CA2247267A1 - Method for producing laminated articles - Google Patents
Method for producing laminated articles Download PDFInfo
- Publication number
- CA2247267A1 CA2247267A1 CA002247267A CA2247267A CA2247267A1 CA 2247267 A1 CA2247267 A1 CA 2247267A1 CA 002247267 A CA002247267 A CA 002247267A CA 2247267 A CA2247267 A CA 2247267A CA 2247267 A1 CA2247267 A1 CA 2247267A1
- Authority
- CA
- Canada
- Prior art keywords
- resin
- laminate
- coating
- gasket
- film
- 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.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
- B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
- B44C5/0423—Ornamental plaques, e.g. decorative panels, decorative veneers containing fibreglass elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
- B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
- B44C5/043—Ornamental plaques, e.g. decorative panels, decorative veneers containing wooden elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44F—SPECIAL DESIGNS OR PICTURES
- B44F9/00—Designs imitating natural patterns
- B44F9/04—Designs imitating natural patterns of stone surfaces, e.g. marble
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
- C04B26/02—Macromolecular compounds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/005—Processes for mixing polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/30—Fillers, e.g. particles, powders, beads, flakes, spheres, chips
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2317/00—Animal or vegetable based
- B32B2317/16—Wood, e.g. woodboard, fibreboard, woodchips
Abstract
The subject invention provides a method for producing a laminated article and the laminated article resulting from such method which comprises contacting a rigid substrate (8) with a plastic material (7) in a liquid or semi-liquid state, the plastic material being held in place by a gasket (9) or spacer and in contact with a flexible film (6) and maintaining contact between the substrate (8) and plastic material (7) under conditions so that the plastic material (7) hardens and adheres to the substrate (8) to form the article. The invention also concerns a plastic edge piece (18) which may be cast and attached to the exposed edges of the laminated article and which has the same appearance as the plastic laminate.
Description
"METHOD FOR PRODUCING
LAMINATED ARTICLES"
R~rk~rolln~ of the ll~v~-~tion This application is a continuation of Serial No. 08/206,810 filed March 4, 1994, now U.S. Patent No. 5,504,126; and a continuation-in-part of Serial No. 08/219,335, filed March 29, 1994, abandoned in favor of Serial No. 08/347,278, filed November 30, 1994.
Serial No. 08t206,81Q itself is a co~tim)~tion-in-part of Serial No. 07/882,839 filed May 15, 1992, now U.S. Patent No. 5,304,592; Serial No. 08/51,627 filed April 22, 1993, now U.S. Patent No. 5,476,89; and Serial No. 08/35,720 filed March 23, 1993. Both Serial Nos. 07/822,839 and 08/51,627 are in turn co~ ions-in-part of Serial No. 07/788,982 filed November 7, 1991, now ~nt10n~l. The co..l~ of the above referenced appli~ n.c are hereby incorporated by reference into the present disclosure.
The subject invention relates generally to a method of plc~ g la~ A1~1 boards, 15 sheets or articles -- useful as partitions, shelves, cou"l~.lo~s and bathroom vanities -which is more eco..l~..ie~l and less labor-intencive than eYictin~ methotlc The present method also enables a consumer to purchase standard size l~...il.~t~d boards, sheets or articles, customize the shape of the l~min~te for the con~m~r'S individual use, and join the articles to provide a finished look without the need of professional ~ict~nee. One aspect of the invention 20 provides a method of m~nuf~ture of an article which comprises a substrate and a plastic coating. The plastic coating may be an in situ polymerized thermoplastic or thermoset material l~min~tf d to any rigid substrate but preferably a cellulosic product such as wood or particle board. Where a mineral-like appearance is desired, the subject invention may utilize the compositions disclosed in my earlier patent applications, which have the appearance of 25 natural stone.
SU~3 111 UTE SHEET (RULE 26) W O 98/30391 PCTrUS97/00130 Another aspect of the invention provides a plastic edge piece which is ~tt~r.hed to the exposed wood edges of the coated article of the present invention after being cut by the consumer. Generally the plastic edge piece is made of the same plastic material as is l~min~tecl to the substrate. The collsul-ler conceals the edge piece and seams between adjacent coated boards by applying additional plastic m~t.o.ri~l in liquid form. After curing, the area of the applied plastic is then sanded for smoothness.
The present invention also provides a method for producing coated ~ul~ tes and l~min~tes in which the surface smoothness and ~pedl~lce can be controlled to any desired form. The present invention is particularly useful for the production of l~min~tes comprising a surface layer of a highly filled thermoplastic or thermoset resin having a mineral appearance on a rigid support.
The subject invention also has several economic advantages. First, it uses existing machinery, namely l~min~ting or co~ ssion molding machines. Second, the product is m~ .r~ ...Gd in a way to ...i~ i7e the labor involved in cu~lollli;~illg the articles and s~nrling. Third, the l~nin~tes are made without the use of solvents which can constitute an 20 environmental hazard unless expensive l~eca~tulh.g techniques are used.
