USRE27201E - Apparatus and process for producing an embossed plastic laminate - Google Patents
Apparatus and process for producing an embossed plastic laminate Download PDFInfo
- Publication number
- USRE27201E USRE27201E US27201DE USRE27201E US RE27201 E USRE27201 E US RE27201E US 27201D E US27201D E US 27201DE US RE27201 E USRE27201 E US RE27201E
- Authority
- US
- United States
- Prior art keywords
- embossing
- film
- embossed
- lamina
- laminate
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
- 238000000034 method Methods 0.000 title abstract description 35
- 239000002650 laminated plastic Substances 0.000 title description 5
- 238000004049 embossing Methods 0.000 abstract description 88
- 239000000758 substrate Substances 0.000 abstract description 56
- 239000000463 material Substances 0.000 abstract description 25
- 229920001169 thermoplastic Polymers 0.000 abstract description 15
- 239000004416 thermosoftening plastic Substances 0.000 abstract description 15
- 238000010030 laminating Methods 0.000 abstract description 9
- 229920003023 plastic Polymers 0.000 abstract description 8
- 239000004033 plastic Substances 0.000 abstract description 8
- 239000010408 film Substances 0.000 description 63
- 239000002023 wood Substances 0.000 description 28
- 229920002554 vinyl polymer Polymers 0.000 description 11
- 239000010409 thin film Substances 0.000 description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 8
- 230000007547 defect Effects 0.000 description 6
- 229920005989 resin Polymers 0.000 description 6
- 239000011347 resin Substances 0.000 description 6
- 239000000839 emulsion Substances 0.000 description 5
- 238000003475 lamination Methods 0.000 description 5
- -1 polyethylene Polymers 0.000 description 5
- 229920000915 polyvinyl chloride Polymers 0.000 description 5
- 239000004800 polyvinyl chloride Substances 0.000 description 5
- 238000001816 cooling Methods 0.000 description 4
- 239000011120 plywood Substances 0.000 description 4
- 229920000642 polymer Polymers 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 239000011093 chipboard Substances 0.000 description 3
- 229920001577 copolymer Polymers 0.000 description 3
- 239000004744 fabric Substances 0.000 description 3
- 239000002985 plastic film Substances 0.000 description 3
- 229920006254 polymer film Polymers 0.000 description 3
- 229920006266 Vinyl film Polymers 0.000 description 2
- 239000002826 coolant Substances 0.000 description 2
- 230000001419 dependent effect Effects 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 239000000178 monomer Substances 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 229920006255 plastic film Polymers 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 2
- BQCIDUSAKPWEOX-UHFFFAOYSA-N 1,1-Difluoroethene Chemical compound FC(F)=C BQCIDUSAKPWEOX-UHFFFAOYSA-N 0.000 description 1
- OEPOKWHJYJXUGD-UHFFFAOYSA-N 2-(3-phenylmethoxyphenyl)-1,3-thiazole-4-carbaldehyde Chemical compound O=CC1=CSC(C=2C=C(OCC=3C=CC=CC=3)C=CC=2)=N1 OEPOKWHJYJXUGD-UHFFFAOYSA-N 0.000 description 1
- 101100045546 Arabidopsis thaliana TFCE gene Proteins 0.000 description 1
- 229920002799 BoPET Polymers 0.000 description 1
- 229920002284 Cellulose triacetate Polymers 0.000 description 1
- 229920008712 Copo Polymers 0.000 description 1
- 239000005041 Mylar™ Substances 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 1
- 229920002433 Vinyl chloride-vinyl acetate copolymer Polymers 0.000 description 1
- NNLVGZFZQQXQNW-ADJNRHBOSA-N [(2r,3r,4s,5r,6s)-4,5-diacetyloxy-3-[(2s,3r,4s,5r,6r)-3,4,5-triacetyloxy-6-(acetyloxymethyl)oxan-2-yl]oxy-6-[(2r,3r,4s,5r,6s)-4,5,6-triacetyloxy-2-(acetyloxymethyl)oxan-3-yl]oxyoxan-2-yl]methyl acetate Chemical compound O([C@@H]1O[C@@H]([C@H]([C@H](OC(C)=O)[C@H]1OC(C)=O)O[C@H]1[C@@H]([C@@H](OC(C)=O)[C@H](OC(C)=O)[C@@H](COC(C)=O)O1)OC(C)=O)COC(=O)C)[C@@H]1[C@@H](COC(C)=O)O[C@@H](OC(C)=O)[C@H](OC(C)=O)[C@H]1OC(C)=O NNLVGZFZQQXQNW-ADJNRHBOSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical compound C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 description 1
- 229920002301 cellulose acetate Polymers 0.000 description 1
- 229920001727 cellulose butyrate Polymers 0.000 description 1
- 229920006184 cellulose methylcellulose Polymers 0.000 description 1
- 229920006026 co-polymeric resin Polymers 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000002596 correlated effect Effects 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- UIWXSTHGICQLQT-UHFFFAOYSA-N ethenyl propanoate Chemical compound CCC(=O)OC=C UIWXSTHGICQLQT-UHFFFAOYSA-N 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- XUCNUKMRBVNAPB-UHFFFAOYSA-N fluoroethene Chemical compound FC=C XUCNUKMRBVNAPB-UHFFFAOYSA-N 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 230000000266 injurious effect Effects 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000001923 methylcellulose Substances 0.000 description 1
- 235000010981 methylcellulose Nutrition 0.000 description 1
- 229920003052 natural elastomer Polymers 0.000 description 1
- 229920001194 natural rubber Polymers 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000000123 paper Substances 0.000 description 1
