CN1295923A - 控制层压板光泽的方法 - Google Patents
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Abstract
公开了一种形成光泽性装饰层压板的方法。该方法通过如下步骤实现:叠置一具有顶层的装饰层压板组合体、流延其中聚丙烯隔离片材用以改进所得装饰层压板的光泽特性的方式处理的骤冷辊处理的聚丙烯隔离片材、将聚丙烯隔离片材放置在装饰层压板组合体的顶层上、对装饰层压板组合体和聚丙烯隔离片材加热加压以足以使装饰层压板粘结并使聚丙烯隔离片材与装饰层压板组合体的顶层可剥离地粘结及从装饰层压板组合体的顶层除去聚丙烯隔离片材以得到具有理想的光泽特性的装饰层压板。
Description
本申请为1998年6月5日提交、题为“纹理隔离片材,用其制造纹理装饰层压板的方法以及包括该片材的装饰层压叠层板”且现悬置的美国专利申请流水号09/092480的部分继续申请。
本发明涉及装饰层压板。更具体而言,本发明涉及一种生产光泽性装饰层压板的方法以及使用流延的聚丙烯隔离片材控制层压板光泽的方法。
高压装饰层压板目前被制造成具有光滑的光泽性表面、纹理表面或深度雕刻和压花的表面。作为常规的背景知识,由热压压固制备的装饰层压板已工业生产很多年且广泛用于建筑和家具行业,作为柜台和桌子顶部、浴室和厨房工作表面、护墙板、铺地产品、间壁和门。这些装饰层压板可以描述为含有许多薄板,这些薄板经压固形成带有表面装饰的单元结构。该表面装饰可以象单色一样简单到象压花仿木纹装饰一样复杂。
装饰层压板一般包含多层合成树脂浸渍的纸板,其经热压粘结形成单元结构。在通常的实践中,装饰层压板组合体从下至上包括一个由一个或多个用酚醛树脂浸渍的片材组成的芯,其上是用密胺树脂浸渍的装饰片材。该装饰片材可以进一步用密胺浸渍的贴面层覆盖。该芯或基件用来赋予层压板以刚性且通常包括固体基材,该基材可以在或不在最初的层压步骤之前形成。在叠置之前,芯件片材用苯酚甲醛树脂的水醇溶液浸渍,干燥并在热烘箱中部分固化,最后切割成片材。
该芯例如包括多张90-150磅的酚醛树脂浸渍的牛皮纸片材和基材。牛皮纸用基本完全固化的酚醛树脂彻底浸渍并粘结(所述树脂已在最初的层压步骤中转化为热固性状态)。基材可以是预固化的塑料层压板如玻璃纤维增强的热固性聚酯树脂层压板等,木制品如硬纤维板、废木屑或碎料板、胶合板等,矿质基板如水泥-石棉板、石膏板、糊墙纸板等,或这些基材的组合。
装饰片材使层压板具有吸引性外观。装饰片材也决定装饰层压板的表面特性。例如装饰片材的组成决定装饰层压板的耐化学试剂性、耐热性、耐光性、抗震性和耐磨性。装饰片材通常由高质量50-125令重的、颜料填充的且已用密胺-甲醛树脂的水醇溶液浸渍的α纤维素纸张制造。然后将树脂浸渍的装饰片材干燥、部分固化并最后切割成片材。装饰片材的颜料填充的α纤维素纸张可包括单色、装饰性设计或天然材料如木材、大理石、皮革等的照相凹版印刷复制品。纤维素纸张的美学特性由装饰层压板制成时该层压板的装饰性设计展现。
装饰层压板通常通过将树脂浸渍的芯和装饰片材置于钢板之间并将层压叠置体在约800-1600psi范围的压力下处理足以压固该层压板和固化该树脂的时间(一般约25分钟至1小时)而得到。压力和热使得纸片材中的树脂发生流动,固化并压实各片材成为单一的层压体,这在本领域中称为装饰高压层压板。最后,将形成的装饰层压板粘结于增强基材如胶合板、硬纤维板、石棉板、碎料板等上。
通常,一次形成不只一个层压板。通过在一个叠置体中插入多个组合片材形成多重层压板。在组合片材之间设置隔离片材以分隔叠置在一起的各层压板。在压固之后,隔离片材允许各层压板分离。
