MXPA00000265A - System and method for adhering laminate to an alternate substrate material - Google Patents

Abstract

A system and method for substantially permanently bonding decorative laminates to a polymeric or other alternative substrate material are disclosed. A preferred embodiment of the present invention utilizes a corona treater to increase surface tension of surfaces of a substrate material in order to provide for improved adhesive bonding. Thereafter, a film of adhesive is applied to the surfaces to be mated with laminates, the laminates are mated with the substrate surfaces having the adhesive film, and pressure is applied during curing of the adhesive. Precise control of parameters such as the thickness of the adhesive, the amount of catalyst introduced, the amount of pressure applied during curing, the duration of the application of pressure, the amount of heat present during curing, and the like allows operation of the present invention to provide a suitably permanent bond between dissimilar materials such as high pressure decorative laminate, ABS polymeric substrate, and high pressure laminate backer.

Description

SYSTEM AND METHOD FOR ADHERING SHEET TO AN ALTERNATIVE SUBSTRATE MATERIAL RELATED REQUESTS • The present application relates to the patent application of E.U.A. co-pending and commonly assigned, serial number 08 / 978,026, entitled "Polymeric Foam Substrate and its Use as a Combination with Decorative Surfaces", filed on Nov. 10, 1997, the description of which is incorporated herein by reference.

TECHNICAL FIELD The present invention relates in general to the manufacture of laminated products such as can be used for decorative floors, countertops and table tops, and wall panels, and more particularly to the manufacture of such laminate products. • use a polymeric substrate material or other material alternative.

BACKGROUND In the past, laminated products such as counters and decorative table tops and / or protectors, floors and wall panels, have included adhesive lamination of a previous layer, which jUj ^ g ^ provides decoration or protection properties to a substrate material such as pressed fiber construction material or particle building material. In general, the previous layer will include one or more layers of decoration paper that by itself • they are formed in adhesive form by using various types of resins, such as melamine formaldehyde and phenolic resins. For example, a high pressure decorative sheet may comprise a very thin sheet impregnated with melamine resin and with aluminum oxide to provide abrasion resistance, a decorative sheet arranged below, and several sheets of decoration paper impregnated with phenolic resin arranged under the decorative sheet. When combined under high pressure, in the order of approximately 70.3 kg / cm2, and in the presence of heat, in the order of approximately 149 ° C, the melamine resin and phenolic resin will interlock to provide a mechanical bond between these layers. However, said prior layers are inherently thin and somewhat flexible and, therefore, benefit from the application of a thicker substrate and preferably more • rigid, such as the aforementioned substrates of material of pressed fiber construction or particle building material, to add strength and / or thickness to the resulting product. For example, when used as a flooring material to stimulate hardwood flooring, the high pressure sheet described above does not have a profile consistent with the hardwood floor that can replace and, therefore, may be unacceptable. In addition, said thin profile fights against the use of techniques used in the * Atí ^^ t *? to? mt ^^ m installation of floors, which provides a consistent surface from an insurance deck, such as a tongue or groove treatment used to provide insurance planks. In addition, such relatively thin materials may not • exhibit other characteristics of a desired material, such as the resonance it replaces from a hardwood floor. Accordingly, prior substrates such as pressed fiber building material or particle building material have been used to provide desired characteristics for rolled products. However, substrates such as pressed fiber building material or particle building material are relatively heavy materials causing a resultant sheet product including said substrate for present excessive total weight of the product. In addition, these fibrous substrates of the prior art are subject to dissolution, twisting, and other unwanted characteristics upon exposure to moisture. These characteristics are not desired in particular for • substrates used in decorative or protective sheets, since These sheets are typically installed only to provide a decorative and protective surface in a humid environment, or other environment hostile to said materials. Accordingly, there is a need in the art for a laminate product that uses an alternate substrate material (ASM), that is, synthetic or non-cellulosic substrate material, which provides desired attributes, such as stiffness, density, weight and value The desired deflection of load deflection when presented in suitable thicknesses for use in a laminated product, at the same time providing superior resistance to environmental conditions such as humidity. As described in the above-referenced patent application entitled "Polymeric Foam Substrate and its Use as Combination with Decorative Surfaces", polymeric materials, such as foamed acrylonitrile-butadiene-styrene (ABS), crushed into sheets of a thickness desired, provide properties of a desired substrate. However, the use of said ASMs presents problems in the production of a desired laminated product. For example, the leaves • of polymeric materials suitable for use as a laminated substrate, that is, a high pressure decorative laminate substrate (HPDL), are generally not gas penetrable, as well presenting problems in the adhesion of an anterior surface there with the necessary mechanical integrity, i.e., anterior surface and substrate coupled in a sufficiently permanent manner, as well as the desired appearance, i.e., substantial surface • smooth without bubbles or pimples associated with gas pockets locked. In addition, materials suitable for use as ASMs often do not initially present a surface that is acceptable to provide an anterior surface to be fixed in a substantially permanent adhesive manner there under the conditions wherein can use such laminated products. These adhesion problems are compounded in the circumstances where said decorative and / or protective laminate products are usually deployed, including environments where high temperature and / or humidity variations are experienced or where heavy objects, such as furniture, by and / or moved on the # rolled product. Problems with the adhesion of an anterior surface to ASMs are further compounded, because the material such as polymeric materials mentioned above, deform or loosen the solidity when exposed to temperatures at which they can be cured. many useful adhesives. For example, the above-mentioned ABS material begins to distort appreciably at temperatures in excess of 70 ° C. Accordingly, there is a need in the art for a system and method for substantially permanently laminating a desired anterior surface, such as the decorative and / or protective layer mentioned above, in an ASM, such as the above-mentioned foamed ABS material, to result in a laminate with desired characteristics that include a minimum level of mechanical integrity and that meet a standard of minimum appearance consistent with its use as a decorative and / or protective surface treatment.

BRIEF DESCRIPTION OF THE INVENTION These and other objects, aspects and technical advantages are achieved by a system and method where a selected ASM, such as the * £ 1 m * ^ - aiMiimmiMsm Mm? Foamed ABS material mentioned above or another synthetic material, is treated at the beginning in order to provide a higher surface tension, and then with a controlled amount of adhesive which, in combination with the application of pressure according to a regime • predetermined, it is used to fix an anterior or first superstructure, i.e., a high pressure decorative sheet, and / or a posterior or second superstructure, i.e., a high pressure sheet supporting surface there. Accordingly, a laminated product having an anterior surface, such as as the decorative and / or protective layer mentioned above, fixed substantially permanently to a substrate or core # composed of an alternate substrate material that provides advantages over substrate materials of the prior art, such as the aforementioned advantages of resistance to environmental, weight advantages, and the like. A preferred embodiment of the present invention utilizes a light discharge treatment of a conductor to treat the surface of the alternate substrate material. Therefore, • an electric charge imparted by the discharge treatment luminous deposits a luminous discharge of a conductor on a surface of the ASM to which sheets will be applied, that is, a surface that must accept the aforementioned anterior surface and / or a surface that must accept the posterior surface mentioned above, in order to provide a surface tension increased to a surface to accept laminations. It should be appreciated that the increased surface tension increases in a t ßa? ^^ ^ tMu ^ * Significant is the ability of the adhesives used in accordance with the present invention to bond to the ASM surface and, thus, to substantially permanently prevent the resultant sheet product from laminating. According to a preferred embodiment of the present invention, a urethane adhesive is deposited on the surface treated with light discharge in a uniform coating of a controlled thickness. Preferably, the urethane adhesive used is a two-part urethane adhesive in order to provide a bond of sufficient strength and present desired aesthetic qualities in the finished product. However, an alternative modality of • the present invention uses a one part urethane adhesive, such as where increased duration is desired and where the increased healing time, ie time, is desired or not tolerable. of preparation. Another alternative embodiment of the present invention utilizes water-based adhesive, so that where prolonged or continuous exposure to moisture is not expected with respect to the edges of the laminated product, wherein said adhesive is exposed, • and, therefore, may be susceptible to dissolution due to the water infiltration and in cases where a long cure time (i.e., cure times greater than 48 hours) is allowed before subsequently stressing the rolled material, such as by cutting, deflection, fabrication or hard movement. Preferably, a product preparation regime laminate according to the present invention includes the use of mechanical manipulation in order to ensure the interface of the adhesive applied with all the points of the surface of the ASM and the surface of the anterior and / or posterior surface accepted there. Also, the preferred preparation regime includes exposure to a controlled pressure, such as by cold pressing or, • alternatively, a hot press or pressurized heated rollers. However, it should be appreciated that the use of a hot press with ASMs, such as the polymeric materials of the aforementioned preferred embodiment, should be carefully controlled in order to utilize a heat that is not inconsistent with the solid state of the ASM. Accordingly, the present invention provides technical advantages in that ASM is treated, coated with adhesive, and has desired laminated surfaces to result in a laminated product with mechanical integrity and desired appearance. at the same time providing superior characteristics with respect to weight and duration associated with the use of an alternative substrate material. Furthermore, it should be appreciated that the treatment, coating and lamination in accordance with the present invention are suitable for use in automated manufacturing lines. allowing the manufacture of a quantity of ASM laminate product for demands associated with the use of the product as countertop / table cover, floor surface, wall panels, and the like. The foregoing has broadly described the aspects and advantages techniques of the present invention so that the detailed description of the invention will be better understood below. Plus further aspects and advantages of the invention forming the subject of the claims of the invention will be described below. It should be appreciated by those skilled in the art that the specific conception and embodiment described may be used. • as a basis for modifying or designing other structures to carry out the same purposes of the present invention. Those skilled in the art must also realize that said equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. 10 BRIEF DESCRIPTION OF THE DRAWINGS For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings in which: Figure 1 shows a cross-sectional view of a laminate product of alternative substrate material arising from the operation of the present invention; and Figure 2 shows a compliance lamination apparatus with the present invention.

DETAILED DESCRIPTION Paying attention to figure 1, a product is shown laminate of alternative substrate material (ASM) provided in accordance with the present invention in a cross section usually as a rolled product 100. Laminated product 100 includes surface material 101 of the anterior or first superstructure, substrate material 102 or core, and material 103 of the rear or second superstructure surface. • However, it should be appreciated that there is no limitation that an anterior surface material and a back surface material are interfaced with an ASM selected in accordance with the present invention. For example, an alternative embodiment of a laminated product provided in accordance with the present invention may include only an anterior surface material or only a rear surface material in an interface with an ASM • selected. However, a preferred embodiment of the present invention includes the use of back surface material 103 to balance the application of front surface material 101. In a For example, it is likely that the thermal expansion and / or contraction of the anterior surface material 101 and substrate material 102 are different. Accordingly, the application of the back surface material 103 provides means by which the twisting of the laminated product associated with environmental changes can be prevented. by balancing the expansion / contraction forces of the previous surface material. Furthermore, it should be appreciated that, although reference is made to the anterior and posterior surfaces, the present invention is not limited to the application of a layer of laminate material for any particular surface of a substrate material. For example, in addition to or in the alternative to the anterior and posterior surfaces mentioned above, the material can be fixed substantially permanently to any or all sides of a selected substrate material, if desired. The above surface material 101 provides preferably • a decorative and / or protective layer having properties of the desired lamination product. For example, the above surface material 101 can provide an exposed surface once in interface with ASM 102 that provides a decorative print suitable for use as a wall panel, such as a door closure. tub or shower, as a kitchen shelf, or as a floor plank. In addition or alternatively, this exposed surface of • front surface material 101 can provide a protective surface suitable for use in humid environments or that is heat resistant and / or abrasion resistant. Although not shown in Figure 1, the above surface material 101 itself can be a rolled product. For example, the above surface material 101 can be prepared by using a layer of decorative paper having a desired pattern printed on it. • same that is impregnated with melamine-formaldehyde resin and laminates to one or more sheets of decoration paper impregnated with phenol formaldehyde resin. The surface of the decorative layer to be exposed in the final product can be prepared by joining a liner layer, such as a thin paper impregnated with the same type of melamine formaldehyde resin. Where you are going to use the rolled product 100 in a high wear environment, as used in floors, a filler may be included in the liner to provide abrasion resistance and / or a non-slippery surface. Such fillers may include alumina, calcium carbonate, ground glass fibers, crushed glass fibers, or the like. The rear surface material 103 can be used to • provide a laminated product installation surface including the ASM that is most suitable for interfacing with a surface that the laminate must cover or to present a more consistent surface with the tools, adhesives, and techniques of a product installer base laminate.

