GB2087307A - A product with a decorative surface layer and a process for the production of the product - Google Patents

A product with a decorative surface layer and a process for the production of the product Download PDF

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Publication number
GB2087307A
GB2087307A GB8132080A GB8132080A GB2087307A GB 2087307 A GB2087307 A GB 2087307A GB 8132080 A GB8132080 A GB 8132080A GB 8132080 A GB8132080 A GB 8132080A GB 2087307 A GB2087307 A GB 2087307A
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GB
United Kingdom
Prior art keywords
carrier
surface layer
decorative surface
product
elastomer
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.)
Granted
Application number
GB8132080A
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GB2087307B (en
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.)
Perstorp AB
Original Assignee
Perstorp AB
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Filing date
Publication date
Priority claimed from SE8101107A external-priority patent/SE451560B/en
Application filed by Perstorp AB filed Critical Perstorp AB
Publication of GB2087307A publication Critical patent/GB2087307A/en
Application granted granted Critical
Publication of GB2087307B publication Critical patent/GB2087307B/en
Expired legal-status Critical Current

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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
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/082—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising vinyl resins; comprising acrylic resins
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/085—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyolefins
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • 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
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/42—Layered products comprising a layer of synthetic resin comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
    • 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
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
    • 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
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
    • 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
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/06—Layered products comprising a layer of paper or cardboard specially treated, e.g. surfaced, parchmentised
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • B44C3/02—Superimposing layers
    • 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
    • B44C5/0415—Ornamental plaques, e.g. decorative panels, decorative veneers containing metallic elements
    • 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
    • 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
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1207—Heat-activated adhesive
    • B32B2037/1215—Hot-melt adhesive
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/026—Wood layer
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/028—Paper layer
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • 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
    • B32B2311/00—Metals, their alloys or their compounds
    • B32B2311/12—Copper
    • 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
    • B32B2311/00—Metals, their alloys or their compounds
    • B32B2311/24—Aluminium
    • 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
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • B32B2317/125—Paper, e.g. cardboard impregnated with thermosetting resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/16—Wood, e.g. woodboard, fibreboard, woodchips
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    • B32B2323/00—Polyalkenes
    • B32B2323/04—Polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2325/00—Polymers of vinyl-aromatic compounds, e.g. polystyrene
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    • B32B2355/00—Specific polymers obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in a single one of index codes B32B2323/00 - B32B2333/00
    • B32B2355/02—ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
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    • B32B2451/00—Decorative or ornamental articles

Abstract

A product, for example in the form of a facing element for a door, a skirting board, a shadow rail, a window-frame, a door, a flower-pot or a waste-paper basket, which product is provided with a decorative surface layer on at least one face thereof, wherein the product comprises a carrier of thermoplastic material, to which carrier a decorative surface layer of wood, veneer, metal or a layer comprising thermoset plastics material is firmly attached by a hot melting elastomer.

Description

SPECIFICATION A product with a decorative surface layer and a process for the production of the product The present invention relates to a plastics material product, for example in the form of a facing element for a door, a skirting board, a shadow rail, a window frame, a door, a flower-pot or a waste-paper basket, which product is provided with a decorative surface layer. A shadow rail is a rail attached to the wall of a room adjacent the ceiling to effectively conceal the joint or corner between the wall and the ceiling.
It has been proposed before to make, for example, a facing element for a door, a skirting board and a shadow rail of a thermoplastic material, such as polyvinyl chloride. These products are manufactured by extrusion. This permits a continuous rational production, and the strips are, in principle, obtained in infinitely long lengths, which are then cut to a desired length.
The products produced heretofore have many good qualities, but they also have certain undesirable qualities. Thus many people do not accept the products, and do not purchase the products. For example the prior strips are easily scratched and they tend to collect dirt due to the electrostatic charge arising by virtue of the nature of the material from which the product is formed. Moreover, it has not been possible to manufacture such products with a decorative or patterned surface. Finally, it has been found that the products cannot be nailed into position, which skilled workers regard as a serious disadvantage.
According to one aspect of this invention there is provided a product, for example in the form of a facing element for a door, a skirting board, a shadow rail, a window-frame, a door, a flower-pot or a waste-paper basket, which product is provided with a decorative surface layer on at least one face thereof, wherein the product comprises a carrier of thermoplastic material, to which carrier a decorative surface layer of wood, veneer, metal our a layer comprising thermoset plastics material is firmly attached by a hot melting elastomer.
A hot melting elastomer is an elastomer which fuses or melts, and thus becomes tacky, at a high temperature.
Preferably, the carrier is made of a vinyl plastic, such as polyvinyl chloride, polystyrene, acryl butadiene-styrene (ABS), polypropene or polyethylene. However, also other thermoplastic materials with corresponding qualities can be used.
Where the decorative surface layer consists of a wood veneer, it is preferred that the veneer is impregnated, or has a protectively coated surface, so that the veneer has water-repellant properties. For example, the veneer may be treated with an acid curing resin, a polyurethane resin, a polyester resin, an epoxy resin, a nitro-cellulose resin or a polyacry late resin can be used. It is also possible to use an autoclave impregnated veneer.
The veneer can be cut to suitable lengths or can be endless.
If the decorative surface layer consists of metal, then preferably brass, copper or aluminium is used.
From the viewpoint of costs, it is then most practicable to use thin foils. However, thicker metal layers can be used if desired.
As mentioned above, the decorative surface layer can comprise a thermoset plastics material. It is possible to use at least a single sheet, for example of paper or cloth impregnated with a thermoset plastics material, although a multi-sheet laminate is preferably used as a decorative surface layer. Such a laminate can be produced by pressing together two or more sheets, for example of paper or cloth, impregnated with thermoset plastics material at a high pressure and at an elevated temperature.
Nowadays such laminates can be manufactured continuously. However, it is still common for the pressing of such a laminate to be made batchwise in a multistage press where the material for many laminates is pressed at the same time. Before the pressing can take place, separate sheets of paper or cloth impregnated with a thermosetting plastic material are stacked on top of each other to form so-called press packages. This is most frequently effected manually.
However, in the abovementioned continuous pressing two or more continuous sheets of a paper or cloth impregnated with a thermosetting plastics material are fed into a continuous press. The finished laminate can then be obtained as rolls.
The thermoset laminate can be made in a conventional way from some sheets of so-called core paper impregnated with a phenol-formaldehyde resin and one or two overlay paper sheets of better quality impregnated with malamine-formaldehyde resin, for example.
Regardless of whether the decorative surface layer consists of a single sheet, for example of paper or cloth impregnated with a thermoset plastics material or of a laminate, it is suitable in both cases to use the same kind of thermosetting plastics material.
Preferably at least one of the following thermosetting plastics materials is used: melamineformaldehyde, phenol-formaldehyde, ureaformaldehyde, polyester, a derivative of any one of these, an analogous plastic such as cresolformaldehyde, for example, or a terpolymer, such as melamine-urea-formaldehyde or phenol-urea formaldehyde.
The hot melting elastomer which is used to firmly attach the decorative surface layer to the thermoplastic material carrier is preferably based on ethylene-vinylacetate or on a polyamide or may consist of a polymer of styrene-butadiene-rubber (SBR). Other elastomers with similar properties might also be used.
According to another aspect of the invention there is provided a process for the production of a product according to the invention wherein a decorative surface layer of wood veneer, metal or a layer comprising thermoset plastic, which decorative layer is provided with a layer of a hot melting elastomer on one side, is joined with a carrier of a thermoplastic material by means of the elastomer.
Preferably the decorative layer is joined to the carrier in connection with or just after the formation of the carrier, when the carrier is still warm.
In such a case the heat of the carrier is used to heat the elastomer so that the elastomer becomes sticky and can work as an adhesive joining layer between the decorative surface layer and the carrier. Thus, normally it is not necessary to add any extra heat to ensure that elastomer becomes sticky. From the viewpoint of handling and economy this is extremely important. Also the reliability is very high.
Consequently, it is possible for the decorative surface layer to be pre-coated on the back side with a hot melting elastomerwhich is allowed to cool after the application, and before the decorative surface layer is applied to the carrier.
Then the elastomer does not get properly sticky before it is heated again to about 140 - 240 C. Of course, the fusion temperature within this interval depends on the elastomer used. Thus, usually an elastomer based on ethylene-vinylacetate has a fusing point of 140 - 220cm, while an elastomer based on a polyamide usually has a fusing point of 180 260"C.
The elastomer coated decorative surface layer can be manufactured in a rational way at a large factory and can then be distributed to other factories where the finished product is produced in connection with the production of the thermoplastic material carrier.
If the product according to the invention consists of an elongate article, such as a door, a facing element for a door, a skirting board or a shadow rail for example, it is extremely preferable to make the thermoplastic carrier continuously by extrusion.
Then a continuous sheet of a decorative surface layer, coated on one side with a hot melting elastomer, is brought to adhere to the extruded carrier when the carrier is still warm after the extrusion step. The decorative surface layer is then applied to the extruded carrier when the carrier has left the moulding die, but before it has leftthe conventional calibration chamber, where the shape of the carier is finely adjusted.
In an especially preferably process according to the invention, the elastomer coated side of the decorative surface layer is pressed againstthe carrier in the said calibration chamber by means of overpressure or vacuum existing there.
There is a very substantial advantage obtained with the preferred process according to the invention where the carrier is extruded and then joined immediately with a continuous sheet of a decorative surface layer, which advantage consists in that generally it is not necessary to make any alterations to the extruder at all. Moreover, of course, the production is especially rational.
When the carrier is produced by injection moulding or moulding, rather than by extrusion, advantages may also be obtained. Among other things, great and unique possibilities of giving the products a special decorative surface are obtained. In such a case one or more sheets of a decorative surface layer material, coated with a hot melting elastomer on one side, are arranged in a mould which is to be used for the injection moulding or moulding of the thermoplastic material carrier before the mould is filled with the plastic material. The coated parts of the surface layer material are then firmly joined to the carrier, when it is formed in the mould.
In order that the invention may be more readily understood, and so that further features thereof may be appreciated, the invention will now be described, by way of example, with reference to the accompanying drawings in which: Figure 1 is a diagrammatic view of one process for making a product in accordance with the invention; and Figure 2 is a corresponding diagrammatic view of4 an alternative process for making a product in accordance with the invention.
Figures 1 and 2, both schematically illustrate embodiments of the invention where a thermoplastic material carrier is produced continuously by extrusion. The carrier is then joined with a continuous decorative sheet comprising a thermosetting plastics material laminate, which is coated on its back side with a hot-melting elastomer, that is to say a thermoplastic elastomer which melts at an elevated temperature. In the embodiment shown in Figure 1 the thermosetting decorative sheet is coated with a hot-melting elastomer as part of the process of joining the decorative sheet to the carrier.
However, in the embodiment shown in Figure 2 a roll of the decorative sheet which has been previously coated with a hot-melting elastomer is joined to the thermoplastic material carrier.
Referring initially to Figure 1, a carrier 7 of thermoplastic material, for example of polyvinyl chloride, is extruded by means of an extruder 1. A decorative sheet comprising thermoset plastics material 4 is withdrawn from a roll and is then coated on its back side with a hot-melting elastomer in a coating equipment 6. For example, the elastomer can be based on ethylene-vinylacetate and may have a fusing point of about 180 - 21 0 C. The decorative sheet comprising thermoset plastics material is preferably in the form of a laminate consisting of three sheets of paper impregnated with melamine-formaldehyde plastic, which sheets have been laminated in a continuous press.
The elastomer coated sheet 4 is guided over guide rollers 5 towards a conventional calibration chamber 2. Such a calibration chamber2 has previously normally been used only to finely adjust the shape of the carrier. However, in the described embodiment of the invention the elastomer coated side of the decorative sheet 4 is joined with the carrier in the calibration chamber 2, which in this case had a temperature of 160 - 1 900C. The temperature that the elastomer coating is exposed to is enough to make the elastomer sufficiently sticky to cause the decorative sheet to be adhered to the carrier.
The joining of the laminate and the carrier is facilitated by the overpressure or the vacuum existing in the calibration chamber 2.
When the laminate 4 and the carrier 7 have been joined to form the desired plastics product in the calibration chamber 2, the product is chilled in a subsequent cooler 3, usually a water cooler. Then the product is cut to desired lengths. However, this is not shown on the Figure.
The reference numerals on Figure 2 relate to the same details as on Figure 1. However, in this embodiment, the decorative sheet 4 is already coated with a hot melting elastomer on the back side. Therefore, no coating equipment 6 is included in this modified process. Otherwise the process shown in Figure 2 corresponds wholly with that shown in Figure 1.
The invention is not limited to the embodiments shown, since these can be modified in different ways within the scope of the present invention.

Claims (24)

1. A product, for example in the form of a facing element for a door, a skirting board, a shadow rail, a window-frame, a door, a flower-ot or a waste-paper basket, which product is provided with a decorative surface layer on at least one face thereof, wherein the product comprises a carrier of thermoplastic material, to which carrier a decorative surface layer of wood, veneer, metal or a layer comprising thermoset plastics material is firmly attached by a hot melting elastomer.
2. A product according to clam 1, characterized in that the carrier is made of a vinyl plastic.
3. A product according to claim 2 wherein the carrier is made of polyvinyl chloride, polystyrene, acryl-butadiene-styrene (ABS), polypropene or polyethylene.
4. A product according to any one of the preceding claims wherein the decorative surface layer consists of wood veneer, which is impregnated, or which has a protectively coated surface, so that the veneer has water repellant properties.
5. A plastic product according to any one of claims 1 to 3 wherein the decorative surface layer consists of brass, copper or aluminium.
6. A product according to claim 5, wherein the decorative surface layer of brass, copper or aluminium consists of a thin foil.
7. A product according to any one of claims 1 to 3 wherein the decorative surface layer consists of at least a single sheet of material impregnated with a thermoset plastics material.
8. A product according to claim 7 wherein the or each said sheet of material comprises paper or cloth.
9. A plastic product according to claim 7 or 8, wherein the decorative surface layer consists of a multi-sheet laminate.
10. A product according to any one of claims 7 to 9, characterized in that the decorative surface layer contains at least one of the following thermosetting plastics materials: melamine-formaldehyde, phenolformaldehyde, urea-formaldehyde, polyester, or a derivative of any one of these plastics, or an analogous plastic, such as cresol-formaldehyde, or a terpolymer, such as melamine-urea-formaldehyde or phenol-urea-formaldehyde.
11. A product according to any one of the preceding claims wherein the hot melting elastomer is based on ethylene-vinylacetate or on a polyamide or consists of a polymer of styrene-butadiene-rubber (SBR).
12. A process for the production of a product according to any one of the preceding claims, wherein a decorative surface layer of wood veneer, metal or a layer comprising thermoset plastics, which decorative layer is provided with a layer of a hot melting elastomer on one side, is joined with a carrier of a thermoplastic material by means of the elastomer.
13. A process according to claim 12 wherein the decorative layer is joined to the carrier in connection with or just after the formation of the carrier, when the carrier is still warm.
14. A process according to claim 12 or 13, where the product consists of an elongate article such as a door, a facing for a door, a skirting board or a shadow rail for example, wherein the thermoplastic carrier is produced continuously by warm extrusion and a continuous sheet of a decorative surface layer, coated on one side with a hot melting elastomer, has said one side brought into contact with the extruded carrier, when the carrier is still warm after the extrusion step, and thus adheres to the carrier.
15. A process according to claim 14, wherein the elastomer coated side of the decorative surface layer is brought into contact with the extruded carrier after the carrier has left the extrusion die, but before it has left a conventional calibration chamber where the shape of the carrier is finely adjusted.
16. A process according to claim 15, wherein the elastomer coated side of the decorative surface layer is pressed against the carrier in the calibration chamber by means of overpressure or vacuum existing there.
17. A process according to claim 12, which comprises arranging one or more sheets of said decorative surface layer material which are coated on one side with a hot melting elastomer in a mould which is part of an injection moulding or other moulding apparatus, introducing thermoplastic material into said mould at an elevated temperature, and moulding the plastic to form the carrier, the decorative surface layer material becoming firmly joined to the carrier produced during said moulding step.
18. A product according to claim 1 and substantially as herein described.
19. A product substantially as herein described with reference to Figure 1 of the accompanying drawings.
20. A product substantially as herein described with reference to Figure 2 of the accompanying drawings.
21. A process according to claim 1 and substantially as herein described.
22. A process substantially as herein described with reference to Figure 1 of the accompanying drawings.
23. A process substantially as herein described with reference to Figure 2 of the accompanying drawings.
24. Any novel feature or combination of features disclosed herein.
GB8132080A 1980-10-24 1981-10-23 A product with a decorative surface layer and a process for the production of the product Expired GB2087307B (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE8007476 1980-10-24
SE8101107A SE451560B (en) 1980-10-24 1981-02-19 PROCEDURE FOR MANUFACTURING A LONG-TREATED PLASTIC PRODUCT PROVIDED WITH DECORATIVE LAYER