近年来,纹理装饰层压板已变得越来越流行。纹理表面的范围从较浅的凹陷,如纹理(例如缎面、无光和半光泽)表面,到较深雕刻或压花的表面,后者具有显著的三维效果,如木纹、皮革、板岩、抽象图案、创造性设计等。在制造光泽纹理性装饰层压板的情况下,目前需要非常昂贵的技术以确保所需的纹理和光泽被赋予装饰层压板。
尽管其物理特性、制造的容易性和其费用长久以来已经使得聚丙烯成为在装饰层压板的生产中用作隔离片材的理想材料,但历史上看聚丙烯隔离片材产生的装饰层压板具有有限的光泽。例如,流延的聚丙烯隔离片材历史上看已生产出较无光的装饰层压板,其层压板光泽度小于6。类似地,吹塑的聚丙烯隔离片材通常仅产生约为10-12的光泽度。
因此,仍然需要一种生产具有优异的光泽特性的装饰层压板的方法和设备。本发明提供了如此一种方法和设备。
因此本发明的目的是提供一种形成光泽性装饰层压板的方法。该方法通过如下步骤实现:叠置一具有顶层的装饰层压板组合体、流延其中聚丙烯隔离片材用以改进所得装饰层压板的光泽特性的方式处理的骤冷辊处理的聚丙烯隔离片材、将聚丙烯隔离片材放置在装饰层压板组合体的顶层上、对装饰层压板组合体和聚丙烯隔离片材加热加压以足以使装饰层压板粘结并使聚丙烯隔离片材与装饰层压板组合体的顶层可剥离地粘结以及从装饰层压板组合体的顶层除去聚丙烯隔离片材以得到具有理想的光泽特性的装饰层压板。
本发明还有一个目的是提供一种装饰层压叠层板,包括具有顶层的装饰层压板组合体和施用于装饰层压板组合体顶层的聚丙烯隔离片材。该聚丙烯隔离片材为用以改进所得装饰层压板的光泽特性的方式处理的骤冷辊处理的流延聚丙烯隔离片材。
本发明还有一个目的是提供一种装饰层压板,其按照上述方法制造。
本发明的其他目的和优点从下列描述和与其结合的附图可以更加明了,这些附图说明了本发明的一些实施方案。
图1为本发明包括聚丙烯隔离片材的层压叠层板的示意图。
图2为加压和加热后的层压叠层板的示意图。
图3为所得装饰层压板的示意图。
本发明的详细实施方案公开如下。但应该理解的是,所公开的实施方案仅仅举例说明本发明,且本发明可以各种形式具体化。因此,本文公开的详情不应解释为限制性的,而仅仅是权利要求书的基础和教导本领域熟练技术人员如何制造和/或使用本发明的基础。
参照图1,公开了包括装饰层压板组合体10和聚丙烯隔离片材12的装饰层压叠层板1。装饰层压叠层板1用于制造本发明的光泽性装饰层压板18。
装饰层压叠层板1通过首先叠置具有顶层14的装饰层压板组合体10而组合。也就是说,用于生产装饰层压板的各片材被叠置以备用于压实该层压板的加热和加压步骤。还流延聚丙烯隔离片材12。聚丙烯隔离片材12用以改进所得装饰层压板的光泽特性的方式涂敷的骤冷辊处理。然后将聚丙烯隔离片材12放置于层压板组合体10的顶层14上,形成层压叠层板1,并对层压板组合体/聚丙烯隔离片材16加热和加压以足以粘结装饰层压板组合体10的各层并使聚丙烯隔离片材12与装饰层压板组合体10的顶层14可剥离地粘结(见图2)。最后,从所形成的装饰层压板18的顶层14上除去聚丙烯隔离片材12以得到具有所需光泽特性的装饰层压板(见图3)。在大多数情况下,控制光泽度以生产约为10-30的光泽性层压板。然而,因为层压板的所需光泽度变化,所以可以任何理想的方式控制光泽度且不必得到保持在本发明范围内的约为10-30的层压板光泽度。
装饰层压板18可以是本领域熟练技术人员熟知的许多树脂基装饰层压板中的任一种。根据本发明的一个实施方案且如上所讨论的,装饰层压板18包括装饰性片材或顶层14和芯20,如图3所示。