In addition, or alternatively, the back surface material 103 may provide a protective layer having properties of the desired lamination product as described above with respect to the anterior surface 101. As with the anterior surface 101, the surface material back 103 can be a rolled product. For example, the back surface material 103 can be prepared by using layers of printed paper, lining paper or decoration paper impregnated with melamine resin and layers of decoration paper impregnated with phenolic resin which are laminated together. Therefore, the Back surface material 103 can be used as an HPDL holder well known in the art to provide an exposed surface adapted for installation in the structure such as a lower floor, untreated wood products from a counter or cabinet, and the like. 25 It should be noted that, in addition to the above-mentioned laminated compositions used as surface materials above .Mathes and / or later, which may include such laminated compositions as high pressure decorative sheet, low pressure decorative sheet, and high pressure holder, the above and / or after surface material used in accordance with the present invention • may include non-laminated compositions, with solid surface material, i.e., solid surface countertop material, and metal. Accordingly, although laminated surface materials can be referred to herein, such surface materials should not be limited to materials that by themselves laminate, but to materials that can be laminated on the substrate material. Preferably, the substrate material 102 is an alternative substrate material as shown and described in the above-referenced patent application entitled "Foam Substrate Polymeric and its Use as a Combination with Decorative Surfaces, "the disclosure of which has been incorporated herein by reference, for example, a preferred embodiment of the present invention utilizes a foamed, foamed sheet of blended ABS, as it can be understood predominantly from ABS, but may also contain ABS / polycarbonate, high impact polystyrene, and possibly, at low levels, polyvinyl chloride, nylon, polyphenylene oxide, or similar engineering plastics, as well as fillers such as calcium carbonate, formed as is shown in the patent application with reference above as a substrate material. However, it should be appreciated that the present invention can be used to provide a Laminated product with any number of alternative substrate materials. For example, the alternative embodiment of the present invention can use such alternative substrate materials as ASB, ABS / PC, nylon, PVC, or similar materials alone or • in combination, if desired. Although not apparent from the illustration of Figure 1, the inferium of the above surface material 101 and substrate material 102 preferably includes a layer of adhesive material (not shown) to provide mechanical integrity of the material of the substrate. above surface and substrate material in the resulting laminate. Also, the interface of the back surface material 103 and the substrate material 102 preferably includes a layer of adhesive material (not shown) to provide mechanical integrity of the back surface material and substrate material in the backing material. resulting laminate product. By providing a sufficiently strong joint that is substantially free of irregularities, including gas bubbles and impurities, the adhesive material layers of the preferred embodiment of the present invention provide a resultant laminate that provides resistance to delamination reached from a monolithic structure. Attention is drawn to Figure 2 wherein the rolling apparatus 200 of the preferred embodiment adapted to produce rolled products including an ASM according to the present invention is shown. According to this preferred embodiment, the Table feeder 201 is used to sustain a supply of ASM tables that will be used to provide a product laminate according to the present invention. For example, a stack or bundles of 121.92 cm by 243.84 cm sheets of substrate material can be held by, or in communication with, the table feeder 201 so that a desired number of ASM tables can be fed for treatment. of surface and lamination according to the present invention. In the preferred embodiment, the ASM tables are fed in series by the table feeder 201 to provide a substantially continuous stream of substrate material to be formed in a desired rolled product. Although described herein as tables, it will be appreciated that substrate material configurations other than those typically considered as tables may be provided with laminated covers in accordance with the present invention. By For example, substrate material provided in commonly used forms in construction structures, such as mosaics, bricks, columns, molds and the like can be used, if desired. In addition, the present invention is not limited to the use of any • particular size of component or resulting product. For example, instead of the 121.92 cm by 243.84 cm sheets mentioned above, tables with more consistent dimensions can be laminated with floor plank according to the present invention. Of course, it will be appreciated that economy can be carried out by using larger dimension components and cutting the product resulting in desired sizes.

- »* * *» - -..- ^^^^^^^^^^. ^ I! J ^^^ iAfe ^ Eae », ..-. J. ^^ m > 3EMS Preferably, the table feeder 201 feeds the ASM tables to components adapted to prepare the surface of the ASM tables for lamination. In the preferred embodiment illustrated in Figure 2, said components include light discharge treater 202 adapted to prepare surfaces of ASM boards to receive lamination. The light discharge treater 202 is adapted to receive ASM boards, as can be provided from the table feeder 201 by an automatic conveyor mechanism, and is used to condition the surface of 0 ASM boards in order to improve adhesion or bonding of sheets by the rolling apparatus 200. In the preferred embodiment, the light discharge treater 202 imparts an electric charge which deposits a light discharge, that is, a discharge of a light discharge conductor when the potential difference between the conductor 5 and ASM table in close proximity exceeds a value, but not enough to cause a spark or arc, on the surface resulting in the oxidation of the surface of the ASM table and increases the surface tension of the same. Experimentation has revealed that treating surfaces of ASM tables 0, such as the co-mixed ABS of the aforementioned preferred embodiment, increases the surface tension from about 34 dynes to 60+ dynes. Said experiment has also revealed that the increased surface tension significantly increases the ability of the adhesives to stick to the ASM surface and, thus, to provide a laminated product more resistant to delamination. Attention is paid to Next table, where it can be seen that the results of the experiment using both a one-component urethane adhesive and a two-component urethane adhesive, provide substantial improvement in the mechanical integrity of the product • laminate resulting from the treatment with luminous discharge, mentioned above, of the ASM tables. It will be appreciated that the connecting force provided in the following table is the result of a 90 ° Instron tension pull of the substrate material from the material of the laminated surface. 10 From the above table, it is also evident that the relative smoothness of the surface of the substrate material to be laminated affects the mechanical integrity of the resulting laminate. Optical microscopy reveals that such rough surfaces are often the product of the substrate material that • has a somewhat fibrous surface that under amplification looks like tangled spaghetti or entangled tree branches providing holes and tunnels that lead to internal spaces of the substrate material. These voids may allow adhesive, such as under the pressure of expanding gases associated with the cure of adhesives, to migrate inward from the surface and, therefore, provide less adhesive at the interface between the substrate and the sheet for mechanical bonding. . In addition, • 15 characteristics of the rough surface allow the adhesive to bond to many areas that will break the main body of the substrate with very little pressure. In addition, the increased roughness associated with the fibrous material arranged in such a way that it can also give a false indication about the thickness of an applied adhesive coating.

Accordingly, it should be appreciated that the adjustment of the amount of adhesive used between surfaces of substrate material Relatively smooth and relatively rough can be used to further improve the resulting mechanical integrity. In accordance with a preferred embodiment, on the surfaces of the ASM table to receive the sheet that is going to • placing in an adequate condition to substantially permanently bond with laminated surfaces, i.e., the anterior and posterior surface materials, ASM tables are provided, such as through continuous transport by the automatic conveying mechanism mentioned above, to a cleaner brush 203. The brush cleaner 203 is adapted to accept one of the ASM boards, such as through the use of a mechanism • Automatic conveyor, and to remove unwanted particle material from the surfaces of the ASM tables through interaction of the brush with them. It will be appreciated that the brush cleaner 203 and the light discharge treater 202 can be reversed in order in the rolling apparatus 200, if desired. However, the preferred embodiment arranges the brush cleaner subsequent to the light discharge treater in order to ensure cleaning of attracted particle material. to the ASM tables that arise from an accumulation of static electricity associated with the light discharge treatment. In a preferred embodiment, brushes are provided to remove particulate matter, such as particles from the ASM material itself, and other contamination from all surfaces of the ASM tables that go through there. Alternatively, only the surfaces selected from the ASM tables, such as the surface or surfaces of the Do immMtt ASM boards to receive lamination, clean them by brush cleaner 203. Consequently, more complex handling of ASM tables, such as scrapping brushes to clean a bottom surface of the ASM tables or rotation of ASM boards, can be avoided. ASM tables • to present clean surfaces in their own orientation for cleaning. It should be appreciated that, although the brush cleaner 203 is described herein as providing brushes to interact with ASM boards fed by it, the brush cleaner 203 can use different crayons than those that discard sows in contact with a surface of the ASM table to be cleaned. For example, nozzles can be arranged within the brush cleaner 203 which direct a high pressure gas flow, such as compressed air, and / or liquid, such as water or a cleaning solvent, into a surface of the ASM table to be cleaned, thus defining a pressure cleaning brush, such as an air brush. For example, a liquid cleaning brush, comprising a number of the nozzles mentioned above, can be followed by a gas cleaning brush, comprising a second series of the nozzles mentioned above, in order to clean waste liquid from the ASM table. Furthermore, it should be understood that traditional bristle brushes and pressure cleaning brushes can be used in combination or in the alternative as it is considered advantageous. Since the material of the ASM tables is preferably composed of plastic, such as the foamed sheet of ABS mentioned above, you can have accumulation of electricity static on the surface of the ASM tables and, consequently, related problems. For example, the rubbing of ASM boards together, such as when they are removed from a stack in the table feeder 201, the ASM boards rubbing against other surfaces, such as • an automatic conveyor system, and the surface of the ASM boards brushed by the bristles of the brushes, can result in static electricity causing unwanted effects such as particle material on the surfaces or the ASM boards sticking or other problem. Accordingly, the apparatus of lamination 200 preferably includes adaptation to minimize the introduction of static electricity charge to the tables • of ASM and / or to discharge any static electricity charge accumulated there. For example, the brush cleaner 203 can be adapted to include static discharge strips that are discarded for cause the discharge of ASM table surfaces. In addition or alternatively, the brushes of the brush cleaner 203 can be adapted to reduce the amount of static electricity accumulation associated with their use, such as by themselves by providing a static discharge path or by providing ionized gas or liquid. suitable to neutralize any resultant static electricity charge. On the surfaces of an ASM board to receive lamination of a desired cleaning, i.e., properly cleaned by the brush cleaner 203 or originally provided in a state thus improving the need for a brush cleaner 203, the ASM tables of the preferred embodiment of the ******** * ^^. .-? ^ i ^ aMm * ** lamination 200 are provided to the adhesive applicator 204, such as through further transportation by the automatic conveying mechanism mentioned above. Adhesive application 204 prepares the surface of the ASM boards to elongate sheets adhesively. In the preferred embodiment, the adhesive applicator 204 provides a controlled coating of adhesive to the surfaces of the ASM board that must receive lamination. However, in an alternative embodiment, the adhesive applicator 204 prepares the surface of the ASM boards by itself, such as by applying a catalyst or other suitable agent to cause the surface material of the ASM board to be coupled. adhesive to a particular sheet, instead of applying a discrete adhesive material thereto. In the preferred embodiment, wherein the adhesive applicator 204 provides an adhesive coating to the surfaces of the ASM boards, the applied adhesive can be any of a number of suitable adhesives to be used to provide the desired bond between the ASM and the adhesive. laminated material. For example, if desired, one-component urethane adhesives, two-component urethane adhesives, water-based adhesives, including polyvinyl acetate (PVA), ethylene vinyl acetate (VAE) and / or polyvinyl alcohol (PVOH) may be used. ), water-based adhesives modified with water-based urethane dispersions for entanglement, or the like. It should be appreciated that the use of particular adhesives may be desired over other adhesives in certain applications, although ^ - ^^ each adhesive provides a satisfactory bond. For example, single-component adhesives, such as the one-component urethanes mentioned above, typically provide longer durability than multi-component adhesives, such as the two-component urethanes mentioned above, and are thus often subject to application processes. continuous such as those that use an adhesive application roller. However, such one-component adhesives often require an external catalyst, such as water, to speed curing at speeds more suitable for production speed. The addition of the external catalyst is difficult to apply quantitatively and • consistent due to the amount of minutes required to initiate the reaction. In addition to the application of an external catalyst such as water, the curing of said one component adhesives can be catalyze followed with a heat application. However, since the ASM of the preferred embodiment is a polymeric plastic, sufficient heat can not be obtained to cure said adhesive of a component in a desired amount of time without adversely affecting the shape or solidity of the substrate material. In addition, the chemical reaction of the adhesives of a component removes carbon dioxide gas that can be enclosed in the bond line due to the non-porous nature of the sheet and the ASM material. The gas enclosed then produces gas pockets of various sizes, which cover the surface of the product producing a panel with poor cosmetic appearance, as well as decreasing the mechanical integrity of the rolled product. Bliss - - ^^ - > ~ - - ~ ^ - * ~ ^ .- - - ^ .. > »-.» .- - ^^ «tt te *» gas discharge can be controlled through the use of a hot press during curing and / or its damages can be mitigated through techniques that allow the escape of gases, such as piercing the sheet and / or substrate material or providing channels in the application of the adhesive or the surfaces of the materials to be joined, as well as the use of gas scavengers such as calcium oxide, barium hydroxide, or the like . The preferred embodiment of the present invention utilizes a two component urethane adhesive, such as MOR-AD 695-28 available from Morton International, Inc., Chicago, IL. Accordingly, the components of the urethane adhesive are mixed • In order to create the desired union. In the preferred embodiment, the adhesive applicator 204 includes a Meter Mix system, such as is available from Graco. Inc .. Minneapolis, MN, to introduce components of the urethane adhesive together in controlled quantities in order to ensure proper cure of the resulting adhesive material. The Meter Mix system feeds each component of the adhesive separately in a static mixer that is preferably located just before a spreader of adhesive that is in communication with adhesive rolls. By properly selecting the amount of catalyst, such as amine or tin catalyst, which is provided in the "A" component of the adhesive when it is made, a sufficient duration can be had by the resulting adhesive to allow this application by the adhesive rolls. mentioned before. Accordingly, a preferred embodiment of the adhesive applicator 204 includes adhesive rolls arranged such that a ^^^^^^^^^ ^^^^ jg ^ g ^^^^^ ig ^^^^^^ r ^ Mi) ^^ Two-component urethane adhesive coating with a controlled thickness is deposited on a desired surface of an ASM table that passed by. Of course, alternative techniques can be used to "Mixing and / or dispensing multi-component adhesives in accordance with the present invention, if desired. For example, spray nozzles can be used so that a multi-component adhesive is mixed, such as by the Meter Mix system mentioned above, or where the components are mixed internally just before dispensing to an individual nozzle for sprinkler assortment by nozzles on the surface of an ASM board to result in a coating of a controlled thickness. Alternatively, multiple series of spray nozzles can be used, where each series of nozzles is associated with a different component of the adhesive, without the benefit of the mixing system to result in a coating of a suitable mixture of the adhesive components that depend on the spray mixture of the components. However, it should be appreciated that the use of a material spray to provide a coating adhesive can not be desired when there are dangerous or harmful chemicals in the adhesive. In addition, the results of excessive spraying and similar unwanted assortment often have aspersion spray and therefore can not provide a desired solution in a particular application. Another alternative embodiment of the present invention utilizes a globule assortment technique for depositing a coating ^ to the adhesive of a controlled thickness on the surface of an ASM board. For example, a linear extrusion head that provides an assortment hole substantially the width of an ASM board can be used to deposit adhesive by forming an adhesive globule between the extrusion head and the surface of the ASM table that, as customized that the table moves in relation to the extrusion head, causes an adhesive coating of uniform thickness to be deposited. Accordingly, the mixing system described above can be used to combine the components of a multi-component adhesive immediately before its introduction into the extrusion head which is just before the application of the adhesive material to the substrate. In addition, the copy of the extrusion head where the adhesive material is accumulated before extrusion by the extrusion head, is substantially protected from exposure to external atmosphere or environment and, thus, can be used to provide a satisfactory duration for discarding the adhesive according to the present invention. Although described above with respect to multi-component adhesives, it should be appreciated that adhesive assortment techniques alternative to the adhesive roll described with respect to the multi-component urethane adhesive can be used with one-component adhesives. Its use has been described herein with reference to multi-component adhesives since the assortment of such adhesives can benefit from techniques that do not introduce the multiple components together to the actual assortment or to a point in the assortment process almost near the assortment real in the surface to be coated as possible in order to avoid unwanted curing of adhesive material in the assortment system of the adhesive applicator 204. It should be noted that the preferred embodiment of the applicator • adhesive 204 is adapted to provide a coating of adhesive material on all sides of an ASM board to be laminated. For example, in order to have the rolled product shown in Figure 1 with a back surface material and an anterior surface material adhered to the substrate material, a Preferred adhesive adhesive applicator 204 includes adhesive rolls disp > ui these up and under an ASM table fed there to provide the desired coating of adhesive on the front and back sides of the ASM board. An alternative embodiment of the adhesive applicator 204 may use an adhesive applicator apparatus, such as the adhesive roll mentioned above, only on one side of an ASM board and providing a multi-surface coating of the ASM board by handling the ASM board by itself, such as by flipping or rotating the table of ASM. In another alternative embodiment of the present invention, the Lamination apparatus 200 is adapted to provide application of a number of lamination surfaces less than desired, such as by providing lamination of only one side of the substrate material. Accordingly, a substrate material can pass through the laminating apparatus 200 a number of times of orientations different in order to result in the desired number of sides or surfaces receiving a laminated surface. This modality is you may want, for example, only where a surface is typically laminated and, thus, multiple laminations can be accommodated in those cases where it is sometimes desired. In addition, since the surfaces of the substrate material are left uncoated by the adhesive applicator of said alternative embodiment, subsequent handling of the substrate material can be simplified, i.e., a simple conveyor belt apparatus can be used to transport a substrate. substrate material with an anterior surface coated with adhesive to a station to receive the material from previous surface. However, it should be appreciated that such modality is not usually desired by providing lamination of • multiple surfaces due to the increased manufacturing time associated with the production of the complete rolled product and an increased risk of there being twist during the time between the application of the first laminated surface and a second laminated surface. Accordingly, the preferred embodiment operates to apply at least opposite sides of laminated surface in substantially contemporary fashion and, therefore, provides application of adhesive to at least opposite sides of the substrate wherein said sides should receive lamination. As mentioned before, the adhesive applicator 204 preferably provides a coating or film of adhesive in a substantially uniform, controlled thickness. It should be appreciated that adhesives such as those suitable to provide a product laminate able to withstand the problems of floors, countertops, or wall panels, are usually expensive. Therefore, ÍÉ £ Ü-B¡e-t. it is desired to apply said adhesives sparingly. However, limiting the savings application of such adhesives is the competent concern that a sufficient amount of adhesive is applied to provide a substantially permanent bond. In mentioning these, as well as others, competent concerns, experimentation has revealed that the application of adhesives in the scale of about 3 to about 10 mils in thickness is generally suitable for applications as described above. Preferably , the thickness of an applied film of urethane adhesive is on a scale of 3 to 5 mils with the most preferable adhesive film having a thickness of about 4 mils. Similarly, preferably the thickness of an applied film of water-based adhesive is on the scale of 4 mils from 15 inch to 8 mils with the most preferable adhesive film having a thickness of about 6 mils. Of course, there are a number of features that can affect the selection of a particular adhesive film thickness, such as the relatively rough nature of a film surface. substrate to be laminated, as discussed above. Accordingly, one skilled in the art will appreciate that the selection of an adhesive film thickness, even outside the preferred thickness scale described above, may be desired under particular conditions. 25 In addition to the techniques described above for depositing a film of adhesive material on a surface of an ASM board, yecaaaaae * ,,, J.

The adhesive applicator 204 s% can adapt to further catalyze the curing of an adhesive. For example, where urethane adhesives are used, such as the one-component urethane adhesives mentioned above, the adhesive applicator 204 may include nozzles to introduce a water spray to the adhesive film in order to catalyze the reaction. In a preferred embodiment, this water spray is supplied at a controlled rate selected from the scale of approximately .2g / sqft. A .7g / sqft. to a one component urethane adhesive such as Mor-Ad 858-155, available from Morton International. It should be appreciated that decreasing the introduction of this catalyst significantly decreases the strength of the bond, while increasing the introduction of this catalyst can catalyze the reaction a lot, which in turn produces the aforementioned gas that can be enclosed like bubbles or pimples. Accordingly, a balance between the strength of the bond and the curing action of the adhesive is needed in order to result in a laminate with desired characteristics. Experimentation has revealed that a highly preferable scale of water spray dispensed to the urethane adhesive of the preferred embodiment is about .5g / sqft to .55g / sqft and very preferable is .5g / sqft when the thickness of the adhesive is used. very preferred urethane adhesive film mentioned before 4 mils. By coating the surfaces of the ASM board with an adhesive material with the adhesive applicator 204, ASM boards of the preferred embodiment of the laminating apparatus 200 are provided to the m ^^^^ ¡m 1 ^^ j | | || ^ table 205 to receive rolling surface materials. It should be appreciated that the transport of an ASM board from the adhesive applicator 204 to the table 205 can be by the automatic conveyor mechanism mentioned above. However, since a preferred embodiment of the present invention provides adhesive coating of an anterior and posterior surface of ASM boards, particular conveyor mechanisms such as a conveyor belt mechanism commonly used in manufacturing facilities to provide a table may not be preferred. of ASM coated from the adhesive applicator 204 to the table 205. Accordingly, a conveyor mechanism adapted to provide the necessary manipulation of an ASM board between the adhesive applicator 204 and the table 205 without substantially modifying a film coating can be used. of adhesive there. In a preferred embodiment of the present invention, a conveyor mechanism adapted to couple substantially only the uncoated edges of ASM boards between the adhesive applicator 204 and the table 205 is used. Alternatively, human interaction can be used to remove ASM boards. coated with the adhesive applicator 204 and depositing the ASM boards on the table 205. Where a back surface material and a surface material anterior to the substrate material are to be adhered, the table 205 preferably places a surface material of Selected lamination, preferably the back surface material, for the interface of a coated surface of the substrate material. By ...- «s-K & iasßs? For example, the coated ASM board moves in juxtaposition with a sheet of subsequent substrate material having substantially the same dimensions as the ASM board by the aforementioned conveyor mechanism. Then, the substrate material and the back surface material are interposed, i.e. the substrate material and the back material are placed in contact with the other material, so that the edges of each are substantially aligned. Also, the above surface material having substantially the same dimensions as the The ASM table is placed in juxtaposition with it and then the substrate material and the previous surface material are • they interfere as described above. Of course, although it is described in the preferred embodiment as having the same dimensions, there is no limitation of the present invention to surfaces laminated with dimensions consistent with those of the substrate. For example, multiple pieces of anterior surface material can be combined to cover an anterior surface of the substrate. Also, the laminated surface material or substrate may have a substantially smaller dimension than the coupled component • 20 and, therefore, the material extending beyond the coupled component can be cut, if desired. It should be appreciated that the placement of the above surface material and the back surface material in juxtaposition with the substrate material for the interface as described above, is can achieve in one step. For example, the table 205 can retain the anterior and posterior surface materials in ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^^ juxtaposition, where a cavity is retained there enough for the introduction of a coated ASM board. At the time of the introduction of the coated ASM board, the table 205 can provide relative movement, such as lifting a surface of the • table, to result in the back surface material in interface with a back surface of the substrate material and the above surface material in interface with a front surface of the substrate material. Although it was described earlier with reference to the interface of a front and back surface material, it should be appreciated that the table of the present invention can be adapted for the interface • Suitable from any number of rolling surface materials to a substrate material. For example, in the alternative mode where only one surface of the substrate material should receive a rolling surface material, the table 205 of the present invention can retain this surface material in position, so that when a coated substrate material is moved in a corresponding position, the surface material is interposed as it is. described earlier. Also, the surfaces Further to or in the alternative of the posterior and anterior surfaces described above, may be provided with a laminated surface for the month 205 by retaining said surface materials in their own orientation and interfacing with a corresponding surface of the substrate material. By having lamination surface materials in phase with a substrate, the preferred embodiment of the present invention provides the resulting combination of materials for the layer 206 layer homogenizer, such as by transport by the above-mentioned automatic conveying mechanism. The layer interface homogenizer 206 is used to ensure that substantially the entire mating surface of the laminated surface material and a corresponding mating surface of the substrate material engage the adhesive and, therefore, engage the other material. Such affirmative coupling of the coupling surfaces ensures that there are no gas bubbles present at the interface, which can degrade the mechanical integrity of the resulting laminated product. • In a preferred embodiment, layer 206 homogenizer utilizes rolls arranged to accept the ASM board and interface laminated surfaces and to exert a pressure controlled, preferaapproximately 2.81 kg / cm2, in each laminated surface, so that the enclosed gases leave and total coupling of the coupling surfaces is achieved. Accordingly, the above mentioned automatic conveyor mechanism can pass the ASM table and rolling surfaces in interface below or between the rollers arranged to rotatacouple the exposed surfaces of the lamination surfaces. In addition or alternatively, the layer interface homogenizer 206 may include hot rollers, such as may be used In order to accelerate the curing of an adhesive, they are arranged to rotationally couple surfaces. Therefore, in addition to providing •? ^! JiiSttz ¿? ÍSbssSSwßßSSsa? Zz. ^. ..z-zizztzc? á .. -. ... « .-. > . MWWfeiaffia ........... . gjB-BBa? i. "_. ^^^ 'frji affBiiHHrirMffiTi homogeneity to the interface, the layer interface homogenizer 206 can encourage the healing of the bond between the surfaces. In addition, through the application of a proper amount of pressure and a proper amount of heat, the hot rollers of this embodiment can be used to provide a suitable joint without the additional application of pressure as described below with respect to a press of adhesive cure. Of course, it must not be forgotten that, as described above, the application of such heat must be carefully controlled in order to avoid non-harmful effects. desired in the particular alternative substrate material selected. Accordingly, a preferred embodiment of the • Hot rollers mentioned above use heat in said rolls sufficient to provide a desired heat to an adhesive without causing the temperature of the substrate material to exceed 70 ° C. By For example, a roller operating temperature can be selected which, when conducted thermodynamically through a surface such as the laminated surface at a speed at which the rollers couple the material, provides a heat to the substrate material within the material. acceptable limits. In addition or alternatively, The heating of the rollers can be actively controlled, such as by a processor-based system operating under the control of a series of instructions, by controlling a temperature of substrate material and adjusting the temperature of the rollers to prevent excessive heating of the rollers. substrate material. 25 In order to fully and properly cure the bond between the substrate material and the laminated surface material, the The preferred MTU of the present invention maintains substantial and substantially continuous pressure on the substrate material and the interface laminated surface material until that union has developed, however, as anticipated to be desired • large quantities of the resulting rolled product and that the application of the above-mentioned pressure during the healing of the joint will be relatively extensive, the rolling apparatus 200 of the preferred embodiment includes an area in degrees where an adequate amount of material can be collected of substrate and material of interfaced laminate surface for introduction into a press to provide the desired pressure over an acceptable length of time. Again with attention to Figure 2, the preferred embodiment of the laminating apparatus 200 includes a receiving stack 207 of the is a curing station, wherein the substrate material and the interface laminated surface material accumulate in a stack, such as may be formed by repeatedly depositing substrate material that is interfaced with laminated surface material in an upper part of the substrate. another by the automatic conveyor mechanism mentioned before. Accordingly, a quantity of substrate material and interfaced laminated surface material can be accumulated over a period consistent with the cycle of a press, such as the adhesive curing press 208, by providing the above mentioned pressure on a desired amount. of time with with respect to a pre-accumulated stack of substrate material and interfaced laminated surface material.

M ^ I ^ ¡^ / sm ^ ¿& For example, a desired bond can be formed through the application of a particular pressure to the substrate material and interface unit of laminated surface material over a selected period. In the preferred embodiment that uses the adhesive of • Two component urethane Mentioned above, the application of pressure of approximately 1.41-2.46 kg / cm2, more preferably 2.11 kg / cm2 over a lapse of approximately 2 hours resulted in a suitable joint for use of the laminate as a flooring material. It should be appreciated that the accumulation of substrate material and surface material laminated at the interface before the desired application of pressure to provide the desired bond provides time when the adhesive interfaced with the coupling surfaces can be cured without application. of the desired pressure. Nevertheless, As described above, the preferred embodiment of the present invention utilizes an adhesive having an associated duration, such as can be selected or adjusted by controlling the amount of a catalyst component of a multi-component adhesive or by controlling the amount of catalyst additional input to adhesive, sufficient for said grade of materials. Furthermore, it should be appreciated that the preferred embodiment wherein staggered material is piled, i.e., a first substrate material and unit of laminated surface material are arranged on a table and then each subsequent substrate material and unit of material of The laminated surface is placed in series there, the units of material placed first in the staggered pile (the longest to be staggered) benefit from the pressure associated with the mass of additional material units stacked there. Of course, such staging of interphase material is not consistent with a desired bond or otherwise it is not desired, a sufficient number of presses can be implemented to allow the application of pressure for a desired amount of time without stepping or without significant stepping times. In order to present an acceptable exchange in a number of presses required to provide the desired amount of pressure over the desired amount of time, a preferred embodiment of the present invention uses a number of presses that when divided into the desired amount of time for pressure, healing is consistent with an acceptable stepping time. For example, in the preferred embodiment described above using the pressure application for 2 hours, if a step time of 1 hour is acceptable for a particular used adhesive, 2 cure presses may be used. Accordingly, in a preferred embodiment, the adhesive cure press 208 comprises a two-stage press. Here material is accumulated for one hour in a stack in the receiving stack 207 of the curing station which is then accepted in a first step of the adhesive curing press 208 where a desired pressure is applied. Then, once more material is accumulated for one hour in a stack in the receiving stack 207 of the curing station. At the end of this hour, the material that was accepted at the beginning in a first stage of the healing press of »**** ^. ... ... ***** M ~~. - ^^^ jí &sßsS = Sßta adhesive 208 is released from pressure and is accepted in a second step of the adhesive cure press 208 where a desired pressure is applied once more. Then, the newly accumulated material is accepted in the first step of the adhesive cure press 208 where a desired pressure is applied. Then, once again material is accumulated for one hour in a stack in the receiving stack 207 of the curing station and the above process is repeated. It should be appreciated that the embodiment described before the adhesive cure press 208 provides for simplified continuous production of the laminate as will be typically desired. However, the present invention is not limited to the use of a multi-stage press arrangement as described. For example, a number of steps in addition to the two described in accordance with the present invention can be used. Alternatively, the present invention can be alternated by providing an accumulated stack among the available number of presses, so as to avoid pressure release as a stack of material moves from one stage to another, if desired. Although described above as providing a consistent amount of pressure, the present invention can operate to provide varying amounts of pressure, such as at particular amounts in the cure of an adhesive. For example, a first pressure, preferably less, can be used in a first step of the adhesive curing press 208 in order to encourage the cure of the adhesive without displacing a substantial portion thereof, and a second pressure, preferably greater , can be used in a The second step of the adhesive cure press 208 is to encourage the substantially complete cure of the adhesive at a point where the adhesive will cure sufficiently that its unwanted migration due to added pressure is not a problem. . Of course, a multi-stage curing press is not required to provide the variable pressure application of the present invention, since a press used in curing the adhesive may have applied pressure adjusted during the process. The curing press 208 can be adapted to provide heat or other conditions, such as atmospheric pressure, humidity in the air, gas composition, or the like, conductive to the cure of the adhesive material. For example, the curing press 208 may provide a flow of hot air over a compressed stack of material to maintain the material at a desired temperature. during the healing. The application of said conditions can be controlled intelligently, such as by a processor-based system operating under the control of a series of instructions. For example, the processor-based system mentioned earlier can • control a temperature of substrate material and adjust the air flow temperature to avoid excessive heating of the substrate material. It should be appreciated that, although described above with respect to the application of a layer on a back and / or previous surface, the present invention can be used to provide any number of sheets to a surface. For example, when introducing a laminated product that arises from the operation of the apparatus of lamination 200 in the rolling apparatus 200 a second time, additional sheets of the laminated surface material can be added, such as where additional layers are required to provide a desired level of protection or a desired thickness of the resulting rolled product. additional, substantially as those shown in Figure 2, associated with the application of multiple layers of laminated surface material can be included within the rolling apparatus 200, if desired. Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made without departing from the spirit and scope of the invention as defined by the appended claims. ^ ¡^^^ ¿^^^^ & w