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GB2087307A true GB2087307A (en) 1982-05-26
GB2087307B GB2087307B (en) 1985-01-30

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DK (1) DK468781A (en)
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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2589393A1 (en) * 1985-11-05 1987-05-07 Charbonnages Ste Chimique COMPLEX LAMINATE MATERIAL AND METHOD FOR MANUFACTURING THE SAME
EP0561086A1 (en) * 1990-08-22 1993-09-22 Nippon Decoluxe Kabushiki Kaisha Decorative laminate board
WO1997006942A1 (en) * 1995-08-17 1997-02-27 Meeth Ernst Josef Process for producing profiled materials, in particular for door and window production
WO2003053720A2 (en) * 2001-12-21 2003-07-03 Louis Granville Broeders Applying a decorative finish to metal surfaces
AT411180B (en) * 1999-06-02 2003-10-27 Dfs Technology & Service Ag WINDOWS OR DOORS AND METHODS THEREOF OR THEIR PRODUCTION
DE102006049913A1 (en) * 2006-10-18 2008-04-24 Schmuhl Faserverbundtechnik Gmbh & Co. Kg Surface finished shaped articles, e.g. automobile bodywork components, have elastic intermediate layer between thermoplastic film and plastics support to ensure smooth surface
WO2020136098A3 (en) * 2018-12-24 2020-08-13 Dsm Ip Assets B.V. Method for producing a multilayer panel provided with a water impervious coating

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4101106A1 (en) * 1991-01-16 1992-07-23 Krauss Maffei Ag METHOD AND DEVICE FOR PRODUCING LAMINATED MOLDED PARTS

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DD94476A (en) *
DE1779556C3 (en) * 1968-08-27 1974-05-09 Basf Ag, 6700 Ludwigshafen Method for producing a five-layer component

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2589393A1 (en) * 1985-11-05 1987-05-07 Charbonnages Ste Chimique COMPLEX LAMINATE MATERIAL AND METHOD FOR MANUFACTURING THE SAME
US4956224A (en) * 1985-11-05 1990-09-11 Societe Chimique Des Charbonnages S.A. Articles produced from a laminate and process for their manufacture
EP0561086A1 (en) * 1990-08-22 1993-09-22 Nippon Decoluxe Kabushiki Kaisha Decorative laminate board
WO1997006942A1 (en) * 1995-08-17 1997-02-27 Meeth Ernst Josef Process for producing profiled materials, in particular for door and window production
US6237208B1 (en) 1995-08-17 2001-05-29 Ernst-Josef Meeth Process for producing profiled materials, in particular for door and window production
AT411180B (en) * 1999-06-02 2003-10-27 Dfs Technology & Service Ag WINDOWS OR DOORS AND METHODS THEREOF OR THEIR PRODUCTION
WO2003053720A2 (en) * 2001-12-21 2003-07-03 Louis Granville Broeders Applying a decorative finish to metal surfaces
WO2003053720A3 (en) * 2001-12-21 2004-01-22 Louis Granville Broeders Applying a decorative finish to metal surfaces
DE102006049913A1 (en) * 2006-10-18 2008-04-24 Schmuhl Faserverbundtechnik Gmbh & Co. Kg Surface finished shaped articles, e.g. automobile bodywork components, have elastic intermediate layer between thermoplastic film and plastics support to ensure smooth surface
WO2020136098A3 (en) * 2018-12-24 2020-08-13 Dsm Ip Assets B.V. Method for producing a multilayer panel provided with a water impervious coating

Also Published As

Publication number Publication date
DE3141410A1 (en) 1982-06-24
DK468781A (en) 1982-04-25
NO813532L (en) 1982-04-26
GB2087307B (en) 1985-01-30
NO159780B (en) 1988-10-31
NO159780C (en) 1989-02-08

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