更具体地说,装饰层压板18包括一个由一层或多层酚醛树脂浸渍的牛皮纸20a组成的芯20和一个由印花层22和密胺贴面层24组成的装饰性片材14,密胺贴面层24中掺有Al2O3以改进耐磨性。如上所讨论的,基材可以随后与最终的装饰层压板18粘结而赋予层压板以刚性;例如基材可以选自多种材料,即胶合板、碎料板、刨花板、中密度纤维板等。尽管优选的装饰层压板如上所公开,但在不背离本发明精神的前提下可以使用宽范围的装饰层压板。
正如本领域熟练技术人员所熟知的,流延聚丙烯隔离片材通过挤出、压炼、冷却和切割聚丙烯隔离片材而得到。根据本发明,聚丙烯隔离片材12通常可以描述为丙烯均聚物或丙烯与任何其他α-烯烃的共聚物。
选择用于本发明的聚丙烯的熔体流动指数以提供生产高光泽纹理装饰层压板所必要的所需物理性能。通常而言,熔体流动指数为约1-20,其利用ASTM D-1238测量。熔体流动指数优选为约5-15,更优选为约7-12,利用ASTM D-1238测量。
适用于本发明的聚丙烯的非限制性商业实例包括购自Fina(Dallas,Texas)的EOD97-06和EOD96-01以及购自Exxon Chemical的ESCORENE聚丙烯PD4443。EOD97-06和EOD96-01的熔体流动为12g/10min(ASTM D-1238,条件“L”),密度为0.91g/cc(ASTMD-1505),拉伸强度为5800psi(ASTM D-638),屈服伸长率为10%,拉伸模量为280000psi(ASTM D-638),挠曲模量为270000(ASTMD-790),熔点为333°F(DSC)且再结晶点为261°F。ESCORENE聚丙烯PD4443的熔体流动为7.25g/10min(ASTM 1238),密度为0.90g/cm3(ASTM D792),加工方向的拉伸强度为3300psi,加工方向和横向的屈服伸长率均为5%,断裂拉伸强度在加工方向为8000psi,在横向为7000psi,加工方向和横向的断裂伸长率均为660%,雾度为2/5%,光泽度为85%且摩擦系数为0.3。
如本领域熟练技术人员所熟知的,为生产聚丙烯存在各种方法和催化剂。因此,在不背离本发明精神的前提下可以利用各种方法和催化剂。
例如,根据本发明可以使用传统的齐格勒-纳塔催化剂体系。齐格勒-纳塔催化剂体系利用由烷基铝助催化的过渡金属化合物。在二十世纪五十年代早期,齐格勒-纳塔型聚烯烃催化剂的常规制备方法以及制造和随后使用的常规方法在聚合领域是众所周知的。
更具体而言,齐格勒-纳塔型聚合催化剂基本上为衍生自过渡金属如钛、铬或钒的卤化物的与金属氢化物和/或金属烷基化物(一般是有机铝化合物)的配合物。该催化剂组分通常由承载在与烷基铝配合的镁化合物上的卤化钛组成且甚至可以包括电子给体。该类催化剂体系的实例示于下列美国专利中:4107413,4294721,4439540,4115319,4220554,4460701和4562173;这些专利的公开内容在此引作参考。这些仅仅是几百件涉及主要设计用于聚合丙烯和乙烯的催化剂和催化剂体系的已颁专利中的一些。
“金属茂”催化剂也可以用于本发明中。“金属茂”催化剂包括金属茂和烷基铝组分。金属茂催化剂体系的过渡金属化合物具有两个或多个环戊二烯基环配体。因此,二茂钛、二茂锆和二茂铪均已在用于生产聚烯烃的这类含“金属茂”催化剂体系中用作过渡金属组分。
如上所述,常规的流延聚丙烯隔离片材通过模头挤出并用骤冷辊处理以在受控条件下冷却挤出的片材。本发明使用以预定方式处理的骤冷辊以赋予挤出的聚丙烯隔离片材以理想的硬度和光滑性。当将这些聚丙烯隔离片材用于制造装饰层压板时,所得装饰层压板具有受控的光泽度。
