KR20010024427A - Abrasion resistant laminate and method for making same - Google Patents

Abstract

The present invention relates to an aesthetically pleasing, water resistant / waterproof and flexible abrasive wear resistant laminate formed by laminating a wear resistant durable multilayer top assembly to a base layer of a low cost, water resistant polymer substrate. The durable multilayer wear resistant top layer assembly includes a wear resistant top layer, a decorative layer and a core layer. The polymeric base layer comprises a water resistant substrate positioned in the top layer assembly and laminated there with a water resistant adhesive. Such abrasion resistant laminates are applicable in any situation where decorative and / or abrasion resistant products can be used and are particularly useful in the flooring industry.

Description

Abrasion resistant laminate and its manufacturing method {ABRASION RESISTANT LAMINATE AND METHOD FOR MAKING SAME}

It is known that the abrasive resistant particles can be applied on or within the epidermal layer or decorative sheet to enhance the abrasive resistance of the laminate. Examples of techniques for applying these particles are described in Lane 3,798,111, Mehta 5,141,799, and Ungar, 4,713,138, the epidermal layer. Or each description, including a method of introducing abrasive resistant particles on or within a decorative layer, is incorporated herein by reference.

It is also well known to use polymer substrates, in particular polyvinyl chloride, to decorate the floor and counter top. However, this type of flooring has many problems, including their limited aesthetics as well as the durability and surface wear characteristics of the product. Many consumers have relied on the use of stones, such as granite and marble, in an effort to increase the durability of flooring in crowded places, such as department stores, office buildings and large general stores. While these stones are durable, they are very expensive for the average consumer. An example of a wear resistant flooring with a wear resistant or wear resistant top layer laminate is currently PERGO It is manufactured by Perstorp Flooring AB (Sweden) under the trade name. PERGO The brand includes a surface layer providing strength and durability, a decorative layer having a design and a base layer or substrate layer providing strength, stability and heat resistance. The surface layer consists of cured melamine resin in combination with cellulose paper and contains hard abrasive resistant particles in the layer. The decorative layer consists of paper or melamine resin. PERGO The product shall be laminated with a surface layer and a decorative layer on a base or substrate layer based on wooden products. Such wood based substrates are generally particle boards but may also comprise medium density fiberboards or hardboards. The strength and water resistance of such wood-based substrates are selected based on the environment in which the flooring is used, such as general household, large family / medium commercial or general commercial.

PERGO The use of wood-based substrates and other similar forms of laminate in the product has many disadvantages associated with them, the most important of which provides some water resistance to the wood-based substrate and ensures that the product will only be exposed to a limited amount of moisture. In order to do so, several steps must be taken. In addition, care must be taken when installing this product so that sufficient adhesive is used between the planks to prevent water from penetrating the wood substrate. Another disadvantage of these laminates is that they are susceptible to environmental conditions, expansion and contraction because they have wood-based substrates. Therefore, they cannot be directly bonded to a surface such as a floor, but must be installed in a "floating" form. To install a "floating" floor, it is necessary to provide special tongues and grooves along the edges of the product to minimize the movement of the planks with respect to each other during and after installation. The glue is applied along these edges to secure the floor plank in place on the floor. Another drawback of wood-based substrate flooring is that it is generally necessary to replenish the foam layer made of polyethylene in order to provide cushioning and to reduce noise when impacting the floor. The installation of such flooring is very complicated and often requires installation by skilled professionals, which is costly to many consumers.

The present invention eliminates all of the above drawbacks by providing an aesthetically pleasing, sound-absorbing and abrasive resistant product in which a multilayer wear resistant top layer assembly is laminated to a polymeric base substrate rather than a wood based substrate. The product of the present invention not only provides a water resistance and / or water resistance by using a polymeric base substrate, but also eliminates the cost of the manufacturer sticking directly to the surface to form a tongue and groove along the edge of the product. In addition, the article of the invention is located between the article and the surface to be installed thereon, an additional layer, such as a polyethylene film deposition barrier layer and / or a polyethylene foam layer, to provide moisture resistance, sufficient resilience or cushioning and sound absorption capabilities. Does not require the use of. Thus, the product of the present invention can be easily installed by ordinary consumers without paying the cost of hiring a skilled professional.

Summary of the Invention

The present invention provides a wear resistant laminate having a wear resistant durable multilayer surface assembly laminated to a base layer comprised of a polymeric substrate. Abrasion resistant laminates are aesthetically pleasing, sound absorbing, durable, wear resistant, water resistant / water resistant, stress resistant and inexpensive to manufacture and easy to install. In addition, the laminate is flexible and has reduced wrinkles and distortions. The wear resistant laminates of the present invention are particularly useful for the manufacture of floorings but can be useful wherever desired for products having the above characteristics, such as counter tops, table tops, store fixtures, wall decor.

The wear resistant article of the present invention comprises a durable wear resistant top layer assembly comprising a wear resistant top layer, a decorative layer and a core layer. The wear resistant top layer can be a separate top layer with abrasive resistant particles dispersed on its surface or on the sheet itself. Optionally, the wear resistant top layer can be formed by directly coating the abrasive on the decorative layer or by dispersing the abrasive in the decorative sheet. The technique of dispersing the abrasive in the top layer or decorative sheet occurs during the papermaking step of the top layer or decorative sheet. Known techniques can be used to apply the abrasive resistant particles.