Claims (1)

1. CLAIMS 1. A system for providing a unitary structure from a polymeric substrate material and a superstructure material, said system comprising: means for treating a coupling surface of said substrate material to increase the surface tension of the coupling surface; means to apply an adhesive to said surface of 10 treated mesh of said substrate material, wherein the application of said adhesive results in a coating • substantially uniform adhesive having a desired thickness on said treated coupling surface of said substrate material; 15 means for interfacing a coupling surface of said superstructure material with said coupling surface coated with said substrate material; means to homogenize an interface between said surface of • coupling of said superstructure and said surface of 20 coated substrate coupling said material, wherein said homogenizer means operates to remove gases enclosed in said interface and to ensure substantially full surface contact of said coupling said superstructure with the adhesive coating of said mating surface coated 25 of said substrate material; Y (|| Ei || IL lí ||| É |? Í Ih means for compressing the superstructure interface and substrate with a selected pressure and for a duration controlled in order to cure the adhesive and provide a bonding interface of a desired force 2. The system according to claim 1, wherein said means for treating the coupling surface comprises: a light discharge treater arranged to deposit a light discharge on a surface of the substrate. claim 1, where Said thickness of said adhesive coating is selected from the scale of about 3 to about 10 mils. 4. The system according to claim 1, wherein said adhesive is a urethane adhesive and wherein said thickness 15 of said adhesive coating is selected from the scale of about 3 to about 5 mils. 5. The system according to claim 1, wherein said adhesive is a water-based adhesive and wherein said thickness of said adhesive coating is selected from the 20 scale from about 4 to about 6 thousandths of an inch. 6. The system according to claim 1, wherein said adhesive applicator means comprises a mixing apparatus for mixing components of a multi-component adhesive. 25 in a desired proportion. XJXÍI *** ^. ^ **, ** ^^ ¡l ^^ ^^ & H ^ g ^ 7. - The system according to claim 1, wherein said adhesive applicator means comprises: means for introducing a catalyst agent to said adhesive coating applied to said treated coupling surface of said substrate material. 8. The system according to claim 7, wherein said catalyst agent introducing means comprises: a spraying jet apparatus that can operate to supply a controlled amount of said catalyst agent to said agent. 10 adhesive coating applied to said treated coupling surface of said substrate material. 9. The system according to claim 1, wherein said adhesive applicator means comprises an adhesive assortment apparatus per roll. 10. The system according to claim 1, wherein said adhesive applicator means comprises an as- pective adhesive assortment apparatus. 11. The system according to claim 10, wherein said spray adhesive assortment apparatus 20 comprises: a first series of spray orifices associated with a first component of said adhesive; and a second series of spray orifices associated with a second component of said adhesive, wherein said first and second 25 second adhesive components are mixed by spray assortment. ^^^^^^^^^^^^ «^^ Mß ^^^ ^^^^^^^^^^^^^^^^^^ 12. - The system according to claim 1, wherein said adhesive applicator means comprises an adhesive globule assortment apparatus. 13. The system according to claim 1, in • where said adhesive is a one component urethane adhesive. 14. The system according to claim 1, wherein said adhesive is a two component urethane adhesive. 15. The system according to claim 1, wherein said adhesive is a water-based adhesive. 16. The system according to claim 15, in • wherein said water-based adhesive is selected from the group consisting of: PVA; VAE; PVOH; and water-based adhesives modified with 15 aqueous-based urethane dispersions. 17. The system according to claim 1, wherein said interface homogenizing means comprises at least one roller arranged to rotatably couple a surface of one of said substrate material and said substrate material. 20 superstructure. 18. The system according to claim 17, wherein said at least one roller imparts a pressure of approximately 2.81 kg / cm2 to said coupled surface. 19. The system according to claim 1, further comprising: stepped means for accumulating interface superstructure and substrate material to handle volume by said compression means. 20. The system according to claim 19, in # wherein said compression means is a press adapted to accept the accumulations of said superstructure in interface and substrate material for the application of controlled pressure there and to accept other accumulations of said superstructure in interface and substrate material for the application of a pressure controlled 10 there, where a time of accumulation of said superstructure in interface and substrate material can be reduced by staggered acceptance of said accumulated and said accumulated others. 21. The system according to claim 1, further comprising: means for cleaning said coupling surface of said substrate material before treating said coupling surface by said treatment means. 22. The system according to claim 1, wherein said superstructure material is a decorative sheet of 20 high pressure. 23. The system according to claim 1, wherein said superstructure material is a low pressure decorative sheet. 24. The system according to claim 1, in Wherein said superstructure material is a solid surface material. 25. - The system according to claim 1, wherein said superstructure material is a sheet of metal. 26. The system according to claim 1, wherein said superstructure material is a sheet holder. • high pressure. 27.- A method for providing a unitary structure from a polymeric substrate material and a superstructure material, said method comprising the steps of: cleaning a coupling surface of said material 10 substrate to provide said substantially particle-free coupling surface; treating said coupling surface of said substrate material to increase the surface tension of the coupling surface; 15 providing a substantially uniform adhesive layer of a desired thickness to said mating surface of said substrate material; placing a mating surface of said superstructure material in juxtaposition with said surface of 20 coupling said substrate material to establish an interface there; homogenizing said interface to provide a substantially uniform interface between said superstructure material and said substrate material; and compressing said interface to encourage healing of said adhesive layer. 28. - The method according to claim 27, wherein said step for treating the coupling surface comprises: depositing a luminous discharge on said surface of • coupling of said substrate material. 29. The method according to claim 27, wherein said step of providing adhesive layer comprises the step of: depositing a urethane adhesive to said coupling surface in a uniform film of a thickness of about 10 3 to approximately 5 thousandths of an inch. 30. The method according to claim 29. in wherein said step of providing adhesive layer further comprises the step of: spraying a catalyst onto said uniform film of said 15 urethane adhesive. 31. The method according to claim 29, wherein said urethane adhesive is a multi-component urethane adhesive, and wherein said step of providing an adhesive layer further comprises the step of: mixing components of said urethane adhesive of multiple components in selected controlled amounts to allow sufficient time for the application of said urethane adhesive, to place said coupling surfaces, and to homogenize said interface without requiring compression curing of said 25 urethane adhesive for an undesired length of time in order to provide a desired bond. ^^^ - ^ - ^^ - - - Wflr "* 1" 6 »- '- J-fc .. ^ iiüAmam s ^ 32. - The system according to claim 31, wherein said unwanted length of time for compression cure of said urethane adhesive includes lengths of time substantially in excess of 2 hours. • The method according to claim 27, further comprising the step of: accumulating superstructure material in interface and substrate to compress in volume in said compression step. 34.- The method according to claim 33, in Wherein said compression step comprises the steps of: accepting cumulative said interfacial superstructure material and substrate for the application of controlled pressure there; and accept other accumulations of said superstructure material 15 in interphase and substrate for the application of controlled pressure there. 35.- A system for producing a laminated product having a synthetic core material, said system comprising: a luminous discharge treater arranged to receive a 20 piece of said synthetic core material and imparting a luminous discharge on at least one first surface of said piece; an adhesive applicator arranged to receive said piece of said synthetic core material and deposit an adhesive film at least on said first surface of said piece; 25 a sheet position arranged to receive said piece of said synthetic core material and a corresponding piece of a first laminated material and to couple a first surface of said piece of said first laminated material having no adhesive film deposited there with said first surface of said piece of said synthetic core material having said • adhesive film deposited therein so as to provide a combined unit having sheets including said piece of said first laminate, said adhesive film, and said piece of said synthetic core material; a roller assembly arranged to couple said unit 10 combined and to impart substantially orthogonal pressure to said sheets; a combined unit stacking position arranged to receive combined units having pressure imparted there by said roller assembly and to accumulate said units 15 combined received in a stack, wherein a combined unit having a piece of said synthetic core material first to receive said piece of said first laminate material is disposed on a bottom of said stack with units combined with a piece of said material synthetic core to then receive a 20 piece of said first laminate material is disposed closer to the top of said stack; and a press apparatus arranged to accept said first stack of combined units and to apply a desired pressure while said combined unit stacking position accumulates 25 combined units received additional in a second stack. 36. - The system according to claim 35, further comprising: a feeder assembly of synthetic core material arranged to accept a plurality of material pieces of • Synthetic core and for singular said plurality for processing by said system. 37.- The system according to claim 35, further comprising: a cleaner arranged to receive said piece of said 10 synthetic core material and to clean at least said first surface of said piece. • The system according to claim 37, wherein said cleaner comprises: brushes for cleaning said at least said surface 15 piece of said synthetic core material. 39.- The system according to claim 38, wherein said cleaner further comprises: static electricity neutralizers to discourage the presence of a static electricity charge of at least 20 said first surface of said piece of said synthetic core material. 40.- The system according to claim 35, wherein said adhesive deposited on said first surface of said piece of said synthetic core material is an adhesive of 25 urethane. - - * --- * - - - * - - *** «* - *» - • and *** m ^^ ^ * z *? A to. 41. - The system according to claim 40, wherein said adhesive applicator comprises: a water spray apparatus for introducing a controlled amount of water into said adhesive film. 42. The system according to claim 41, wherein said controlled amount of water is selected from the scale of about .2g / sqft to about .7g / sqft. 43.- The system according to claim 40, wherein said controlled amount of water is approximately 10.5g / sqft. 44.- The system according to claim 35, in # wherein said roller assembly comprises: means for providing a controlled amount of heat for a combined coupled unit. 45. The system according to claim 44, wherein said means providing heat is controlled to result in a temperature experienced by said piece of said synthetic core material of said combined unit not exceeding 70 ° C. 'flp 46.- The system according to claim 35, in Wherein said press apparatus comprises: means for providing a controlled amount of heat for an accepted stack of said combined units. 47. The system according to claim 44, wherein said means providing heat is controlled to result in a temperature experienced by said synthetic core material of said accepted stack not exceeding 70 ° C. ^^^ ^ ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^ ^^^^^ ^^ S ^^^^^^^^^^^^^^^^ 48. - The system according to claim 35, wherein said press apparatus accepts said second stack of combined units for a time in which said first stack of combined units is coupled to said press apparatus ^? > while said combined unit stacking position accumulates additional received combined units in a third stack. 49.- The system according to claim 35, wherein said light discharge treater is also arranged for 10 impart a light discharge on a second surface of said piece of said synthetic core material, said applicator of • adhesive is also arranged to deposit a film of adhesive on said second surface of said piece of said synthetic core material, and said sheet position is also arranged for 15 coupling a first surface of a piece of a second laminate material having no adhesive film deposited there with said second surface of said piece of said synthetic core material having said adhesive film deposited there in order to provide said combined unit with sheets including said 20 piece of said first laminate material, a first adhesive film, said piece of said synthetic core material, a second adhesive film, and said piece of said second laminate material. 50.- The system according to claim 49, in Wherein said first surface of said piece of said synthetic core material and said second surface of said piece of said SSa ^^^^^^^^^^^^^^^^^^^^^ & ^. Synthetic core material are opposite sides of said synthetic core material. 51.- The system according to claim 49, wherein said first laminate is a decorative sheet and said second laminate is a holder. 52. The system according to claim 51, wherein said decorative sheet is selected from the group consisting of: a high pressure decorative sheet; a decorative sheet of 10 low pressure; a sheet of solid surface material; and a sheet of • metallic material. 53. The system according to claim 51, wherein said holder is a high pressure decorative sheet holder. •