EP1602784B1 - Verfahren zur Herstellung eines Dekorlaminats - Google Patents

Verfahren zur Herstellung eines Dekorlaminats Download PDF

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Publication number
EP1602784B1
EP1602784B1 EP20050252241 EP05252241A EP1602784B1 EP 1602784 B1 EP1602784 B1 EP 1602784B1 EP 20050252241 EP20050252241 EP 20050252241 EP 05252241 A EP05252241 A EP 05252241A EP 1602784 B1 EP1602784 B1 EP 1602784B1
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EP
European Patent Office
Prior art keywords
weight
stage polymer
polymer
paper
shell
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 - Fee Related
Application number
EP20050252241
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English (en)
French (fr)
Other versions
EP1602784A3 (de
EP1602784A2 (de
Inventor
James T. Brown
John Robert Haigh
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.)
Rohm and Haas Co
Original Assignee
Rohm and Haas Co
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Filing date
Publication date
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Priority to EP20050252241 priority Critical patent/EP1602784B1/de
Publication of EP1602784A2 publication Critical patent/EP1602784A2/de
Publication of EP1602784A3 publication Critical patent/EP1602784A3/de
Application granted granted Critical
Publication of EP1602784B1 publication Critical patent/EP1602784B1/de
Expired - Fee Related 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
    • 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
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/50—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by form
    • D21H21/52—Additives of definite length or shape
    • D21H21/54—Additives of definite length or shape being spherical, e.g. microcapsules, beads
    • 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
    • D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H17/37—Polymers of unsaturated acids or derivatives thereof, e.g. polyacrylates

Definitions

  • Voided, or hollow emulsion polymers are generally prepared by swelling a multi-stage polymer, having a core and a shell, in such a way that one or more voids form in the interior of the emulsion polymer particle.
  • Hollow emulsion polymers are often used in paints, coatings, inks, sunscreens, paper manufacture, and several other industrial arenas. In the paper industry, hollow emulsion polymers are used to make the surface of the paper, among other things, smoother, brighter, and more opaque. Additional benefits of hollow sphere polymers is that, when used alone, or in combination with costly opacifying pigments, such as titanium dioxide, a more cost effective system is obtainable.
  • the paper typically utilized during the manufacture of decorative laminates has a high pigment content.
  • the acid-functional monoethylenically unsaturated monomer is preferably added to the polymerization of the shell stage polymer over the 100% of the total shell stage monomer feed, based on the total weight of the shell stage monomer feed, more preferably over the first 50% of the feed, even more preferably over the first 25% of the feed, and most preferably over the first 10% of the feed.
  • seed polymer is used to refer to an aqueous emulsion polymer dispersion, which may be the dispersion containing the first-formed polymer stage, or it may be the emulsion polymer dispersion obtained at the end of any subsequent stage, except the final stage of the sequential polymerization.
  • a core stage polymer which is intended to be encapsulated by one, or more, subsequent stages of emulsion polymerization, may itself be termed a seed polymer for the next stage.
  • a seed polymer may be utilized to form the nuclei on which the core stage polymer is formed.
  • a core having a molecular weight in the lower part of the range such as from 500,000 down to as low as about 20,000
  • a chain transfer agent such as 0.05% to 2% or more thereof, examples being alkyl mercaptans, such as sec-butyl mercaptan.
  • a composition containing the hollow sphere polymer is incorporated into a decorative laminate paper during the wet-end formation of the decorative laminate paper.
  • wet-end is meant herein, the part of the decorative laminate paper processing, during which a predominantly cellulosic fiber pulp slurry is formed into a wet sheet on a paper machine, by techniques that are well known in the art.
  • the hollow sphere polymer and at least one pigment, along with other ingredients, as necessary, are added to, and mixed with the slurry, which is then formed into a wet sheet of paper that contains, or incorporates, the hollow sphere polymer. Any suitable pigment may be used, however titanium dioxide is preferred.
  • Typical temperatures applied to the crosslinking resin-impregnated decorative laminate paper are in the range of from 100°C to 300°C, preferably from 125°C to 250°C, more preferably from 140°C to 200°C.
  • the resulting decorative laminate has improved opacity, above that obtainable in a decorative laminate prepared utilizing only a pigment, as well as lower cost, where a costly pigment, such as titanium dioxide, is used.
  • the paper sample thus formed is dried in an oven at 95°C at 50% relative humidity for 10 minutes. This drying process is repeated at a range of temperatures (50 to 90°C), relative humidities (20 to 80%), and drying times (2 to 20 minutes).

Landscapes

  • Graft Or Block Polymers (AREA)
  • Laminated Bodies (AREA)

Claims (7)

  1. Verfahren zur Herstellung eines Dekorlaminats, umfassend die Schritte:
    (I) des Herstellens eines Papiers mittels:
    (a) des Bereitstellens eines Hohlkugelpolymers, hergestellt durch:
    i. das Bilden eines Kernphase-Polymers durch das Polymerisieren mindestens eines ethylenisch ungesättigten Monomers, das Säurefunktionalität enthält,
    ii. das Verkapseln des Kernphase-Polymers mit einem Hüllphase-Polymer durch das Emulsionspolymerisieren mindestens eines ethylenisch ungesättigten Monomers in der Gegenwart des Kernphase-Polymers,
    wobei das Hüllphase-Polymer das Eindringen einer fixierten oder permanenten Base zuläßt,
    iii. das Inkontaktbringen der resultierenden Mehrphase-Polymerteilchen mit der fixierten oder permanenten Base, wobei entweder (1) das Hüllphase-Polymer mindestens 1% säurefunktionelles Monomer umfasst oder (2) das Inkontaktbringen in der Gegenwart eines Lösungsmittels erfolgt;
    (b) des Inkontaktbringens des Papiers mit einer Zusammensetzung, die das Hohlkugelpolymer und mindestens ein Pigment umfasst; und
    (c) des Trocknens des Papiers;
    (II) des Imprägnierens des Papiers mit einem Vernetzungsharz;
    (III) des Anwendens von Druck auf das Papier und
    (IV) des Aussetzens des Papiers Temperaturen von 100°C bis 300°C, um das Dekorlaminat zu bilden.
  2. Verfahren nach Anspruch 1, wobei das Kernphase-Polymer durch das Polymerisieren von etwa 5 Gew.-% bis etwa 100 Gew.-%, basierend auf dem Gesamtgewicht des Kernphase-Polymers, des ethylenisch ungesättigten Monomers, das Säurefunktionalität enthält, und von 0 Gew.-% bis etwa 95 Gew.-%, basierend auf dem Gesamtgewicht des Kernphase-Polymers, mindestens eines nichtionischen monoethylenisch ungesättigten Monomers gebildet ist,
    wobei das Hüllphase-Polymer durch das Polymerisieren von etwa 90 Gew.- % bis etwa 99.9 Gew.-%, basierend auf dem Gesamtgewicht des Hüllphase-Polymers, mindestens eines nichtionischen monoethylenisch ungesättigten Monomers und von etwa 0,1 Gew.-% bis etwa 10 Gew.-%, basierend auf dem Gesamtgewicht des Hüllphase-Polymers, eines säurefunktionellen monoethylenisch ungesättigten Monomers gebildet ist, und
    wobei das säurefunktionelle monoethylenisch ungesättigte Monomer der Polymerisation des Hüllphase-Polymers über die 100% der gesamten Hüllphase-Monomer-Zufuhr zugegeben wird, wenn die Teilchengröße des Kernphase-Polymers von etwa 130 nm bis etwa 2,0 Mikrometer beträgt.
  3. Verfahren nach Anspruch 1, wobei das Kernphase-Polymer durch das Polymerisieren von etwa 5 Gew.-% bis etwa 100 Gew.-%, basierend auf dem Gesamtgewicht des Kernphase-Polymers, des ethylenisch ungesättigten Monomers, das Säurefunktionalität enthält, und von 0 Gew.-% bis etwa 95 Gew.-%, basierend auf dem Gesamtgewicht des Kernphase-Polymers, mindestens eines nichtionischen monoethylenisch ungesättigten Monomers gebildet ist,
    wobei das Hüllphase-Polymer durch das Polymerisieren von etwa 90 Gew.- % bis etwa 99.9 Gew.-%, basierend auf dem Gesamtgewicht des Hüllphase-Polymers, mindestens eines nichtionischen monoethylenisch ungesättigten Monomers und von etwa 0,1 Gew.-% bis etwa 10 Gew.-%, basierend auf dem Gesamtgewicht des Hüllphase-Polymers, eines säurefunktionellen monoethylenisch ungesättigten Monomers gebildet ist, und
    wobei das säurefunktionelle monoethylenisch ungesättigte Monomer der Polymerisation des Hüllphase-Polymers über die ersten 50% der gesamten Hüllphase-Monomer-Zufuhr zugegeben wird, wenn die Teilchengröße des Kernphase-Polymers weniger als etwa 130 nm beträgt.
  4. Verfahren nach Anspruch 1, wobei das Hüllphase-Polymer vernetzt ist.
  5. Verfahren nach Anspruch 1, wobei das Inkontaktbringen des Papiers das Inkorporieren der Zusammensetzung in dem Papier während der Nasspartie-Bildung des Papiers umfasst.
  6. Verfahren nach Anspruch 1, wobei das Inkontaktbringen des Papiers das Beschichten des Papiers mit der Zusammensetzung umfasst.
  7. Dekorlaminat, gebildet durch das Verfahren nach einem der Ansprüche 1 bis 6.
EP20050252241 2004-04-23 2005-04-09 Verfahren zur Herstellung eines Dekorlaminats Expired - Fee Related EP1602784B1 (de)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP20050252241 EP1602784B1 (de) 2004-04-23 2005-04-09 Verfahren zur Herstellung eines Dekorlaminats

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP04291068 2004-04-23
EP04291068 2004-04-23
EP20050252241 EP1602784B1 (de) 2004-04-23 2005-04-09 Verfahren zur Herstellung eines Dekorlaminats

Publications (3)

Publication Number Publication Date
EP1602784A2 EP1602784A2 (de) 2005-12-07
EP1602784A3 EP1602784A3 (de) 2009-05-13
EP1602784B1 true EP1602784B1 (de) 2010-10-13

Family

ID=35261980

Family Applications (1)

Application Number Title Priority Date Filing Date
EP20050252241 Expired - Fee Related EP1602784B1 (de) 2004-04-23 2005-04-09 Verfahren zur Herstellung eines Dekorlaminats

Country Status (1)

Country Link
EP (1) EP1602784B1 (de)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1632537B1 (de) * 2004-09-02 2013-03-13 Rohm And Haas Company Verfahren zur Verwendung von hohlen Polymerkugeln

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4594363A (en) * 1985-01-11 1986-06-10 Rohm And Haas Company Production of core-sheath polymer particles containing voids, resulting product and use
US4726986A (en) * 1986-09-17 1988-02-23 Westinghouse Electric Corp. Decorative laminates having a thick chemical resistant outer layer
EP0959176B1 (de) * 1998-05-18 2012-09-05 Rohm And Haas Company Pigmentäre organische Hohlkugelteilchen für Papier oder Papierbeschichtungen

Also Published As

Publication number Publication date
EP1602784A3 (de) 2009-05-13
EP1602784A2 (de) 2005-12-07

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