EP0065043B1 - Méthode pour conférer des effets de couleur en clair ou en ombre à des strafifiés texturés décoratifs - Google Patents

Méthode pour conférer des effets de couleur en clair ou en ombre à des strafifiés texturés décoratifs Download PDF

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Publication number
EP0065043B1
EP0065043B1 EP81302205A EP81302205A EP0065043B1 EP 0065043 B1 EP0065043 B1 EP 0065043B1 EP 81302205 A EP81302205 A EP 81302205A EP 81302205 A EP81302205 A EP 81302205A EP 0065043 B1 EP0065043 B1 EP 0065043B1
Authority
EP
European Patent Office
Prior art keywords
laminate
textured
pigment
release sheet
pigmented
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
EP81302205A
Other languages
German (de)
English (en)
Other versions
EP0065043A1 (fr
Inventor
Gilbert Daniel Endrizzi
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.)
NewPage Wisconsin System Inc
Original Assignee
Consolidated Papers Inc
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
Application filed by Consolidated Papers Inc filed Critical Consolidated Papers Inc
Priority to AT81302205T priority Critical patent/ATE10461T1/de
Priority to DE8181302205T priority patent/DE3167414D1/de
Priority to EP81302205A priority patent/EP0065043B1/fr
Publication of EP0065043A1 publication Critical patent/EP0065043A1/fr
Application granted granted Critical
Publication of EP0065043B1 publication Critical patent/EP0065043B1/fr
Expired legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/28—Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
    • 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
    • B44C3/005—Removing selectively parts of at least the upper layer of a multi-layer article
    • 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
    • B44C3/08—Stamping or bending
    • B44C3/085—Stamping or bending stamping
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F9/00—Designs imitating natural patterns
    • B44F9/02—Designs imitating natural patterns wood grain effects

Definitions

  • This invention relates to a method of imparting color highlights or shadows to a textured surface of decorative laminates in the course of production of decorative plastics laminates, which are extensively used in making furniture, counter tops, panelling and other decorative or functional surfaces.
  • a plurality of sheets of resin impregnated kraft paper are stacked together to form a core or backing.
  • the resin employed is a heat curable type such as phenol formaldehyde.
  • a decorative sheet of paper having a printed design or solid color and impregnated with a melamine resin is laid over the core, and an overlay sheet, usually melamine impregnated alpha cellulose paper, is superimposed over the decorative sheet. In some instances, especially where the final product is of solid color, the overlay sheet may be omitted.
  • a panel of particle board may be substituted for the core sheets.
  • a release sheet composed of relatively non-adhereable paper, plastics film or aluminum foil is interposed between the decorative surface and the caul to prevent adhesion between the caul and the decorative surface.
  • U.S. Patent No. 1,742,516 describes a process wherein a design or letter is embossed in a laminate by using an engraved caul having the design depossed therein.
  • U.S. Patent No. 1,997,358 and No. 2,133,081 describe the texturizing of plastics laminates utilizing an embossed metal caul.
  • U.S. Patent No. 2,606,855 discloses a process of using a master to make a number of textured caul plates from a stack of resin impregnated paper. Similar techniques utilizing embossed or debossed plastics laminates as molding cauls are described in U.S. Patent No. 3,303,081 and No. 3,311,520. U.S. Patent No. 3,373,068 describes the use of particulate matter on the decorative sheet to impart texture thereto.
  • a laminate that simulates another product, a good example being a wood grained surface.
  • a decorative sheet having a colored wood grain printed thereon, and the decorative surface may also be textured during the subsequent molding process. It is not usually possible or convenient, however, to impart a texture conforming to the print pattern, and the resulting product does not have the combined texture and appearance of a naturally stained wood wherein the grain is highlighted by differential absorption of the stain into the grain, saw marks or depressed areas of the wood.
  • the present invention represents a further improvement in the production of textured decorative laminates, which allows for greater realism, warmth and a contrasting textural quality heretofore not attainable.
  • a release sheet having a coating of pigment thereon is applied over the decorative surface before the laminate is pressurized against a textured molding caul.
  • the release sheet may be composed, for example, of a sheet of polymeric material having a thin layer of ink applied substantially uniformly on the surface against which the panel or laminate is to be molded.
  • the pigment is uniformly transferred to the texturized surface, the color of the pigment being selected so as to contrast with the color of the decorative sheet.
  • the release sheet is removed to expose a textured surface that is substantially uniformly colored by the pigment.
  • the decorative surface is then subjected to surface rubbing, brushing or light abrasion to the extent necessary to remove color from the raised or embossed portions while allowing more color to remain in the depressed or debossed areas, thus highlighting or shadowing the texture and providing added visual dimension to the appearance of the textured surface.
  • any of the well known methods of making textured laminates may be employed.
  • a variety of textures are possible, such as wood grain, fabric, decorative objects, writing or printing, as well as many others.
  • the process of making the textured laminate from a textured caul is conventional, and the present invention resides in imparting color highlights to the textured surface.
  • the core is made up from a plurality of resin impregnated kraft sheets. These sheets are normally impregnated with a phenolic resin, allowed to at least partially dry, and then stacked in a superimposed relation.
  • the number of sheets utilized may vary and ordinarily the number will vary between three and six.
  • Other core materials, such as particle board, may be used.
  • a resin impregnated decorative sheet which in the case of the preferred embodiment will be a sheet having color, printing, or other decoration thereon, for example, printing that resembles a grained wood panel.
  • a protective overlay sheet of fine paper such as alpha cellulose.
  • the overlay and print sheet are impregnated with a heat curable resin, preferably with a noble thermosetting resin such as melamine formaldehyde resin or the like.
  • the decorative sheet may be replaced by metal foil.
  • the sandwich of the aforesaid materials is placed between a pair of rigid caul plates.
  • the caul plate facing the decorative sheet is provided with a desired textured surface by any of the well known and conventional methods, and a release sheet is placed between the caul and the outer sheet of the laminate.
  • the assembly is placed in a heated press, and the sandwich is subjected to heat and pressure for a time sufficient to cure the resin in the laminate, i.e. typically 500 to 2,000 p.s.i. (3,447x10 3 to 13,790x10 3 Pa), 200° to 400°F (93.3° to 204.4°C), and 15 to 60 minutes.
  • the resulting product is a rigid laminate having a hard, durable decorative and textured surface.
  • the textured caul is prepared by any suitable method.
  • the caul plate may be a rigid metal plate with any desired texture etched thereon by conventional methods.
  • FIG. 3 Another suitable method for preparing a textured caul plate is described in U.S. Patent No. 3,616,011.
  • a consumable original textured panel or sheet is sandwiched between a pair of resin impregnated or resin containing overlay sheets of a size slightly larger than the original.
  • the overlay sheets and the curable resin therein may be of any of a wide variety of acceptable materials, such as various heat curable resins, such as melamine, phenolic, epoxy, urea formaldehyde and others.
  • Each of the overlay sheets is covered by a release sheet, and the release sheets in turn may be backed by a stack of padding sheets, such as sheets of kraft paper.
  • the resulting assembly is then placed in a molding press between a pair of cauls, and the assembly is heated and compressed between the cauls in a conventional manner until the resin is cured. Upon curing, the overlay sheets bond to the textured core and assume the texture of the core.
  • the resulting laminate which may be textured on one or both sides, is used as a molding caul to make textured decorative laminates, as hereinbefore described.
  • the method of imparting color highlights in accordance with the present invention is carried out as part of the formation of the textured decorative laminate. Color is applied to the decorative surface during the pressure molding procedure, and any excess color is removed from the textured surface after completion of the molding operation.
  • a special release sheet is used and is an important feature of the invention.
  • the release sheet to be used is first coated on one side with a pigment, and the pigmented side is placed against the decorative surface prior to the pressure forming of the textured laminate.
  • the color of the pigment is preferably selected to be darker than the color of the decorative sheet or in any event is preferably of a contrasting or highlighting color.
  • pigments carried in a solvent and binder system capable of being coated onto the release sheet and dried after application are preferred, such as printing inks. It is not necessary to apply the ink to the release sheet in accordance with any pattern, and in fact, a substantially uniform and unpatterned application is preferred to assure complete coverage of the decorative surface. Uniform coating of the ink onto the release sheet by conventional rotogravure methods has been found suitable for this purpose.
  • the material for the release sheet may be selected from any of the materials in common use and include foil, polymer films and treated paper films.
  • Polypropylene film is especially preferred due to its ability to release the ink when placed under the heat and pressure conditions used in the laminating process.
  • the components of the decorative laminate, pigmented release sheet and textured caul are then assembled as a sandwich as aforesaid and are compressed in the aforesaid manner at sufficient pressures and temperatures to cause curing and bonding of the resin impregnated sheets.
  • the textured surface of the caul is imparted to the decorative surface, and at the same time, the release sheet conforms to the irregular surfaces and transfers pigment thereon substantially uniformly onto the decorative surface of the laminate.
  • the release sheet is stripped away from the textured decorative surface, which is now substantially uniformly coated with the pigment.
  • caul plate having a textured surface on both sides since an assembly of caul plates and resin impregnated paper assemblies may be compressed and heated simultaneously.
  • five cauls can be used in a single molding operation to produce ten decorative panels.
  • wood grain print sheet is utilized, and a wood grain texture is imparted to the laminate.
  • the pattern of the print sheet need not coincide with the texture pattern to produce the desired results, thus eliminating the problem or bringing the patterns into exact register.
  • the pigmented textured surface of the laminate is now subjected to an operation in which some or all of the pigment remaining on the embossed areas is removed from such areas of the surface while allowing a greater amount of pigment to remain in the debossed areas.
  • This operation may be accomplished by surface rubbing or brushing, exposing the lighter shades of the raised grain or texture and enhancing a three dimensional shadow effect.
  • a suitable procedure is to brush the textured surface with rotary bristle or tampico brushes, preferably in the direction of the grain pattern.
  • Such apparatus is conventionally used in a dull rubbing operation to reduce the gloss of the decorative surface of laminates, and any equivalent procedure for mechanically removing the pigment from the high spots would be effective.
  • the pigment used preferably will be one having high adherence properties, but in any event it is believed that some of the pigment migrates into the resinous surface, particularly in the debossed areas which are subjected to the greatest molding pressure, and becomes bonded therein as the resin is cured.
  • the resulting laminate will thus have a textured surface with a greater concentration of pigment in the debossed areas than in the embossed areas.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Claims (8)

1. Méthode pour conférer des effets de lumière ou d'ombre à un stratifié décoratif, méthode caractérisée en ce qu'elle comprend les étapes consistant à préparer un stratifié décoratif texturé par moulage sous pression en utilisant une feuille que l'on peut enlever, pigmentée, pour transférer un pigment sur ce stratifié, et à frotter ensuite la surface du stratifié texturé, pigmenté, dans la mesure nécessaire pour éliminer une certaine proportion du pigment déposée, en retirant plus de pigment des zones en relief des stratifiés texturés que des zones en creux de ces stratifiés.
2. Méthode pour conférer des effets de lumière ou d'ombres à un stratifié décoratif texturé, méthode caractérisée en ce qu'elle comprend les étapes consistant à préparer un assemblage de feuilles imprégnées de résine polymérisable à chaud, à placer une feuille amovible ayant une surface pigmentée sur une surface extérieure de cet assemblage, la surface pigmentée se trouvant face à face avec la surface extérieure, à comprimer et chauffer cet assemblage avec la feuille amovible, dans des conditions où la résine est polymérisée et où l'assemblage est collé pour former un stratifié en provoquant le transfert du pigment de la feuille amovible sur la surface extérieure, à retirer la feuille amovible du stratifié polymérisé, quand les opérations de pression et de chauffage sont terminées, pour mettre à nu la surface texturée, pigmentée, et à frotter ensuite cette surface dans la mesure nécessaire pour éliminer une plus grande quantité de pigment des surfaces en relief que des surfaces en creux de cette surface.
3. Méthode selon la revendication 2, caractérisée en ce que la feuille amovible est une feuille de polypropylène.
4. Méthode selon l'une quelconque des revendications 2 et 3, caractérisée en ce que le pigment est une encre liquide appliquée sur la feuille amovible et séchée sur celle-ci.
5. Méthode selon la revendication 4, caractérisée en ce que l'encre est appliquée sensiblement uniformément sur la feuille amovible.
6. Méthode selon l'une quelconque des revendications 2 à 5, caractérisée en ce que le frottement de la surface texturée, pigmentée comprend un brossage par une brosse rotative.
7. Méthode suivant l'une quelconque des revendications 2 à 6, caractérisée en ce que la surface extérieure porte en impression une apparence de grain de bois, et que le pigment est d'une nuance qui contraste avec celle de la surface extérieure.
8. En relation avec la production d'un stratifié décoratif présentant une surface extérieure texturée, où le stratifié est formé en préparant un assemblage comprenant des feuilles imprégnées de résine, en appliquant une feuille amovible sur une feuille extérieure de cet assemblage, et formant un stratifié en chauffant et comprimant cet assemblage entre deux plaques servant de moules, une de ces plaques ayant une surface texturée venant en face de la feuille amovible et suivant à donner à cette surface extérieure un fini texturé, méthode pour conférer des effets colorés de lumière ou d'ombres à la surface extérieure texturée du stratifié, cette méthode comprenant les étapes consistant à garnir la feuille amovible d'un revêtement de pîgment faisant face à cette surface extérieure de telle façon que le pigment soit transféré de la feuille amovible sur cette surface extérieure au cours de l'étape de chauffage et de compression et pendant qu'une texture est donnée à la surface extérieure, à retirer la feuille amovible après formation du stratifié, pour mettre à nu la surface extérieure pigmentée, pour mettre à nu la surface extérieure pigmentée, texturée, et à frotter la surface texturée de manière à enlever plus de pigment des zones en relief que des zones en creux de cette surface.
EP81302205A 1981-05-19 1981-05-19 Méthode pour conférer des effets de couleur en clair ou en ombre à des strafifiés texturés décoratifs Expired EP0065043B1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
AT81302205T ATE10461T1 (de) 1981-05-19 1981-05-19 Methode zum verleihen von licht- oder schattenfarbeffekten an dekorative, texturierte schichtstoffe.
DE8181302205T DE3167414D1 (en) 1981-05-19 1981-05-19 Method of imparting color highlights or shadows to a textured decorative laminate.
EP81302205A EP0065043B1 (fr) 1981-05-19 1981-05-19 Méthode pour conférer des effets de couleur en clair ou en ombre à des strafifiés texturés décoratifs