具体而言,已经发现在高温浴(例如120°F)中镀铬的骤冷辊生产的聚丙烯隔离片材可得到高光泽层压板。当纹理首先施用于骤冷辊(下面将更详细讨论)时,镀铬处理包括用显微学上光滑的擦亮(shiny)工具雕刻抛光的辊(在雕刻过程中不使用酸)。
另外,已经发现用TEFLON,聚四氟乙烯,和无电镍(electrolessnickel)的共淀积层处理的骤冷辊可以生产出产生理想结果的聚丙烯隔离片材。类似地,用电抛光处理的骤冷辊也提供理想的结果。此外,用镍底层以及TEFLON和无电镍的共淀积层处理的骤冷辊改进了由TEFLON和无电镍的共淀积层处理的简单骤冷辊提供的结果。
按照本发明的优选实施方案,TEFLON和无电镍的共淀积涂层以及具有TEFLON和无电镍的共淀积涂层的镍底层优选使用ENDURACOATINGS,Inc.(Warren,Michigan)的200系列“Infused Matrix”涂敷技术获得。该200系列“Infused Matrix”涂敷公开于所附手册中,该手册在本文引作参考。对于骤冷辊的电抛光,使用如“电抛光-使用,质量标准和规格用户指南(ELECTROPOLISHING a User’s Guide ToApplications,Quality Standards and Specifications)”,1998年1月,第8版,Delstar Corporation所述的技术进行电抛光,该文献在本文引作参考。
上面所讨论的各骤冷辊赋予流延聚丙烯隔离片材以光滑的微观表面。据信处理骤冷辊以增加所得聚丙烯隔离片材的硬度和光滑特性优化了高光泽装饰层压板的生产。事实上,据信流延聚丙烯隔离片材的硬度和光滑特性对所得装饰层压板的光泽而言是关键的。因此且如上所讨论的,流延聚丙烯隔离片材应具有的熔体流动指数为约1-20,利用ASTM D-1238测量。该熔体流动指数优选为约1-20,利用ASTMD-1238测量。熔体流动指数优选为约5-15,更优选为约7-12。
此外,所得聚丙烯隔离片材应具有无不规则性且光滑的微观表面。正如本领域熟练技术人员肯定能理解的,可以使用各种骤冷辊涂层和/或处理技术,只要所得聚丙烯具有上面所讨论的所需特性。
骤冷辊的温度也可以用来控制按本发明制造的所得层压板的光泽度。例如,在可接受的范围内增加骤冷辊的温度可以增加按本发明制造的所得层压板的光泽度。这样,层压板光泽度的轻微变化易于通过简单增加或降低骤冷辊的温度而控制。据信温度的变化影响所得聚丙烯隔离片材的结晶结构,且最终影响使用该聚丙烯隔离片材制造的层压板的光泽度。
上面所讨论的聚丙烯隔离片材也可以用于同时赋予装饰层压板以纹理。共同拥有的1998年6月5日提交、题为“纹理隔离片材,用其制造纹理装饰层压板的方法以及包括该片材的装饰层压叠层板”且在本文引作参考的美国专利申请流水号09/092480公开了一种有用的纹理技术,其可以与本发明的光泽方法同时使用以创造纹理化光泽性装饰层压板。
然而,纹理可以通过任何能形成向装饰层压板施加纹理的纹理隔离片材的合适加工方法与光泽同时施加。按照本发明的优选实施方案,优选使用挤出和流延来同时产生高光泽度和纹理。
简言之,将聚丙烯以熔融状态强行通过挤出模头,然后随着熔融的挤出物在骤冷辊之间通过而冷却成片材。骤冷辊对该片材的前表面提供所需纹理。使纹理片材的背表面光滑。
