed at a speed of about 120 feet per minute. As an alternative to oven drying, infrared heat may be used. The use of infrared heat is preferable, particularly in the case of particle board in order to reduce grain raise.
After the drying step (4) is completed, the temperature of the adhesive coated substrate is adjusted to about 121C. The substrate and the vinyl film to be adhered are then subjected to pressure and are preferably passed under a rubber roll, according to methods well known in the art, in order to laminate the vinyl film to the adhesive coated substrate~
1~37~05 The invention will be better understood by reference to the accompanying drawing, which illustrates the coated substrate and the hot roll process of this invention.
A solid substrate 10, such as particle board, is coated with adhesive 11 (step 1) and dried (step 2). It is then coated with a second adhesive 12 (step 3), which may be the same adhesive previously used and is dried (step 4). The temperature of the coated substrate 13 is then adjusted to about 121C.
Coated substrate 13 and a vinyl film 14 having a thickness of from about 1 to about 10 mils and are together passed under a rubber roll 15 in order to cause adhesion of the vinyl film 14 to the coated substrate 13. The vinyl film 14 is conveniently obtained from a supply roller, not shown.
The following Example will further illustrate the invention but is in no wise to be construed as limiting the scope thereof.
EXAMPLE
A vinyl film laminate, utilizing Columbus Coated and Firestone's 6 mil vinyl (Flexible Film), is formed by applying to a 1/2" particle board substrate a resin adhesive system consisting of 80 parts by weight of vinyl acetate/ethylene emulsion (Du Pont ELVAX* 1875) and 20 parts by weight of acrylic ester co-polymer (Rohm and Haas Rhoplex* N-495). The first adhesive coat is dried at a temperature from about 38 to about 177C. A second adhesive coat is applied and dried in the foregoing manner to afford the adhesive coated substrate. The surface temperature of the adhesive coated substrate is adjusted to about 121C and the vinyl film is applied by means of a rubber roller. The resulting bond provides peel values of 8-9#/linear inch as opposed to no bond with a single adhesive coat.
*"ELVAX" and "Rhoplex" are trade marks.
1~3'74~S
The adhesive system may additionally contain from about 3 to about 10 percent by weight, preferably 10 parts by weight, of methyl pyrrolidone.
- 5a -B
,
Claims (5)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A process for forming a bond between a vinyl film surface and a wood substrate, which process comprises the steps of i) applying an adhesive to said substrate;
ii) drying the adhesive; and iii) adhering a vinyl film to the adhesive under elevated temperature and pressure, characterized by (1) applying a first resinous adhesive coat to said substrate, said resinous adhesive being a composition consisting essentially of from about 80 to about 95 parts by weight of a first aqueous vinyl acetate copolymer emulsion and from about 5 to about 20 parts by weight of a first acrylic ester homo-polymer or copolymer;
(2) drying said first adhesive coat at a temperature of from about 38°C to about 177°C;
(3) applying a second resinous adhesive coat con-sisting essentially of from about 80 to 95 parts by weight of a second aqueous vinyl acetate copolymer emulsion identical to the first emulsion and from about 5 to about 20 parts by weight of a second acrylic ester homopolymer or copolymer identical to the first acrylic ester homopolymer or copolymer over said first adhesive coat;
(4) drying said second adhesive coat at a temperature of from about 30°C to about 177°C;
(5) heating the so coated substrate to about 121°C
and (6) applying, under pressure, a vinyl film of from about 1 to about 10 mils to the heated, adhesive coated substrate to form a laminate; wherein the first and second vinyl acetate copolymers are copolymers of vinyl acetate and an unsaturated monomer copolymerizable therewith, said vinyl acetate consti-tuting from about 20% to about 30% by weight of the copolymer.
ii) drying the adhesive; and iii) adhering a vinyl film to the adhesive under elevated temperature and pressure, characterized by (1) applying a first resinous adhesive coat to said substrate, said resinous adhesive being a composition consisting essentially of from about 80 to about 95 parts by weight of a first aqueous vinyl acetate copolymer emulsion and from about 5 to about 20 parts by weight of a first acrylic ester homo-polymer or copolymer;
(2) drying said first adhesive coat at a temperature of from about 38°C to about 177°C;
(3) applying a second resinous adhesive coat con-sisting essentially of from about 80 to 95 parts by weight of a second aqueous vinyl acetate copolymer emulsion identical to the first emulsion and from about 5 to about 20 parts by weight of a second acrylic ester homopolymer or copolymer identical to the first acrylic ester homopolymer or copolymer over said first adhesive coat;
(4) drying said second adhesive coat at a temperature of from about 30°C to about 177°C;
(5) heating the so coated substrate to about 121°C
and (6) applying, under pressure, a vinyl film of from about 1 to about 10 mils to the heated, adhesive coated substrate to form a laminate; wherein the first and second vinyl acetate copolymers are copolymers of vinyl acetate and an unsaturated monomer copolymerizable therewith, said vinyl acetate consti-tuting from about 20% to about 30% by weight of the copolymer.
2. A process as in claim 1 wherein the vinyl acetate copolymer emulsion contains about 45% water.
3. A process as in claim 1 wherein the first and second acrylic ester homopolymer or copolymer are each selected from the group of acrylic acid ester homopolymers, methacrylic acid ester homopolymers and copolymers thereof, where the acrylic acid and methacrylic acid are esterified with alcohols selected from the group consisting of polyhydric alcohols and cyclo-aliphatic monyhydric alcohols.
4. The process of claim 1 wherein the first and second resinous adhesive coat additionally contains about 3 to about 10 percent by weight of methyl pyrrolidone.
5. A process as in claim 2 wherein the vinyl acetate copolymer is a vinyl acetate-ethylene copolymer.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US88065478A | 1978-02-23 | 1978-02-23 | |
| US880,654 | 1978-02-23 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1137405A true CA1137405A (en) | 1982-12-14 |
Family
ID=25376775
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000317695A Expired CA1137405A (en) | 1978-02-23 | 1978-12-11 | Laminating vinyl film to wood via two adhesive coats |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1137405A (en) |
-
1978
- 1978-12-11 CA CA000317695A patent/CA1137405A/en not_active Expired
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |