DE2025756A1 - Decorative laminates with removable protective cover - Google Patents

Description

PATENT LAWYERS
DR., I. M AAS "' ^w
DR. W. P-FEJ F; FER
F. VOITHENLEITNER
8 MUNICH "2? '*
LUNGEREBSTR.J25.-.TEL 39Ό2 36

22 955

Formica Corporation "Cincinnati, Ohio, V.St.A ,

Decorative laminates with removable protective cover

Decorative laminates or laminates have been used for many Years. These decorative laminates are made by Combination of several resin-impregnated fiber material, layers or plies under heat and pressure to form a uniform Structure made. In general, there are several core layers or plies, their number depending on the desired thickness of the laminate about 3 to 9, and these core layers are generally made of Kraft paper coated with a curable phenolic resin is impregnated. These core layers are not only decisive for the thickness of the laminate, they also work on stiffening. On top of the core is generally a decorative layer made up of a whole Sheet made of oc cellulose paper or made of stained surface can consist of an α-cellulose sheet on which a decorative Pattern, e.g. a flower pattern, a wood grain,

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geometric figures or the like are printed. The decorative layer is generally with a so-called precious resin, z.3. the melamine Foririaldehydharzen, eggs: urea _s ormaldehydharzen the epoxy resins, polyester resins and the like, impregnated?. Crcwimschtonfall, and especially when the decorative layer has a printed pattern, a cover layer can be arranged over the decorative layer, which generally consists of a fine quality α-cellulose paper sheet coated with a thermosetting resin, preferably of the same class as that resin used for impregnating the decorative layer is impregnated. After the consolidation or connection under heat and pressure is complete, the cover layer becomes transparent so that the decorative layer can easily be seen through the cover layer = other protective cover layers have also been used, eg thermoplastic non-porous films. The term "precious resin ¹¹ is a common market term used to indicate that the resin does not darken during consolidation or solidification under heat and pressure, in contrast to the warts for the core _9, e.g. the phenolic resins which become during the Print consolidation can stain dark brown and sometimes even black. When removing these decorative laminates from the press and performing post-processing such as edge dressing, back sandblasting, and surface finishing, it is common, and it is also common, to arrange the laminates in stacks ^ laminates with front to. front and back to back each other set, whereby at least in the arrangements with front side to front side of a sheet of tissue paper is sandwiched therebetween in order to avoid an adverse scratching. This stacking is time consuming and kost-

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playful and generally requires at least 2, sometimes even 4 workers to stack the laminates and insert the tissue paper between the touching one another. the faces of the laminates in the stack.

The invention therefore particularly provides a removable protective coating on the surface of decorative laminates to facilitate their handling when arranged in stacks, so that the risk of a

Scratching the decorative surface is eliminated. "

The invention is a decorative laminate, the one on its decorative side or surface removable film that is made from a mix of one predominant toenge of a pestful acid soap and a smaller one Amount of a nonionic detergent and a curative. The coating agent used for Coater: the decorative laminate used according to the invention is an aqueous dispersion a mixture of a predominant amount of a soap and a minor amount of a nonionic detergent. The fatty acids used to make soaps j

are well known and have been used in soap production for years used. For example, it is customary to use soaps made from fatty acids with 16 to 18 carbon atoms, e.g. palmetic acid, stearic acid and some unsaturated ones Acids, e.g. palmitoleic acid, oleic acid, linoleic acid and linolenic acid. The soaps are made by saponifying the acid with the help of a base, either for which Sodium hydroxide or potassium hydroxide is used. The amount of soap in the whole composition of soap, detergent and a coupling agent, based on the solids content, about 50 to 92

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SAD

Weight percent of the total weight of the pesticides in the composition. Preferably about 60 to 88 percent by weight of the soap is based on the total weight of the soap, detergent and coupling agent used. That is accordingly Detergent in an amount of about 4 to 48 percent by weight and preferably about 10 to 38 percent by weight, based on the total pesticide weight of detergent, coupling agent and soap.

The third essential component in the mixture is a proportionate amount of a polyhydric alcohol, e.g. ethylene glycol or diethylene glycol, which serves as a coupling agent to maintain a homogeneous solution and as a leveling agent to prevent piss eyes or other surface disruptions in the finished coating . Correspondingly, the coupling agent is present in an amount of about 1 to 4 %, and preferably about 2 to 3%, based on the total weight of soap, detergent and coupling agent. The total of the three components is 100 #. The aqueous solution of this coating agent, as used for the purposes of this invention, containing about 2 to 10 weight percent of the Peststoffe and water as R _e st. The solids content of the solution can be varied to achieve different thicknesses of the finished pilm deposited on the decorative surface of the laminate. For example, pilms can be deposited to a thickness of about 0.005 to 0.025 mm (0.20 to 1 mil), and preferably 0.005 to 0.013 mm (0.20 to 0.50 mil).

Numerous nonionic detergents for the erfindungsgeßäß Purposes are commercially available under the trademark "Tergitol". It deals

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■ - 5 -

are alkylphenyl ethers of polyethylene glycol. Typical for these commercial products are

Tergitol non-ionic "

Alkyl phenyl ether of polyethylene glycol

Other commercial products of a similar nature available under the trademark "Triton" can be used will.