当在本发明中使用该纹理技术时,骤冷辊首先被纹理化以赋予被处理聚丙烯片材以所需的纹理。纹理化的骤冷辊然后通过施用铬镀层(chrome)或通过用TEFLON,聚四氟乙烯,和无电镍的共淀积层涂敷而修整。类似地,骤冷辊可以用镍底层以及TEFLON和无电镍的共淀积层涂敷。另外,骤冷辊可以仅用电抛光进行处理,或骤冷辊可以在施用镍/TEFLON共淀积层或铬镀层之前电抛光。
与形成纹理隔离片材的方法无关,关键的是通常在聚丙烯仍处于其软化温度以上的同时,优选在仍处于熔融温度以上的同时将纹理赋予聚丙烯隔离片材。所得纹理化隔离片材具有纹理化前表面和光滑背表面。
本发明的纹理可以呈任何可以想象的形式、尺寸或图案。通常而言,纹理表面的峰谷高度Rz可以为任何所需高度,但优选大于100μ英寸,更优选大于约200μ英寸,甚至更优选大于约300μ英寸。
本发明纹理化隔离片材的厚度可在宽范围内变化。若该片材太薄,则纹理将不会转移。经济方面的因素限定了该片材厚度的上限。通常,纹理化隔离片材的厚度至少为1密耳,优选至少1.5密耳,更优选至少2密耳。
纹理化聚丙烯隔离片材为装饰层压板提供纹理表面且也在常规装饰层压叠层板之间用作隔离片材。因此,本发明的聚丙烯片材可以用于层压板的成组加工或本发明的聚丙烯片材可以用于制造单一层压板片材以简单地赋予所需纹理和光泽。无论本发明聚丙烯隔离片材是用于对装饰层压板提供纹理与否,该聚丙烯片材均以下列方式施用于装饰层压板上。
典型的装饰层压板组合体包括几层支撑有热固性树脂浸渍的装饰层的热固性树脂浸渍的芯料(优选牛皮纸),其上可以进一步用热固性树脂浸渍的贴面片材贴面。所用热固性树脂优选为用于芯料的酚醛树脂,且优选用于装饰层和贴面片材的透明密胺甲醛树脂。隔离片材的纹理表面排列得紧靠装饰层压板组合体的最顶层(如果它是装饰片材或贴面片材的话),而纹理隔离片材的光滑背表面排列得紧靠相邻叠层板的芯料或钢板。
当在合适的层压压板之间压制时,纹理隔离片材将纹理赋予第一叠层板的最顶层并用于使第一叠层板和相邻叠层板之间隔离。层压领域众所周知的平板式压制组件在层压过程中提供必要的热和/或压力。
在实践中,可以根据需要使用抗氧剂、防粘连剂、滑爽剂、交联剂、稳定剂、紫外线吸收剂、润滑剂、发泡剂、抗静电剂、有机和无机阻燃剂、增塑剂、染料、颜料、滑石、碳酸钙、碳黑、云母、玻璃纤维、碳纤维、芳族聚酰胺树脂、石棉以及其他本领域已知的填料。
用于本发明中的聚丙烯可以进一步与一种或多种其他热塑性塑料共混或掺入其中。合适的其他热塑性塑料包括聚烯烃,尤其是聚乙烯,其他聚丙烯,聚酯,聚丙烯酰胺,聚酰胺,聚碳酸酯,聚氨酯,聚丙烯腈和丁二烯/苯乙烯。优选的聚乙烯包括线性低密度聚乙烯。
尽管已经描述和说明了优选的实施方案,但应该理解的是此种公开并不用于限制本发明,而是用于覆盖落在后附权利要求书所限定的本发明要旨和范围内的所有改变和可变的结构。
Claims (21)
1.一种形成光泽性装饰层压板的方法,包括如下步骤:叠置一具有顶层的装饰层压板组合体;流延其中聚丙烯隔离片材用以改进所得装饰层压板的光泽特性的方式处理的骤冷辊处理的聚丙烯隔离片材;将聚丙烯隔离片材放置在装饰层压板组合体的顶层上;对装饰层压板组合体和聚丙烯隔离片材加热加压以足以使装饰层压板粘结并使聚丙烯隔离片材与装饰层压板组合体的顶层可剥离地粘结;和从装饰层压板组合体的顶层除去聚丙烯隔离片材以得到具有理想的光泽特性的装饰层压板。
2.根据权利要求1的方法,其中骤冷辊用聚四氟乙烯和无电镍的共淀积涂层处理。
3.根据权利要求2的方法,其中骤冷辊用镍底层进一步处理。
4.根据权利要求1的方法,其中骤冷辊用电抛光处理。
5.根据权利要求1的方法,其中装饰层压板组合体的顶层包括压花层和贴面层。
6.根据权利要求1的方法,其中聚丙烯的熔体流动指数为约1-20。
