EP4234266A1 - Stratifié et procédé de production d'un stratifié - Google Patents

Stratifié et procédé de production d'un stratifié Download PDF

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Publication number
EP4234266A1
EP4234266A1 EP22158176.2A EP22158176A EP4234266A1 EP 4234266 A1 EP4234266 A1 EP 4234266A1 EP 22158176 A EP22158176 A EP 22158176A EP 4234266 A1 EP4234266 A1 EP 4234266A1
Authority
EP
European Patent Office
Prior art keywords
laminate
decorative layer
polymeric
polymeric interlayer
embossing
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.)
Pending
Application number
EP22158176.2A
Other languages
German (de)
English (en)
Inventor
David Price
Joseph GIANSIRACURA
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.)
Depco TRH Pty Ltd
Original Assignee
Depco TRH Pty 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
Application filed by Depco TRH Pty Ltd filed Critical Depco TRH Pty Ltd
Priority to EP22158176.2A priority Critical patent/EP4234266A1/fr
Publication of EP4234266A1 publication Critical patent/EP4234266A1/fr
Pending 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

Definitions

  • the present invention relates to a laminate and a method for producing a laminate.
  • Laminates with a decorative surface are well known, including HPL (high pressure laminate), CPL (continuous pressure laminate), LPM (low pressure melamine) and furthermore include finish foils, nonwovens, veneers based on wood, and thin ceramic material.
  • Decorative laminates with multilayer structures may be used in the construction of a wall, ceiling, door, room divider, benchtops, cabinetry, furniture, flooring or alternative decorative applications.
  • thermosetting melamine formaldehyde resins such as high pressure laminate (HPL) and continuous pressure laminate (CPL) are thin and hard and when damaged can release sharp hazardous shards of material. Thin hard ceramic materials are also susceptible to breakage.
  • the surface of a LPM panel is usually created in a hot press during the partial flow of resin from the impregnated decor paper into a woodpanel substrate such as particleboard or MDF/HDF (fibreboards).
  • a woodpanel substrate such as particleboard or MDF/HDF (fibreboards).
  • This process of attaching the impregnated papers to a woodpanel substrate is irreversible.
  • laminates such as HPL or CPL the surface is created when combining impregnated papers in a hot press before the laminate is later glued to a substrate using only sufficient adhesive to bond the laminate to a substrate and avoid leakage of the adhesive from the edges.
  • Decorative materials such as finish foils, nonwovens, wood based veneers or thin ceramic materials are also glued to a substrate, therefore along with HPL and CPL it remains possible to influence at least one or more characteristics during the construction of the final multilayer laminate structure.
  • the optical impression of a smooth HPL, CPL or LPM surface or an over-all texture does not always meet current market demands that the laminate look less synthetic.
  • the surface of a laminate is a mirror image of a pressplate or endless belt used during the thermohardening of the melamine-formaldehyde resin (MF resin) under pressure in a hot press.
  • the surface may be smooth, matte or have an abstract embossing design, or have a structure such as a woodgrain pattern.
  • E-I-R Embossed in Register
  • the specification of the decor paper for a controlled expansion of the printed decor paper during impregnation and controlled placement of the impregnated paper and substrate in the hot press equipped with cameras are examples of the considerable amount of technical development that have occurred to achieve a texture on the surface of a laminate that is substantially in register with the printed design, realising an Embossed-in-Register (E-I-R) effect.
  • E-I-R Embossed-in-Register
  • Multilayer structures using HPL, CPL, finish foils, a nonwoven, a wood based veneer or thin ceramic material as the decorative surface will, with enhanced safety, improved thermal insulation, improved fire retardancy and a visually pleasing embossing in register with the printed motif, present an attractive commercial advantage in the marketplace.
  • a laminate comprising a decorative layer and one or more polymeric interlayers, wherein the decorative layer comprises one or more impregnated papers, a finish foil, a nonwoven, a veneer based on wood, a ceramic material, a high pressure laminate, a continuous pressure laminate or a low pressure melamine or combinations thereof.
  • the decorative layer is selected from the group consisting of one or more impregnated papers, a finish foil, a nonwoven, a veneer based on wood, a ceramic material, a high pressure laminate, a continuous pressure laminate and a low pressure melamine or combinations thereof.
  • the one or more impregnated papers can be impregnated with a resin, preferably a MF resin.
  • a polymeric interlayer may include an embedded wire connected to a sensor for data collection.
  • An embedded measurement device (sensor), whether contained in the polymeric interlayer or situated elsewhere in the laminate construction, may be included to capture one or more measurements, for example a pressure sensor, a vibration sensor, an air quality sensor or a resistive thermal device such as a Pt100 thermocouple device.
  • the embedded wire may be used to increase the temperature of the decorative surface.
  • the result of the polymeric interlayer being securely adhered to the decorative layer, such as HPL, CPL or thin ceramic material, is that if any damage occurs, the adhesion to the polymeric interlayer minimizes the possibility that any shards or larger sharp pieces separate from the surface and create a hazard.
  • Pre-impregnated finish foils can be produced on a paper machine and later as a unicolour or printed product are glued to a substrate.
  • Nonwoven materials can also be produced on a paper machine and consist of cellulose or synthetic fibres.
  • Pre-impregnated finish foils and nonwovens are usually manufactured with latex binder without any added formaldehyde. Nonwovens have a low wet expansion which is advantageous for Embossed-in-Register applications.
  • standard wood based veneers are usually between 0.4 - 0.6mm and thin ceramic material usually between 3 - 6mm.
  • the laminate further comprises a substrate supporting the one or more polymeric interlayers and the decorative layer.
  • the substrate can be a reconstituted woodpanel, a plywood, a cross laminated timber, a plasterboard, a fibre-cement sheet, a hardboard, a brick or concrete or a solid wood structure.
  • a particleboard, fibreboard or oriented strand board (OSB) can be used.
  • the substrate may have fire retardant characteristics, or have a fire retardant coating on one or more sides.
  • the multilayer composite product comprising the decorative layer and the one or more polymeric interlayers and optionally a thermal insulation layer, and/or a fire retardant layer, may be directly attached to substrate.
  • the material of the one or more polymeric interlayers is preferably selected from the group consisting of ionoplast material, polyvinyl butyral, ethylene vinyl acetate and thermoplastic polyurethane or combinations thereof.
  • Polymeric interlayers of various material, thicknesses and functions are commercially available, for example an ionoplast (ionomer based) material (e.g. Kuraray SentryGlas ® ) or polyvinyl butyral (e.g. Kuraray Trosifol ® ) or ethylene vinyl acetate (e.g. Folienwerk-Wolfen evguard ® , Satinal Strato ® or SWM Intl.
  • the polymeric interlayer is attached to the non-decorative side of the decorative layer, such as the HPL, CPL, finish foil, nonwoven, wood based veneer or thin ceramic material, before combining with a substrate.
  • the polymeric interlayer may be attached to a substrate and later the decorative layer is attached to form the laminate in form of a multilayer composite product.
  • An advantage would be to combine at least the decorative layer, at least one polymeric interlayer, and the substrate to form the laminate in form a multilayer composite product in a single process, which includes embossing the laminate surface in register with the printed design on the laminate surface.
  • Polymeric interlayers are commercially available with a thickness of about 3mm or less, for example Kuraray SentryGlass ® ionoplast interlayers are available in standard thicknesses between 0.76mm and 3.04mm, while Kuraray Trosifol ® PVB interlayers are available in standard thicknesses between 0.38mm and 2.28mm. Evguard ® EVA polymeric interlayer is available in thicknesses from 0.2 - 1.4mm. Commercially available polymeric interlayer material is available in widths up to about 3.2m in sheet or roll form. The choice of polymeric interlayer can be influenced by a number of factors, such as dwell time and temperature in a press.
  • SentryGlas ® is up to 100 times stiffer than polyvinyl butyral, and SentryGlas ® ionoplast interlayer has a higher thermal stability compared to polyvinyl butyral interlayer.
  • One or more polymeric interlayers of different thickness or different raw material, or to achieve different objectives may be incorporated in one laminate product.
  • the polymeric interlayer is not intended as a visible external layer of the laminate product, there is no need for the polymeric interlayer to meet any specification for light transmission, it may even be used when having exceeded the manufacturer's recommended use-by-date.
  • one polymeric interlayer is directly attached to the decorative layer.
  • This polymeric interlayer is preferably irreversibly attached, more preferably glued, to the decorative layer.
  • the further polymeric interlayers can be attached to other polymeric interlayers or further layers of the laminate.
  • an adhesion promotor with the polymeric interlayer, or in certain circumstances further improve the bond between the decorative layer and the polymeric interlayer with an additional amount of adhesive.
  • an elevated temperature to combine the various layers of a multilayer laminate product and to cause the polymeric interlayer to itself form an adhesive nature is preferred.
  • the laminate according to the invention comprises one or more protective layers.
  • one of the protective layers is directly attached to the side of the polymeric interlayer that is not attached to the decorative layer.
  • Each of the further protective layers can be attached to the layer that is directly attached to the polymeric interlayer or to any other layer of the multilayer laminate.
  • the one or more protective layers can be polyethylene terephthalate films, quartz cellulose papers or retardant felts.
  • the protective layers may differ from each other or be the same.
  • a protective layer or layers may be incorporated to enhance the performance of the polymeric interlayer, for example Trosifol ® PET (Kuraray) adhered to the side of the polymeric interlayer not attached to the laminate to avoid sticking in a hot press.
  • the material of the one or more protective layers is selected from the group consisting of polyethylene terephthalate, a mixture of quartz and cellulose and a fire retardant felt material or combinations thereof.
  • the protective layer may itself present a decorative aspect or a company logo on the reverse side of the laminate, such as a HPL or CPL laminate.
  • a protective layer used to prevent the polymeric interlayer sticking in the hot press may itself have a technical function, such as providing a fire retarding function. More than one protective layer may be included in the multilayer laminate construction.
  • a protective layer such as a fire retardant material based on quartz and/or fire retardant felt is included in the laminate multilayer construction.
  • a suitable protective layer in the form of a fire retardant layer is a paper based on a mixture of quartz and cellulose.
  • a fire retardant felt based on cotton linters and a flame retardant may be used as protective layer. It may be advantageous to use both in combination to achieve a higher fire retardant performance.
  • the laminate comprises a thermal insulation layer.
  • the thermal insulation layer is preferably made of expanded polystyrene.
  • the thermal insulation layer preferably has a thickness in the range from 2 to 10 mm. However, even a thicker thermal insulation can be used. Nevertheless, it is an advantage to achieve the thermal insulation without having to substantially increase the thickness of the multilayer construction. Expanded polystyrene such as Neopor ® containing graphite provides thermal insulation with a 4mm thickness equal to a 262mm thick concrete.
  • the polymeric interlayer preferably a dispersion containing a recycled polymeric interlayer material from which the polymeric interlayer can be made, can be used to impregnate or coat the one or more protective layers, for example a glass nonwoven material, or fire retardant felt and/or a quartz cellulose paper.
  • a suitable press for combining the layers of the laminate may be a short-cycle press or a compression molding press.
  • the laminate may be also prepared without a press, for example using hot roll lamination or manual lay-up techniques.
  • the decorative layer has an embossing on the side facing away from the one or more polymeric interlayers.
  • the embossing is in register with a printed pattern on the decorative layer.
  • E-I-R embossing substantially in register
  • E-I-R textures range from a few tens of microns to more than one hundred microns, however unlike the 3D shape postforming of a HPL or CPL where all layers of the HPL or CPL are stretched to form an arc with a radius many times the thickness of the laminate, during embossing according to the invention the laminate, e.g. HPL, CPL or LPM, remain in a planar position while the "hills and valleys" of the texture are forced only into the upper MF resin layer. There is no need to heat the laminate through and through as required for postforming, it is sufficient and preferred that the laminate remains in a planar state and the heating of the laminate surface is localised to the upper surface strata.
  • the textured press tool may be heated or unheated when applying the embossing to the laminate surface. Textures that are not required to be In-Register with a printed pattern may also be produced according to the invention.
  • the decorative layer surface is subjected to radiation that softens its outermost region.
  • the laminate is placed in a press where a textured press tool is brought into contact with the softened decorative layer surface and pressure applied to form an embossing substantially in register with the printed design of the laminate surface.
  • the choice of radiation equipment is not limited by wavelength, it may be UV, IR or microwave. If the softening of the decorative layer surface could be achieved when the decorative layer is positioned in the press, that would avoid handling of the laminate while the surface is in the softened phase.
  • the E-I-R embossing of a decorative surface material e.g. HPL or CPL material, may be completed before the decorative surface is combined with at least one polymeric interlayer, any protective layers and a substrate.
  • a decorative layer e.g. a LPM panel
  • embossed according to the invention requires no further lamination, except for sealing the edges with an edgebanding.
  • the newly embossed decorative layer according to the invention is coated with a clear coating.
  • a press for consolidating various layers of the laminate may also be used to provide an embossing using a textured pressplate, alternatively an embossing can be applied from one or more embossing rolls.
  • the texture of the embossing roll or rolls is co-ordinated with the printed pattern using a camera vision system to control the start position of the embossed roll or rolls relative to the print.
  • the press tool may be heated or be used without heating.
  • the laminate can comprising a further decorative layer arranged on the side of the laminate opposite to the other decorative layer.
  • a laminate according to the invention can be prepared by a method comprising the step of combining a decorative layer with one or more polymeric interlayers.
  • the combining step includes the step of adhering one of the polymeric interlayers to the decorative layer and/or the step of increasing the temperature.
  • the polymeric interlayer can be combined with a substrate before being combined with the decorative layer.
  • the method can comprise the step of embossing the decorative layer.
  • the combining step and the embossing step are carried out simultaneously.
  • the embossing step can comprise the step of softening, preferably by irradiating, the surface of the decorative layer.
  • the method can comprise the step of producing the polymeric interlayer.
  • the polymeric interlayer is produced by forming a dispersion from recycled polymeric interlayers.
  • the one or more polymeric interlayers are formed from recycled polymeric interlayer material.
  • the polymeric interlayer may be manufactured from recycled polymeric interlayer materials.
  • a polymeric interlayer can be manufactured from 100% recycled PVB trimmings, and due to changes in light transmission properties, and contamination, the recycling of PVB polymeric interlayer is limited, and most PVB polymeric interlayer recovered when recycling automotive windshields are incinerated or buried. Therefore, in an effort to reduce the environmental impact, it would be preferable to use a polymeric interlayer manufactured from recycled material recovered from windscreens or other laminated glass materials.
  • Recycled PVB polymeric interlayer material in the form of a dispersion is commercially available and may be used with or without a crosslinking agent, for example a blocked isocyanate containing crosslinking agent.
  • the combining step of the method according to the invention preferably comprises the step of coating the decorative layer with a mixture comprising the polymeric interlayer material and/or a mixture from which the polymeric interlayer is formed.
  • the polymeric interlayer is formed from recycled polymeric interlayer material, and either coated directly to the non-decorative side of the decorative layer or coated into and onto a substrate, such as a carrier material, which is subsequently attached to the non-decorative side of the decorative layer.
  • the polymeric interlayer in either sheet or roll format is attached on the non-decorative side of the decorative layer in the lay-up with the impregnated papers that will form the decorative layer.
  • the method can comprise one or more, so also all, of the steps of adding a substrate, adding one or more protective layers, adding a thermal insulation layer, adding an embedded measurement device (sensor), pressing the obtained product.
  • At least one polymeric interlayer with an outermost protective film is combined with 2 or more impregnated papers in a hot press to form a hybrid HPL or hybrid CPL sheet.
  • the meaning of hybrid is that the HPL or CPL sheet differs from standard HPL and CPL which do not incorporate a polymeric interlayer.
  • At least one polymeric interlayer and at least one fire retardant material layer is combined with 2 or more impregnated papers in a hot press to form a hybrid HPL or hybrid CPL sheet.
  • At least one polymeric interlayer is adhered to the non-decorative side of a HPL, CPL, finish foil, nonwoven, wood based veneer or thin ceramic material, and the composite material attached to a substrate.
  • At least one polymeric interlayer and at least one fire retardant layer is adhered to the non-decorative side of a HPL, CPL, finish foil, nonwoven, wood based veneer or thin ceramic material, and the composite material attached to a substrate.
  • the HPL or CPL or LPM surface is preheated immediately before an embossing of the laminate surface.
  • the embossing may be In-Register with a printed design.
  • HPL or CPL, and at least one polymeric interlayer are combined with a substrate in a press using a press tool to impart an embossing to the laminate surface.
  • the surface of the laminate is preheated immediately prior to the embossing action, and the embossing may be substantially In-Register with the printed design of the laminate surface.
  • a fire retardant layer is included in the HPL, CPL, finish foil, nonwoven, wood based veneer or thin ceramic material multilayer composite product, located between the polymeric interlayer and the substrate.
  • a thermal insulation layer is included in the HPL, CPL, finish foil, nonwoven, wood based veneer or thin ceramic material multilayer composite product, located between the polymeric interlayer and the substrate.
  • a thermal insulation layer may be attached in a separate process step to a substrate, and the laminate attached to the thermal insulation layer side of the substrate.
  • This concept is also applicable where there is no fire retardant layer used in the manufacture of HPL or CPL with a polymeric interlayer, meaning that the impregnated paper / polymeric interlayer is in a separate process step attached to the thermal insulation / substrate.
  • the polymeric interlayer is a dispersion manufactured from recycled polymeric interlayers and is coated on and into a carrier material, for example a fire retardant material layer, and later the coated carrier material layer in attached to the non-decorative side of the HPL, CPL, finish foil, nonwoven, wood based veneer or thin ceramic material.
  • a carrier material for example a fire retardant material layer
  • the recycled polymeric interlayer dispersion is coated directly onto the non-decorative side of the HPL, CPL, finish foil, nonwoven, wood based veneer or thin ceramic material.
  • the recycled polymeric interlayer may include an embedded measurement device (sensor).
  • the polymeric interlayer has an embedded wire used to increase the temperature of the decorative surface.
  • the increase in surface temperature may provide a pleasing effect if the application should be for example as a flooring component.
  • the increase in surface temperature may change the colour of all or part of the decorative surface if the decorative surface contains thermochromic pigments or dyes.
  • an embedded measurement device is placed in the polymeric interlayer and records changes in room temperature.
  • the embedded measurement device is connected to a microprocessor and programmed to regulate the heating or cooling system of the room.
  • the 12 examples present only a limited number of possible process steps or combinations and are not limiting different process steps or combinations to achieve the objectives of the invention. Furthermore, the number of layers that form the multilayer laminate product is not restricted in any way and the laminate may have 2 decorative sides, and not necessarily be a symmetric construction.

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  • Laminated Bodies (AREA)
EP22158176.2A 2022-02-23 2022-02-23 Stratifié et procédé de production d'un stratifié Pending EP4234266A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP22158176.2A EP4234266A1 (fr) 2022-02-23 2022-02-23 Stratifié et procédé de production d'un stratifié

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP22158176.2A EP4234266A1 (fr) 2022-02-23 2022-02-23 Stratifié et procédé de production d'un stratifié

Publications (1)

Publication Number Publication Date
EP4234266A1 true EP4234266A1 (fr) 2023-08-30

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ID=80446779

Family Applications (1)

Application Number Title Priority Date Filing Date
EP22158176.2A Pending EP4234266A1 (fr) 2022-02-23 2022-02-23 Stratifié et procédé de production d'un stratifié

Country Status (1)

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EP (1) EP4234266A1 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1999006210A1 (fr) * 1997-07-30 1999-02-11 The Dow Chemical Company Laminage du bois a basses temperatures
US8209928B2 (en) * 1999-12-13 2012-07-03 Faus Group Embossed-in-registration flooring system
EP3393800A1 (fr) * 2015-12-22 2018-10-31 Trespa International B.V. Panneau décoratif
AU2019271977A1 (en) * 2018-11-29 2020-06-18 Depco-Trh Pty Ltd Enhanced tactile and auditory properties from hard materials

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1999006210A1 (fr) * 1997-07-30 1999-02-11 The Dow Chemical Company Laminage du bois a basses temperatures
US8209928B2 (en) * 1999-12-13 2012-07-03 Faus Group Embossed-in-registration flooring system
EP3393800A1 (fr) * 2015-12-22 2018-10-31 Trespa International B.V. Panneau décoratif
AU2019271977A1 (en) * 2018-11-29 2020-06-18 Depco-Trh Pty Ltd Enhanced tactile and auditory properties from hard materials

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