Brief D~ lion of Drawinps Figure 1 illustrates the use of a 4' x 8' x 518" particle board as the substrate in the l~min~te using 1/2" x 0.07" cardboard strips to form the gasket (2) which is preferably stapled 25 (3) to the board. Channels (4) allow excess casting resin to flow from the mold.
Figure 2 illustrates the molding process of this invention in which a thin plastic film (6) is stretched over a shim or platen (5) of a molding press. The flowable casting or coating W O 98/30391 PCT~US97/00130 5 resin (7) is placed on top of the film (6) and if desired can be smoothed using a doctor blade.
The substrate (8) with the gasket (9) ~ttaçll~d is lowered on the spread resin (7) and the assembly is co~llpl~ssed between the platens (5). The assembly is then heated to cure the resin and adhere the resin to the substrate.
Figure 3 illustrates the process of the present invention in which the casting resin is lO applied to both major surfaces of a substrate. Thus in an addition to the film (6), resin (7) and gasket (9) attached to the substrate (8) a second gasket (10) is ~tt~.hÇd to the opposing major surface of the substrate (8) to contain the second application of resin (1 1 ) on top of which is stretched the plastic film (12) in contact with the platen or shim (5) ofthe molding press.
Figure 4 illustrates a l~min~te (1) COlll~liSillg a board (16) with surface coatings on 15 opposite sides (17) to which is ~tt~clled an edge piece (18) pre-cast from the same composition as the coating, by means of dowels (19).
Figures 5, 6 and 7 show edge pieces in cross section fini~hed in various shapes by the customer or pre-fini~h~l by the producer prior to attaehment to a ~ubsll~le.
20 Summary of tbe Invention The subject invention provides a method for producing a pr~folllled, l~min~ted article having a desired surface appearance which comprises cont~sting a substrate with a curable plastic material in a liquid or semi-liquid state, said plastic material being held in place by a gasket or spacer and being in contact with a flexible film, m~ irlg the contact between the 25 substrate, plastic material and the flexible film under conditions such that the plastic material hardens and adheres to the subsllal~, and recovering a 1;....i..;.~ed article having the surface appearance of the flexible film. The present invention also relates to l~min~tes having a wo 98/303gl PCT/US97/00130 S smooth mineral surface al)pe;~lce.
The invention further concerns a plastic edge piece which may be cast separately and attached to the exposed edges of the l~min~ted article and which has the same appearance as the plastic l~min~te 10 Detailed I)esr ;IJtion of the Invention The present invention is based on a coll.pression molding process for the m~nllf~ctllre of a l~min~tçd article which comprises forming a layered structure of a thin flexible film, a polymerizable coating resin or simi}ar flowable coating material, retained in the structure by a compressible gasket, and a substrate, the casting resin being present in sufficient quantity to 15 fill the cavity created by the gasket, the substrate and the film, applying ~ressul~ to the structure and thereafter curing the casting resin or coating material to obtain a l~min~te of substrate and cured casting resin or coating material having the surface appearance of the flexible film. If desired and at times necessary to prevent warping of the substrate during the molding process, a second liquid coating resin or coating material is applied to the opposing 20 surface of the substrate again held in place by a gasket. The coating resin can be the same or dirr~lellt m~teri~l from the one applied to the first substrate. If desired another film is interposed between the liquid coating and the platen of the press.
Once in place in the molding press the liquid casting resin or coating material, gasket and substrate are ~les~ ;7çcl and the coating m~teri~l iS polymerized to completion, normally 25 by heating the coating material to a~ilivale the further polymerization. The res-llting l~rnin~te is removed from the press, together with the film which can be retained on the l~min~te for protection against surface scratches and gouges. Removal of the film provides a coating that WO98/30391 Pcr/uSs7/00130 5 duplicates the surface characteristics of the film and in this way one can obtain l~min~tPd structures with surfaces that require no further working for the intPtlrled use.
The present invention also includes the l~nin~te made by the process of the present invention and particularly l~min~te having co~tin~,C which contain greater than 30% by weight of the coating of a immi~cjhle particulate filler to provide a smooth mineral 1 0 appearance.
The coating employed in the present invention can be a pre-polymerized liquid thermoplastic or thermoset resins. Suitable pre-polymerized or partially polymerized thermoplastic resins include acrylic resins such as polymethyl methylmethacrylate, and methyl methacrylate copolymers such as are obtained by copolymerization with alkyl 15 acrylates, acrylic acid, methacrylic acid, styrene, and acrylic polyesters. Preferably however the coating or casting resins employed in the present invention are thermosettable polymers such as unsaturated polyesters, epoxy resins, polyurethane resins, crosslink~hle acrylic resins and cro~link~hle styrene resins. The prepolymerized resins are employed in liquid form, the liquidity resl~lting inherently from the low molecular weight of the resin or by solution in 20 monomer. of the thP~ sett-ble resins the prerell~d resins are the unsalu~led polyester resins derived from the con-lPn~tion of an aromatic dicarboxylic acid or anhydride such as isophthalic acid with one or more diols such as propylene glycol, neopentyl glycol, ethylene glycol, or diethylene glycol in the presence of an unsaturated dicarboxylic acid or anhydride such as maleic anhydride. The prepolymerized ullsalul~ted polyester is then dissolved in a 25 vinyl monomer such as styrene to form the liquid coating composition. Li4uid u-lsalulated polyesters which can be cured by further polym~ri7~tion to form tough solid coatings are well known in the art, any of which can be used in the present invention as coating materials. The WO 98/30391 PCTtUS97/00130 5 resin, including any filler should have a fluidity at room tel.lpe.~lu.c adequate to fill the cavity created by the gasket, the substrate and the film in the press and also in the event of any excess, flow out of the mold through the ch~nn~!c provided in the gasket. Coating compositions having viscosities in the range of 500 to 40,000 centipoises are suitable in the process of the present invention.
As indicated, the casting resins or coating compositions employed in the present invention are p~crc,~bly filled resin co-..posilions which give the coating an inol~lic mineral surface appearance. Fillers employed in coating compositions to give surfaces having a mineral appearance are well known in the art, having been described in my own patent, U.S.
Patent No. 5,304,592, Nogi et al U.S. Patent No. 5,034,377, and Buser et al U.S. Patent Nos.
4,085,246 and 4,159,301, the te~hingc of which are hereby incorporated by reference.
Particularly p~crc -cd fillers which give rise to a granite surface are separately ~ ,d thermoplastic or thermoset resin composites co~ il-g evenly distributed inorganic particulates. Such composites are then crushed and pulverized to a desired particle size for inclusion in the coating composition. As disclosed in these references, the same type of resin 20 employed as a coating or casting resin can also be employed to form the filler. The plerellcd fillers employed include particulates of thPmoset polyesters and/or acrylic resins col~ llg such powdered illOlgal~iC materials as talc, silica, gypsum, powdered glass, clay, silicates and particularly ahlmin~c including ~h.. i.. ll trihydrate. The fillers can be employed over a wide concentration range from 2% to 70% by weight of the total coating composition but are 25 preferably employed in the range of 30% to 50% by weight of the total coating composition.
The casting resin or coating composition usually also COIll~lillS a catalyst which initiates or accelerates the further polymerization such as a peroxide or similar free-radical initiator. Additionally the coating composition may also contain pigments, u-v light stabilizers, antioxidants, coupling agents and mold release agents.
The flexible film employed between the platens of the press and the casting resin or coating composition provides its surface characteristic to the ree~ ing l~min~te Generally speaking it is desired to produce a l~min~te having a smooth surface that does not require further fini.ching. Such finish is ~ccQmplished by having a thin flexible plastic film which does not adhere to the l~min~te or only adheres slightly so that it can be easily removed from the l~min~te but still adheres sufficiently to serve as a protective layer prior to use of the l~min~te. Plastic films useful in the process of the present invention include polyolefin films, polyvinylidene chloride films and preferably polyester films commercially available under the tr~ n~me "Mylar."
The gasket material can be any solid material including metal, plastic or wood.
Preferably, however, the gasket material can be controllably coll~rcssed to a desired thickness by the application of p,c~u, c used in the molding process. Materials that exhibit a 10% or greater reduction in the molding process have been found to be suitable. One particularly preferred m~terial is cardboard since it can be readily cut to provide the gasket and also can be complessed to the desired thickness considering the limits of its con.plessibility. It also with~t~nfl~ any tcnll)cl~luie enco~l~e,cd in the molding process.
Hard rubber, elastomeric polyolefins and flexible polyurethane foams are also useful as g~ eting m~t.o.ri~l as are many composites made from resins and cellulosic fibers.
The ~ubsl~le to which the coating is applied can be any semi-rigid or rigid m~t~having a surface providing adhesion to the coating or casting resin composition. In general the process of the present invention is used with cellulosic type of material, such as solid WO 98/3039l PCT/US97/00l30 5 wood boards, plywood, balsa sheets, particle boards and related composites co~ g cellulosic fibers. other substrates or cores for the 1~min~te~ of the present invention include high density polyurethane foam, honeycomb structures of reinforced cardboard, fiberglass or carbon fiber reinforced sheets and similar structures. Where the ~ubsll~le is not rigid enough to support the coating as produced in the present invention without warping, it may be 10 desirable to apply a similar or different second coating on the opposig surface of the substrate which can be applied in the same way as the first coating such as illustrated in Figure 3.
The size of sheets employed is only limited by the size of the molding equipment employed and includes, in addition to the 4' x 8' already described sheets, dimensions from less than l' to 12' or more.
The process of the present invention can be con~ cte-1 in any of the commercially available co~l-plession molding presses and p~c~e,ably in one that provides for heating ofthe platens to raise the telllpcl~lul e of the coating layer to allow for rapid curing. Generally spe~'-ing, it is desired to heat the coating composition to a temperature within the range of 70~ to 300~ F. The pl~ Ul~S employed may vary, but generally speaking it is not necess~ry to use ~res~ules in excess of l 00 psi. The process is contin11ed for a time adequate to polymerize subst~nti~lly all of the polymerizable ingredients in the coating or casting resin.
In place of using a second coating on the opposing major surface, the rigidity of a substrate or core can also be enh~nced during the molding process by 1~min~tin~ the opposing surface of the substrate to an additional sheet comprising a composite of a partially cured resin and a fibrous material in which resin cures and adheres to the substrate during the molding process.
WO 98130391 Pcr/uS97/00130 In some inct~nceS, particularly where the l~nin~teS of the present invention areintenrled to be used as countertops, it may be desirable to provide an edge coating for the l~min~te Such edges can be provided in several ways such as by spraying, brushing or otherwise coating the edge of the board with the same composition as was used in forming the l~min~te or there may be used a pre-cast edge or nose strip which is attached to the edge of the l~min~te by means of dowels or similar devices as illustrated in Figure 4. If desired, any visible seam between the l~ e and the edge or nose strip can be additionally coated so that the seam is hidden. In order to ~ , uniformity of al)pea~ ce and plupc~lies the edge piece should be cast from the same composition that is employed for the surface layer of the l~min~te The present invention is further illustrated, but not in any way limited, by thefollowing specific embodiment of the invention.
Over the top of heatable platen of a commercial molding press large enough to ~ccc,....-.odate a 4' x 8' sheet is stretched a two mil commercially available polyester film.
Using a doctor blade, a flowable casting resin having a viscosity of 20,000 centipoises at room temperature (as measured on a R.V.F. 100 Brookfield Viscosimeter using a Springdale #6 spindle at 100 rpm) is evenly spread to a thickness of slightly more than 1/16". The particular flowable casting resin was a cornmercially available ul~saLul~ted polyester composition sold as "Granicoat". The ~l~alulated polyester contained a polymerized resin filler designed to give the coating composition a granite al)pea,~lce. Preparation of such filler is described in my co-pending application SN 08/051,627 filed April 22, 1993 which is hereby incol~o,at~d by reference.
To a 4' x 8' x 5/8" particle board are stapled along the edges of the board 1/2" wide WO 98/30391 PCT~US97/00130 5 0.07" thick cardboard strips forming a gasket to contain the casting resin as illustrated in Figure 1. Channels are provided at the comers of the gasket to allow excess casting resin to flow from the mold. The gasketed surface of the board is placed in contact with the spread resin as illustrated in Figure 2.
The assembly is subjected to a p.~ule of approxim~tely 100 psi and the platen in 10 contact with the resin is heated to a tel,.?e,~lur~ of 200~F. which is i~ .ed for a period of 5 minlltes thereby fully curing and adhering the coating to the board.
The resulting l~min~te contains a 1/16" layer of smooth surfaced granite like m~t~ri~l firmly attached to the particle board with the polyester film adhered to the surface of the co~tin~. The film can be mechanically removed at any time and pler~l~bly is retained to 15 serve as protection for the surface until final use of the board.
The uncoated edges of the particle board can be sawn offor spray coated or brushed with the casting resin to provide a fini~h~cl article. Preferably the uncoated edge portions are sawn off and replaced with a doweled edge piece (illustrated in Figure 4) cast from the same composite as is used for the surface of the l~min~te.
LAMINATED ARTICLES"
R~rk~rolln~ of the ll~v~-~tion This application is a continuation of Serial No. 08/206,810 filed March 4, 1994, now U.S. Patent No. 5,504,126; and a continuation-in-part of Serial No. 08/219,335, filed March 29, 1994, abandoned in favor of Serial No. 08/347,278, filed November 30, 1994.
Serial No. 08t206,81Q itself is a co~tim)~tion-in-part of Serial No. 07/882,839 filed May 15, 1992, now U.S. Patent No. 5,304,592; Serial No. 08/51,627 filed April 22, 1993, now U.S. Patent No. 5,476,89; and Serial No. 08/35,720 filed March 23, 1993. Both Serial Nos. 07/822,839 and 08/51,627 are in turn co~ ions-in-part of Serial No. 07/788,982 filed November 7, 1991, now ~nt10n~l. The co..l~ of the above referenced appli~ n.c are hereby incorporated by reference into the present disclosure.
The subject invention relates generally to a method of plc~ g la~ A1~1 boards, 15 sheets or articles -- useful as partitions, shelves, cou"l~.lo~s and bathroom vanities -which is more eco..l~..ie~l and less labor-intencive than eYictin~ methotlc The present method also enables a consumer to purchase standard size l~...il.~t~d boards, sheets or articles, customize the shape of the l~min~te for the con~m~r'S individual use, and join the articles to provide a finished look without the need of professional ~ict~nee. One aspect of the invention 20 provides a method of m~nuf~ture of an article which comprises a substrate and a plastic coating. The plastic coating may be an in situ polymerized thermoplastic or thermoset material l~min~tf d to any rigid substrate but preferably a cellulosic product such as wood or particle board. Where a mineral-like appearance is desired, the subject invention may utilize the compositions disclosed in my earlier patent applications, which have the appearance of 25 natural stone.
SU~3 111 UTE SHEET (RULE 26) W O 98/30391 PCTrUS97/00130 Another aspect of the invention provides a plastic edge piece which is ~tt~r.hed to the exposed wood edges of the coated article of the present invention after being cut by the consumer. Generally the plastic edge piece is made of the same plastic material as is l~min~tecl to the substrate. The collsul-ler conceals the edge piece and seams between adjacent coated boards by applying additional plastic m~t.o.ri~l in liquid form. After curing, the area of the applied plastic is then sanded for smoothness.