7.根据权利要求6的方法,其中聚丙烯的熔体流动指数为约5-15。
8.根据权利要求7的方法,其中聚丙烯的熔体流动指数为约7-12。
9.根据权利要求1的装饰层压板方法,其中流延步骤还包括将纹理表面赋予聚丙烯隔离片材。
10.根据权利要求9的方法,其中聚丙烯隔离片材的纹理表面直接施用于装饰层压板组合体的顶层。
11.一种装饰层压叠层板,包括:具有顶层的装饰层压板组合体;施用于装饰层压板组合体顶层的聚丙烯隔离片材,其中聚丙烯隔离片材为用以改进所得装饰层压板的光泽特性的方式处理的骤冷辊处理的流延聚丙烯隔离片材。
12.根据权利要求11的装饰层压叠层板,其中骤冷辊用聚四氟乙烯和无电镍的共淀积涂层处理。
13.根据权利要求12的装饰层压叠层板,其中骤冷辊用镍底层进一步处理。
14.根据权利要求11的装饰层压叠层板,其中骤冷辊用电抛光处理。
15.根据权利要求11的装饰层压叠层板,其中装饰层压板组合体的顶层包括压花层和贴面层。
16.根据权利要求11的装饰层压叠层板,其中聚丙烯的熔体流动指数为约1-20。
17.根据权利要求16的装饰层压叠层板,其中聚丙烯的熔体流动指数为约5-15。
18.根据权利要求17的装饰层压叠层板,其中聚丙烯的熔体流动指数为约7-12。
19.根据权利要求11的装饰层压叠层板,其中聚丙烯隔离片材包括纹理表面。
20.根据权利要求19的装饰层压叠层板,其中聚丙烯隔离片材的纹理表面直接施用于装饰层压板组合体的顶层。
21.一种由权利要求1-10中任一项的方法制造的装饰层压板。
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US09/441,075 US6423167B1 (en) | 1998-06-05 | 1999-11-16 | Method for controlling laminate gloss |
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EP (1) | EP1101606B1 (zh) |
KR (1) | KR100365248B1 (zh) |
CN (1) | CN1295923A (zh) |
AT (1) | ATE225712T1 (zh) |
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CN101293364B (zh) * | 2007-04-24 | 2014-04-02 | 迪乐公司 | 木单板贴面的装饰层压板产品及其制造方法 |
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US6423167B1 (en) | 2002-07-23 |
EP1101606B1 (en) | 2002-10-09 |
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DE60000567T2 (de) | 2003-07-03 |
KR20010051690A (ko) | 2001-06-25 |
AU5660700A (en) | 2001-05-17 |
DE60000567D1 (de) | 2002-11-14 |
CA2319683A1 (en) | 2001-05-16 |
AU737713B2 (en) | 2001-08-30 |
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