The core layer may comprise at least one, preferably two or more layers of materials that provide reinforcement of the assembly. This core layer may generally comprise a sheet of paper, such as a sheet of kraft paper impregnated with a resin such as a phenolic resin. The core layer may also include one or more additional layers of fiberglass, polypropylene, polyester, nylon, carbon fiber or other known water resistant materials. The additional layer may also consist of a woven or nonwoven sheet, which may or may not be impregnated with a resin such as a phenolic resin. In addition, the core layer may consist only of one or more such water resistant sheets, thereby eliminating the use of kraft paper sheets. The use of such additional layers reduces the swell and shrinkage differences of the laminate to provide dimensional stability and flexibility, as well as to provide improved effects and anti-punk properties.

Already known laminates generally need to impregnate the decorative layer with a resin, typically melamine resin, in an amount of about 35-40% by weight of the sheet. In the present invention, the amount of such impregnated resin is 0.40% by weight of the sheet, preferably 0-30% by weight of the sheet. Decorative sheets that do not use resin or use reduced amounts have more stabilized laminates with reduced curling, reduced shrinkage, greater flexibility, greater strength, less fracture and less cracking. to provide.

A polymeric substrate is provided to form the base layer for the wear resistant laminate. This polymeric base layer is bonded to the bottom surface (or core layer bottom side) of the top layer assembly with a water resistant adhesive.

A thin balance layer is deposited on the bottom surface of the polymeric substrate to provide balance of the product, reduce the curling and / or distortion of the product, help the product to match the bottom surface and improve sound absorption properties. .

The wear resistant top layer assembly can be attached to the polymeric substrate by two different techniques. The first of these techniques is to laminate the wear resistant top layer assembly layers and apply heat and high pressure to the assembly to cure and laminate the layers to one another to form a high pressure laminate. This high pressure laminate is then bonded to the polymeric substrate with a water resistant adhesive.

Another technique for forming such a product is to use a low pressure method. The low pressure method can be performed according to two techniques. The first of these techniques requires laminating all the layers together in a single step by laminating all layers of a wear resistant top layer assembly, a water resistant adhesive and a polymeric substrate base layer and applying heat and low pressure to the stack to cure the layers. . The second technique requires initially laminating the wear resistant top layer assembly under heating and low pressure and then adhering the laminate to the polymeric substrate base layer with a water resistant adhesive.

The final product of the present invention has a hard, wear resistant, scratch resistant and fouling resistant surface on a flexible support substrate with a thin soft balance sheet. These panels are flexible enough to match the slightly irregularities on the surface to which they are bonded, are inexpensive to manufacture, have soft cushioning and sound absorption, and are easy to construct.

Further features and advantages of the present invention will become more apparent from the following detailed description, which is described with reference to the accompanying drawings.

FIELD OF THE INVENTION The present invention relates to wear resistant laminates, and more particularly, to wear resistant laminates having a wear resistant, durable multilayer surface assembly laminated to a base substrate formed from an inexpensive and waterproof polymer substrate. This abrasive laminate is applicable in any situation where decorative and / or abrasive products can be used, particularly useful in the flooring industry.

1A-C illustrate cross-sectional views of various, commercially available decorative materials.

2 shows a cross-sectional view of an abrasive resistant laminate according to the invention in expanded form.

3 shows a cross-sectional view of an abrasive wear laminate according to the present invention in which the wear resistant top layer is laminated under heating and pressure to form a laminate before being applied to the base substrate.

4A shows the sequence of steps for producing a laminate according to a first embodiment of the present invention, wherein the laminate is formed by a single pressing step.

4B is a sequence of steps for making a laminate according to a second embodiment of the present invention, wherein a durable wear resistant top layer assembly layer is laminated in a first step and the laminate is sequentially bonded to a base substrate in a second step. It is shown.

5 shows an exemplary process for forming the inventive laminate corresponding to the embodiment shown in FIG. 4B.

1A-1C are cross-sectional views of various decorative materials currently available to consumers as described in the background of the invention. 1A includes a vinyl chloride sheet 1. This sheet has a limited aesthetic and very little wear resistance to scratching, scuffing and / or tearing. FIG. 1B comprises a laminate composed of a transparent vinyl chloride top layer 2, a vinyl chloride decorative sheet 3 and a vinyl chloride basesheet 1. FIG. 1B provides a larger decorative requirement range, but the upper transparent vinyl chloride sheet 2 has little protection against this decorative sheet and is often scratched, scuffed and / or contaminated. 1C shows a marble chip layer 4. It is durable but very expensive, making it difficult for the average consumer to buy.

2 shows a cross-sectional view of the inventive abrasive resistant laminate in expanded form. This laminate comprises a durable top wear resistant layer assembly 5, an adhesive layer 9 and a base layer 10. The top wear resistant layer assembly 5 comprises a wear resistant top layer or surface layer 6, a decoration layer 7 and a core layer 8. The base layer 10 is bonded to the upper wear resistant layer assembly via an adhesive layer 9. This base layer 10 comprises a polymeric substrate, such as polyvinyl chloride. The balance layer 11 is adhered to the lower surface of the polymeric substrate to reduce or control the lamination of the laminate and provide additional cushioning to the product.

