EP0054405B1 - Procédé pour la préparation de stratifiés décoratifs - Google Patents

Procédé pour la préparation de stratifiés décoratifs Download PDF

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Publication number
EP0054405B1
EP0054405B1 EP19810305807 EP81305807A EP0054405B1 EP 0054405 B1 EP0054405 B1 EP 0054405B1 EP 19810305807 EP19810305807 EP 19810305807 EP 81305807 A EP81305807 A EP 81305807A EP 0054405 B1 EP0054405 B1 EP 0054405B1
Authority
EP
European Patent Office
Prior art keywords
paper
decorative laminate
pigment
manufacture
binder
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.)
Expired
Application number
EP19810305807
Other languages
German (de)
English (en)
Other versions
EP0054405A1 (fr
Inventor
John Allen Sandys Newman
Alison Mary Ritchie
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
DEVON VALLEY INDUSTRIES LIMITED
Original Assignee
Devon Valley Industries Ltd
Wiggins Teape Group Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
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First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=10517958&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=EP0054405(B1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Devon Valley Industries Ltd, Wiggins Teape Group Ltd filed Critical Devon Valley Industries Ltd
Publication of EP0054405A1 publication Critical patent/EP0054405A1/fr
Application granted granted Critical
Publication of EP0054405B1 publication Critical patent/EP0054405B1/fr
Expired legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/18—Paper- or board-based structures for surface covering
    • D21H27/22—Structures being applied on the surface by special manufacturing processes, e.g. in presses
    • D21H27/26—Structures being applied on the surface by special manufacturing processes, e.g. in presses characterised by the overlay sheet or the top layers of the structures
    • 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
    • B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper

Definitions

  • This invention relates to a process for the manufacture of decorative laminates, to the laminates so made and to a paper for use in the process.
  • Decorative laminates are used, for example, for surfacing furniture, particularly kitchen or other furniture where it is desirable to have a water- resistant, easily-wipeable surface, for counter tops in shops and cafes and for building panels. They may be white or coloured, and may be plain or printed, for example with a woodgrain or other pattern. Printing may be in several colours, and is usually effected by a rotogravure technique.
  • One well-known type of decorative laminate (usually known as a high-pressure laminate) consists of several so-called core sheets for imparting strength to the laminate, a decorative sheet serving to mask the uppermost core sheet and to afford the laminate an attractive surface, and an overlay sheet on top of the decorative sheet (the overlay sheet becomes transparent during manufacture of the laminate, and so does not mask the decorative sheet).
  • a so-called barrier sheet can be provided between the decorative sheet and the uppermost core sheet to afford an additional masking effect.
  • All the sheets forming the laminate are impregnated with a thermo-setting resin, for example a phenolic resin or a melamine- formaldehyde or other aminoplast resin (the various sheets making up the laminate are not usually all impregnated with the same resin).
  • the impregnating resin in the case of the decorative sheet is most commonly a melamine formaldehyde resin.
  • the resin is usually present in an amount of the order of 100% w/w.
  • the decorative sheet normally carries the print.
  • the overlay sheet may carry the print on its surface which contacts the decorative sheet.
  • the core sheets are normally of strong, relatively inexpensive paper, for example unbleached softwood kraft paper. Such paper is not of uniform or particularly attractive appearance, and is not suitable for high quality printing. For this reason, it is necessary for the decorative sheet to be sufficiently opaque to mask the unattractive and non-uniform appearance of the uppermost core sheet, and for it to be suitable for high quality printing.
  • a sheet of chipboard or similar material is used directly as a support for the decorative sheet, instead of the core sheets.
  • the decorative sheet in such a laminate serves to mask the chipboard rather than the core sheets.
  • Barrier sheets are not normally used in this type of laminate since chipboard is normally of a lighter shade than core sheets and hence is more easily masked.
  • plastic base surface paper In addition to being opaque and suitable for printing, it must be absorbent so that it may easily be impregnated with resin during a single pass through an impregnating bath, which typically takes about 20 sec. The same applies to the overlay sheet if it is to be printed.
  • the absorbency of plastic base surface paper is typically in the range 30 to 65 mm/10 min if for use in a high-pressure laminate, or in the range 25 to 45 mm1/10 min if for use in a low-pressure laminate (in the Klemm method a strip of paper 15 mm wide is suspended vertically with one end in a dish of the liquid concerned and the distance the liquid soaks up the paper in ten minutes is measured).
  • the absorbency of an overlay sheet is typically in the higher part of the range quoted for plastic base surface paper for use in a high-pressure laminate.
  • the absorbency of plastic base surface paper may also be quoted in terms of porisity as measured by a Gurley porosity tester, since porosity is related to speed of absorbency in this instance.
  • Plastic base surface paper typically has a Gurley porosity (20 oz) in the range 10 to 25 sec/100 ml preferably 20 to 25 sec/100 ml, if for use in a high-pressure laminate, or in the range 15 to 50 sec/100 ml if for use in a low-pressure laminate, although values of 70 sec/100 ml or more are acceptable.
  • plastic base surface paper and overlay paper to be absorbent results in a relatively rough paper surface which is not particularly suitable for high quality gravure printing.
  • the rough surface makes it difficult to obtain complete print coverage from every gravure cell.
  • the absorbent nature of the paper allows ink to penetrate into the sheet and print intensity is therefore reduced.
  • plastic base surface and overlay paper can be printed to a high standard, provided larger quantities of ink are used than would be needed on a good printing surface or provided a lower absorbency is acceptable.
  • pigment coating such as is commonly used in the manufacture of high quality printing papers.
  • coatings enhance printability not only by increasing surface smoothness, which would be acceptable in plastic base surface and overlay papers, but also by decreasing absorbency to an extent which would not be acceptable in such papers.
  • Pigment-coated art papers typically have a Klemm absorbency below 5 mm/10 minutes, which is well below that required in plastic base surface and overlay papers.
  • GB-A-653531 refers to an impregnation time of 20 minutes, which is far in excess of the 20 second impregnation times now conventional. Since GB-A-674149 and FR-A-1048836 are closely related to GB-A-653531, it is to be supposed that the papers they disclose would likewise have unacceptably long empregnation times.
  • US-A-3798111 discloses the application of hard abrasion resistant pigments to a wet web for use as a surface paper, whilst the web is still on the wire of a papermaking machine, for example by means of a secondary headbox. The resulting dried paper is subsequently printed.
  • US-A-3578483 discloses the application to a surface paper of a discontinuous solvent-based pigment coating composition. The resulting web is subsequently printed.
  • the present invention provides in a first aspect a process for the manufacture of a decorative laminate comprising the steps of:
  • the present invention provides a decorative laminate surface or overlay paper carrying a continuous coating composition comprising a pigment and a binder on a surface thereof at a coatweight of up to 10 gm- 2 , said paper having a Gurley porosity of about 10 to 70 sec/100 ml and said pigment being kaolin, calcium carbonate, titanium dioxide or barium sulphate.
  • the coatweight and the weight ratio of pigment to binder must be chosen carefully.
  • the preferred dry coatweight is in the range of from 2.5 to 3 gm- 2 .
  • the weight ratio of pigment to binder in the coating is preferably in the range 5:1 to 1:1, more preferably from 2.5:1 to 3.5: 1.
  • the Gurley porosity (567 g) of the coated paper is preferably in the range 20 to 50 sec/100 ml.
  • the pigment is preferably one having a Mohs' hardness of less than 7, for example kaolin, calcium carbonate in precipitated or ground form, titanium dioxide or barium sulphate. Pigments having a Mohs' hardness greater than 7, such as alumina or hydrated alumina, various natural or synthetic alumino-silicates or silica or silica gel may however be used.
  • the binder may be starch, casein, latex, polyvinyl alcohol or an aminoplast or other cross-linking resin.
  • the liquid coating composition comprising the pigment and binder is applied by size press treatment, although other coating techniques may be used, for example air-knife coating. It will be appreciated that size press treatment normally results in a coating being applied to both surfaces of the paper web.
  • the decorative laminate surface or overlay paper may be calendered before being impregnated.
  • the present plastic base surface of overlay paper enables an improvement in print quality to be obtained as a result of more complete ink transfer from the gravure cells and of less ink absorption. It also permits a reduction in ink usage for a print of specified quality, or, for the same ink usage affords a better print than would be obtained on the same paper if it were not coated.
  • a sheet of plastic base surface paper having a grammage of 100 gm- 2 was size press coated with an aqueous coating containing a mixture of kaolin (supplied by English China Clays under the designation "Supreme”), esterified starch and mealmine-formaldehyde resin in a weight ratio of 3:1:0.001.
  • the coating was then dried, the dry coatweight being 3 gm- 2.
  • the absorbency of both the coated and the uncoated paper was found to be 30 mm/10 min.
  • the Gurley porosity (567 g) of the coated paper was found to be 24 sec/100 ml, and that of the uncoated paper was 18 sec/100 ml.
  • Both the coated paper and a sample of uncoated plastic base surface paper were then printed with the same amount of ink using a gravure printing process.
  • the optical reflectivity of the uncoated paper was 20% whereas that of the coated paper was 10%.
  • Both papers absorbed a sufficient amount of resin to make satisfactory laminates and the colour or shade of the unprinted surface of a laminate containing the coated paper was judged to be the same as that of a laminate . containing uncoated paper.
  • a sheet of plastic base surface paper having a grammage of 120 gm- 2 was size press coated with an aqueous coating containing a mixture of barium sulphate (precipitated), esterified starch and melamine formaldehyde resin in a weight ratio of 3: 1: 0.001.
  • the coating was then dried and calendered, the dry coatweight being 7 gm- 2 .
  • the Gurley porosity (567 g) of the coated paper was found to be 26 sec/100 mi, and that of the uncoated paper was 14 sec/100 ml.
  • Both the coated paper and a sample of uncoated plastic base surface paper were then printed with the same amount of ink using a gravure printing process.
  • the optical reflectivity of the uncoated paper was 20% whereas that of the coated paper was 18%.
  • Both papers absorbed a sufficient amount of resin to make satisfactory laminates and the colour or shade of the unprinted surface of a laminate containing the coated paper was judged to be the same as that of a laminate containing uncoated paper.
  • a sheet of plastic base surface paper having a grammage of 120 gm- 2 was size press coated with an aqueous coating containing a mixture of titanium dioxide (supplied by British Titan Products, under the designation ALF), esterified starch and melamine formaldehyde resin in a weight ratio of 3:1:0.001.
  • the coating was then dried and calendered, the dry coatweight being 6.6 gm- 2 .
  • the Gurley porosity (567 g) of the coated paper was found to be 69 sec1100 ml, and that of the uncoated paper was 14 sec/100 ml.
  • Both the coated paper and a sample of uncoated plastic base surface paper were then printed with the same amount of ink using a gravure printing process.
  • the optical reflectivity of the uncoated paper was 20% whereas that of the coated paper was 17%.
  • Both papers absorbed a sufficient amount of resin to make satisfactory laminates and the colour or shade of the unprinted surface of a laminate containing the coated paper was judged to be the same as that of a laminate containing uncoated paper.
  • a sheet of plastic base surface paper having a grammage of 120 gm- 2 was size press coated with an aqueous coating containing a mixture of calcium carbonate (under the designation Hyd- rocarb) esterified starch and melamine formaldehyde resin in a weight ratio of 3:1:0.001.
  • the coating was then dried and calendered, the dry coatweight being 5.5 gm- 2 .
  • the Gurley porosity (567 g) of the coated paper was found to be 50 sec/100 ml, and that of the uncoated paper was 14 sec/100 ml.
  • Both the coated paper and a sample of uncoated plastic base surface paper were then printed with the same amount of ink using a gravure printing process.
  • the optical reflectivity of the uncoated paper was 20% whereas that of the coated paper was 17%.
  • Both papers absorbed a sufficient amount of resin to make satisfactory laminates and the colour or shade of the unprinted surface of a laminate containing the coated paper was judged to be the same as that of a laminate containing uncoated paper.

Landscapes

  • Laminated Bodies (AREA)
  • Paper (AREA)

Claims (13)

1. Procédé pour la fabrication de stratifiés décoratifs comprenant les étapes consistant:
(a) à appliquer une composition liquide aqueuse de revêtement contenant un pigment et un liant sur une surface d'un papier enduit ou d'un papier de surface stratifiée décorative, préalablement formé et séché, en vue d'obtenir une couche de revêtement continu,
(b) à imprimer le motif désiré sur ladite surface revêtue dudit papier;
(c) à imprégner le papier imprimé résultant avec une résine thermodurcissable; et
(d) à stratifier le papier imprégné sur un support, dans des conditions permettant de durcir la résine et ainsi fournir ledit stratifié décoratif, caractérisé par le fait que:
(e) le poids de couche à sec du revêtement continu sur la surface du papier enduit ou du papier de surface stratifiée décorative est d'au plus 10 g/m-2; et que
(f) la porosité Gurley (567 g) du papier enduit ou du papier de surface stratifiée décorative ainsi couché est d'environ 10 à 70 sec/100 ml.
2. Procédé oour la fabrication de stratifiés décoratifs selon la revendication 1, caractérisé par le fait que le revêtement est appliqué à ladite surface du papier enduit ou du papier de surface stratifiée décorative, préalablement formé et séché, selon un poids de couche de 2,5 à 3 g/M-2.
3. Procédé pour la fabrication de stratifiés décoratifs selon la revendication 1, caractérisé par le fait que l'absorption Klemm du papier de surface pour base plastique est dans le domaine de 25 à 65 mm/10 min.
4. Procédé pour la fabrication de stratifié décoratif selon la revendication 1, caractérisé par le fait que le pigment a une dureté Moh inférieure à 7.
5. Procédé pour la fabrication de stratifiés décoratifs selon la revendication 4, caractérisé par le fait que le pigment est choisi parmi le kaolin, le carbonate de calcium, le dioxyde de titane ou le sulfate de baryum.
6. Procédé pour la fabrication de stratifiés décoratifs selon la revendication 1, caractérisé par le fait que le rapport en poids de pigment au liant est compris entre 5:1 et 1:1.
7. Procédé pour la fabrication de stratifiés décoratifs selon la revendication 6, caractérisé par le fait que le rapport du pigment au liant est compris entre 2,5:1 et 3,5:1.
8. Procédé pour la fabrication de stratifiés dédo- ratifs selon la revendication 1, caractérisé par le fait que le revêtement est appliqué par traitement à l'aide d'une presse encolleuse (ou "size press").
9. Procédé pour la fabrication de stratifiés décoratifs selon la revendication 1, caractérisé par le fait que le liant est choisi parmi l'amidon, la caséine, du latex, de l'alcool polyvinylique ou une résine aminoplaste ou toute autre résine réticulée.
10. Papier enduit ou de surface stratifiée décorative comportant une composition de revêtement continu contenant un pigment et un liant sur leur surface selon un poids de couche d'au plus 10 gtm-2, ledit papier ayant une porosité Gurley (567 g) d'environ 10 à 70 sec/100 ml, et ledit pigment étant du kaolin, du carbonate de calcium, du dioxyde de titane ou du sulfate de baryum.
11. Papier enduit ou de surface stratifiée décorative selon la revendication 10, caractérisé par le fait que la composition de revêtement a un poids de couche de 2,5 à 3 g/m-2.
12. Papier enduit ou de surface stratifiée décorative tel que revendiqué selon l'une quelconque des revendications 10 ou 11, caractérisé par le fait que le rapport en poids du pigment au liant est compris entre 5:1 et 1:1.
13. Papier enduit ou de surface stratifiée décorative tel que revendiqué selon la revendication 12, caractérisé par le fait que le rapport en poids du pigment au liant est compris entre 2,5:1 et 3,5:1.
EP19810305807 1980-12-12 1981-12-09 Procédé pour la préparation de stratifiés décoratifs Expired EP0054405B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB8039933 1980-12-12
GB8039933 1980-12-12

Publications (2)

Publication Number Publication Date
EP0054405A1 EP0054405A1 (fr) 1982-06-23
EP0054405B1 true EP0054405B1 (fr) 1985-02-13

Family

ID=10517958

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19810305807 Expired EP0054405B1 (fr) 1980-12-12 1981-12-09 Procédé pour la préparation de stratifiés décoratifs

Country Status (5)

Country Link
EP (1) EP0054405B1 (fr)
JP (1) JPS57501950A (fr)
CA (1) CA1170513A (fr)
DE (1) DE3168974D1 (fr)
WO (1) WO1982002067A1 (fr)

