MXPA99009379A - Profile cover with solid chapassuperficial foam nucleus and methods to form and use the mi - Google Patents

Abstract

Methods for making contoured solid surface laminates (SSL) are provided where a pre-cured or uncured LSS is placed inside a mold under conditions to impart an outline to the LSS and to allow the stresses imparted to the LSS to relax during molding. In particular, both batch or continuous methods are provided to form the LSS contours

Description

PROFILE COVER WITH SOLID SURFACE-SHEET FOAM NUCLEUS AND METHODS TO FORM AND USE THE SAME BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a shaped or contoured article that includes a top layer and a back support layer and optionally, an impact layer interposed therebetween, methods of forming and using it. More particularly, the present invention relates to solid surface contoured lamination (LSS) for use as covers or coverage of bars, desk covers, or other surface components, where the surfaces include a decorative top layer bonded to or coextruded with a member backup that has been formed in such a way that the LSS can be easily arranged over and fixed to a substructure in a simple installation, and to methods for forming and using the LSS. 2. Description of the Related Art Conventional laminate products are well known in the art. These are generally prepared by laminating a decorative layer and one or more layers of kraft paper simultaneously using various types of resins, such as melamine formaldehyde and phenolic resins. The resulting decorative laminate is then adhered to a substrate, usually agglomerate or agglomerate board. The product prepared in this way is known as high pressure decorative laminate. Alternatively, the low pressure decorative laminate is prepared by laminating a decorative layer, with or without a coating layer, directly on a chipboard or agglomerate board substrate, using the same type of resins used in the high pressure decorative laminate . However, although the use of wood-based substrates provides the necessary rigidity for structural uses such as flooring or roofing material, these wood-based substrates are heavy and can warp in the presence of moisture. A possible solution to these problems would be to use polymeric substrates to prepare the laminates. However, polymeric laminates tend to be considerably more expensive, especially those that have the stiffness and performance characteristics desired for use in laminate applications. The foamed polymers are known and are used in several final structural uses. The preparation of polymer foams and their conventional uses are described in Kirk Othmer Chemical Technology Encyclopedia, 4th Edition, Volume 11, John Wiley and Sons, NY, pages 730-783 (1997), as well as the "Foam Handbook". Polymeric and Foaming Technology ", edited by D. Klempner and KC Frisch, Hanser Publishers, NY (1991), the contents of both of which are hereby incorporated by reference. Another problem that exists is the generation of polymeric waste, either as waste from manufacturing or through the disuse of several commercial products that use polymeric materials such as housing, supports and various internal parts of the product. These products include things such as televisions, stereos, computers, printers, typewriters, etc. Due to the nature of these products and the rapid advancement of the technology that surrounds them, these types of products are being replaced with increasing frequency. A problem that arises then is how to dispose of the polymer-based parts of these devices in an environmentally sound manner, as well as in an economically sound manner.

In addition to the foam backing substrates, other backing materials have also been used in the production of solid surface laminates (LSS). LSS are basically a composite structure that includes a decorative surface applied (attached or bonded) to a substrate. A disadvantage of the LSS constructions is that the installations of the LSS to the substructures generally requires simultaneously gluing several different components to achieve a given composite structure. In this way, the flat portions of the structure are made of flat pieces of LSS, while the curved components of the structure may comprise one or many separate pieces of LSS arranged and joined together in the final shape of the structure. Therefore, this would represent a breakthrough in technique to be able to make formed or contoured LSS structures that can simply be transported to the installation site and placed and joined in place without having to simultaneously paste many different subcomponents to achieve a form desired contouring such as a kitchen bar that has an arched protection against splash and a curved front lip or edge down.

BRIEF DESCRIPTION OF THE INVENTION According to one embodiment of the present invention, there is provided a shaped or contoured article that includes a top layer attached to a backing member or substrate where the shape or contour is imparted to the article after the top layer is attached to the backing member. back. According to another embodiment of the present invention, there is provided a shaped or contoured article that includes a top layer attached to a backing member or substrate where the shape or contour is imparted to the article during the bonding or co-extrusion of the substrate the top layer. According to still another embodiment of the present invention, there is provided a method for making a shaped article including the step of attaching a top layer to a backing member or substrate to form a composite article, placing the composite article in a mold and Apply sufficient heat and pressure for a sufficient time to make the article formed or contoured. According to yet another embodiment of the present invention, there is provided a method for making a shaped article that includes the step of co-extruding an upper layer and a backing member or substrate to form a composite article, placing the composite article with -extruded in a mold and apply enough heat and pressure for a sufficient time to make the article formed or contoured. According to yet another embodiment of the present invention, there is provided a method for making a shaped article that includes the step of coextruding an upper layer and a backing member or substrate to directly form a contoured or formed composite article. According to still yet another embodiment of the present invention, there is provided a method for installing the contoured articles of the present invention to a sub-structure. These and other embodiments of the present invention will be apparent to those skilled in the art upon reviewing this disclosure, including its drawings and claims.

DETAILED DESCRIPTION OF THE INVENTION The inventor has found that laminated or contoured or contoured solid surface composite materials (LSSC or LSSP) can be prepared, either by first forming the solid surface laminate (LSS) and then subsequently forming the LSS into an LSSC or by forming the LSS in an LSSC in a stage, where the LSSC is designed for the installation of a stage over appropriate substructures such as substructures of kitchen bars or the like. The LSSC of the present invention can be prepared from any LSS including paper-based, plastic-based or metal-based surfaces bonded to, extruded on or co-extruded with a substrate or backing member. The solid surface laminate (LSS) can be described as very thin solid surface products (< thick surface products of 100 mils), typically polyacrylics containing fillers, which are disclosed in the patent application of the United States Serial No. 08 / 899,118, filed July 23, 1997, incorporated herein by reference. Paper-based laminates or laminated decorative sheet composite assemblies or composite materials include several layers of core material impregnated with thermal hardening resin (preferably kraft paper) that holds a decorative layer impregnated with thermal hardening resin, which may also be covered with a layer sheet impregnated with thermal hardening resin. The thermal hardening resin employed is preferably a phenol formaldehyde resin for the core material, and preferably a transparent formaldehyde melamine resin for the decorative and cover sheets. The decorative or covering sheets or layers can also be textured during consolidation. Generally, several laminates are made at the same time with a detachment sheet interposed between them for easy separation after consolidation. The laminates are typically consolidated or cured by pressing the composite material enclosed between the appropriate lamination press plates such as a platen press assembly as is well known in the lamination art., is used to provide the necessary heat and / or pressure during the lamination. In addition to paper-based laminates, the present invention can also utilize plastic-based surface coatings to make the LSS. The composition of the plastic-based surface coating includes those described in U.S. Patent Nos. 4,085,246; 4,458,039; 4,533,680; 4,938,825 and 5,318,737, incorporated herein by reference. The present invention may also employ the microlayer decorative laminate disclosed in U.S. Patent Application Serial No. 09 / 082,872, filed May 21, 1998, incorporated herein by reference. The decorative microlayer laminate can generally be described as including a decorative layer that can be either a solid color or a decorative printed paper having a resin coating on its wear surface, a backing capable of bonding impregnated with resin, and optionally, one or more core layers impregnated with resin, and further optionally, one or more cover layers impregnated with resin. In a method for making the decorative micro-plate laminate, the resin is first impregnated in the cover and partially cured. The cover is placed on the solid color or decorative printed paper that has not been impregnated with the 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 cover is adjusted to provide the amount of resin needed for a wear-resistant surface and to impregnate the decorative paper. In another method for making the decorative micro-laminate laminate, the resin is coated on the decorative surface of the solid color decorative paper, which is laminated together with one or more core sheets impregnated with optional resin and the backing sheet impregnated with resin . The resin impregnates the decorative paper and is partially cured. The present invention also utilizes solid surface materials, typically polychloric, that contain various fillers. Commercially available products include the Gibralter® products sold by Wilsonart International, Inc. The present invention can also be used with the solid surface sheet, conventionally thinner, typically polyacrylic solid surface coating materials containing various fillers, such such as the commercially available SSV® products (1/8"thick) sold by Wilsonart International, Inc. The present invention can also be used with the solid surface coating dimensional laminate disclosed in U.S. Patent Application No. No. 08 / 161,265, Gaa, filed September 26, 1998, and incorporated herein by reference.This dimensional laminate of solid surface coating has an appearance of enhanced pattern depth, provided by having decorative cover sheets of pattern sheets 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 placed in such a way that each pattern is offset from each other by making each pattern visible through the upper decorative cover layer or sheet of the formed laminate. As a non-limiting example, it is assumed that each pattern is a wood grain pattern, then during the placement of each wood grain pattern it would be arranged in such a way that the patterns do not substantially overlap, ie the patterns are deviated in the x plane and one of the other. In addition to the plastic-based surface cover, the LSSC of the present invention can also use metal surface covers or metal laminate surface. The metal surfaces are simply a given measure of the rolled metal, including, without limitation, sheets of aluminum, iron and their alloys such as any of the known types of steel, copper, zinc, copper-zinc alloys such as brass or bronze. , cobalt, chromium, titanium, other metals, or mixtures or combinations thereof. Metal laminates are composite materials in paper-based or plastic-based layers that incorporate a thin metallic foil e >; the same. Moreover, the surface coating cover may include a combination of paper-based, plastic-based and metal-based components in some pattern disposed on the substrate to give a composite surface design or embossed structure. The paper-based, plastic-based and metal-based surface coatings or laminates useful in the practice of the present invention may also include, as desired and / or as necessary, additives including, without limitation, antioxidants, antiblocking agents , release agents, crosslinking agents, stabilizers, ultraviolet ray absorbers, lubricants, foaming agents, antistatic agents, organic and inorganic flame retardants, plasticizers, dyes, pigments, talc, calcium carbonate, carbon black, mica , glass fibers, carbon fibers, aramid resin, asbestos, as well as other fillers as are known in the art. These laminates, paper-based, plastic-based or metal-based, are then either bonded to or extruded onto or co-extruded with a substrate to form an LSS. Once the LSS is formed, then the LSS will generally have a substantially flat cross-sectional profile. In one embodiment of this invention, once the LSS is made and optionally before or after curing further deformation, the LSS is placed inside a mold for a time and at a temperature and at a pressure sufficient to produce a profile on the LSS. Contoured cross section. The conditions of time, temperature and pressure must be such that the resulting LSSC is formed in a substantially relaxed state. That is, the LSS is preferably formed in a mold under appropriate conditions and such that the stresses imparted to the LSS during the mold are substantially released or, that is, the composition set of the LSS components are allowed to soften during the molding process. In a preferred embodiment of this invention, an LSSC is formed by first coating a cover surface substrate with an adhesive and placing a decorative surface thereon to form a pre-cured LSS. Next, the LSS is placed in a vacuum mold at an elevated temperature and a reduced pressure. The temperature is sufficiently high that the substrate and the surface cover are both flexible or capable of forming under vacuum or capable of molding. The mold is closed and a vacuum is applied to the mold containing the LSS. The vacuum and temperature are maintained for a sufficient time for the LSS to assume the shape of the mold, to become contoured. If the temperature is below the cure temperature of the LSS adhesive, then, after a sufficient time for the LSS to assume the shape of the mold and be subjected to relaxation of any of the stresses imparted to the system during vacuum formation , the mold temperature can be raised above the curing activation temperature. The curing temperature is then maintained for a sufficient time to ensure that adequate curing of the adhesive forms sufficient bond strength to substantially inhibit delamination during cooling and subsequent use. After curing or molding, the mold with the LSS in there is generally allowed to cool to a temperature close to the ambient temperature for a sufficient time to allow for relaxation during cooling. Once cooled sufficiently, the LSSC is released from the mold. Typically, the mold release temperature is between about room temperature or between about 10 degrees centigrade and about 38 degrees centigrade. Preferably, the release temperature is between about 16 degrees centigrade and about 27 degrees centigrade and particularly, between about 18 degrees and about 24 degrees. Usually, the molding temperature is above both the flexibility temperature of the pre-LSS and the curing temperature of the adhesive such that molding and curing are occurring simultaneously. However, when the process conditions are such that the molding temperature is above both of the pre-LSS's flexibility temperature and the curing temperature of the adhesive system, careful control must be exercised over molding time and the coefficient of elevation of the temperature to avoid the excess tension in the resulting LSS during the molding / curing operation. Typically, the molding temperature is controlled, to a greater limit, by the softening temperature of the material that is placed inside the mold. For the plastic-based LSS, the molding temperature is preferably above a higher Tg of the components forming the LSS. In this way, if the LSS has a Tg of 149 degrees centigrade, then then the temperature of the mold will be set at a temperature of -149 degrees centigrade and preferably above 149 degrees centigrade. The temperature of the upper mold is generally controlled by the components of the LSS as well. If the components of the LSS have melting point temperatures, then the mold temperature must be maintained sufficiently below the lower melting point temperature so that the material does not flow in the molten state or mix internally. Preferably, the mold temperature should not exceed a temperature of about -12 degrees centigrade below the lowest melting point temperature, particularly, the mold temperature should not exceed a temperature of about -9 degrees centigrade below the temperature of the mold. lower melting temperature, especially, the temperature of the mold should not exceed a temperature of about -7 degrees Celsius below the lowest melting point temperature. If the LSS components do not have melting point temperatures, then the mold temperature is bound above the lowest decomposition temperature of the LSS composition. For most LSS and LSS previously cured, the mold temperature will be in the range of about 122 degrees centigrade to about 260 degrees centigrade. Of course, the LSS having a metal surface, the temperature will be high enough that the metal will take the shape of the mold and relax the tensions during the molding, but below the decomposition of the substrate. Even in metal surface LSS, mold temperatures in the range of about 122 degrees to about 260 degrees centigrade are suitable, with molding temperatures in the range of about 177 degrees centigrade to about 260 degrees centigrade being preferred. The pressure used in vacuum forming or molding is widely below atmospheric pressure of about 760 mm of mercury. Preferably, the pressure is less than about 500 millimeters of mercury, and particularly less than about 380 millimeters of mercury.

In another preferred embodiment of this invention, an uncured LSS or a previously cured LSS is placed inside a conventional thermal mold at a temperature and pressure for a sufficient time to form the LSS in a desired cross-sectional shape or contour and is allows the resulting LSSC to relax to release the stresses formed in the LSS during the molding process. In yet another embodiment of this invention, an uncured or previously cured LSS is placed within a mold where the mold is rotated relative to a horizontal condition such that a main planar portion of the LSS forms an angle? with the horizontal line that passes through the mold. The angle ? It is adjusted in such a way that gravity can help in the molding process. In this way, if the LSSC is going to be in the form of a kitchen counter, it will have two bends with almost right angles. A bend will be associated with a splash guard and the second bend will be associated with an opposite edge of the LSSC. If the mold is rotated away from the horizontal by the angle?, Then gravity will help the molding process. For such a cross-sectional contour, the angle? it will preferably be between about 30 degrees and about 60 degrees, with about 40 degrees to about 50 degrees being particularly preferred and about 45 degrees being especially preferred. Of course, the angle? The exact preferred will depend on the number and location of bends or bends that are molded into the LSSC. In thermal molding, the LSS is maintained at a pressure and temperature sufficient to allow the material to conform to the contour shape of the mold. Although the temperature is as previously disclosed, the pressure must be maintained in such a way that the resulting LSS does not reduce in thickness by more than about 10% of its thickness without molding, preferably not more than 5%, and particularly not more than about 2%. Although the molding time will depend to a certain extent on what limit on the temperature and pressure of the molding process used, and up to a certain limit on the starting temperature of the release temperature (elevation and cooling), generally, the molding time will be from about one minute to about 24 hours. Preferably, the molding time will be between about five minutes and about four hours, with molding times of between about 10 minutes and one hour being particularly preferred, and being especially preferred between about 15 minutes and 40 minutes. To aid in molding operation, the methods of the present invention can be practiced using one or more standard molding release agents as are known in the art. Although the illustrative embodiments of the invention are described with particularity, it will be understood that several other modifications will be apparent to and can be readily made by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and descriptions set forth herein, but rather that the claims should be construed as encompassing all characteristics of the patentable novelty that resides in the present invention. , including all the features that would be treated as equivalents thereof by those skilled in the art to which this invention is based.

Claims (18)

1. A method for making contoured solid surface laminates comprising; (a) applying a decorative layer to a substrate to form a solid surface laminate (LSS); (b) place the LSS inside a mold; and (c) molding the LSS to produce a contoured LSS; where the conditions are sufficient such that the contoured LSS is formed in a relaxed state.

2. The method according to claim 1, wherein the LSS comprises a flat portion forming a plane, and wherein in step (c) the molding is carried out in a manner that flatly forms an angle? with the horizontal during the molding, where? it is in the range of about 30 to about 60 degrees. The method according to claim 1, wherein the decorative layer is selected from the group consisting of solid surface material, solid surface sheet, solid surface laminate, solid surface dimensional laminate, and decorative laminate. micro plate. The method according to claim 2, wherein the molding is carried out at a temperature above the highest Tg of the components of the LSS, and at a pressure below 760 mm of mercury during a molding time in the interval from about one minute to about 12 hours. The method according to claim 3, wherein the temperature is in the range of about 122 degrees centigrade to about 260 degrees centigrade, and the pressure which is below about 500 millimeters of mercury and the molding time is in the interval from about 10 minutes to about 4 hours. The method according to claim 4, wherein the temperature is in the range of about 163 degrees centigrade to about 204 degrees centigrade, the pressure is below 380 millimeters of mercury and the molding time is in the range from about 15 minutes to about two hours. A method for making contoured solid surface laminates comprising: (a) applying a decorative layer to a substrate to form a solid surface laminate (LSS) comprising a flat portion forming a plane; (b) place the LSS inside a mold; and (c) that mold the LSS to produce a contoured LSS; where the conditions are sufficient such that the contoured LSS is formed in a relaxed state, and where the molding is carried out in a way that the plane forms an angle? with the horizontal during the molding, where? it is in the range of about 30 to about 60 degrees. The method according to claim 7, wherein the decorative layer is selected from the group consisting of solid surface material, solid surface sheet, solid surface laminate, solid surface dimensional laminate, and decorative laminate. micro plate. The method according to claim 8, wherein the molding is carried out at a temperature above the highest Tg of the components of the LSS, and at a pressure below 760 mm of mercury during a molding time in the interval from about 1 minute to about 12 hours. The method according to claim 9, wherein the temperature is in the range of about 122 degrees centigrade to about 260 degrees centigrade, and the pressure which is below about 500 millimeters of mercury and the molding time is in the interval from about 10 minutes to about 4 hours. The method according to claim 10, wherein the temperature is in the range of about 163 degrees centigrade to about 204 degrees centigrade, the pressure is below 380 millimeters of mercury and the molding time is in the range from about 15 minutes to about 2 hours. 12. The method according to claim 8, wherein the molding temperature is above the highest Tg of the components of the LSS, and the molding pressure is above 760 mm of mercury, and the molding time is in the range of about 1 minute to about 12 hours. The method according to claim 8, wherein the molding temperature is above the highest Tg of the components of the LSS, and the molding pressure is above 760 mm of mercury, and the molding time it is in the range of about 1 minute to about 12 hours. 14. A mold comprising: (a) a top plate having a smooth or textured interior surface; (b) a lower platen having a smooth inner surface; (c) an articulation system attached to both the upper and lower platens for opening and closing the mold; (d) a heating system for heating the plates; (e) a temperature probe for monitoring a temperature of the plates; and (f) a temperature controller for adjusting and maintaining the temperature of the plates. The mold according to claim 8, wherein the mold is rotated away from the horizontal by an angle.. 16. The mold according to claim 8, wherein the angle? it is between approximately 30 and 60 degrees in relation to the horizontal. 17. The mold according to claim 8, wherein the angle? it is between approximately 40 and 50 degrees in relation to the horizontal. 18. A method for continuously developing contoured solid surface laminates comprising: (a) feeding a decorative surface composition to a feeder of a first extruder; (b) feeding a backing material to a feeder of a second extruder; and (c) coextruding the decorative surface composition and the backing material through dies designed to form a contoured solid surface laminate.