3 and 4B illustrate an embodiment in which the upper wear resistant layer is laminated under heating and pressure to form a laminate 12 before it is attached to the base substrate. This laminate 12 comprises a layer, such as the top wear resistant layer 5 described in FIG. 2, in particular a wear resistant top layer 6, a decorative layer 7 and a core layer 8. This laminate is sequentially laminated to the base layer 10.

This laminate 12 may be produced by a high pressure or low pressure method as described in detail below. The balance layer 11 is also adhered to the lower surface of the polymeric substrate to reduce or control the lamination of the laminate and to provide additional cushioning to the article.

The top wear resistant layer assembly can be attached to the polymeric substrate by two different techniques. The first of these techniques is to laminate the layers of the top wear resistant layer assembly and heat them to high pressure to cure and laminate the two layers to form a high pressure laminate. High pressure laminates are generally laminates produced at pressures above 750 psi and at temperatures above about 250 ° F. This high pressure laminate is subsequently bonded to the polymeric substrate using a water resistant adhesive. The steps for this technique are illustrated in Figure 4B.

Another technique for forming the product of the present invention is to use a low pressure method. The low pressure method can be performed with two techniques. The first of these techniques is to laminate all of the layers forming the top wear resistant layer assembly, the water resistant adhesive layer and the polymeric substrate base layer, apply heat and low pressure to the stack to cure the two layers and laminate the two layers together in a single step. Required. The steps of this technique are illustrated in Figure 4A.

A second technique for carrying out the low pressure method requires first laminating the layers of the top wear resistant layer assembly under heating to low pressure and then adhering the laminate to the polymeric substrate base layer with a water resistant adhesive. The steps of this technique are illustrated in Figure 4B. The low pressure laminate may be formed in a double belt press from a static press or in a continuous configuration. Low pressure laminates are generally laminates formed by heating to about 325-375 ° F. at 300 psi. FIG. 5 is consistent with FIG. 4B, wherein the layers of the top wear resistant layer assembly are first laminated under conditions to form a high pressure or low pressure laminate 18 and the high pressure or low pressure laminate is subsequently laminated to the polymeric base layer 16. Illustrates a method of forming the laminate of the present invention. Element 14 illustrates the continuous application of glue to polymeric base layer 16 by transferring polymeric base layer 16 to the nip of a pair of glue rollers 15. Element 17 illustrates the provision of a high pressure or low pressure laminate 18 and element 19 is an adhesive coated polymeric base layer 16 and base layer with the laminate and the core layer 23 therebetween. (16) illustrates stacking a balance layer 20 positioned below. This lamination is then placed on the flat plate press 21 and heat and pressure are applied via the flat plate 22. Element 24 illustrates the transfer of laminated product 29 to a router to form strip 25. This strip is then cut into tiles 27 in element 26. The product is transported and packaged to a packaging and shipping location as shown by element 28.

The wear resistant layer or surface layer 6 may have abrasive particles coated or dispersed therein on its surface. In addition, although the wear resistant top layer is shown as a separate surface sheet, FIG. 2 can be formed by coating the wear resistant layer directly on the decorative sheet 7 or dispersing the abrasive on the decorative sheet 7. The technique of applying the abrasive to the surface sheet or decorative sheet occurs during the initial manufacturing steps of the surface sheet or decorative sheet. Examples of techniques for applying internal abrasive particles on or within surface sheets and / or decorative sheets are described in the above-described Lane, Meta and Unga patents, which are described in detail below.

Lane US Pat. No. 3,798,111 describes the introduction of small mineral particles into and / or near the top layer of base paper during its manufacture. Thus, the abrasive particles are introduced after the base layer is still supported on the forming wire in the wet state. After its manufacture the paper can be printed, impregnated and used in the laminating operation as a print sheet without the need to use a surface.

U. S. Patent No. 5,141, 799 to Mehta shows a wear resistant surface sheet and a decorative sheet, either of which may contain abrasive particles. Meta's patent describes the formation of an internal abrasive surface sheet with three separate techniques. The first technique is to mix internal abrasive aggregates with paper sticks. A second technique is to constantly add amorphous silica in the form of an aqueous slurry to the paper wet web surface through the paper machine's second headbox. The third process is to prepare the cellulose pulp chopped by conventional means, and then to transfer the pulp made into a paper machine where the pulp is converted into paper sheet form in a conventional manner. While in the wet web form of paper, the required amount of abrasion resistant abrasive aggregates is applied on the wet web surface in the form of an aqueous slurry from the second headbox of the paper machine. The final wet sheet containing the abrasive particles is wet pressed to facilitate adhesion of the abrasive particles to or within the sheet.

Meta's patent also describes that the decorative layer itself eliminates discrete surface layers, including abrasive particles. The particles are attached to the decorative layer by providing a base layer for the printed decorative layer. This base layer is formed on a wire of a conventional paper machine. The top layer comprising internal abrasive aggregates is added to the molded wet bay layer carried by the forming wire of the paper machine. This top layer may comprise fibers. In general, the base layer should be shaped fairly well prior to application of the top layer, but not too moisture free, allowing the top layer components to be partially mixed and combined with the base layer.

US Pat. No. 4,713,138 to Ung describes a multi-layer wear resistant top layer laminate. This patent, US Pat. No. 5,141,799, to Meta, discloses a wear resistant surface sheet and a decorative sheet, either of which may contain the abrasive particles. Meta's patent describes the formation of an internal abrasive surface sheet with three separate techniques. The first technique is to mix internal abrasive aggregates with paper stock. A second technique is to constantly add amorphous silica in the form of an aqueous slurry to the paper wet web surface through the paper machine's second headbox. The third process is to prepare the cellulose pulp chopped by conventional means, and then to transfer the pulp made into a paper machine where the pulp is converted into paper sheet form in a conventional manner. While in the wet web form of paper, the required amount of abrasion resistant abrasive aggregates is applied on the wet web surface in the form of an aqueous slurry from the second headbox of the paper machine. The final wet sheet containing the abrasive particles is wet pressed to facilitate adhesion of the abrasive particles to or within the sheet.

Meta's patent also describes that the decorative layer itself eliminates discrete surface layers, including abrasive particles. The particles are attached to the decorative layer by providing a base layer for the printed decorative layer. This base layer is formed on a wire of a conventional paper machine. To the molded wet base layer carried by the forming wire of the paper machine is added a sour layer comprising internal abrasive aggregates. This top layer may comprise fibers. In general, the base layer should be shaped fairly well prior to application of the top layer, but not too moisture free, allowing the top layer components to be partially mixed and combined with the base layer partially.

U. S. Patent No. 4,713, 138 issued to Coa describes a multilayer wear resistant top layer laminate. This patent describes simultaneous impregnation and coating of a laminate decorative sheet with a mixture of a liquid impregnating resin and a polishing composition consisting of microcrystalline cellulose and abrasion resistant mineral particles such as alumina. This mixture is deposited on the upper surface of the decorative sheet which absorbs the liquid resin remaining on top of the layer consisting of the internal polishing composition and a small amount of resin. This layer forms the upper wear resistant layer of the laminate. After drying, the decorative layer can be used directly for the preparation of high and low pressure decorative laminates.

The wear resistant layer 6 can be formed by a variety of known techniques depending on whether the final product is a solid color laminate or a printed laminate. The wear resistant layer of solid color laminate can be formed by three techniques. First, the colored pulp is placed on the forming wire of the paper machine to form a first layer and a second layer of uncolored pulp comprising an abrasive is attached thereto. It is to use an abrasive coated surface layer that can be placed on a second colored decorative layer and made by known techniques as described in the aforementioned lane or meta patent. A third technique is to provide melamine saturated colored paper and include abrasive before placing it in the oven to cure the paper.

If the final product is a printed laminate with a design on top of it, the wear resistant layer cannot be formed by two techniques. The first is to form separate surface layers made by known techniques. The second is to coat the abrasive directly before drying it on the resin impregnated printing paper.

When using the surface layer as a wear resistant layer, whether it is a solid product or a printed product, this surface layer impregnates the alpha cellulose or paper sheet with a thermosetting resin such as melamine, polyester or diallyl phthalate and on or on the sheet. It is possible to prepare a transparent sheet prepared by applying the abrasive particles, such as alumina, silica or a mixture thereof. Preferably any known abrasive particles having a moh hardness of at least 6 may be used. This layer protects the decorative layer 7 and provides a surface that is resistant to contamination, scratching and chemicals.

When the surface layer or coated paper layer containing the abrasive particles is pressed to the particle side, a low layer such as alpha cellulose or the like is placed on top of the abrasive grain layer to protect the presim plate with little effect on the predetermined abrasive resistance characteristics of the top layer. It is apparent to those skilled in the art that a basis weight surface can be used.

The decorative layer 7 is printed or colored paper treated or untreated with resin. Melamine, polyester or diallyl phthalate may also be used for this treatment. If the decorative layer is resin impregnated a small amount of resin should be used. The amount of resin used is in the range of about 0-40%, preferably 0-30% per paper weight. Conventional products are generally known to require about 35-40% resin per weight of paper used, but in the present invention this amount is reduced or eliminated to prevent product from curling, reduce cracking and improve solubility. Let's do it.

The core layer 8 may be formed of one or more layers of undecorated paper treated with a thermosetting resin such as phenol, melamine or mixtures thereof. This core layer provides reinforcement for the assembly. In addition, the core layer prevents the surface defects of the polymeric base substrate layer from transferring to the surface of the upper wear resistant layer upon compression. This core layer comprises the above-described paper sheet, which is generally referred to as kraft paper and impregnated with phenolic resin. This core layer may comprise one or more additional layers of fiberglass, polypropylene, polyester, nylon, carbon fiber or any known water resistant material. This additional layer is a knitted or nonwoven sheet and these sheets can be impregnated with a resin such as phenol. In addition, the core layer may consist of only one or more of these layers to avoid the use of kraft paper layers. The use of such additional layers reduces the expansion and contraction differences of the laminates to provide dimensional stability and flexibility, as well as to provide improved effects and anti-punk properties. A preferred arrangement for the core layer 8 is to provide two sheets of resin impregnated paper and sandwich one of the additional layers described above between these paper layers. The additional layer may or may not be initially impregnated with the resin. Upon pressing of the laminate the resin of the paper sheet migrates to this additional layer. Preferred additional layers include a fiberglass layer having a basis weight of about 25-60 g / m ² .

As mentioned above, in existing laminates, it is required to impregnate the decorative sheet with a resin such as melamine resin in an amount of about 35-40% of the sheet. The amount of impregnating resin used in the present invention is in the range of 0-40%, preferably 0-30% per sheet weight. The absence or use of a small amount of melamine resin in the decorative sheet provides a more stabilized laminate with reduced knurling, greater flexibility, greater strength and less cracking.

A polymeric substrate is provided to form the base portion for the abrasive wear laminate. This polymer base layer is bonded to the bottom surface (or core layer bottom side) of the top layer assembly with a water resistant adhesive. The polymeric substrate layer has a shore A handness of 50-100, preferably about 85. This substrate can be formed from a variety of materials such as polyvinyl chloride, polyurethane, natural and synthetic rubber, polyolefins, and polyester elastomers or any other well known material that exhibits certain properties for the present invention. This substrate is also flexible and waterproof. Preferred materials for forming the substrate are reused scrap materials, such as reused polyvinyl chloride scrap materials, because recycled scrap materials have economic advantages. When using reusable scrap materials for a substrate, it is desirable to laminate a balance layer on the bottom surface of the substrate. The balance layer is described in more detail below. Substrates can also include fillers, additives and modifiers such as carbon black, talc, clays, silicates, other minerals, and the like, known in the art.

The thin balance layer is generally laminated to the bottom of the polymeric substrate to provide balance, to reduce the curling and / or distortion of the product, and to provide soft cushioning. This balance layer can be selected from paper treated with a phenol resin, melamine resin and / or acrylic resin; Glass fiber treated with polyvinyl chloride resin; Non-woven ; Soft polyvinyl chloride layer; Or a virgin polyvinyl chloride layer. Virgin polyvinyl chloride appears to be the most effective to minimize curling when using reusable vinyl polymeric.

The effect of curling or distortion of the laminate can be reduced by reducing the amount of thermoplastic resin used to use the decorative sheet.

The waterproof adhesive 9 used may consist of neoprene, nitrile, acrylic, polyester, urethane, rubber, vinyl or any other well known polymer or combination of polymers. Any adhesive may be used, as long as it is waterproof and, for example, matches the layer in contact with the base substrate layer 10 and the core layer 8. The adhesive 9 may be coated on the bottom surface of the core layer 8 or the top surface of the base substrate layer 10. The adhesive 9 may optionally be a separate adhesive film, such as a polyurethane or phenolic film adhesive.

The final product of the present invention has hard abrasion resistance, scratch resistance and fouling resistance on a flexible support layer having a thin soft balance sheet. The product is nominally 400 cycles or more based on NEMA TABER ABRASION LD3 3.13 (1995) and can be increased by adding additional abrasives on top of it. The product is flexible enough to match the small irregularities of the applied surface, can be easily constructed, has a variety of decorative properties, is relatively inexpensive to manufacture and can be used in moisture-sensitive environments. Although abrasive polishing laminates have particular utility in the manufacture of floorings, these laminates are useful wherever a product having some or all of the above properties is desired. Examples of other uses of the product may include the manufacture of counter tops, table tops, store furniture, walls, and the like.

The examples described below represent examples of the wear resistant laminates and methods of making the laminates of the present invention in which various amounts, forms, and / or two laminate components and various techniques for forming the laminates can be used in the present invention. It should not be limited to this.

Example 1

Decorative laminates and polymeric bases were assembled to prepare a wear resistant layer.

I. Decorative laminates include:

A) A common melamine formaldehyde resin, such as that produced by Mid Corporation, Dayton, Ohio, is impregnated and staged B in an oven to yield a resin content of 68-72%, generally 69.2%, 6-8 30 pounds / rim surface containing hard particles, such as alumina or silica, providing a volatile content of%, generally 7.5% and a flow of 8-25%, generally 18%;

B) Saturated paper impregnated with 0,5%, generally 20%, B-staged and printed with 65 pounds / rim composite grain having a volatile content of 3-5%, generally 4.5%; And

C) impregnated with an aqueous phenol formaldehyde resin and staged B to give a resin content of 27-30%, generally 29.2%, 6-9%, generally 7.8% and 2-5%, generally 3.1 A core pack that provides% flow and includes two sheets of 97 pounds / rim of saturated kraft paper. Between the craft sheet typically 25-60g / m between ^two, in general, is, unsaturated non-woven mats, such as fiberglass of 35g / m ² is placed.

These layers are laminated in a conventional multi-opening press, which typically contains 14 laminates and 8 plates to form a high pressure laminate (HPL). Heat and pressure are applied at about 297 ° F. under a pressure of about 1200 psi (81 bar) for a total press cycle of one hour. This laminate was then trimmed and sanded to a predetermined thickness.

II. The polymeric base can be formed in the following steps.

A) Polyvinyl chloride scraps, pigments, additives and fillers were mixed in a Banbury mixer and 2 roll mill until uniform. Examples of the amount and form of these components that can be used include 100 parts of polyvinyl chloride scrap; 3 parts carbon black dye; 2 parts of chemical additives; And 10 parts of clay filler.

