MXPA99008739A - Compositions of polymeric foam and method for manufacturing them, substrates made of these compositions and method to manufacture them, products made from these substrates and method to manufacture - Google Patents

Abstract

A polymeric foam composition is provided for use as a substrate in decorative compositions having at least one decorative layer on the substrate, wherein the substrate is prepared by foaming a composition made of (i) a resin matrix of one or more polymers selected from acrylonitrile-butadiene-styrene (ABS) polymers, polycarbonates, polystyrenes, polyphenylene oxide, and polyvinyl chloride polymers, preferably obtained from recycled plastics. The resulting foam composition has sufficient physical and mechanical properties for use in place of fiber board or particle board in the preparation of different decorative products, such as decorative laminate, decorative micro-plate laminate, metal films, metal foils, sheets of metal, solid surface materials, solid surface sheet, solid surface laminate, and solid surface dimensional laminate

Description

COMPOSITIONS OF POLYMERIC FOAM AND METHOD TO MANUFACTURE THEM, SUBSTRATES MADE OF THESE COMPOSITIONS AND METHOD FOR FRABRICARLOS, PRODUCTS MADE OF THESE SUBSTRATES AND METHOD TO MANUFACTURE THEM BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to polymeric compositions, to methods for making these compositions, to substrates made from these compositions, to methods for manufacturing these substrates, to products made from these substrates, and methods to manufacture these products. In another aspect, the present invention relates to foamed polymer compositions, methods for making these compositions, substrates made from these compositions, methods for making these substrates, products made from these substrates, and methods for making these products. In still another aspect, the present invention relates to foamed polymeric compositions having suitable mechanical properties to be made into substrates useful for supporting decorative surfaces to be incorporated into products such as building materials, floors, furniture, table or counter cover, and panels. of wall, to methods for making these compositions, to methods for making these substrates, and to methods for making these products. In yet another aspect, the present invention relates to foamed polymeric compositions having suitable mechanical properties to be made into substrates useful for supporting decorative surfaces, such as laminates, decorative laminates of micro-sheets, metal products, solid surface materials, solid surface sheeting, solid surface laminate, solid surface dimensional laminate, any or all of which may be incorporated into products such as building materials, floors, furniture, table or counter cover, and wall panels, to methods for making these compositions, to methods for manufacture these substrates, and methods to manufacture these products. ______ Description of Related Art Conventional laminate products are well known in the art. In general, they are prepared by laminating a decorative layer and one or more layers of brown paper together, using different types of resins, such as melamine, formaldehyde and phenolic resins. The resulting decorative laminate is then adhered to a substrate, typically fiber board or particle board. The product thus prepared is known as a decorative high-pressure laminate. Alternatively, a low pressure decorative laminate is prepared by laminating a decorative layer, with or without an overlay, directly on a fiber board or a particle board substrate, using the same type of resins used in the high pressure decorative laminate. However, although the use of these wood-based substrates provides the necessary rigidity for structural uses, such as floors and back-covers, these wood-based substrates are heavy and can deform in the presence of moisture. A possible solution to these problems would be to use polymeric substrates to prepare laminates. However, polymeric materials tend to be considerably more expensive, especially those that have the desired stiffness and performance characteristics for use in laminated applications. Foamed polymers are known and used in different structural end uses. The preparation of polymeric foams and their conventional uses are described in Kirk Othmer Encyclopedia of Chemical Technology, 4th edition, volume 11, John Wiley and Sons, NY, pages 730-783 (1997), as well as the "Handbook of Polymeric Foams and Foam". Technology ", edited by D. Klempner and KC Frisch, Hanser Publishers, NY (1991), the content of both being incorporated herein by reference. Another problem that exists is the generation of polymer waste, either as manufacturing tails, or through the obsolescence of different commercial products that use polymeric materials such as accommodation, supports, and different internal parts of the product. These products include things such as televisions, stereos, computers, printers, typewriters, and so on. Due to the nature of these products, and the rapid advancement of technology around them, these types of products are being replaced more frequently. A problem that arises then is the manner of disposing the polymer-based parts of these devices in a manner suitable for the environment, as well as in an economically appropriate manner. In accordance with the above, it would be useful to have a substrate material that overcomes the above drawbacks of wood-based substrates, while having minimal costs. Furthermore, if this substrate is made of polymeric material, it would be convenient to have a product that can be made from recycled polymers.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a polymeric foam composition having sufficient rigidity and mechanical properties to be used as a substrate in structural and decorative applications, such as laminate floors or a decorative laminate. or. A further object of the present invention is to provide a polymeric foam composition having the above properties, which is prepared from recycled plastics. A still further object of the present invention is to provide a method for manufacturing a substrate from the above foam compositions. A still further object of the present invention is to provide a product comprising a member formed of the above foam compositions, which supports a decorative member. Non-limiting examples for the decorative member include laminates, microlayer laminates, solid surface materials, solid surface sheet, solid surface laminate, solid surface dimensional laminate. A still further object of the present invention is to provide a method for manufacturing the above product. In accordance with one embodiment of the present invention, a multi-layered decorative product is provided. The product includes a substrate comprising a polymeric foam comprising a resin matrix of at least one polymer selected from the group consisting of polymers of acrylonitrile-butadiene-styrene, polycarbonate-coughs, polystyrenes, polyphenylene oxide, and polymers of polyvinyl chloride. The product also includes one or more decorative layers bonded to this substrate, wherein the decorative layer is selected from the group consisting of a decorative laminate, a decorative laminate of micro-plates, metal films, metal foils, metal foils, materials surface solids, solid surface sheet, solid surface laminate, and solid surface dimensional laminate. In a more specific embodiment of this embodiment, the resin matrix comprises at least one member selected from the group consisting of fire-retardant acrylonitrile-butadiene-styrene polymers, and glass-filled acrylonitrile-butadiene-styrene polymers. In a more specific embodiment of this embodiment, the resin matrix comprises recycled materials, preferably obtained by recovering plastic materials from an electronic device. According to another embodiment of the present invention, there is provided a method for manufacturing the multilayer decorative product described above. The method generally includes fixing together a substrate comprising a polymeric foam comprising a resin matrix of at least one polymer selected from the group consisting of acrylonitrile-butadiene-styrene polymers, polycarbonates, polystyrenes, polyphenylene oxide, and polyvinyl chloride polymers, together with one or more decorative layers, wherein the decorative layer is selected from the group consisting of decorative laminate, decorative micro-plate laminate, metal films, metal foils, metal foils, solid surface materials , solid surface sheet, solid surface laminate, and solid surface dimensional laminate.

BRIEF DESCRIPTION OF THE DRAWINGS A more complete appreciation of the invention and many of its advantages will be readily obtained, as it becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawing, in which: which: Figure 1 shows a typical laminated construction showing the substrate (1), the decorative laminate layer (2), and the backing layer (3).

DETAILED DESCRIPTION OF THE INVENTION The polymeric foam compositions of the present invention can be formed into substrates having sufficient structural properties to allow use as the support member for decorative materials, such as laminates, microlayer laminates, solid surface materials, solid surface veneer, solid surface laminate, solid surface dimensional laminate.

The polymeric foam substrate of the present invention can be prepared from any foamable polymer, provided that the prepared foam has the structural and mechanical properties necessary for the final use. In particular, it is preferred that the substrate has a compression setting that is approximately equal to or better than the conventional medium, or the conventional medium or high density fiber board or particleboard (where the compression setting is measured from in accordance with ASTM F970, as a decrease in thickness as a function of the compressive tension). Preferably, this decrease in thickness at 140 kg / cm is at most 0.254 millimeters, more preferably when much 0.127 millimeters, and most preferably when much 0.0254 millimeters. In addition, the polymeric foam substrate of the present invention preferably has a coefficient of linear thermal expansion (according to ASTM D-696) of 17.78 x 10 ~ 5 cm / cm / ° C, more preferably 5.08 x 10 ~ 5 to 1.27 x 10 ~ 5 cm / cm / ° C, and most preferably 2.54 x 10 ~ 5 to 1524 x 10"5 cm / cm / ° C. Preferably, the polymeric foam comprises one or more members selected from the group consisting of poly (acrylonitrile / butadiene / styrene) resins (hereinafter referenced herein) as ABS), such as flame-retardant ABS resins, and glass-filled ABS resins, polycarbonate, high impact polystyrene (HIPS), polystyrene, polyphenylene oxide (PPO), and polyvinyl chloride (PVC). it may be virgin polymer or recycled polymer Preferably, the foam of the substrate is prepared from a blended resin system containing, but not limited to, one or more of the aforementioned polymers. not filled, although from a point of view of impact resistance and property music, the filled polymers are best. In a more preferred embodiment, the polymer is obtained from recovered plastics castings and parts of electronic equipment, such as computers, printers, televisions, stereos, and so on. This recovered plastic is obtained through the removal of substantially all iron-based metals and other non-plastic parts of electronic equipment, followed by plastic granulation. Within the context of the present invention, the term "substantially" means > 95 percent of the original amount of iron-based metals and other non-plastic parts in electronic equipment, preferably > 99 percent of the original amount. The recovered plastic is usually a mixture of 2 or more of the aforementioned preferred polymers, with 50 percent or more, preferably 75 percent or more, of ABS, with or without flame retardant or glass fillers. The polymer used in the preparation of the polymeric foam of the present invention can be foamed using any conventional blowing agent, such as exothermic blowing agents, endothermic blowing agents, or combinations thereof, as long as the size of the polymer can be adjusted. foam cells to provide the structural and mechanical properties required in the desired end use. The preparation of foamed polymers is known in the art and is described, for example, in the Kirk Othmer Encyclopedia of Chemical Technology and in the aforementioned "Handbook of Polymeric Foams and Foam Technology". Preferred exothermic blowing agents include azodicarbonamide blowing agents. Exothermic blowing agents tend to provide a larger cell size in the foam produced than the endothermic blowing agents. A preferred endothermic blowing agent is a combination of calcium carbonate (or bicarbonate) and carboxylic acid. Suitable carboxylic acids are known in the manufacture of foams, and should be able to help initiate the formation of CO2 from carbonate or calcium bicarbonate. These carboxylic acids include, but are not limited to, acids such as citric acid. In high load end uses, such as laminate floors, the use of only an exothermic blowing agent tends to provide a foam with insufficient compressive strength, due to the very large size cells. Although the use of an endothermic blowing agent only requires larger amounts of the blowing agent (thus increasing the material and processing costs), without the ability to generate sufficient density reduction to reduce the overall weight of the blowing agent. foam to a desired level for handling. Accordingly, in a preferred embodiment of the present invention, the blowing agent is a combination of an exothermic blowing agent and an endothermic blowing agent. In particular, the most preferred blowing agent is a combination of a blowing agent of azodicarbonamide and CaC 3 (or bicarbonate / carboxylic acid). The determination of the amount of blowing agent required, and the proportion of endothermic / exothermic blowing agents is within the ability of one of ordinary skill in the art of preparing polymeric foams, and depends on the desired final properties of the foam . Preferably, the blowing agent is used in an amount of up to 3 percent of the polymer, more preferably 1 to 2 percent by weight of the polymer. The polymer of the present invention can be used alone or with one or more fillers, in order to obtain the desired physical properties of the resulting foam. Preferably, the filler may be one or more conventional fillers, more preferably one or more fillers selected from the group consisting of calcium carbonate, talc, silica, glass fibers, alumina, and wolastonite. These fillers also include surface-treated fillers. More preferably, the filler is surface-treated calcium carbonate, commercially available as DF30T from Franklin Industrial Minerals, of Dalton, GA. The ratio of resin: filler is from 100: 0 to 30:70, preferably from 90:10 to 50:50, more preferably from 75:25 to 65:35. In an illustrative embodiment, the recovered polymer is compounded with the surface-treated calcium carbonate with filler (DF30T) in a resin ratio: CaCO3 of 70:30. The blowing agent is composed of a separate type of granule. This separate granule can be prepared from the same resin that forms most of the recovered polymer, and from a different resin that is represented in the recovered polymer blend. The blowing agent containing the granule is then added to the recovered polymer / -fill mixture in an amount sufficient to bring the blowing agent to a level of about 1.5 percent, based on the overall mixture. The resulting mixture can be extruded and blow directly. In an alternative manner, the blowing agent itself (in a non-granulated form) can be added directly to the recovered polymer / filler mixture in the extruder. The polymer is foamed to a level of density reduction sufficient to meet the requirements of the desired end use. For non-loaded applications, the polymer can be foamed up to a density reduction of up to 75-80 percent. For final cargo-carrying applications, such as back-cover and floor applications, the polymer is preferably foamed up to a density reduction of up to about 50 percent, more preferably a density reduction of 25 to 35 percent, and very preferably a density reduction of about 30 percent. The density reduction, as used in the present invention, is the percentage by which the density of the foamed product is lower than the density of the non-foamed polymer. The foamed polymeric product of the present invention can be used as a substrate for a wide variety of end uses. In particular, the foam product of the present invention can be used as a replacement for a fiberboard or particle board substrate in laminated products, such as high wear laminate floors and high pressure decorative laminates, such as are used in the countertops or kitchen covers. The foam product of the present invention can also be used as a substrate for the decorative microlayer laminate disclosed in the United States Patent Application Serial Number 09 / 082,872, filed May 21. of 1998, incorporated herein by reference. The microlayer decorative laminate can generally be described as including a decorative layer which can be a solid color or printing decorative paper having a resin coating on its wear surface, an adhesive backing impregnated with resin, and optionally, a more core layers impregnated with resin, and optionally also, one or more superposed layers impregnated with resin. In a method for manufacturing a decorative microlayer laminate, the resin is first impregnated in the overlay, and partially cured. The overlay is placed on solid or printing colored decorative paper that has not been impregnated with resin, and optionally together with one or more core sheets impregnated with resin, and a backing sheet impregnated with resin, all of which are laminated together under heat and pressure. The resin content in the overlay is adjusted to provide the amount of resin needed for a wear-resistant surface, and to impregnate the decorative paper. In another method for manufacturing a decorative laminate of a microlayer, the resin is coated on the decorative surface of solid color decorative paper, which is laminated together with one or more optional resin impregnated core sheets, and the backing sheet impregnated with resin . The resin impregnates the decorative paper and is partially cured. The foam product of the present invention can also be used as a substrate for metal products, decorative films, sheets, sheets, or the like, made of metals. The foam product of the present invention can also be used as a substrate for solid surface materials, usually polyacrylics containing different fillers. Commercially available products include the Gibralter products sold by Wilsonart International, Inc. The foam product of the present invention can also be used as a substrate for solid surface sheet, conventionally thinner, usually polyacrylic solid surface materials containing different fillers, such as such as the commercially available SSVMR products (3,175 millimeters thick) sold by Wilsonart International Inc. The foam product of the present invention can also be used as a substrate for a solid surface laminate, that is, for very thin solid surface products ( solid surface products from <2.54 millimeters thick), typically polyacrylics containing different fillers, which are disclosed in United States Patent Application Serial Number 08 / 899,118, filed July 23, 1997, incorporated into the present as a reference. The foam product of the present invention can also be used as a substrate for a solid surface dimensional laminate, disclosed in the United States of America Patent Application Number Series, entitled "Solid Surfacing Dimensional Laminate, and Methods for Making and Using Same", by Peter C. Gaa, presented in a manner concurrent with the present, and incorporated herein by reference. This solid surface dimensional laminate has a better pattern depth appearance, provided by placing overlays of decorative sheets in patterns placed in such a way that each pattern or part thereof is visible through the top of the final consolidated laminate. A plurality of patterned decorative layers are extended, such that each pattern is offset from the others, making each pattern visible through the upper decorative layer or overlay sheet of the laminate formed. As a non-limiting example, suppose that each pattern is a wood grain pattern, and then during the extension of each wood grain pattern it would be arranged in such a way that the patterns do not substantially overlap, that is, the patterns become outdated in the xy plane and from each other. In the practice of the present invention, the foamed polymer composition can be extruded separately, and then bonded to the selected decorative member, or when appropriate, the polymeric foam composition of the present invention can be co-extruded with the desired decorative member for form a co-extruded product in multiple layers. By way of example, the use of the foamed composition of the present invention will be described as a substrate for laminate floors. However, this should not be seen as limiting the present invention to laminate flooring applications, since those skilled in the art will readily recognize the wide range applicability of the foam composition of the present invention in many different end uses. Fig1 shows a typical laminate struct showing the substrate (1), the decorative laminate layer (2), and the backing layer (3). In the preparation of a laminated product, the decorative surface is conventionally prepared using a decorative paper layer having the desired pattern printed thereon. In the case of floors, the pattern is often a wood grain finish, although any pattern is possible. This decorative layer is impregnated with melamine-formaldehyde resin, and is laminated to one or more sheets of brown paper, which have been impregnated with phenol-formaldehyde resin. The surface of the decorative layer to be exposed in the final product is usually prepared by bonding an overlay, typically a sheet of thin paper impregnated with the same type of melamine-formaldehyde resin. Preferably, for flooring applications, a filler is also included in the overlay, in order to provide abrasion resistance and a non-skid surface in the final product. Suitable fillers include alumina, calcium carbonate, ground glass fibers, powdered glass fibers, and the like. Once the decorative layer is prepared, it can be adhered to the polymeric foam core composition of the present invention, using conventional adhesives, the non-limiting examples of which include polyvinyl acetate / hane adhesives, polychloroprene contact adhesives, One-component hane, two-component hane adhesives, and other solvent-based adhesive systems. Non-limiting examples of the preferred adhesives include polyvinyl acetate / hane adhesives, and two-component hane adhesives. The most preferred adhesive is a two component hane adhesive. A non-limiting example of a commercially available two-component adhesive from Morton International is Mor-Ad 695-28T, as the "A" hydroxyl-terminated component, and Mor-Ad 695-28 as the "B" component of isocyanide. The lower part of the floor section containing the polymeric foam composition of the present invention, is a conventional backing sheet used in high pressure decorative laminate and in conventional laminate floors. The backing sheet is prepared by laminating one or more sheets of brown paper impregnated with melamine-formaldehyde resin. The resultant laminate also adheres to the underside of the polymeric foam composition, using a conventional adhesive as discussed above. Obviously, modifications and further variations of the present invention are possible in light of the above teachings. Accordingly, it should be understood that, within the scope of the appended claims, the invention may be practiced in a manner different from that specifically described herein.

Claims (16)

1. A multi-layer decorative product, which comprises: (a) a substrate comprising a polymeric foam comprising a resin matrix of at least one polymer selected from the group consisting of acrylonitrile-butadiene-styrene polymers, polycarbonates, polystyrene, polyphenylene oxide, and polyvinyl chloride polymers; and (b). one or more decorative layers bonded to the substrate, wherein the decorative layer is selected from the group consisting of decorative laminate, decorative micro-plate laminate, metal films, metal foils, metal foils, solid surface materials , solid surface sheet, solid surface laminate, and solid surface dimensional laminate.

2. The multilayer decorative product of claim 1, wherein the resin matrix comprises at least one member selected from the group consisting of fire retardant acrylonitrile-butadiene-styrene polymers, and acrylonitrile-butadiene-polymers. styrene filled with glass.

3. The multi-layer decorative product of claim 1, wherein the resin matrix comprises at least one member selected from the group consisting of high impact polystyrenes.

4. The multi-layer decorative product of claim 1, wherein the resin matrix comprises recycled materials. The multi-layer decorative product of claim 4, wherein the resin matrix is obtained by recovering plastic materials from an electronic device. 6. The multi-layer decorative composition of claim 1, wherein the substrate has a decorative layer on each of two opposite sides of the substrate. A method for manufacturing a decorative product in multiple layers, the method comprising: (a) attaching together a substrate comprising a polymeric foam comprising a resin matrix of at least one polymer selected from the group consisting of polymers of acrylonitrile-butadiene-styrene, polycarbonate-coughs, polystyrenes, polyphenylene oxide, and polyvinyl chloride polymers, together with one or more decorative layers, wherein the decorative layer is selected from the group consisting of decorative laminate, decorative laminate of microlayer, metal films, metal foils, metal sheets, solid surface materials, solid surface sheet, solid surface laminate, and solid surface dimensional laminate. The method of claim 7, wherein the resin matrix comprises at least one member selected from the group consisting of fire retardant acrylonitrile-butadiene-styrene polymers, and glass-filled acrylonitrile-butadiene-styrene polymers. . The method of claim 7, wherein the resin matrix comprises at least one member selected from the group consisting of high impact polystyrenes. The method of claim 7, wherein before step (a), the resin matrix is obtained by recovery. The method of claim 10, wherein, before step (a), the resin matrix is obtained by recovering plastic from electronic devices. The method of claim 7, wherein step (a) comprises fixing a decorative layer on each of two opposite sides of the substrate. The method of claim 7, wherein, in step (a), fixing the substrate with the decorative layer is by coextruding the decorative layer with the substrate. The method of claim 7, wherein, in step (a), fixing the substrate with the decorative layer is by bonding the decorative layer to the substrate using an adhesive. The method of claim 13, wherein the adhesive is selected from the group consisting of polyvinyl acetate / urethane adhesives, polychloroprene contact adhesives, one-component urethane adhesives, two-component urethane adhesives, and solvent based adhesive systems. 16. The method of claim 14, wherein the adhesive is selected from the group consisting of polyvinyl acetate / urethane adhesives, and two-component urethane adhesives.