Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
  • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
  • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
• • 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
  • B44C5/043—Ornamental plaques, e.g. decorative panels, decorative veneers containing wooden elements

Definitions

• Serial No. 08/206,810 itself is a continuation-in-part of Serial No. 07/882,839 filed May
• the subject invention relates generally to a method of preparing laminated boards, sheets or articles — useful as partitions, shelves, countertops and bathroom vanities -which is more economical and less labor-intensive than existing methods.
• the present method also enables a consumer to purchase standard size laminated boards, sheets or articles, customize the shape of the laminate for the consumer's individual use, and join the articles to provide a finished look without the need of professional assistance.
• One aspect of the invention provides a method of manufacture of an article which comprises a substrate and a plastic coating.
• the plastic coating may be an in situ polymerized thermoplastic or thermoset material laminated to any rigid substrate but preferably a cellulosic product such as wood or particle board. Where a mineral-like appearance is desired, the subject invention may utilize the compositions disclosed in my earlier patent applications, which have the appearance of
• Another aspect of the invention provides a plastic edge piece which is attached to the
• the plastic edge piece is made of the same plastic material as is
• the area of the applied plastic is then sanded for smoothness.
• the present invention also provides a method for producing coated substrates and
• the present invention is particularly useful for the production of laminates comprising
• thermoplastic or thermoset resin having a mineral appearance
• the subject invention also has several economic advantages. First, it uses existing
• the laminates are made without the use of solvents which can constitute an
• Figure 1 illustrates the use of a 4' x 8' x 5/8" particle board as the substrate in the
• Channels (4) allow excess casting resin to flow from the mold.
• Figure 2 illustrates the molding process of this invention in which a thin plastic film
• the flowable casting or coating resin (7) is placed on top of the film (6) and if desired can be smoothed using a doctor blade.
• the substrate (8) with the gasket (9) attached is lowered on the spread resin (7) and the
• FIG. 3 illustrates the process of the present invention in which the casting resin is
• Figure 4 illustrates a laminate (1) comprising a board (16) with surface coatings on
• composition as the coating by means of dowels (19).
• FIGS 5, 6 and 7 show edge pieces in cross section finished in various shapes by the
• the subject invention provides a method for producing a preformed, laminated article
• plastic material in a liquid or semi-liquid state, said plastic material being held in place by a
• the present invention also relates to laminates having a smooth mineral surface appearance.
• the invention further concerns a plastic edge piece which may be cast separately and
• the present invention is based on a compression molding process for the manufacture
• the coating resin can be the same or
• the present invention also includes the laminate made by the process of the present invention
• the coating employed in the present invention can be a pre-polymerized liquid
• thermoplastic or thermoset resins Suitable pre-polymerized or partially polymerized
• thermoplastic resins include acrylic resins such as polymethyl methylmethacrylate, and
• methyl methacrylate copolymers such as are obtained by copolymerization with alkyl
• the coating or casting resins employed in the present invention are thermosettable polymers
• the prepolymerized resins are employed in liquid form, the
• thermosettable resins the preferred resins are the unsaturated polyester resins
• glycol or diethylene glycol in the presence of an unsaturated dicarboxylic acid or anhydride
• the prepolymerized unsaturated polyester is then dissolved in a
• polyesters which can be cured by further polymerization to form tough solid coatings are well
• the resin including any filler should have a fluidity at room temperature adequate to fill the
• compositions having viscosities in the range of 500 to 40,000 centipoises are suitable in the
• the casting resins or coating compositions employed in the present invention As indicated, the casting resins or coating compositions employed in the present invention
• inventions are preferably filled resin compositions which give the coating an inorganic mineral
• Such composites are then crushed and pulverized to a desired particle size for
• fillers employed include particulates of themoset polyesters and/or acrylic resins containing
• powdered inorganic materials as talc, silica, gypsum, powdered glass, clay, silicates and
• the fillers can be employed over a
• the casting resin or coating composition usually also contains a catalyst which
• the coating composition may also contain pigments, u-v light
• coating composition provides its surface characteristic to the resulting laminate.
• Such finish is accomplished by having a thin flexible plastic film which
• the laminate but still adheres sufficiently to serve as a protective layer prior to use of the
• Plastic films useful in the process of the present invention include polyolefin films,
• the gasket material can be any solid material including metal, plastic or wood.
• the gasket material can be controllably compressed to a desired
• particularly preferred material is cardboard since it can be readily cut to provide the gasket
• Hard rubber, elastomeric polyolefins and flexible polyurethane foams are also useful as
• gasketing material as are many composites made from resins and cellulosic fibers.
• the substrate to which the coating is applied can be any semi-rigid or rigid material
• cellulosic type of material such as solid wood boards, plywood, balsa sheets, particle boards and related composites containing
• cellulosic fibers other substrates or cores for the laminates of the present invention include
• substrate or core can also be enhanced during the molding process by laminating the opposing
• Such edges can be provided in several ways such as by spraying, brushing or
• any visible seam between the laminate and the edge or nose strip can be additionally coated
• edge piece should be cast from the same composition that is employed for the surface layer of
• #6 spindle at 100 rpm is evenly spread to a thickness of slightly more than 1/16".
• the unsaturated polyester contained a polymerized resin
• the assembly is subjected to a pressure of approximately 100 psi and the platen in
• contact with the resin is heated to a temperature of 200 °F. which is maintained for a period of
• the resulting laminate contains a 1/16" layer of smooth surfaced granite like material
• the film can be mechanically removed at any time and preferably is retained to
• the uncoated edges of the particle board can be sawn off or spray coated or brushed
• the uncoated edge portions are

Landscapes

• Life Sciences & Earth Sciences (AREA)
• Engineering & Computer Science (AREA)
• Wood Science & Technology (AREA)
• Casting Or Compression Moulding Of Plastics Or The Like (AREA)
• Laminated Bodies (AREA)

Applications Claiming Priority (3)

Publications (1)

Family

ID=27170804

Family Applications (1)

Country Status (2)

Families Citing this family (1)

Family Cites Families (6)

• 1997
  • 1997-01-06 EP EP97902839A patent/EP0912343A1/de not_active Withdrawn
  • 1997-01-06 WO PCT/US1997/000130 patent/WO1998030391A1/en not_active Application Discontinuation

Non-Patent Citations (1)

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