The present invention also provides a method for producing coated ~ul~ tes and l~min~tes in which the surface smoothness and ~pedl~lce can be controlled to any desired form. The present invention is particularly useful for the production of l~min~tes comprising a surface layer of a highly filled thermoplastic or thermoset resin having a mineral appearance on a rigid support.
The subject invention also has several economic advantages. First, it uses existing machinery, namely l~min~ting or co~ ssion molding machines. Second, the product is m~ .r~ ...Gd in a way to ...i~ i7e the labor involved in cu~lollli;~illg the articles and s~nrling. Third, the l~nin~tes are made without the use of solvents which can constitute an 20 environmental hazard unless expensive l~eca~tulh.g techniques are used.
Brief D~ lion of Drawinps Figure 1 illustrates the use of a 4' x 8' x 518" particle board as the substrate in the l~min~te using 1/2" x 0.07" cardboard strips to form the gasket (2) which is preferably stapled 25 (3) to the board. Channels (4) allow excess casting resin to flow from the mold.
Figure 2 illustrates the molding process of this invention in which a thin plastic film (6) is stretched over a shim or platen (5) of a molding press. The flowable casting or coating W O 98/30391 PCT~US97/00130 5 resin (7) is placed on top of the film (6) and if desired can be smoothed using a doctor blade.
The substrate (8) with the gasket (9) ~ttaçll~d is lowered on the spread resin (7) and the assembly is co~llpl~ssed between the platens (5). The assembly is then heated to cure the resin and adhere the resin to the substrate.
Figure 3 illustrates the process of the present invention in which the casting resin is lO applied to both major surfaces of a substrate. Thus in an addition to the film (6), resin (7) and gasket (9) attached to the substrate (8) a second gasket (10) is ~tt~.hÇd to the opposing major surface of the substrate (8) to contain the second application of resin (1 1 ) on top of which is stretched the plastic film (12) in contact with the platen or shim (5) ofthe molding press.
Figure 4 illustrates a l~min~te (1) COlll~liSillg a board (16) with surface coatings on 15 opposite sides (17) to which is ~tt~clled an edge piece (18) pre-cast from the same composition as the coating, by means of dowels (19).
Figures 5, 6 and 7 show edge pieces in cross section fini~hed in various shapes by the customer or pre-fini~h~l by the producer prior to attaehment to a ~ubsll~le.
20 Summary of tbe Invention The subject invention provides a method for producing a pr~folllled, l~min~ted article having a desired surface appearance which comprises cont~sting a substrate with a curable plastic material in a liquid or semi-liquid state, said plastic material being held in place by a gasket or spacer and being in contact with a flexible film, m~ irlg the contact between the 25 substrate, plastic material and the flexible film under conditions such that the plastic material hardens and adheres to the subsllal~, and recovering a 1;....i..;.~ed article having the surface appearance of the flexible film. The present invention also relates to l~min~tes having a wo 98/303gl PCT/US97/00130 S smooth mineral surface al)pe;~lce.
The invention further concerns a plastic edge piece which may be cast separately and attached to the exposed edges of the l~min~ted article and which has the same appearance as the plastic l~min~te 10 Detailed I)esr ;IJtion of the Invention The present invention is based on a coll.pression molding process for the m~nllf~ctllre of a l~min~tçd article which comprises forming a layered structure of a thin flexible film, a polymerizable coating resin or simi}ar flowable coating material, retained in the structure by a compressible gasket, and a substrate, the casting resin being present in sufficient quantity to 15 fill the cavity created by the gasket, the substrate and the film, applying ~ressul~ to the structure and thereafter curing the casting resin or coating material to obtain a l~min~te of substrate and cured casting resin or coating material having the surface appearance of the flexible film. If desired and at times necessary to prevent warping of the substrate during the molding process, a second liquid coating resin or coating material is applied to the opposing 20 surface of the substrate again held in place by a gasket. The coating resin can be the same or dirr~lellt m~teri~l from the one applied to the first substrate. If desired another film is interposed between the liquid coating and the platen of the press.
Once in place in the molding press the liquid casting resin or coating material, gasket and substrate are ~les~ ;7çcl and the coating m~teri~l iS polymerized to completion, normally 25 by heating the coating material to a~ilivale the further polymerization. The res-llting l~rnin~te is removed from the press, together with the film which can be retained on the l~min~te for protection against surface scratches and gouges. Removal of the film provides a coating that WO98/30391 Pcr/uSs7/00130 5 duplicates the surface characteristics of the film and in this way one can obtain l~min~tPd structures with surfaces that require no further working for the intPtlrled use.
The present invention also includes the l~nin~te made by the process of the present invention and particularly l~min~te having co~tin~,C which contain greater than 30% by weight of the coating of a immi~cjhle particulate filler to provide a smooth mineral 1 0 appearance.
