EP0875623A1 - A process for manufacturing pliable decorative paper sheets and a paper laminate material obtained through such a process - Google Patents

A process for manufacturing pliable decorative paper sheets and a paper laminate material obtained through such a process Download PDF

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Publication number
EP0875623A1
EP0875623A1 EP98103328A EP98103328A EP0875623A1 EP 0875623 A1 EP0875623 A1 EP 0875623A1 EP 98103328 A EP98103328 A EP 98103328A EP 98103328 A EP98103328 A EP 98103328A EP 0875623 A1 EP0875623 A1 EP 0875623A1
Authority
EP
European Patent Office
Prior art keywords
substrate
paper
melamine
layer
formaldehyde resin
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.)
Withdrawn
Application number
EP98103328A
Other languages
German (de)
English (en)
French (fr)
Inventor
Giovanni Carrara
Mario Cugnolu
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.)
Liri Industriale Srl
Original Assignee
Liri Industriale Srl
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 Liri Industriale Srl filed Critical Liri Industriale Srl
Publication of EP0875623A1 publication Critical patent/EP0875623A1/en
Withdrawn legal-status Critical Current

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Classifications

    • 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
    • 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
    • D21H23/00—Processes or apparatus for adding material to the pulp or to the paper
    • D21H23/02—Processes or apparatus for adding material to the pulp or to the paper characterised by the manner in which substances are added
    • D21H23/22—Addition to the formed paper
    • D21H23/70—Multistep processes; Apparatus for adding one or several substances in portions or in various ways to the paper, not covered by another single group of this main group
    • D21H23/72—Plural serial stages only
    • 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
    • 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
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/33—Synthetic macromolecular compounds
    • D21H17/46—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H17/47—Condensation polymers of aldehydes or ketones
    • D21H17/49—Condensation polymers of aldehydes or ketones with compounds containing hydrogen bound to nitrogen
    • D21H17/51—Triazines, e.g. melamine
    • 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
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/33—Synthetic macromolecular compounds
    • D21H17/46—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H17/54—Synthetic macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds obtained by reactions forming in the main chain of the macromolecule a linkage containing nitrogen
    • D21H17/57—Polyureas; Polyurethanes
    • 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
    • D21H25/00—After-treatment of paper not provided for in groups D21H17/00 - D21H23/00
    • D21H25/04—Physical treatment, e.g. heating, irradiating
    • D21H25/06—Physical treatment, e.g. heating, irradiating of impregnated or coated paper