The method of applying the film to the decorative laminate side is suitable for continuous implementation. The preferred method is to apply the aqueous one after a polishing step or after a post-treatment Spray a solution of the film-forming material onto the surface while the laminate is still hot, whereupon the water and other volatile substances are evaporated, and a uniformly deposited protective film leave behind. The laminates can be stacked face-to-back without scratching the surface will. This * 'ilm can be easily removed after removal, shipping, storage and finishing removed from the surface by washing with water will. Another method for applying the aqueous solution of the film-forming material is to the laminates, when they are removed from the hot press and are still hot, immediately with the aqueous lo-

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The solution is to be sprayed, whereupon the water and other volatile substances are evaporated and leave a uniformly deposited protective film. Spraying is a preferred method for applying the aqueous solution of the film-forming material to the surface, but other application methods can also be used, for example roller application, slot nozzle application and the like. The degree of coating with the release protection must be coordinated taking into account the film thickness required for scratch resistance and a possibly transferable amount that would have a disadvantageous effect on the gluability and slip resistance when stressed by the friction properties. Scratch sensitivity can be tested by a variety of methods including visible scratch marks, abrasion testing with a segmented rotating test wheel, rubbing laminate against laminate, and other friction tests. The following describes the apparatus and test method used to test scratch sensitivity. The test device consists of a horizontal rotating turntable 91 cm (36 ") in diameter which carries coated and uncoated laminates on its top Rotating direction pulls abrasive blocks across the surface of the tested samples. The axes of the turntable and the wheel are offset by about 51 cm. (: 2O "). The wheel has a metal rim with four spokes." The turntable and the wheel are mechanically coupled to each other and are driven by ... an electric motor ... so that the turntable rotates at 12 revolutions per minute in one direction,

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while the wheel rotates in the opposite direction at a slightly higher speed. Three real wooden blocks Weighing 0.45 kg (1 pound) each, each bearing several strips of laminate on the underside, the edge-to-edge mounted are on the to be tested Surfaces and placed in the area bounded by the wheel. By turning on the motor, the Turntable and wheel set in motion. That I spinning wheel drags the blocks across the surface of the test samples. The blocks move on one. Circular path over a stationary plate, the one with the rotating disk is flush and are again fed back through the wheel and gezOtjeu over the surface of the test samples. After 1, 2, 5, 10, 15 or more revolutions, the rotary disk and the wheel are turned off and the surface the laminate is examined for any noticeable scratches. Except for this scratch sensitivity test were sit these coated laminates, further tests,

binding
For example, on load-bearing capacity / printability, removability of the coating and the like. Ease of removal even after prolonged storage is a requirement that the product must meet. The product cost is also an important limitation so that there is a cost saving for the overall packaging. Printability without smearing of the velor surfaces is also achieved, for example, by the kajnahrcen according to the invention.

The invention is illustrated by the following examples explained.

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- 8 Example 1

A common decorative laminate is sprayed with a 3.2 # aqueous solution of the coating agent immediately after passing through a surface matting machine while the surface is still hot. * By shaking the hot decorative laminate, the water is evaporated and leaves behind as a deposit on the front the laminate a 0.0064 mm (0.25 mil) thick film of the mixture of 83 fi a Tallölfettsäujreseife, # 14 detergent ( "Te ¹¹ Sitoi" NP-35 non-ionic) and 3 # diethylene glycol.

Samples of the coated laminate are compared to uncoated laminates according to the scratch test described above. After one cycle on the turntable, the uncoated laminate shows noticeable scratches or scratches. At the same time, parts of the surface coating are removed with water and the surface is examined. No scratches are visible after one cycle. The test is continued and the surface of the coated laminate is examined after 5, 10 and 15 revolutions. The first faint scratches are observed after 15 cycles. With the protective coating according to the invention, the scratch resistance is increased by 1,500 % . An imprint of a label in a logotype on the coated decorative side can be easily removed with water. In contrast, when printing on an uncoated laminate surface that is matt or semi-matt, the trademark is difficult to remove because the printing ink tends to penetrate the laminate surface.

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Example 2

The procedure of Example 1 is repeated in all essential details, with the exception that on the surface of the laminate a film with a Thickness of 0.015 mm (0.50 mil) is deposited. When testing the scratch resistance, printability and resilience results similar to those in Example 1 are obtained.

Example 3

The procedure of Example 1 is repeated in all essential details with the exception that the Peststoffkonzentration the aqueous solution is 5 i "^ alas evaporation of the water in the coating agent by shaking the hot decorative surface is a film of the mixture of 64 $ Tallölfettsäureseife , 33 $ detergent ("Tergitol" NP-35 nonionic) and 3 % ethylene glycol with a uniform thickness of about 0.0064 mm (0.25 mil). When the laminates are tested for scratch resistance, printability and bond strength, practically the same results as in Example 1 are obtained.

Example 4

The procedure of Example 1 is with the exception repeated that the laminates were removed from the press and placed in the hot state with the aqueous solution of the film-forming Material to be sprayed. When testing the coated laminate, equivalent test results are obtained as obtained in example 1.

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Example

The procedure of Example 1 is exceptions repeats that the laminate before spraying with the. aqueous solution is at room temperature (25 ° C). The sprayed laminate is passed through a heating section to remove volatile substances from the protective film and can be processed further when dry.

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Claims (3)

'- 11 Pa te η ta η s ρ rü che .Lambda..sub.i Decorative Sei.ichtstoff, characterized in that it DAT on its decorative side has a removable film of a mixture of about 50 to ^c j2 # a fatty acid soap, about 4 to 48 $ o of a nonionic Detnrgens and about 1 to 4% by means of a clutch, all percentages are by weight and taken together are $ 100, which is from 0.005 to 0.025 mm (0.2 to 1 mil) thick. 2. Decorative laminate according to claim 1, characterized in that the fatty acids in the soap come from tall oil. 3. The decorative laminate of claim 1 characterized in that the film has a thickness of about 0.005 to 0.013 (0.2 to 0.5 mils) . 009849/1891 ^bath