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP81302205A EP0065043B1 (fr) 1981-05-19 1981-05-19 Méthode pour conférer des effets de couleur en clair ou en ombre à des strafifiés texturés décoratifs

Publications (2)

Publication Number Publication Date
EP0065043A1 EP0065043A1 (fr) 1982-11-24
EP0065043B1 true EP0065043B1 (fr) 1984-11-28

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP81302205A Expired EP0065043B1 (fr) 1981-05-19 1981-05-19 Méthode pour conférer des effets de couleur en clair ou en ombre à des strafifiés texturés décoratifs

Country Status (3)

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EP (1) EP0065043B1 (fr)
AT (1) ATE10461T1 (fr)
DE (1) DE3167414D1 (fr)

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2684915A1 (fr) * 1991-12-16 1993-06-18 Vandelanoite Pierre Procede de finition d'un materiau compose de panneaux a base de fibres de bois.
EP1304235A1 (fr) * 2001-10-19 2003-04-23 MZE Engineering GmbH Procédé de production d'une couche de vernis structurée à l'aide d'un film transfert
BE1015550A5 (nl) * 2003-06-04 2005-06-07 Flooring Ind Ltd Vloerpaneel en werkwijze voor het vervaardigen van dergelijk vloerpan eel.
US20080185092A1 (en) * 2007-02-02 2008-08-07 S.D. Warren Company Tip printing embossed surfaces
US7964243B2 (en) 2007-04-30 2011-06-21 S.D. Warren Company Materials having a textured surface and methods for producing same
ES2405548T3 (es) 2007-11-26 2013-05-31 S.D. Warren Company Métodos para fabricar dispositivos electrónicos mediante impresión de realces y revestimiento por raspado
US8551386B2 (en) 2009-08-03 2013-10-08 S.D. Warren Company Imparting texture to cured powder coatings
FR2963277B1 (fr) * 2010-07-27 2012-08-03 Parisot Meubles Procede de finition d'un element de decoration notamment d'un element de mobilier

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB656842A (en) * 1946-10-19 1951-09-05 Bakelite Corp Resin-surfaced laminated materials
US3373068A (en) * 1966-11-16 1968-03-12 Formica Corp Process for preparing an embossed laminate
US3616011A (en) * 1968-12-04 1971-10-26 Consoweld Corp Process of making textured molding cauls
DE2057148A1 (de) * 1970-11-20 1972-05-25 Wachsmann, Ernst, 7911 Oberelchingen Kunststoffteile mit einer Dekor-Oberfläche, insbesondere Wand- oder Fassadenverkleidungsp latten
US3814647A (en) * 1972-05-24 1974-06-04 Exxon Research Engineering Co High pressure decorative laminate with ink surface registered with embossing
US4092198A (en) * 1975-11-05 1978-05-30 Exxon Research & Engineering Co. Process for high pressure decorative laminate having registered color and embossing and resultant product
AU524574B2 (en) * 1978-09-22 1982-09-23 Formica International Limited Decorative laminate
WO1980002531A1 (fr) * 1979-05-21 1980-11-27 Formica Corp Lamines graves a deux tonalites
AU6314280A (en) * 1979-11-13 1981-05-21 Formica Corporation Decorative laminate by ink coated release medium

Also Published As

Publication number Publication date
ATE10461T1 (de) 1984-12-15
EP0065043A1 (fr) 1982-11-24
DE3167414D1 (en) 1985-01-10

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