DE2441564A1 - LAYER ARRANGEMENT FOR THE PRODUCTION OF A LAMINATE BY THE APPLICATION OF HIGH PRESSURE - Google Patents

Description

THE ORCHARD CORPORATION Oi ¹ AMERICA, 1154 Reco Avenue, Crestwood, Missouri 63126, (V.St.A.)

Layer arrangement for the production of a laminate by applying high pressure

The invention relates to decorative or decorative laminates and in particular a cellulosic fiber material which is the decorative layer within such laminates forms, the laminates being high pressure laminates.

It is already known, decorative, by heat-high-pressure treatment manufacturable laminates, such as those used for facade elements and similar decorative horizontal and / or vertical surface formations are used, thereby producing that a protective layer or oine so-called overlay, a decorative or printed layer and

509814/1004

45

Bremen office:
D-2800 Bremen 1
P.O. Box 786, Feldstrasse 24
»Telephone: (0421) * 74044
Telex: 244958 bopatd
Telegr.: Diagram, Bremen

Bremen accounts: Bremer Bank, Bremen (BLZ 29080010) 1001449

PSchA Hamburg

(BLZ 20010020) 126083-202

Munich office: D-8000 M-inchen 90 Schlotthauer Strasse 3

Telephone: (089) 652321 Telegr.: Telepatent, Munich

BOEHMERT & BOEHMERT

an underlying core or substrate can be used. The edition and the decorative layers usually consist of alpha cellulose fiber paper, which is coated with a melamine formaldehyde resin or a modified melamine resin is impregnated, while the core is normally has four to seven sheets of wrapping paper impregnated with a phenolic resin. The whole arrangement is exposed to hydraulic pressure after the individual layers have been laid on top of one another, causing the layers to stick or fuse together as soon as pressure and temperature are sufficient are high, resulting in the finished laminate in the known manner.

The use of alpha cellulose fiber paper for the decorative or printing layer or sheet has posed various problems in laminate manufacture. Such paper has a basis weight which is relatively high and on the order of about 99 to 210 ks; / 300 m ² (between 45 and 95 US pounds / 5,000 feet ² ) with a relatively low density. However, such a paper must be impregnated with resins of the melamine type in which the dry resin weight is equal to the weight of the paper, so that for example 75 kg of alpha cellulose paper requires the addition of 65 kg of dry resin. . The cost of such materials, as well as the cost of the impregnation processes, are significant and play a significant role because of the overall weight. The impregnated alpha cellulose papers also do not lead to smooth printing surfaces. It is therefore not yet a decoration schi chi; known with a weight which is only a small percentage of the alpha cell

5098U / 100A
- 2 -

BOEHMERT & BOEHMERT

lulose and does not require impregnation

The invention is based on the object of creating a paper which can be used as a decorative or printing layer in high pressure laminates does not require prior resin impregnation for incorporation into the laminate structure, but does so during laminate formation resin penetration should be possible to achieve the desired mechanical strength According to the invention, this object is achieved by a layer arrangement solved, which is characterized by the decorative layer, which consists of a thin, flexible body having fibrous cellulose material with a printed side and a back, the material being unimpregnated is low apparent density, low basis weight, and relatively high porosity having. The subject matter of the invention is also a method for producing a laminate on the basis of such a layer arrangement as well as the composition of the decorative layer and the individual other layers themselves.

According to the invention it is therefore proposed as paper for decoration or printing in a high-pressure laminate to use a paper which has a low apparent density and a low basis weight has, at the same time relatively high porosity, but at the same time it is thin, flexible and is easy to use.

A paper of the type described is proposed which is suitable for the stated application suitable, and is significantly cheaper than alpha cellulose paper, although its use is not at the same time

5098U / 1004

BOEHMERT & BOEHMERT

Resin impregnation should require, so that considerable economic advantages "in laminate production resulting from the use of the paper.

The invention also relates to the production of a high-pressure laminate using a decorative or printing layer which is essentially made of a bleached layer Packing paper consists, the fiber formation of which leads to an increased layer thickness and a reliable one Connection with the support and the core results in high strength, toughness and hardness of the laminate.

The invention furthermore creates a high pressure laminate, y / elches an optimal continuous overall strength resistant to de-glueing, crumbling, cracking, wear and tear due to aging and the like and is suitable for general purposes. Subsequent deformation is also possible.

Further, vo vt eiHhafterweise a high-pressure laminate created, in which a decoration or printing layer, a paper is used which is provided on one side with a thin resin coating, which is suitable to create a connection between the core stack and the decorative layer by the invention, wherein however, the penetration of the core resin and the clad resin cannot be prevented during the lamination process.

A fiber cellulose layer material is also advantageously used or such a so-called paper for use as a decorative or printing layer proposed for the manufacture of high pressure laminates,

5098U / 10CU

BOEHMERT & BOEHMERT

which has a relatively improved printability, which is larger than the alpha cellulose papers used to date. There is also a calendar or other preliminary preparation for printing with excellent clarity of detail possible, all of which known printing processes can be used, including rotogravure.

Finally forms the subject of the 'invention a high-pressure laminate with a thin, fibrous cellulose paper, which forms a decorative layer, whereby the cellulose paper is not impregnated. The laminate meets the industrial requirements for conventional or decorative laminates.

In summary, it can be stated again that the invention is advantageously a decorative paper for arrangement between the layer impregnated with a melamine resin and that with a phenolic resin Impregnated core of a high pressure laminate concerns. The paper is relatively thin, flexible and not impregnated and consists of cellulose fiber material with low apparent density, low basis weight and high porosity while being more uniform Fiber formation. A thin resin layer can be on one side, preferably on the back, of the decorative layer be upset.

In general, it is proposed by the invention, a fibrous cellulose material in layer or Sheet form, hereinafter referred to as "paper", of low apparent density should be used, the basis weight being low and the porosity being high. Other physical characters

- 5 -50981 4/1

BOEHMERT & BOEHMERT

statistics are still to be given. This paper is used for decoration or printing in a layered arrangement used to manufacture a high pressure laminate.

The sheet material of the invention has a low basis weight within a range of about 4.5 to 12 kg (10 to 25 pounds), which is significantly less than ^ the range from 20 to 42 kg (45 to 95 pounds) for Alpha cellulose paper. In addition, no impregnation is required with this layer material, so that the low basis weight represents the total weight, in contrast to alpha cellulose paper, which is an impregnation for example by a melamine resin in the ratio 1; 1 required, reducing the weight of the impregnated Paper is much larger than the lightweight paper used according to the invention. Bleached Wrapping paper is, for example, a material that has the desired properties because it the required ratio between softwood and hardwood fibers owns. With regard to critical properties of the paper, it is noted that this is printability has, which is much larger than that of alpha cellulose paper, which was previously used as the material of Choice for the production of decorative or printing layers for high pressure laminates was available.

The paper according to the invention is not impregnated, i.e., unlike the conventional decorative layer, it does not require any prior impregnation subjected by a melamine formaldehyde resin, but instead it is in the non-impregnated state in the layered arrangement inserted. Because of its different, mutually dependent properties, a

- 6 5 O 9 8 U / 1 OO

BOEHMERT & BOEHMERT

such paper has a porosity and consequently an absorbency which enables the Melamine resin in the overlay layer and the phenolic resin in the substrate during melting hindurehsickerii, which results in a permanent installation of the paper in the laminate without affecting the special decoration or an adverse influence is exerted on the pressure of the paper. The paper according to the invention is in substantially thin and therefore has a low basis weight, which, together with the other properties of the paper, result in other properties such as porosity, Flexibility, cohesion and the like result, which could not previously be realized.

Fibrous cellulose material with the properties mentioned has a considerable capacity for ink absorption Produces prints with high fidelity and can be pretreated for excellent printability ensure, for example by calendering or by machine coating or by otherwise filling and smoothing the printing surface.

The paper according to the invention can preferably be on one side on its back, to be coated, with a thin layer of certain resins, such as It is described further below about the adhesive strength of the paper with respect to the core and so the installation of the paper into the laminate for high interlayer bond strength. Such resins are not impregnated within the decorative layer and therefore have not penetrated into it.

The invention thus forms a fibrous one

- 7 - ■ 50 98 U / 1 0 (K

BOEHMERT & BOEHMERT

Sheet material for use as a decorative layer in high pressure laminates, along with the conventional ones Components of such laminates, for example, namely impregnated alpha cellulose papers, impregnated with Melamine resin, or the like as a support and a core or a substrate, which consists of a multitude of consists of sheets or layers of wrapping paper that are impregnated (soaked) with a phenolic resin. It has it turned out that a paper which is suitable for the decorative layer of a laminate and the porosity required for the core and pad resins to penetrate during the melting process without prior impregnation of the layer would be required, and also to improve the aesthetic appearance, the printability still · to be improved and this paper should at the same time be relatively thin, thus not only the necessary strength, but also the desired flexibility to ensure the structural Relationship and the functional properties of the resulting laminate should be guaranteed, a Must have a variety of interdependent physical properties. The combination of such properties is critical as one is merely accidental realization no paper which is suitable for use can inherit from not all the necessary properties suitable for high pressure laminates.

The paper of the invention, which has a low basis weight does not require any impregnation and is only a fraction of the weight of conventional impregnated Papers having an average basis weight of about 32 kg (65 pounds) and the like Require weight of impregnation resin. The thickness of the

- 8 5098U / 1004

BOEHMERT & BOEIMERT

paper according to the invention is in the range from 1 to 3 mil.

Among the main characteristic properties of such a material, the porosity (Gurley scale) from 1 to 15 sec / 100 ml a considerable role, from which a relatively high porosity can be read off, especially in relation to the porosity of the conventional Licherweise used types of paper that are relatively thick, with a porosity on the Gurley scale results in from 16 to 22 sec / 100 ml. As stated above, the various properties of the invention act Paper in a synergistic way as a combination, which would result in the overall possibility of to avoid impregnation, as is necessary with the conventionally used papers. For For optimal laminate strength, the decorative layer must absorb the resins from the overlay and the core, so as to lead to a hardenable adhesive bond between the individual layers. The cellulosic material low porosity would not try to reinforce the laminate, it would otherwise , have lower internal strength than the rest of the laminate layers.

Another critical property of the invention Paper consists in the low, apparent density, which is in the range of 0.5 to 1.0 gr / m. These Property is a measure of the solid nature of the paper, with a low apparent density being the Permeation of the resin melt during the laminate formation. This results in an improved Strength, whereby it should be noted that, in contrast, a paper with a relatively high apparent

5098UAIO (H.

/ V

BOEHMERT & BOEHMERT

bar density does not absorb resin so easily, so that the desired laminate strength is not in sufficiently results.

Another necessary property is special Burst strength, which is related to the toughness of the fibers of the material when subjected to stretching forces perpendicular to the paper surface. The tighter the paper, the tighter the fer- ^ term laminate, since the paper serves as a reinforcement part embedded in the melamine resin-phenolic resin interface. The burst strength of the invention Paper is larger than that of conventional papers and is in the range of 0.6 to 1.5 points per pound, compared to 0.4 points per pound for the papers previously used. The phrase "points per Pound "is simply a manageable unit - which comes from looking at US pounds per square inch is obtained per unit weight.

The basis weight of the paper of the present invention is in the range of 10 to 25 pounds / 3,000 feet, which is substantial lower than the 65 pounds for the same surface area on conventional papers.

The quality of the paper according to the invention cannot be printed on by conventional papers achieve and enables a clear, distinct print, with high detail specificity and high reproduction fidelity, as they could not be achieved so far. Such printing properties result from the paper according to the invention characteristic and unique properties. It should be noted that the

- 10 - 5098U / 100A

BOEHMERT & BOEHMERT

inventive paper is lighter in weight, however has a greater strength per unit weight than the conventional papers and, although it is thin and is flexible, the use of a stiffening agent such as a resin to carry out the Printing is not required, so that conventional printing techniques without pretreatment in the case of the invention Paper can be used.

The fiber formation of the paper is also critical, because this, together with the other properties, increases the lamination ability and printability of the material influenced. The relatively uniform distribution of the fibers through the paper results in; the GE-, Desired strength in the entire paper surface, which is relatively free of holes. Paper with one Fiber formation within the limits given below can be calendered and taken for fine treatment ink better than was the case with the papers previously used for high-pressure laminates. the Required fiber ratios are as follows:

Softwood 15 to 80%

Hardwood 20 to 85%. '

Typical suitable softwoods are Douglas Fir, True Fir, Spruce, Jack Pine, Lodgepole Pine, and Ponderosa Pine Redwood. Suitable hardwoods are Ash, Basswood, Beech, Birch, Gum Maple, Oak, Yellow Poplar and Populus Sp. Such Fibers have relatively large proportions of fiber cuts and fibrillation. It turned out that that the cutting of fibers results in a denser paper formation. By fibrillation of the fibers if these are broken at their thin walls, where-

- 11 509814/10 04

BOEHMERT & BORHMERT

released by thread-like elements or, in other words, fibrils are generated. Latter have a smaller diameter than the untreated fibers and are therefore more flexible and tangle together better. This allows the formation of a larger number of contact points between fiber and fiber, thereby in turn, greater strength is achieved and the possibility of holes being formed is reduced. Bleached packing paper is an example of such a paper that has the required proportions between softwood fibers and hardwood fibers within the limits given above.

In view of the above, it should be noted that that the paper according to the invention has critical properties in terms of apparent density, burst strength, Porosity, basis weight, smoothness and fiber formation, all of which come together in combination synergistically enable the achievement of a satisfactory laminate, whereby the pressure, reverse winding " Sheet-forming and lay-on properties in conventional impregnated alpha cellulose papers, how they were used for decorative layers, unachievable way to be improved «, By the Use of this paper yields considerable economic benefits.

In the actual use of the paper according to the invention, i.e. in the production of high-pressure laminates, the procedure essentially corresponds to "the one which has been used in industry for years, i.e. the decorative layer or the printing layer to a conventional one, with. placed on a phenolic resin impregnated or soaked core and

«12 -
5098U / 1004

BOEHMERT & BOEHMERT

lent a layer serving as a protective layer, which is impregnated with a melamine-type resin, is placed on top. The stack so formed is then placed between the polished metal plates of a hydraulic press which is then closed, applying such pressure and heat for an appropriate time to fuse the stack into a single composite or laminate. The press pressure can be in the range of about 70 atmospheres (1,000 US-pounds / inch ^2), wherein the temperature of approximately 149 ° C. (300 ⁰ P) and the duration of the treatment is 20 to 30 minutes.

The use of the novel decorative layer according to the invention changes the appearance of the laminate compared to conventional laminates, i.e. those a decorative layer impregnated with melamine resin is not used, although the laminate according to the invention can be somewhat thinner than conventional laminates, namely because the decorative layer paper is relatively thin. However, the total thickness of the laminate can be easily adjusted by introducing one or more additional core layers. In the invention Manufactured laminates are industry accepted attempts at establishing such the properties of decorative laminates are common. Such attempts which have been extensively carried out and included a variety of individual experiments as demonstrated by the National Electrical Manufacturers Association developed are hereinafter referred to as NEMA standards described. Such tests include the wear resistance of the surface, the hot water resistance, the high temperature strength, the strength

- 13 5098U / 1004

BOEHMERT & BOEHMERT

ability of the surface against "burning cigarettes, against staining, against impact and the like, as well like the color fastness of the surface when the laminate is immersed in boiling water. Flexural strength etc. are also noted, all in the manner known in the relevant prior art.

Laminates with a paper according to the invention have the same wide applicability like the previously known laminates and are suitable for general purposes such as horizontal decoration, as well as as vertical surface elements, for example as wall or facade elements and the like, whereby the Laminates post-deformed into a variety of non-planar ones Let shapes form. Such laminates have met the generally required test standards.

The following are the critical properties of the invention Paper summarized as follows:

apparent density porosity (Gurley scale) Burst strength

Basis weight

smoothness
Fiber ratio

Thickness (CALIPER)

Tear strength (transverse direction)

tensile strenght

0.5 to 1.0 g / cm 1 to 15 sec / 100 ml about 0.3 to 0.73 points Ag '(0.6 to 1.5 points / pound)

10 to 25 lbs./3,000 feet ²

maximum 150 Sheffield

Softwood 15 to 80% Hardwood 20 to 85% 1.0 to 3.0 mils
at least 15 p

at least about 1 kg / 2, (2 US pounds / inch)

- 14- -

5098U / 10CU

BOEHMERT & BOEHMERT

As discussed above, the paper according to the invention can be used because of its novel properties install in a high pressure laminate without pre-treatment, apart from the use of a special one Decoration or a print on paper.

From the above it follows that the Cellulose fiber material or the paper which is the decorative layer forms according to the invention, results in the production of high pressure laminates an extraordinary economy, since the cost of Such a paper only about 1/8 to 1/12 of that of the papers used previously, for example the Alpha cellulose paper, due to the elimination of the need for impregnation with melamine resins with the investment costs for the corresponding device becoming superfluous, as well as by avoiding the corresponding space requirements. the The quality of the decoration or the print is clearly better than that which can be found conventionally Alpha cellulose papers used results, due to the smoothness of the material, so that a excellent fidelity is achieved. The ease of use is all the more evident, if you consider that in the conventional process with Alpha cellulose paper the tray impregnation requires oven drying, the dried, impregnated Paper must be rolled up to the desired size for possible cutting. Included It should be noted that this handling prevents dust or foreign materials from flowing into the. Product must be prevented. It is obvious that by avoiding the -impregnation like it was previously necessary, as well as by avoiding the

- 15 509814/1004

BOEHMERT & BOEHMERT

Oven drying gives "a significant reduction in atmospheric pollution. In addition, it is a considerable number of personnel are required to mix the melamine solution and determine the appropriate one Adjust catalysts, resin particles, viscosity and purity. All these process steps are carried out by using the invention Process or the paper according to the invention avoided. The paper according to the invention has a Sufficient internal bond strength, i.e. that which can be attributed to the mutual bonding of the fibers Strength, so that a resin impregnation, as is required for example with alpha cellulose paper is, becomes superfluous.

With the previously known papers, for example In the case of alpha cellulose paper, this inherent bond strength does not exist, so that these tend to tear, if the mechanical strength is not guaranteed by a resin impregnation, for example So by soaking with melamine formaldehyde resins. the Fiber strength is therefore low and therefore does not give the required paper strength. Additionally With the impregnated papers used up to now, it is necessary to carry out hardness tests, to determine beforehand how such impregnated paper, for example alpha cellulose paper, reacts when placed in a press to form a laminate. Since there are variations from item to item can occur which can be attributed to differences in the proportion of impregnation material are, furthermore, on differences in the characteristic properties of the impregnation resins also variations in time, pressure and temperature

- 16 509814/1004

BOEHMERT & BOEHMERT

temperature during the lamination process. With impregnated
Papers therefore have a certain inconsistency from item to item, so that appropriate measurements have to be carried out in order to meet the special requirements of the individual passage. With the invention, however, uniformity and consistency is guaranteed at all times, because of the need for impregnation, which is the source
for all possible variations mentioned above 'is superfluous.

In addition to all the others already described
The invention also guarantees properties • Stability and consistency or uniformity.

Another considerable advantage is achieved according to the invention in that, by avoiding the impregnation process of the decorative layer, the
The resulting laminate does not have the "aggressiveness" that otherwise occurs with laminates, so that the use of the tools does not cause tool damage and the work process can accordingly be carried out easily.

The resulting laminates meet the same standards as those made using conventional techniques Decorative laminates. The improved economic efficiency which results from the use of the paper according to the invention accordingly means none Impairment of the quality of the laminates, but brings even improved properties of the same with it.

From the above it follows that the decorative

- 17 5098U / 1004

BOEHMERT & BOEHMERT

2U1564

Paper according to the invention does not require a coating for the desired integration into the laminate. However, it has been found that this improves the bond between this paper and the core can be that a thin layer of certain resins on one side of the paper, preferably on the back, is provided. Such resins further improve the integration of the paper into the laminate.

The resins which are suitable for such a coating have good adhesive properties in terms of γ / iron the cellulose fibers of the material and are also with the melamine resin of the pad and 'Compatible with the phenolic resins of the core or of the substrate. The resins preferably used work chemically with the impregnation resins and thus result in a high chemical adhesive strength, in addition to physical adhesive effects. Resins this Art can either be on the printed side of the paper (front side coating) or on the unprinted side or reverse side of the paper (reverse side coating) or applied to both sides. It should be noted that these resins are not the decorative layer soak or impregnate, nor serve to strengthen the paper, but only form a very limited, thin surface coating. These resins preferably have a medium one to high polarity because of cellulose and the resins used to impregnate the core, as well as the resins used to impregnate the pad are highly polar.

Among the resins, which have been found to be the desired ones Properties for paper coating are:

- 18 -5098U / 1004

BOEHMERT & BOEHMERT

a) Epoxy resins with an epoxy equivalent weight of about 400 to 6,000 and a softening point in the range of about 60 to 79 ⁰ C (140 to 175 ° P) §

b) Phenolfurfuralharze having a specific gravity from 1.00 to 1.30 and a softening point in the range of approximately 60 to 79 ° C (140-175 ⁰ F) $

c) Resorcinol-formaldehyde resins with a specific weight of 1.00 to 1.30 and a softening point in the range from about 60 to 69 ⁰ C (140 to

d) phenol-formaldehyde resins having a specific gravity of 1.15 His 1.30 "U · ^{11" 3} - a softening point in the range of approximately 77 to 105 ⁰ C (1 0-220 ⁰ P), and?

e) polyvinyl butyral resins with a molecular weight between 34'.0OO and 270,000, a softening point in the range of approximately; 40 to 69 ° C (105 to 15 $ ° P) .. and a specific gravity of approximately 1.00

. to 1.25.

In "accordance with the conventional method wise Coating solutions of the abovementioned resins contain the suitable hardening agent and a solvent. In these solutions, the hardeners make up approximately 0.75 "to 20% of the pesticide content, including paratoluene sulfonic acid, Phosphoric acid, tris (dimethylaminoethyl) phenol, methylbenzyldimethylamine, amides, such as Acetamides, urea, dicyandiamide, sulfones, acid anhydrides, polyamides and polyamidoamines. Suitable solvents show isopropyl alcohol and methyl ethyl ketone on «, although the aforementioned. Resins have proven to be particularly suitable for use in the

BOEHMERT & BOEHMERT

2U1564

For purposes of the invention, other resins can also be effective be used, for example, acrylonitriles, polyvinyl acetals, polyvinyl chloride acetates, polyesters and Urea formaldehyde.

The resin coating applied to this V / eise serves as a reinforcing agent for binding the cellulose fibers, which improves the internal strength of the paper, and also to improve the adhesive effect between the various layers that adhere to the decorative layer adjoin, resulting in improved physical strength and hardness.

In practice, these resins are preferably applied to the unprinted side of the decorative layer, i.e., as a backing coating, application being conventionally used in the printing industry known method, for example by rotogravure, flexography, reverse roller coating, Free-running rollers and measuring rods wrapped with wire. The most satisfactory method is to Rotogravure as the amount of resin solution applied both in terms of handling and the use of the decorative paper is critical. Of the The amount applied must be sufficient to achieve the desired binding of the paper fibers and the bridging to achieve between the core stack and the decorative layer in the subsequent lamination. Excess Solution can have a harmful effect, as it can make the decorative layer transparent, whereby, the appearance in terms of aesthetic quality is affected. Furthermore, too large an amount of the resin solution hinders the penetration or impregnation of the decorative layer paper through the phenolic

- 20 5 O 9 8 U / 10 OA

BOEHMERT & BOEHMERT

resin of the core during lamination.

The optimum amount of resin solution to be applied to the decorative damage has been found to be between 0.5 and 4.0 pounds / 3,000 pounds ² dry weight after solvent evaporation. The coating dimensioning will of course depend on the particular resin chosen. Such. Resins are thermosetting and have the potential for internal crosslinking because of numerous potential active sites.

The following are examples of such resin solutions found useful for use in the invention. Are the same given for example purposes only. It should be noted that the solutions given include a resin, a curing agent, and a compatible solvent.

Example I.

Polyvinyl butyral 99 parts by weight

Phosphoric acid 1 part by weight

Methyl ethyl ketone '400-1000 parts by weight

Example II

Epoxy resin (epoxy equivalents

weight 1,600) "80 parts by weight

Polyamide 20 parts by weight

Isopropyl alcohol 150 parts by weight

- 21 5098U / 1004

BOEHMERT & BOEHMERT

Example III

Epoxy resin (epoxy equivalent weight 4,000), polyamidoamine, methyl ethyl ketone 80 parts by weight 20 parts by weight parts by weight

Example IV

Phenol formaldehyde paratoluene sulfonic acid Methyl ethyl ketone 60 parts by weight

0.6 parts by weight 40 parts by weight

Example V

Phenolformaldehyde Tris (dimethylaminoethy! Phenol) Methyl ethyl ketone 60 parts by weight

0.6 parts by weight 40 parts by weight

Example VI

Resorcinol formaldehyde polymeric amidoamine methyl ethyl ketone 50 parts by weight 6 parts by weight

64 parts by weight

example

PhenoIfurfural Phosphoric acid methyl ethyl ketone 60 parts by weight

0.6 parts by weight 40 parts by weight

A consideration of the examples shows that there are three other types of resins that can be used for manufacture _:

- 22 5098U / 1004

BOEHMERT & BOEHMERT

suitable for the adhesive coating, namely epoxy resins, Phenolic resins and butyrals. According to the current knowledge, the ratio of the resin to the hardener changes depending on the resin used. It is of course clear that the amount of solvent depends on the known techniques is adjusted in an adequate manner so that the solution is good on the decorative layer can be applied and that the solvents evaporate rapidly. If the one with the adhesive layer provided decorative layer used for lamination the solvent must of course be completely evaporated.

The resins specified here for the adhesive coating are all thermoset and crosslinkable, properties that are critical. Also need the coatings in terms of their dry weight are within the specified range.

When using the paper according to the invention, i.e. in the production of high-pressure laminates, the process essentially corresponds to that which has been used in industry for years, with the decorative or printing layer being placed on a conventional core impregnated with phenolic resin. One impregnated with melamine resin. Overlay is applied for protection. The stack formed in this way is then brought between the polished metal plates of a hydraulic press, which is then closed. The treatment is then carried out with sufficient pressure and heat in the appropriate time so as to melt the stack together into a single laminate. The pressure can be in the range of about 70 at (1,000 US pounds / inch ² ), with the temperature

- 23 5 098 U / 1004

BOEHMERT & BOEHMERT

temperature is approximately 149 ⁰ C (30O ⁰ J ¹ ) and the duration of treatment is 20 to JO minutes. ^:

The use of the novel decorative layer according to the invention adversely affects the appearance of the laminate in relation to conventional laminates, which have a decorative or decorative layer impregnated with melamine Printing layer is not used, although the laminate can be somewhat thinner than the conventional laminates, namely because of the relatively small thickness of the Decorative paper. However, the total thickness of the laminate can easily be adjusted by adding one or several additional core layers are inserted. Laminates made according to the invention are industrial accepted tests to determine the standard conditions for decorative laminates. Such Experiments have been carried out extensively and include a variety of experiments conducted by the National Electrical Manufacturers Association were proposed and referred to as MEMA standards will. Among other things, these tests include examinations of the surface strength with regard to wear, boiling water, high temperatures, burning cigarettes, staining, bumps and the like, as well as the color fastness of the surface, immersion of the laminate in boiling water, flexural strength etc., all properties and studies as are well known in the relevant technical field are.

The laminates comprising the thin resin-coated paper of the invention have these] be widely applicable like the conventionally manufactured lami-

- 24 · -5098U / 1004

BOEHMERT & BOEHMERT

nate and are suitable for general purposes, like horizontal decoration, as well as for the coating ^ · direction of vertical surfaces, as facade elements, so for walls and the like, and can be retrofitted deform into a variety of non-planar shapes. Such laminates have met all the test conditions required for such elements are.

The application of the resin coating can be carried out economically accomplish a conventional apparatus that does not add to the cost. The coating can be applied at the same time as printing or for one day or the like later. The coating is brought into a non-sticky state by drying, so that the coated decorative paper is then rolled up for storage without the risk of sticking together can be.

The paper according to the invention has a sufficient internal bond strength, i.e. an inherent bond between the papers, so that a resin impregnation, as previously required, namely, for example, with alpha cellulose paper, not required is. The resin which is applied to the paper according to the invention is a very thin coating and does not penetrate the paper in any way. This means that there is no mechanical reinforcement of the paper in the manner of an impregnation, as is the case with Me laminform aldehyde resins. The novel properties of the invention Papers, together with the thin resin coating, result in improved properties of the manufactured ones

- 25 5098U / 1004

BOEHMERT & BOEHMERT

24A1564

Laminates, while at the same time significantly reducing material and production costs. Through this, that no resin impregnation of the decorative layer is required is, there is a significant technical advance.

As already stated, there is a very important advantage of laminates that have a decorative layer a thin surface coating according to the invention have, in the fact that they can be easily reshaped. The coating seems to have flexibility to improve the decorative layer, so that cracking is avoided in this when the pre-composite bent or otherwise produced from the laminate under pressure and heat into another shape. At the same time as ensuring flexibility, the resin coating leads to the desired fiber integration, so that when cutting or severing a smooth edge results without pulling out fibers. Accordingly, the resins used improve the properties of the paper in a unique way, see above that it is neither too stiff nor too soft.

- 26 5098U / 100A

Claims (1)

BOEHMERT & BOEHMERT EXPECTATIONS 1. Layer arrangement for the production of a laminate ^ by applying high pressure, consisting of a layer, a decorative layer and a core, characterized in that the decorative layer has a thin, having a flexible body made of fibrous cellulosic material with a printed side and a rear side, wherein the material is unimpregnated, low apparent density, low basis weight as well as relative has high porosity. 2. Layer arrangement according to claim 1, characterized in that the support consists of cellulose material, which with one from the group of melamine formaldehyde resins and the resin consisting of modified melamine-formaldehyde resins is impregnated; and that the core a variety of Has cellulose material layers which are impregnated with a phenolic resin, whereby the decorative layer is arranged in this way is that one surface is in direct contact with the core and the other surface is in direct contact with the adjacent surface of the overlay. · 5 · Layer arrangement according to claim Λ or 2, characterized in that the overlay consists of alpha cellulose paper. 4-5 509814/100 4 BOEHMERT & BOEHMERT 4-. Layer arrangement according to one of the preceding claims, characterized in that the decorative layer consists of bleached packing paper. 5. Layer arrangement according to one of the preceding claims, characterized in that the low apparent Density ranges from 0.5 to 1.0 g / cnr. 6. A layer arrangement according to any one of the preceding claims, characterized in that the decorative layer has a porosity of 1 to 15 seconds / 100 ml and a basis weight in the range of 0.016 to 0.04 kg / m ² (10 to US pounds / 3,000 feet ² ) having. 7 »Layer arrangement according to claim 6, characterized in that that the decorative layer has a Sheffield smoothness of a maximum of 150. 8. Layer arrangement according to one of the preceding claims, characterized in that the decorative layer has a bursting strength of about 1.32 to 3.3 points / kg (0.6 to 1.5 points / US pound). 9. Layer arrangement according to one of the preceding claims, characterized in that the decorative layer has a fiber ratio within the following range: Softwood 15 - 80% hardwood 85 - 20%. 10. Layer arrangement according to one of the preceding claims, characterized in that the decorative layer is a From one to three mils thick. - 2 -
5098U / 100A BOEHMERT & BOEHMERT 11. Layer arrangement according to one of the preceding claims, characterized in that at least one side of the decorative layer is provided with an adhesive layer consisting essentially of a thermosetting Resin is made. 12. Layer arrangement according to claim 11, characterized in that the adhesive layer in such a manner is applied that a dry weight between about 0.00081 and 0.0032 kg / m ² (0.5 and 4.0 U.S. pounds / 3,000 ρ Foot) is achieved. 13 · Layer arrangement according to claim 1.1 or 12, characterized characterized in that the adhesive layer is applied to the side of the decorative layer facing the core. 14. Layer arrangement according to one of claims 11 to 13, characterized in that the resins forming the adhesive layer are crosslinkable. 15 · Layer arrangement according to one of claims 11 to 14, characterized in that the thermosetting resin consists of made from phenol formaldehyde, phenol fixnfural, epoxy compounds, Resorcinolformanedehyde and polyvinylbutyral are selected. ~ 16. Layer arrangement according to one of claims 11 to 15? characterized in that the resin is an epoxy resin having an equivalent weight between approximately 400 and 6,000 and a softening point in the range of about 60 to 79 ° C (140 to 174 ° F). 17 · Layer arrangement according to one of claims 1'i to 15, characterized in that the thermosetting resin poly - 3 50981 Ul 1 0OA BOEHMERT & BOEHMERT vinyl butyral (up to 155 ° F 105) and a specific gravity in the range of approximately 1.00 to 1.25 with a molecular weight in the range of approximately 34- · 000 to 270,000, a softening point in the range of about 40-68 ⁰ C. . 18. Layer arrangement according to one of claims 11 to, characterized in that the thermosetting resin Ph§nolformaldehyd with a softening point in the range of approximately 77 to 105 ⁰ C (170 to 220 ⁰ F) and a specific gravity in the range of 1.15 "to 1.30 is. 19 layer arrangement according to one of claims 11 to 15, characterized in that the thermosetting resin is phenol furfural having a softening point in the range of about 60 to 79 ° C (140 to 175 ° F) and a specific gravity in the range of approximately 1.00 to 1.30. 20. Layer arrangement according to one of claims 11 to 15, characterized in that the thermosetting resin resorcino / formaldehyde with a softening point in the range of approximately 60 to 79 ° C (140 to 175 ⁰ F) and a specific gravity in the range of approximately 1, 00 to, 1.30 is. 21. Laminate made from a layer arrangement according to one of the preceding claims. 22. Decorative layer, usable and composed according to one of claims 1 to 20. · 23. A method for producing a high pressure laminate, characterized in that a support layer made of, with one of the melamine formaldehyde resins and modified _ Zf. _ 509814/1004 BOEHMERT & BOEHMERT adorned melamine-formaldehyde resins Resin-impregnated cellulose material "existing layer on top of an unimpregnated decorative layer made of thin, flexible, fibrous cellulose material, which has a printed side and a back, is placed in such a way that the support on the printed Side of the decorative layer lies; and that under the back of the decorative layer a core made up of a plurality consists of layers or sheets of cellulose material, which are laid one on top of the other and each with a Phenolic resin are impregnated, is laid, whereupon the stacked layer arrangement is relatively high pressure and is exposed to a relatively high temperature for a certain period of time, thereby forming the layer arrangement to melt into a single laminate. 24. The method of claim 23, characterized in that the pressure applied to the laminate is on the order of about 70.31 at (1,000 US pounds / square inch) and the temperature is about 149 ⁰ O (30O ⁰ F) and the duration of the temperature and pressure treatment is between 20 and 30 minutes. 25. The method according to claim 23 or 24, characterized by using a decorative layer with a apparent density of 0.5 to 1.0 gr / nr, a porosity from 1 to 15 sec / ml and a basis weight of about 10 to 25 pounds per square inch is used. 26. Laminate according to claim 21, characterized · by Decorative layer with the support and the core layers connecting to one another melting means. - 5 5098U / 1004 BOEHMERT & BOEHMERT 2U1564 27 · Laminate according to claim 26, characterized in that that the connecting the decorative layer with the support Enamel layer through impregnation within the support and the individual layers of the core interconnecting fluxes are produced by impregnation within the core, the Decorative layer is relatively thin, so that the flux penetrate into the decorative layer. ■ "* Ό ■" ■ 50981 Ul 1 0OA