TH6261B - Process for the manufacture of decorative thin sheets, thermosetting - Google Patents

Abstract

Process for producing decorative thermosetting plates with a surface layer that resists scratching which some sheets are stacked with sheets of paper impregnated with thermosetting resin In the continuous paper process will was soaked with advanced thermosetting resin. For example, melamine-formaldehyde resin. At least one side of the paper is coated. With small, dry and hard particles that are evenly distributed at a rate of 2-20 g/m2, usually 3-12 g/m2. Throughout the raised surface of the resin on continuous sheets of paper, the resin is dried where the coated particles impregnated the sheet, collectively known as a prepreg, that can be cut into sheets. sheet or continuous paper will be assigned as a surface layer on the main sheet. and stick together

Claims (15)

1. The process for producing thermosetting laminated decorative sheets with a scratch-resistant top layer involves laminating paper sheets impregnated with thermosetting resin. In this process, a continuous woven paper sheet impregnated with melanin-formaldehyde resin is coated on at least one side with dry, hardened particles averaging 1-80 micrometers, smoothly spread across the entire resin-coated surface of the woven paper. The resin weight ranges from two to 20 g/m², typically 3 to 12 g/m². The resin is then dried, and the coated particles impregnate the paper or woven paper (prepreg), which can then be cut into sheets. At a minimum, the woven paper is laid down as the main top layer and bonded together. 2. The process under Patent 1 in which a layer consisting of a continuous woven paper prepreg or a large number of dry paper sheets not yet coated with resin particles on top of these woven papers or paper sheets containing melamine formaldehyde resin, while the remainder of the continuous woven paper or paper sheets containing phenol-formaldehyde resin or phenol-urea-formaldehyde resin and the continuous woven paper or cut paper bars are continuously or discontinuously scooped onto the outermost surface under high pressure and gradually increasing temperature. 3. The process under Claim 1, in which the primary layer consists of particle sheets or fiber sheets. 4. The process under claim 1 in which a continuous woven paper or sheet of paper coated with particles, consisting of what is called coated paper, is usually alpha-cellulose and/or what is called decorative paper. 5. The process under claim 3 where a continuous woven paper or a sheet of paper coated with particles is attached to a core layer by means of gluing or stacking them together by heat and pressure. 6. A process under any of the claims in clauses 1 through 5 in which solid particles consist of silica, aluminum oxide and/or silicon carbide. 7. A process under any of the claims one through six where the particles have an average size of 5 to 60 micrometers. 8. The process under any of the claims in clauses 1 through 7 in which the continuously woven paper or the particle-coated paper sheets as described above are coated with an alpha-cellulose impregnated with a thermosetting resin, for example, melamine resin. 9. A process under any of the claims in clauses 1 through 8 that uses two particle coating plates. 10. A process under any of the claims in clauses 1 through 9 where the particle-coated side of the paper is continuously woven or attached to the top of a thin overlapping sheet. 11. The process under any of the claims 1 through 10 in which solid, dry particles (2) are applied by an apparatus consisting of a container (1) containing solid particles (2) and a rotating apparatus (3) with an uneven surface under the container (1), in which particles (2) fall from the container (1) onto the rotating apparatus (3) and are smoothly applied to woven paper (4) moistened with a thermosetting resin but not dried before the particles (2) are applied. 12. The process under claim 11 in which the device used also consists of a scraping plate (5) which is placed inside a container (1) which allows for the smooth feeding of particles (2) along the surface of the rotating device (3). 13. The process under claim 11 or 12 where the device used also includes a scraping plate (5) which is located under the container (1) which allows the particle (2) to be fed smoothly along the surface of the rotating device (3). 14. A process under any of the claims 1 through 10 in which solid particles are coated by electrostatic coating. 15. A process under one of the claims 1 through 10 in which frictionally charged solid particles are deposited onto a woven sheet of paper.