CN1337310A - 金属表面高压层压板 - Google Patents

金属表面高压层压板 Download PDF

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Publication number
CN1337310A
CN1337310A CN01122604A CN01122604A CN1337310A CN 1337310 A CN1337310 A CN 1337310A CN 01122604 A CN01122604 A CN 01122604A CN 01122604 A CN01122604 A CN 01122604A CN 1337310 A CN1337310 A CN 1337310A
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laminate
layer
metal
adhesive linkage
present
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CN1202948C (zh
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罗伯特·R·克雷布斯
欧内斯特·L·费尔普斯
吉纳维夫·L·特佩拉
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Wilsonart Co Ltd
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Premark RWP Holdings LLC
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/12—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of metal or with an outer layer of metal or enameled metal
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal 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
    • B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
    • B44C3/02—Superimposing layers
    • 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
    • B44C5/0415—Ornamental plaques, e.g. decorative panels, decorative veneers containing metallic elements
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal
    • Y10T428/31688—Next to aldehyde or ketone condensation product
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal
    • Y10T428/31692—Next to addition polymer from unsaturated monomers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal
    • Y10T428/31692—Next to addition polymer from unsaturated monomers
    • Y10T428/31699—Ester, halide or nitrile of addition polymer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal
    • Y10T428/31703—Next to cellulosic

Abstract

本发明涉及浸渍酚醛树脂的芯材与金属面板连接成为高压层压板。苯乙烯－马来酸酐共聚物的粘接层被放置在芯材和金属面板之间以保证具有要求层的铺层在加热和压制时各层的连接。

Description

金属表面高压层压板
本发明涉及金属表面装饰性层压板，更具体地说，本发明涉及浸渍酚醛树脂的芯材与金属面板接合成为高压层压板。
装饰性层压板在家具业和建筑业已获得广泛的应用。装饰性层压板的耐久性、价格和通用性使得它们适用于几乎任何结构用途。例如，装饰性层压板被发现遍及由地板产品至家具至各种柜顶面。
层板工业在不断地努力改进装饰性层压板的功能。不管这些改进是涉及装饰性层压板地板嵌板用的锁闭舌榫形状，或者改进的表面特性，适用于柜顶面、家具，仓库型架、标志牌、立柱包层、器械前板、推拉板、天花板；住宅橱柜，墙壁嵌板、装饰性贴面和加强灯光，或者饭店，食品服务设备，装饰性层压板制造业的进步使得这种材料等于或优于设计被代替的材料。
考虑到这种情况，现在制造的金属表面层压板是用双面胶带或普通粘接剂将金属面板连接到酚醛树脂高压芯材。除了在层压板铺层的压制和加热步骤之后要求辅助步骤(因而要求时间)这一简单事实之外，使用双面胶带的过程本身就是麻烦和困难的。其结果是金属表面层压板实质上较普通的层压板更昂贵。
此外，虽然使用双面胶带为最终的金属表面层压板提供了稳定性，但在一定的情况下金属面板和芯材之间的连接易于脱开。例如，当金属表面层压板被切割成条材用于制造工件的前缘时，发现双面胶带失效。再者，当弯成半径和进行成形后弯曲而加热时，也发现胶接接头失效。
因此，需要设计一种金属表面层压板，它允许方便的装配和增强金属面板与层压板其余部分的树脂浸渍板之间的结合。本发明提供这样的结构材料。
这样一来，本发明的目的是提供具有金属层、粘接层和聚合物层的层压板。
本发明的另一目的是提供制造金属表面装饰性层压板的方法。这种方法的实现首先是装配由金属层、粘接层和聚合物层组成的层压板铺层。层压板铺层随后加热和压制。
本发明的另一目的是提供按照上述方法制造的金属表面装饰性层压板。
本发明的另一目的是提供制造金属表面装饰性层压板的方法，它包括下列步骤：
装配由金属层、粘接层和聚合物层组成的层压板铺层；
加热和压制层压板铺层。
按照本方法制造的金属表面装饰性层压板的另一实施例，层压板的聚合物层是树脂浸渍层。
按照本方法制造的金属表面装饰性层压板的另一实施例，层压板的粘接层是苯乙烯-马来酸酐共聚物。
按照本方法制造的金属表面装饰性层压板的另一实施例，层压板的聚合物层是树脂浸渍层。
按照本方法制造的金属表面装饰性层压板的另一实施例，层压板的树脂浸渍层是酚醛树脂浸渍层。
按照本方法制造的金属表面装饰性层压板的另一实施例，层压板的金属层是由一组材料选取的，如铜、黄铜、青铜、不绣钢、电镀钢、铝和阳极化铝合金。
本发明的其它目的和优点可通过本发明下面结合附图对相关实施例的说明而明白，附图中：
图1是按照本发明制造的金属表面层压板的示意图。
在这里公开了本发明详细的实施例。然而应该理解，公开的实施例仅为本发明的解释，它可以不同的形式实施。因此，这里公开的细节不应是限制性的，而仅仅是作为权利要求书的基础，以及作为专业人员的教学基础，使其了解如何制造和使用本发明。
参见图1，公开了按照本发明的装饰性层压板10。层压板10具有外部金属表面层12，粘接层14和芯材层16。虽然按照本发明的最佳实施例公开了特定的铺层方案，在不脱离本发明精神的条件下铺层方案可以有某些改变。
金属表面层12可以由现在使用的制造金属表面层压板的各种金属板材中选择，例如，金属表面层可以由一组材料选择，如铜、黄铜、青铜、不锈钢和电镀钢。虽然上面公开了优选的金属，但技术熟练人员可以根据本发明使用广泛的金属。例如，应该理解，按照本发明也可使用铝和阳极化铝合金。
按照本发明使用的金属板材的正确的厚度可以改变，以适应特殊的功能和价格约束。金属板材的厚度最好按使用的普通的层压板加工设备的加工能力而定。考虑这一点，金属板材的厚度应为约0.018cm和0.076cm之间。
粘接层14优选地是DYLARK，它是NOVAChemica/S，Inc.制造的苯乙烯-马来酸酐共聚物，更优选地，粘接层14是DYLARK 481。DYLARK显示出与酚醛树脂浸渍牛皮纸制芯材层16优秀的接合特性。详见下述。DYLARK还显示出与金属表面层12优秀的接合特性。
有关DYLARK与酚醛树脂浸渍牛皮纸的接合，其优秀的接合特性来源于DYLARK共聚物中存在的马来酸酐的羧基。羧基与酚醛树脂接合产生非常稳定的层压板。虽然DYLARK是按照本发明优选的粘接层材料，在不脱离本发明精神的条件下也可使用功能和结构相同的其它聚合物。
有关DYLARK与金属表面层12的接合，其优秀的接合特性来源于DYLARK与金属的氧化层接合的稳定性(见美国专利，NO.4,364,731)或与金属表面有显微不规则性的机械接合(见美国专利No.5,478,414)或者两者的结合。
芯材层16优选地是多层酚醛树脂浸渍板，虽然在不脱离本发明精神的条件下也可使用其它材料。技术熟练人员可以理解，应考虑形成高压装饰性层压板时所需芯材板的正确数目。
按照本发明的最佳实施例，该芯材是由3张酚醛树脂浸渍板材组成。特殊的是按照本发明的最佳实施例，芯材层16用的板材是120-323g/m2的干酚醛树脂浸渍牛皮纸。牛皮纸充分浸渍和与实质上完全固化的酚醛树脂接合，在开始层压步骤时该酚醛树脂已转变至热固性状态。
按照本发明，金属表面高压装饰性层压板10是用与普通装饰性层压板基本相同的方式制成。各层首先叠置和放置在钢板之间，层压板叠层随后在温度范围约143℃至154℃，优选地在149℃，和压力约70.3kg/cm2下经足够时间(通常约20-30min)以便压实层压板和固化树脂。上述温度范围取决于这样的事实，低于上述温度DYLARK不能满意地与金属接合。
压力和热迫使树脂在纸板内流动、固化和压实板材成为一致的层压板物质，在技术中被称为装饰性高压层压板。通常，多张层压板同时成形。多张层压板的成形方式为插入一组成叠的装配的板材，在装配的板材之间放置隔离板材以便分离叠置的不同的层压板。压实之后，隔离板材可使单独的层压板分离开。
下表列出了按照本发明制成的层压板的接合强度(特别的是下列数据涉及由纸芯材/DYLARK/金属/DYLARK/纸芯材组成的层压板的试验)：
金属                  载荷kg/cm2           应力kg/cm2
铜                    790.45                  197.61
黄铜                  790.45                  195.5
青铜                  790.59                  197.61
不锈钢                790.52                  197.61
电镀钢                790.66                  197.68
一旦成形之后，装饰性层板10可以使用于各种结构的建筑物，此外，可以理解，按照本发明制造的装饰性层压板显示出改进的接合强度可使这种金属表面装饰性层板适用于迄今未知的领域。
虽然示出和陈述了不同的最佳实施例，应该理解，本发明不应局限于这些公开内容，而应覆盖所附权利要求书限定的本发明精神和范围内的全部改进和代替的结构。