Families Citing this family (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3313825C1 (de) * 1983-04-16 1991-11-21 Vits-Maschinenbau Gmbh, 4018 Langenfeld Verfahren und Vorrichtung zum Herstellen einer Folie,insbesondere fuer die Beschichtung von Hartfaser-,Span- oder Holzplatten
GR1000651B (el) * 1990-12-27 1992-09-25 Roltex A E Μεθοδος και συσκευη παραγωγης υλης χαρτου/χαρτονομικου με πλαστικοποιησιν και ενιαιον χρωματισμον εκατερωθεν και ειδη παραγομενα εξ αυτης.
JPH06173199A (ja) * 1992-12-04 1994-06-21 Tomoegawa Paper Co Ltd 殺菌紙
JP2599247B2 (ja) * 1994-03-28 1997-04-09 南海プライウッド株式会社 化粧シート及び化粧板
ZA968745B (en) * 1995-10-23 1999-05-25 Maecher Pictureproducts Pty Lt Laminated products
SE9503972L (sv) * 1995-11-10 1996-11-25 Perstorp Ab Ytbeläggningsförfarande
ATA113497A (de) * 1997-07-02 1999-03-15 Kaindl M Dekor-laminat-werkstoff und verfahren zu dessen herstellung
DE19916546C2 (de) * 1999-04-13 2001-05-03 Technocell Dekor Gmbh & Co Kg Tintenstrahl-Aufnahmeschicht
US6702922B2 (en) * 2002-07-17 2004-03-09 Mw Custom Papers, Llc Papers for use in decorative laminates and methods of making the same
FR2870265B1 (fr) 2004-05-13 2006-07-14 Arjowiggins Soc Par Actions Si Papier decoratif et stratifie decoratif le comportant
DE102008008292A1 (de) 2008-02-07 2009-08-13 hülsta-werke Hüls GmbH & Co KG Papierschicht zum Herstellen eines flächigen, bedruckten oder bedruckbaren Bauteils
ES2396008T3 (es) * 2009-03-24 2013-02-18 Hülsta-Werke Hüls Gmbh & Co. Kg Procedimiento para la fabricación de cuerpos de placa con láminas impresas empleando el método de impresión por huecograbado
PL2695745T3 (pl) 2012-08-06 2016-03-31 Unilin Bvba Sposób wytwarzania paneli o powierzchni dekoracyjnej
ES2752557T3 (es) 2014-01-10 2020-04-06 Unilin Bvba Método para fabricar paneles con una superficie decorativa
EP2905145B1 (fr) 2014-02-06 2019-10-23 Unilin, BVBA Procédé de fabrication des panneaux de plancher ayant une surface décorative
CA3033522A1 (fr) * 2016-08-10 2018-02-15 Pressing Developments, L.L.C. Produits stratifies melamines pouvant etre teints, compositions et procedes de fabrication
BE1025875B1 (nl) 2018-01-04 2019-08-06 Unilin Bvba Werkwijzen voor het vervaardigen van panelen

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB653531A (en) * 1948-02-14 1951-05-16 Herbert John Mallabar Improvements in the manufacture of decorative laminated sheet material
GB674149A (en) * 1949-06-30 1952-06-18 Herbert John Mallabar Improvements in the manufacture of decorative laminae
US3578483A (en) * 1969-05-14 1971-05-11 Formica Corp Process for improving the printability of the surface of alpha-cellulose paper to be used as the decorative sheet in a decorative laminate
US3798111A (en) * 1972-03-24 1974-03-19 Mead Corp Multiple layer decorated paper,laminates prepared therefrom and process
JPS5245408B2 (fr) * 1973-12-29 1977-11-16
AT332107B (de) * 1974-09-25 1976-09-10 Isovolta Verfahren zur herstellung von schichtstoffdekorplatten
IL53694A (en) * 1977-01-10 1980-09-16 Nevamar Corp Abrasion resistant laminates and their production
SE446519B (sv) * 1978-11-09 1986-09-22 Nevamar Corp Notningsbestendigt dekorativt laminat samt sett och medel for framstellning derav

Also Published As

Publication number Publication date
JPS57501950A (fr) 1982-11-04
WO1982002067A1 (fr) 1982-06-24
DE3168974D1 (en) 1985-03-28
EP0054405A1 (fr) 1982-06-23
CA1170513A (fr) 1984-07-10

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