The coating employed in the present invention can be a pre-polymerized liquid thermoplastic or thermoset resins. Suitable pre-polymerized or partially polymerized thermoplastic resins include acrylic resins such as polymethyl methylmethacrylate, and methyl methacrylate copolymers such as are obtained by copolymerization with alkyl 15 acrylates, acrylic acid, methacrylic acid, styrene, and acrylic polyesters. Preferably however the coating or casting resins employed in the present invention are thermosettable polymers such as unsaturated polyesters, epoxy resins, polyurethane resins, crosslink~hle acrylic resins and cro~link~hle styrene resins. The prepolymerized resins are employed in liquid form, the liquidity resl~lting inherently from the low molecular weight of the resin or by solution in 20 monomer. of the thP~ sett-ble resins the prerell~d resins are the unsalu~led polyester resins derived from the con-lPn~tion of an aromatic dicarboxylic acid or anhydride such as isophthalic acid with one or more diols such as propylene glycol, neopentyl glycol, ethylene glycol, or diethylene glycol in the presence of an unsaturated dicarboxylic acid or anhydride such as maleic anhydride. The prepolymerized ullsalul~ted polyester is then dissolved in a 25 vinyl monomer such as styrene to form the liquid coating composition. Li4uid u-lsalulated polyesters which can be cured by further polym~ri7~tion to form tough solid coatings are well known in the art, any of which can be used in the present invention as coating materials. The WO 98/30391 PCTtUS97/00130 5 resin, including any filler should have a fluidity at room tel.lpe.~lu.c adequate to fill the cavity created by the gasket, the substrate and the film in the press and also in the event of any excess, flow out of the mold through the ch~nn~!c provided in the gasket. Coating compositions having viscosities in the range of 500 to 40,000 centipoises are suitable in the process of the present invention.
As indicated, the casting resins or coating compositions employed in the present invention are p~crc,~bly filled resin co-..posilions which give the coating an inol~lic mineral surface appearance. Fillers employed in coating compositions to give surfaces having a mineral appearance are well known in the art, having been described in my own patent, U.S.
Patent No. 5,304,592, Nogi et al U.S. Patent No. 5,034,377, and Buser et al U.S. Patent Nos.
4,085,246 and 4,159,301, the te~hingc of which are hereby incorporated by reference.
Particularly p~crc -cd fillers which give rise to a granite surface are separately ~ ,d thermoplastic or thermoset resin composites co~ il-g evenly distributed inorganic particulates. Such composites are then crushed and pulverized to a desired particle size for inclusion in the coating composition. As disclosed in these references, the same type of resin 20 employed as a coating or casting resin can also be employed to form the filler. The plerellcd fillers employed include particulates of thPmoset polyesters and/or acrylic resins col~ llg such powdered illOlgal~iC materials as talc, silica, gypsum, powdered glass, clay, silicates and particularly ahlmin~c including ~h.. i.. ll trihydrate. The fillers can be employed over a wide concentration range from 2% to 70% by weight of the total coating composition but are 25 preferably employed in the range of 30% to 50% by weight of the total coating composition.
The casting resin or coating composition usually also COIll~lillS a catalyst which initiates or accelerates the further polymerization such as a peroxide or similar free-radical initiator. Additionally the coating composition may also contain pigments, u-v light stabilizers, antioxidants, coupling agents and mold release agents.
The flexible film employed between the platens of the press and the casting resin or coating composition provides its surface characteristic to the ree~ ing l~min~te Generally speaking it is desired to produce a l~min~te having a smooth surface that does not require further fini.ching. Such finish is ~ccQmplished by having a thin flexible plastic film which does not adhere to the l~min~te or only adheres slightly so that it can be easily removed from the l~min~te but still adheres sufficiently to serve as a protective layer prior to use of the l~min~te. Plastic films useful in the process of the present invention include polyolefin films, polyvinylidene chloride films and preferably polyester films commercially available under the tr~ n~me "Mylar."
The gasket material can be any solid material including metal, plastic or wood.
Preferably, however, the gasket material can be controllably coll~rcssed to a desired thickness by the application of p,c~u, c used in the molding process. Materials that exhibit a 10% or greater reduction in the molding process have been found to be suitable. One particularly preferred m~terial is cardboard since it can be readily cut to provide the gasket and also can be complessed to the desired thickness considering the limits of its con.plessibility. It also with~t~nfl~ any tcnll)cl~luie enco~l~e,cd in the molding process.
Hard rubber, elastomeric polyolefins and flexible polyurethane foams are also useful as g~ eting m~t.o.ri~l as are many composites made from resins and cellulosic fibers.
The ~ubsl~le to which the coating is applied can be any semi-rigid or rigid m~t~having a surface providing adhesion to the coating or casting resin composition. In general the process of the present invention is used with cellulosic type of material, such as solid WO 98/3039l PCT/US97/00l30 5 wood boards, plywood, balsa sheets, particle boards and related composites co~ g cellulosic fibers. other substrates or cores for the 1~min~te~ of the present invention include high density polyurethane foam, honeycomb structures of reinforced cardboard, fiberglass or carbon fiber reinforced sheets and similar structures. Where the ~ubsll~le is not rigid enough to support the coating as produced in the present invention without warping, it may be 10 desirable to apply a similar or different second coating on the opposig surface of the substrate which can be applied in the same way as the first coating such as illustrated in Figure 3.