B) The mixture was calendered to produce a substrate sheet about 2.4 mm thick;

C) a sheet of commercial black soft virgin polyvinyl chloride was provided;

D) Hot poly nip rolled the virgin polyvinyl chloride sheet to a temperature sufficient to adhere the sheet to the substrate sheet to form a base substrate having a thickness of about 2.5 mm;

E) The base substrate was run on a series of flat rollers to flatten it, and then the substrate was rolled into a roll for post use.

III. The high pressure decorative laminate was bonded to the polymer base in the following steps:

A) The polyvinyl chloride base and the laminate were cut to the same size;

B) A urethane adhesive was coated on the scrap polyvinyl chloride side of the polymer base. Optionally, the adhesive can be applied to the core side (or sanded side) of the decorative laminate.

C) The sanded side of the laminate was placed on the adhesive.

D) The assembly was pressed in a multi-opening press at about 266 ° F. (130 ° C.) and about 212 psi (14.4 bar) until the adhesive cured.

Ⅳ. This sheet was finally cut, inspected and packaged to tile size.

The laminate of this example has abrasion resistance of 10,000 cycles or more based on NEMA TABER ABRASION LD3 3.13 (1995). This abrasive resistance can be increased by applying an additional abrasive surface on top.

Example 2

I. Decorative Laminate:

Decorative laminates can be made in continuous laminate presses using conventional double belt presses. The laminate includes the components as described in Example 1 except using a slightly higher resin content in an amount of about 75% in the surface layer and about 37-38% in the core. Paper and other web components are the same as in Example 1. The dual belt press is pressurized to about 700 psi (48 bar) at a temperature of about 350 ° F. (117 ° C.) to form a low pressure laminate.

Steps (II), III and IV, base forming, gluing and cutting / inspecting steps are the same as in Example 1. This example produces a laminate similar to Example 1.

Example 3

I. Decorative laminate:

High pressure laminates were prepared from the same components as in Example 1 except that a final laminate having a thickness of about 0.7 mm was prepared using heavier fiberglass mats and kraft papers between 35-60 g / m 2. Thicker and / or additional layers were used to produce the final laminate with better impact resistance, which is desirable for heavier areas of use such as commercial decorative materials.

II. Polymer base:

A commercial 3.0 mm thermoplastic urethane base, with 0.4 mm polyvinyl chloride balance sheet, was adhered to the bottom of the decorative laminate.

III. adhesion:

Phenolic film adhesives were used and placed in a hot press at 260 ° F. (130 ° C.) to adhere the decorative laminate to the polymer base.

Ⅳ. Cleavage and inspection were as in Example 1.

Example 4

I. Decorative Laminate:

The continuous laminate of Example 2 was used.

II. Polymer base:

The same polymer base as described in Example 3 was used.

III. adhesion:

Film adhesives and temperatures as described in Example 3 were used.

In all cases, the properties, performance and appearance were the same except for the thickness when using a thicker laminate and base.

While the invention has described the principles of the invention with reference to the preferred embodiments, the invention may be modified in arrangement and detail without departing from the scope and spirit of the invention. Accordingly, it is to be understood that all such modifications and variations that fall within the scope of the appended claims form part of the present invention.

Claims (75)

(a) A durable top wear resistant layer assembly comprising the following layers: Upper wear resistant layer; Decorative layer; And Core layer; (b) a polymer substrate for forming a base layer for the wear resistant laminate, positioned below the top layer assembly; And (c) a water resistant adhesive layer positioned between the top layer assembly and the base layer for adhering the assembly to form an abrasive resistant laminate Abrasion resistant laminate comprising a. 2. The wear resistant laminate of claim 1 wherein the durable top wear resistant layer assembly comprises a high pressure laminate formed by curing and laminating the top layer assembly layer under heat and high pressure before being laminated to the bay layer to form a wear resistant laminate. 2. The wear resistant laminate of claim 1 wherein the durable top wear resistant layer assembly comprises a low pressure laminate formed by curing and laminating a layer of the top layer assembly under heat and low pressure prior to being laminated to the base layer to form a wear resistant laminate. . The low pressure laminate of claim 1, wherein the wear resistant laminate is formed by laying up an upper layer assembly, an adhesive layer and a base layer, and the lamination in a single step, curing and laminating by applying heat and pressure to form the wear resistant laminate. Phosphorous laminate. The wear resistant laminate of claim 1 wherein the wear resistant top layer comprises a surface layer comprising a sheet of resin impregnated paper sheet coated on top of the abrasive particles or dispersed throughout the paper sheet. The wear resistant laminate of claim 1 wherein the wear resistant top layer comprises a coating of abrasive applied directly to the decorative layer or dispersed throughout the decorative sheet. The laminate of claim 1 wherein the decorative layer is impregnated with a thermosetting resin in an amount equal to about 0-40% by weight of paper. The laminate of claim 1 wherein the decorative layer is impregnated with a thermosetting resin in an amount equal to about 0-30% by weight of the paper. The laminate of claim 1 wherein the core layer comprises at least two sheets of resin impregnated paper. The laminate of claim 1 wherein the core layer comprises at least one layer of a woven or nonwoven sheet made of a material selected from the group consisting of fiberglass, polypropylene, polyester, nylon and carbon fiber. 11. The wear resistant laminate of claim 10 wherein a woven or nonwoven sheet layer is positioned between the resin impregnated sheets of claim 9. The laminate of claim 10 wherein the core layer comprises a fiberglass layer having a basis weight of 25-60 g / m ² . The laminate of claim 1 wherein the polymer substrate comprises a flexible waterproofing material selected from the group consisting of vinyls, urethanes, polyolefins, polyesters, synthetic rubbers and natural rubbers. The laminate of claim 1 wherein the polymer substrate comprises a reusable polymer material. The laminate of claim 1 wherein the adhesive layer comprises an adhesive compatible with the core layer and the base layer. The laminate of claim 1 wherein the adhesive layer comprises a film adhesive or a coating of adhesive. The wear-resistant laminate of claim 1 wherein the balance sheet is laminated to the bottom surface of the base layer. 18. The wear resistant laminate according to claim 17, wherein the balance sheet comprises resin treated paper, polyvinyl chloride treated glass fiber, nonwoven fabric, soft polyvinyl chloride or virgin polyvinyl chloride. 19. The wear resistant laminate of claim 18 wherein the balance sheet comprises a virgin polyvinyl chloride sheet. The wear resistant laminate of claim 1 wherein said wear resistant laminate is a flooring material. (a) a durable top wear resistant layer assembly comprising the following layers; Wear resistant top layer; Decorative layer; And Core layer; (b) a base layer located below the top layer assembly, wherein the base layer comprises a polymer substrate made of a reused polymer material; (c) a water resistant adhesive layer positioned between the top layer assembly and the base layer to adhere the top layer assembly to the base layer; And (d) a balance layer bonded to the bottom surface of the base layer Abrasion resistant laminate comprising a. 22. The wear resistant laminate of claim 21 wherein the balance sheet comprises resin treated paper, polyvinyl chloride treated glassfiber, nonwoven fabric, soft polyvinyl chloride or virgin polyvinyl chloride. 22. The wear resistant laminate of claim 21 wherein the recycled polymeric material comprises recycled polyvinyl chloride material and the balance layer comprises a virgin polyvinyl chloride layer. 22. The wear resistant laminate of claim 21 wherein said core layer comprises at least two sheets of resin impregnated paper. 22. The wear resistant laminate of claim 21 wherein the core layer comprises at least one layer of a woven or nonwoven sheet made of a material selected from the group consisting of fiberglass, polypropylene, polyester, nylon and carbon fiber. 26. The wear resistant laminate of claim 25 wherein a woven or nonwoven sheet layer is positioned between the resin impregnated sheets of claim 9. 26. The wear resistant laminate of claim 25 wherein the core layer comprises a fiberglass layer having a basis weight of 25-60 g / m ² . In a method for forming a wear resistant laminate, (a) providing a durable top wear resistant layer laminate comprising the following layers; Wear resistant top layer; Decorative layer; And Core layer; (b) curing the top layer laminate under heat and pressure to form a top layer laminate; (c) providing a polymeric substrate base layer to locate the base layer below the top layer; (d) providing a water resistant adhesive layer for positioning between the top layer laminate and the base layer; (e) adhering the base layer to the top layer laminate to form an abrasive resistant laminate How to include. 29. The method of claim 28, wherein the top layer laminate is formed by applying heat and pressure to form a high pressure laminate. 29. The method of claim 28, wherein the top layer laminate is formed by applying heat and pressure to form a low pressure laminate. 29. The method of claim 28, wherein the wear resistant top layer comprises a surface layer comprising a sheet of resin impregnated paper sheet coated on top of the abrasive particles or dispersed throughout the paper sheet. 29. The method of claim 28, wherein the wear resistant top layer comprises a coating of abrasive applied directly to the decorative layer or dispersed throughout the decorative sheet. 29. The method of claim 28, wherein the decorative layer is impregnated with a thermosetting resin in an amount equal to about 0-40% by weight of the paper. 29. The method of claim 28, wherein the decorative layer is impregnated with a thermosetting resin in an amount equal to about 0-30% by weight of the paper. 29. The method of claim 28, wherein the core layer comprises at least two sheets of resin impregnated paper. 29. The method of claim 28, wherein the core layer comprises at least one layer of a woven or nonwoven sheet made of a material selected from the group consisting of fiberglass, polypropylene, polyester, nylon, and carbon fiber. 