Definitions

  • the present invention refers to a process for manufacturing pliable decorative or ornamental paper sheets suitable for covering surfaces and profiles, as well as the paper laminate material obtained through such a process.
  • a first process provides a first manufacturing step in which a decorative paper substrate of pure cellulose, weighing between 50 and 100 g/m 2 , in case printed with rotogravured patterns reproducing the wood grains or other fancy designs, is impregnated with urea-acrylic resins, a second step in which melamine-polyester resins of the acid-setting type are spread over the so impregnated substrate, and a third step in which the substrate is kiln-dried.
  • finish foils are known as "finish foils”.
  • a second known process provides for manufacturing a continuous thin laminate, usually named "CPL” or "thin laminate", through a first step in which a decorative paper similar to that disclosed with reference to the above process is impregnated with a properly plasticized melamine-formaldehyde resin, and a second step in which the impregnated paper is joined through hot pressing and under pressure to a sheet of vegetable fibers acting as a substrate.
  • CPL continuous thin laminate
  • the so obtained article is constituted by a layer di paper impregnated with melamine-formaldheyde resin imparting hardness and surface strength to the laminate, and by a layer of vegetable fibres that imparts pliability to the laminate and makes easier the subsequent glueing to the surface to be covered.
  • the so obtained laminate has a thickness comprised between 0.15 and 030 mm, a weight comprised between 220 and 300 g/m 2 and can be hot post-formed to be adjusted to the surfaces to be coated.
  • a second object of the present invention is to realize decorative paper sheets that are much thinner than those obtained through the known processes.
  • the decorative paper sheets are obtained by firstly applying a layer of melamine-formaldehyde resin over a paper substrate that has been treated in advance with a urea-acrylic resin.
  • the so obtained supporting sheet or substrate is then finished by means of a hot pressing, in which the layer of melamine-formaldehyde resin is cross-linked.
  • the process of the present invention provides the application of melamine-formaldehyde resins over light-weight paper substrates and their subsequent hot pressing. This way one obtains decorative papers having a considerable pliability that are very suitable for covering surfaces and profiles having strong curvatures.
  • a process for manufacturing pliable decorative paper sheets in accordance with the invention comprises a first step 1 in which it is provided a paper substrate of pure cellulose, having a weight comprised between 40 and 80 g/m 2 , a second step 2 in which said paper substrate is impregnated (e.g. by dipping the substrate) with a urea-acrylic resin, in case modified, and a third step 3 in which said paper substrate is kiln-dried.
  • a urea resin is used that has been obtained by condensing at a temperatures comprised between 90 and 100°C urea and formaldehyde that react while being in a molar ratio comprised between 1-1.1 and 1-2, preferably between 1-1.3 and 1-1.5; either during or after the reaction, it is added a water dispersion of acrylic thermoplastic self-crosslinking polymers in an amount of 5-50 parts by weight, preferably 10-25 parts for 100 parts of urea resin with 55% of dried product.
  • step 3 said substrate has reached a weight that is comprised between 60 and 100 g/m 2 depending on the amount of the impregnating urea-acrylic resin.
  • the process of the invention provides a step 4 for preparing the paper substrate to be printed, and a step 5 for printing decorative or decor patterns on the paper substrate.
  • the paper substrate is treated with products based on acrylic resins in order to further increase its pliability before being printed.
  • the steps 4 and 5 could be omitted when no particular design is required on the decorative papers and the initial coloring of the paper is satisfactory.
  • the melamine resin applied to the paper substrate at step 6 is obtained by condensing - at a temperatures between 90 and 100°C - melamine and formaldehyde that react while being in a molar ratio comprised between 1-1.5 and 1-2, with the addition of modifiers and plasticizers, in a percentage between 1 and 10% by weight, such as triethanol-amine, glycols and paratoluol-sulphonamide, and the addition of 0.1-1% of surfactants, 0.1-1% of cross-linking agents having an acid nature, and 0.1-0.5% of release agents.
  • modifiers and plasticizers in a percentage between 1 and 10% by weight, such as triethanol-amine, glycols and paratoluol-sulphonamide, and the addition of 0.1-1% of surfactants, 0.1-1% of cross-linking agents having an acid nature, and 0.1-0.5% of release agents.
  • the substrate is kiln-dried, step 7, and then finished by being subjected to a cross-linking step 8 through a continuous hot pressing between a pair of steel bands at a pressure comprised between 10 and 50 kg/cm 2 , preferably between 20 and 30 kg/cm 2 , and at a temperature between 140 and 220 °C, preferably between 160 and 200 °C.
  • the decorative paper obtained through the disclosed process has a perfectly uniform surface reproducing the finish of the band, and high hardness and resistance to chemical agents.
  • the decorative paper obtained through the dislosed process has a thickness comprised between 0.06 and 0.10 mm and a weight comprised between 65 and 125 g/m 2 .
  • the article obtained through the disclosed process has an increased pliability with respect to the known articles, and can therefore be applied over surfaces and profiles that are remarkably curved.
  • the process provides for the use of a paper substrate previously impregnated with urea-acrylic resin in a manufacturing step at the paper mill, and the layer of melamine-formaldehyde resin is applied over such pre-preg material.
  • the impregnation with a urea-acrylic resin during the manufacturing of the paper substrate always allows to get a pre-impregnated sheet that is very thin and light-weight, with a weight comprised between 60 and 100 g/m 2 .
  • step 1 of the process according to the invention provides for arranging in advance a pre-impegnated paper substrate that is already adapted to be directly subjected to step 4 preparatory to the print, and then subjected to steps 5 to 8 as alreay discussed.
  • the article obtained through this embodiment of the process has a thickness comprised between 0.06 and 0.10 mm and a weight comprised between 65 and 125 g/m 2 .
  • the final article By starting from a substrate that has been pre-impegnated during the substrate manufacturing in the paper mill, the final article exhibits improved qualities of pliability and capability of adjusting to surfaces and profiles that are markedly curved.
  • pre-impegnated substrates are further of advantage when the paper substrate is very light and thin.
  • the impregnation of light paper substrates e.g. 40 g/m 2
  • the substrate that was pre-impegnated during its manufacture has very good impregnating properties and provides a finished article with improved characteristics of pliability.

Landscapes

  • Laminated Bodies (AREA)
  • Adornments (AREA)
EP98103328A 1997-04-29 1998-02-26 A process for manufacturing pliable decorative paper sheets and a paper laminate material obtained through such a process Withdrawn EP0875623A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITTO970368 1997-04-29
IT97TO000368A IT1292294B1 (it) 1997-04-29 1997-04-29 Metodo per la produzione di carte decorative flessibili e materiale ottenuto con tale metodo.

Publications (1)

Publication Number Publication Date
EP0875623A1 true EP0875623A1 (en) 1998-11-04

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP98103328A Withdrawn EP0875623A1 (en) 1997-04-29 1998-02-26 A process for manufacturing pliable decorative paper sheets and a paper laminate material obtained through such a process

Country Status (2)

Country Link
EP (1) EP0875623A1 (it)
IT (1) IT1292294B1 (it)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2001021892A1 (fr) * 1999-09-21 2001-03-29 Ernst Heller Procede de traitement de bandes de papier, et papier pour impregnation par des resines synthetiques
WO2006130907A1 (en) * 2005-06-06 2006-12-14 Depco-Ppg Pty Ltd Manufacture of an impregnated paper or non-woven
AU2006255480B2 (en) * 2005-06-06 2011-05-19 Depco-Ppg Pty Ltd Manufacture of an impregnated paper or non-woven
CN112900151A (zh) * 2019-11-19 2021-06-04 佛山市西钢装饰材料有限公司 一种三聚氰胺软化纸及其制作工艺
CN113529477A (zh) * 2021-06-11 2021-10-22 中国林业科学研究院木材工业研究所 浸渍胶、浸渍胶膜纸及其饰面板制备方法

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB950704A (en) * 1961-02-22 1964-02-26 Goldschmidt Ag Th Synthetic-resin-impregnated papers and the production thereof
JPS5677114A (en) * 1979-11-29 1981-06-25 Nissan Chem Ind Ltd Production of decorative laminated sheet
JPS62142642A (ja) * 1985-12-17 1987-06-26 イビデン株式会社 連続長尺化粧シ−トと長尺化粧シ−トの連続製造方法
DE3724719A1 (de) * 1987-07-25 1989-02-02 Nortech Chemie Verfahren zum bedrucken eines substrates nach dem transferdruckverfahren
EP0601402A1 (de) * 1992-12-05 1994-06-15 BASF Aktiengesellschaft Verfahren zur Herstellung von imprägnierten Papieren für die Oberflächenbeschichtung

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB950704A (en) * 1961-02-22 1964-02-26 Goldschmidt Ag Th Synthetic-resin-impregnated papers and the production thereof
JPS5677114A (en) * 1979-11-29 1981-06-25 Nissan Chem Ind Ltd Production of decorative laminated sheet
JPS62142642A (ja) * 1985-12-17 1987-06-26 イビデン株式会社 連続長尺化粧シ−トと長尺化粧シ−トの連続製造方法
DE3724719A1 (de) * 1987-07-25 1989-02-02 Nortech Chemie Verfahren zum bedrucken eines substrates nach dem transferdruckverfahren
EP0601402A1 (de) * 1992-12-05 1994-06-15 BASF Aktiengesellschaft Verfahren zur Herstellung von imprägnierten Papieren für die Oberflächenbeschichtung

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
DATABASE WPI Section Ch Week 8133, Derwent World Patents Index; Class A14, AN 81-59261D, XP002065760 *
DATABASE WPI Section Ch Week 8731, Derwent World Patents Index; Class A32, AN 87-217146, XP002065761 *

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2001021892A1 (fr) * 1999-09-21 2001-03-29 Ernst Heller Procede de traitement de bandes de papier, et papier pour impregnation par des resines synthetiques
WO2006130907A1 (en) * 2005-06-06 2006-12-14 Depco-Ppg Pty Ltd Manufacture of an impregnated paper or non-woven
AU2006255480B2 (en) * 2005-06-06 2011-05-19 Depco-Ppg Pty Ltd Manufacture of an impregnated paper or non-woven
CN112900151A (zh) * 2019-11-19 2021-06-04 佛山市西钢装饰材料有限公司 一种三聚氰胺软化纸及其制作工艺
CN113529477A (zh) * 2021-06-11 2021-10-22 中国林业科学研究院木材工业研究所 浸渍胶、浸渍胶膜纸及其饰面板制备方法

Also Published As

Publication number Publication date
ITTO970368A1 (it) 1998-10-29
IT1292294B1 (it) 1999-01-29
ITTO970368A0 (it) 1997-04-29

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