The size of sheets employed is only limited by the size of the molding equipment employed and includes, in addition to the 4' x 8' already described sheets, dimensions from less than l' to 12' or more.
The process of the present invention can be con~ cte-1 in any of the commercially available co~l-plession molding presses and p~c~e,ably in one that provides for heating ofthe platens to raise the telllpcl~lul e of the coating layer to allow for rapid curing. Generally spe~'-ing, it is desired to heat the coating composition to a temperature within the range of 70~ to 300~ F. The pl~ Ul~S employed may vary, but generally speaking it is not necess~ry to use ~res~ules in excess of l 00 psi. The process is contin11ed for a time adequate to polymerize subst~nti~lly all of the polymerizable ingredients in the coating or casting resin.
In place of using a second coating on the opposing major surface, the rigidity of a substrate or core can also be enh~nced during the molding process by 1~min~tin~ the opposing surface of the substrate to an additional sheet comprising a composite of a partially cured resin and a fibrous material in which resin cures and adheres to the substrate during the molding process.
WO 98130391 Pcr/uS97/00130 In some inct~nceS, particularly where the l~nin~teS of the present invention areintenrled to be used as countertops, it may be desirable to provide an edge coating for the l~min~te Such edges can be provided in several ways such as by spraying, brushing or otherwise coating the edge of the board with the same composition as was used in forming the l~min~te or there may be used a pre-cast edge or nose strip which is attached to the edge of the l~min~te by means of dowels or similar devices as illustrated in Figure 4. If desired, any visible seam between the l~ e and the edge or nose strip can be additionally coated so that the seam is hidden. In order to ~ , uniformity of al)pea~ ce and plupc~lies the edge piece should be cast from the same composition that is employed for the surface layer of the l~min~te The present invention is further illustrated, but not in any way limited, by thefollowing specific embodiment of the invention.
Over the top of heatable platen of a commercial molding press large enough to ~ccc,....-.odate a 4' x 8' sheet is stretched a two mil commercially available polyester film.
Using a doctor blade, a flowable casting resin having a viscosity of 20,000 centipoises at room temperature (as measured on a R.V.F. 100 Brookfield Viscosimeter using a Springdale #6 spindle at 100 rpm) is evenly spread to a thickness of slightly more than 1/16". The particular flowable casting resin was a cornmercially available ul~saLul~ted polyester composition sold as "Granicoat". The ~l~alulated polyester contained a polymerized resin filler designed to give the coating composition a granite al)pea,~lce. Preparation of such filler is described in my co-pending application SN 08/051,627 filed April 22, 1993 which is hereby incol~o,at~d by reference.
To a 4' x 8' x 5/8" particle board are stapled along the edges of the board 1/2" wide WO 98/30391 PCT~US97/00130 5 0.07" thick cardboard strips forming a gasket to contain the casting resin as illustrated in Figure 1. Channels are provided at the comers of the gasket to allow excess casting resin to flow from the mold. The gasketed surface of the board is placed in contact with the spread resin as illustrated in Figure 2.
The assembly is subjected to a p.~ule of approxim~tely 100 psi and the platen in 10 contact with the resin is heated to a tel,.?e,~lur~ of 200~F. which is i~ .ed for a period of 5 minlltes thereby fully curing and adhering the coating to the board.
The resulting l~min~te contains a 1/16" layer of smooth surfaced granite like m~t~ri~l firmly attached to the particle board with the polyester film adhered to the surface of the co~tin~. The film can be mechanically removed at any time and pler~l~bly is retained to 15 serve as protection for the surface until final use of the board.
The uncoated edges of the particle board can be sawn offor spray coated or brushed with the casting resin to provide a fini~h~cl article. Preferably the uncoated edge portions are sawn off and replaced with a doweled edge piece (illustrated in Figure 4) cast from the same composite as is used for the surface of the l~min~te.
Claims
What Is Claimed is:
1) A method for producing a laminated article which comprises forming a laminate comprising a rigid substrate, a polymerizable flowable thermosetting resin composition, said resin containing an immiscible solid filler and being held in place by a gasket and a flexible thin film, placing said laminate in a molding press under sufficient pressure to obtain the desired resin layer thickness, maintaining the said laminate in said press under polymerization conditions until essentially completely polymerized and recovering a laminated article comprising a rigid substrate, a thermoset resin composition and a flexible thin film.
2) The method of claim 1 wherein the polymerizable flowable thermosetting resin composition is a filled unsaturated polyester resin.
3) The method of claim 1 wherein the substrate comprises a wood product.
4) The method of claim 2 wherein the polyester resin contains from 30% to 70% by weight of the total composition of a filler resulting in a surface having a mineral appearance.
5) The method of claim 1 wherein the thin flexible film is a polyester film.
6) The method of claim 1 wherein a flowable thermosetting polymerizable resin gasket and flexible film is applied to two opposing surfaces of the rigid substrate.
7) The method of claim 3 wherein the wood product is a particle board.