37. The method of claim 36, wherein the woven or nonwoven sheet layer is positioned between the resin impregnated sheets of claim 9. 37. The method of claim 36, wherein the core layer comprises a fiberglass layer having a basis weight of 25-60 g / m ² . 29. The method of claim 28, wherein the polymer substrate comprises a flexible waterproof material selected from the group consisting of vinyls, urethanes, polyolefins, polyesters, synthetic rubbers and natural rubbers. 29. The method of claim 28, wherein the polymer substrate comprises a reusable polymer material. 29. The method of claim 28, wherein the adhesive layer comprises an adhesive compatible with the core layer and the base layer. The method of claim 28, wherein the adhesive layer comprises a film adhesive or a coating of adhesive. The method of claim 28, wherein the balance sheet is laminated to the bottom surface of the base layer. 44. The method of claim 43, wherein the balance sheet comprises resin treated paper, polyvinyl chloride treated glass fiber, nonwoven fabric, soft polyvinyl chloride or virgin polyvinyl chloride. 45. The method of claim 44, wherein the balance sheet comprises a virgin polyvinyl chloride sheet. 29. The method of claim 28, wherein the wear resistant laminate is a flooring. In a method for forming a wear resistant laminate, (a) providing a durable top wear resistant layer laminate comprising the following layers; Wear resistant top layer; Decorative layer; And Core layer; (b) curing the top layer laminate under heat and pressure to form a top layer laminate; (c) providing a polymeric substrate base layer of reused polymeric material to position the base layer under the top layer laminate; (d) providing a water resistant adhesive layer for positioning under the top layer laminate and the base layer; (e) adhering the base layer to the top layer laminate with the water resistant adhesive layer; (f) providing a balance layer; (g) adhering the balance layer to the bottom surface of the base layer How to include. 48. The method of claim 47, wherein the reused polymeric material comprises the reused polyvinyl chloride material and the balance layer comprises a virgin polyvinyl chloride layer. 48. The method of claim 47, wherein said core layer comprises at least two sheets of resin impregnated paper. 48. The method of claim 47, wherein the core layer comprises at least one layer of a woven or nonwoven sheet made of a material selected from the group consisting of fiberglass, polypropylene, polyester, nylon, and carbon fiber. 51. The method of claim 50, wherein the woven or nonwoven sheet layer is positioned between the resin impregnated sheets of claim 9. 51. The method of claim 50, wherein the core layer comprises a fiberglass layer having a basis weight of 25-60 g / m ² . In a method for forming a wear resistant laminate, (a) providing a durable top wear resistant layer assembly comprising the following layers; Wear resistant top layer; Decorative layer; And Core layer; (b) providing a polymeric substrate base layer to position the base layer below the upper wear resistant layer assembly; (c) providing a water resistant adhesive layer to position the adhesive layer between the top surface assembly and the base layer; (d) curing and laminating the layers in the top surface assembly and forming a wear resistant laminate by applying heat and pressure to laminate the assembly to the base layer. How to include. 54. The method of claim 53, wherein the wear resistant top layer comprises a surface layer comprising a sheet of resin impregnated paper sheet coated on top of the abrasive particles or dispersed throughout the paper sheet. 54. The method of claim 53, wherein the wear resistant top layer comprises a coating of abrasive applied directly to the decorative layer or dispersed throughout the decorative sheet. 54. The method of claim 53, wherein the decorative layer is impregnated with a thermosetting resin in an amount equal to about 0-40% by weight of the paper. 54. The method of claim 53, wherein the decorative layer is impregnated with a thermosetting resin in an amount equal to about 0-30% by weight of the paper. 54. The method of claim 53 wherein the core layer comprises at least two sheets of resin impregnated paper. 54. The method of claim 53, wherein the core layer comprises at least one layer of a woven or nonwoven sheet made of a material selected from the group consisting of fiberglass, polypropylene, polyester, nylon, and carbon fiber. 60. The method of claim 59, wherein the woven or nonwoven sheet layer is positioned between the resin impregnated sheets of claim 9. 60. The method of claim 59, wherein the core layer comprises a fiberglass layer having a basis weight of 25-60 g / m ² . 54. The method of claim 53, wherein the polymer substrate comprises a flexible waterproof material selected from the group consisting of vinyls, urethanes, polyolefins, polyesters, synthetic rubbers and natural rubbers. 54. The method of claim 53 wherein the polymer substrate comprises a reused polymer material. 54. The method of claim 53, wherein the adhesive layer comprises an adhesive compatible with the core layer and the base layer. 54. The method of claim 53, wherein the adhesive layer comprises a film adhesive or a coating of adhesive. 54. The method of claim 53, wherein the balance sheet is laminated to the bottom surface of the base layer. 67. The method of claim 66, wherein the balance sheet comprises resin treated paper, polyvinyl chloride treated glass fiber, nonwoven, soft polyvinyl chloride or virgin polyvinyl chloride. 68. The method of claim 67, wherein the balance sheet comprises a virgin polyvinyl chloride sheet. 54. The method of claim 53, wherein the wear resistant laminate is a flooring. In the method of forming a wear resistant laminate, (a) providing a durable top wear resistant layer assembly comprising the following layers; Wear resistant top layer; Decorative layer; And Core layer; (b) providing a polymeric substrate layer of reusable polymeric material to position said base layer under said top layer laminate; (c) providing a water resistant adhesive layer to position the adhesive layer between the top surface assembly and the base layer; (d) providing a balance layer to position the balance layer below the base layer; (e) curing and laminating the layers in the top surface assembly and forming a wear resistant laminate by applying heat and pressure to laminate the assembly, base layer and balance layer together. How to include. 71. The method of claim 70, wherein the recycled polymeric material comprises recycled polyvinyl chloride material and the balance layer comprises a virgin polyvinyl chloride layer. 71. The method of claim 70, wherein said core layer comprises at least two sheets of resin impregnated paper. 71. The method of claim 70, wherein the core layer comprises at least one layer of a woven or nonwoven sheet made of a material selected from the group consisting of fiberglass, polypropylene, polyester, nylon, and carbon fiber. 74. The method of claim 73 wherein a woven or nonwoven sheet layer is positioned between the resin impregnated sheets of claim 9. 74. The method of claim 73, wherein the core layer comprises a fiberglass layer having a basis weight of 25-60 g / m ² .