Claims (8)

1.一种层压板，它具有：
金属层；
粘接层；以及
聚合物层。
2.按照权利要求1的层压板，其特征在于粘接层是苯乙烯-马来酸酐共聚物。
3.按照权利要求1或2的层压板，其特征在于聚合物层是树脂浸渍层或酚醛树脂浸渍层。
4.按照权利要求1、2或3的层压板，其特征在于金属层选择自下列组：铜、黄铜、青铜、不锈钢、电镀钢、铝和阳极化铝合金。
5.制造金属表面装饰性层压板的方法，它具有以下步聚：
装配由金属层、粘接层和聚合物层组成的层压板铺层；
加热和压制层压板铺层。
6.按照权利要求5的方法，其特征在于粘接层是苯乙烯-马来酸酐共聚物。
7.按照权利要求5或6的方法，其特征在于聚合物层是树脂浸渍或酚醛树脂浸渍层。
8.按照权利要求5、6或7的方法，其特征在于金属层选择自下列组：铜、黄铜、青铜、不锈钢、电镀钢、铝和阳极化铝合金。
CNB011226048A 2000-08-16 2001-06-26 金属表面高压层压板 Expired - Fee Related CN1202948C (zh)

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US09/639,852 2000-08-16
US09/639,852 US6472083B1 (en) 2000-08-16 2000-08-16 Metal surfaced high pressure laminate

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AT (1) ATE255496T1 (zh)
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EP1182031B1 (en) 2003-12-03
EP1182031A1 (en) 2002-02-27
KR100432116B1 (ko) 2004-05-17
CA2344883A1 (en) 2002-02-16
CN1202948C (zh) 2005-05-25
AU753614B2 (en) 2002-10-24
CA2344883C (en) 2004-09-21
DE60101355T2 (de) 2004-10-28
KR20020014719A (ko) 2002-02-25
US6472083B1 (en) 2002-10-29
AU5186501A (en) 2002-02-28
ATE255496T1 (de) 2003-12-15
TWI222406B (en) 2004-10-21

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