8) The method of claim 1 wherein the gasket is compressible at the molding pressures.
9) A laminate comprising a particle board having at least one of its major surfaces coated with a filled thermoset plastic composition containing a filler to provide a mineral appearance to the surface of the coating and a protective film for that coating said laminate having been molded to said board.
10) The laminate of claim 9 wherein the plastic composition is obtained by the further polymerization of an unsaturated polyester resin.
11) The laminate of claim 9 wherein at least one edge of the board is attached to a pre-cast edge piece of the same filled plastic composition.
12) The laminate of claim 10 wherein the protective film is a polyester film.
13) A method of preparing countertop articles which comprises forming a laminate comprising a rigid cellulosic fiber board at least one major surface of which being in contact with a liquid unsaturated polymerizable polyester resin, said resin containing from 30% to 70% by weight of the total composition of a thermoset resin filler providing a mineral appearance, said resin being held in place by a cardboard gasket and a flexible film placing said laminate in a molding press under sufficient pressure to cause the resin to fill the cavity created by the gasket and obtain the desired resin layer thickness, heating the resin layer to a temperature of 70° to 300° F, and recovering a laminate of said fiber board, fully polymerized, thermoset polyester coating and flexible film.
1) A method for producing a laminated article which comprises forming a laminate comprising a rigid substrate, a polymerizable flowable thermosetting resin composition, said resin containing an immiscible solid filler and being held in place by a gasket and a flexible thin film, placing said laminate in a molding press under sufficient pressure to obtain the desired resin layer thickness, maintaining the said laminate in said press under polymerization conditions until essentially completely polymerized and recovering a laminated article comprising a rigid substrate, a thermoset resin composition and a flexible thin film.
2) The method of claim 1 wherein the polymerizable flowable thermosetting resin composition is a filled unsaturated polyester resin.
3) The method of claim 1 wherein the substrate comprises a wood product.
4) The method of claim 2 wherein the polyester resin contains from 30% to 70% by weight of the total composition of a filler resulting in a surface having a mineral appearance.
5) The method of claim 1 wherein the thin flexible film is a polyester film.
6) The method of claim 1 wherein a flowable thermosetting polymerizable resin gasket and flexible film is applied to two opposing surfaces of the rigid substrate.
7) The method of claim 3 wherein the wood product is a particle board.
8) The method of claim 1 wherein the gasket is compressible at the molding pressures.
9) A laminate comprising a particle board having at least one of its major surfaces coated with a filled thermoset plastic composition containing a filler to provide a mineral appearance to the surface of the coating and a protective film for that coating said laminate having been molded to said board.
10) The laminate of claim 9 wherein the plastic composition is obtained by the further polymerization of an unsaturated polyester resin.
11) The laminate of claim 9 wherein at least one edge of the board is attached to a pre-cast edge piece of the same filled plastic composition.
12) The laminate of claim 10 wherein the protective film is a polyester film.
13) A method of preparing countertop articles which comprises forming a laminate comprising a rigid cellulosic fiber board at least one major surface of which being in contact with a liquid unsaturated polymerizable polyester resin, said resin containing from 30% to 70% by weight of the total composition of a thermoset resin filler providing a mineral appearance, said resin being held in place by a cardboard gasket and a flexible film placing said laminate in a molding press under sufficient pressure to cause the resin to fill the cavity created by the gasket and obtain the desired resin layer thickness, heating the resin layer to a temperature of 70° to 300° F, and recovering a laminate of said fiber board, fully polymerized, thermoset polyester coating and flexible film.
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002247267A CA2247267A1 (en) | 1991-11-07 | 1997-01-06 | Method for producing laminated articles |
| EP97902839A EP0912343A1 (en) | 1991-11-07 | 1997-01-06 | Method for producing laminated articles |
| PCT/US1997/000130 WO1998030391A1 (en) | 1991-11-07 | 1997-01-06 | Method for producing laminated articles |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US78898291A | 1991-11-07 | 1991-11-07 | |
| CA002247267A CA2247267A1 (en) | 1991-11-07 | 1997-01-06 | Method for producing laminated articles |
| CN 97193657 CN1215369A (en) | 1997-01-06 | 1997-01-06 | Method for producing laminated articles |
| PCT/US1997/000130 WO1998030391A1 (en) | 1991-11-07 | 1997-01-06 | Method for producing laminated articles |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2247267A1 true CA2247267A1 (en) | 1998-07-16 |
Family
ID=27427467
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002247267A Abandoned CA2247267A1 (en) | 1991-11-07 | 1997-01-06 | Method for producing laminated articles |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2247267A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2005023560A2 (en) * | 2003-09-03 | 2005-03-17 | Weber Et Broutin France | Molding element, production thereof and installation method therefor |
-
1997
- 1997-01-06 CA CA002247267A patent/CA2247267A1/en not_active Abandoned
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2005023560A2 (en) * | 2003-09-03 | 2005-03-17 | Weber Et Broutin France | Molding element, production thereof and installation method therefor |
| WO2005023560A3 (en) * | 2003-09-03 | 2005-06-09 | Weber & Broutin Sa | Molding element, production thereof and installation method therefor |
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