- 230000019612 pigmentation Effects 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 229920001084 poly(chloroprene) Polymers 0.000 description 1
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 238000006748 scratching Methods 0.000 description 1
- 230000002393 scratching effect Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 150000003440 styrenes Chemical class 0.000 description 1
- 229920003051 synthetic elastomer Polymers 0.000 description 1
- 239000005061 synthetic rubber Substances 0.000 description 1
- SRPWOOOHEPICQU-UHFFFAOYSA-N trimellitic anhydride Chemical compound OC(=O)C1=CC=C2C(=O)OC(=O)C2=C1 SRPWOOOHEPICQU-UHFFFAOYSA-N 0.000 description 1
- 229920001567 vinyl ester resin Polymers 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B23/00—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose
- B32B23/04—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose comprising such cellulosic plastic substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B23/08—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose comprising such cellulosic plastic substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N7/00—After-treatment, e.g. reducing swelling or shrinkage, surfacing; Protecting the edges of boards against access of humidity
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C59/00—Surface shaping of articles, e.g. embossing; Apparatus therefor
- B29C59/02—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
- B29C59/04—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts
- B29C59/046—Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing using rollers or endless belts for layered or coated substantially flat surfaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
- B31F1/07—Embossing, i.e. producing impressions formed by locally deep-drawing, e.g. using rolls provided with complementary profiles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/06—Embossing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/18—Handling of layers or the laminate
- B32B38/1866—Handling of layers or the laminate conforming the layers or laminate to a convex or concave profile
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F2201/00—Mechanical deformation of paper or cardboard without removing material
- B31F2201/07—Embossing
- B31F2201/0707—Embossing by tools working continuously
- B31F2201/0715—The tools being rollers
- B31F2201/0723—Characteristics of the rollers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F2201/00—Mechanical deformation of paper or cardboard without removing material
- B31F2201/07—Embossing
- B31F2201/0756—Characteristics of the incoming material, e.g. creped, embossed, corrugated
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F2201/00—Mechanical deformation of paper or cardboard without removing material
- B31F2201/07—Embossing
- B31F2201/0784—Auxiliary operations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2323/00—Polyalkenes
- B32B2323/04—Polyethylene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2323/00—Polyalkenes
- B32B2323/10—Polypropylene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2327/00—Polyvinylhalogenides
- B32B2327/06—PVC, i.e. polyvinylchloride
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2355/00—Specific polymers obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in a single one of index codes B32B2323/00 - B32B2333/00
- B32B2355/02—ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
- Y10T156/1007—Running or continuous length work
- Y10T156/1023—Surface deformation only [e.g., embossing]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
- Y10T156/1039—Surface deformation only of sandwich or lamina [e.g., embossed panels]
- Y10T156/1041—Subsequent to lamination
Definitions
- ABSTRACT OF THE DISCLOSURE An apparatus and process for formng a uniform embossed laminate.
- a uniform pattern is applied to the plastic lamina of a laminate by utilizing a curvilinear crown on the roll to compensate for the deflection of the embossing and backup rolls.
- the laminating process includes the steps of embossing a uniform pattern into the outer surface of a film of thermoplastic polymeric material adhered to a hard plate-like substrate by means of the embossing roll and a backup roll while the film is at an embossing temperature. After embossing, the film is rapidly cooled to set the embossed pattern.
- This invention relative to embossed plastic laminates such as wood substrate-plastic lamina, and toa method of making such embossed laminates.
- Laminates made up of a substrate, such as wood, metal, paper, and cloth, and a thermoplastic film or sheet are in common use.
- lamination has been used in the wood and Wood products industry with materials, such as plywood and hardboard to upgrade these materials by improving durability and appearance, and thereby widen their area of usefulness.
- the plastic film or sheet is normally used to impart a decorative appearance, as well as a more durable surface.
- the decoration may be simple pigmentation or grain printing or embossed patterns, such as wood grain or fabric.
- embossed film In the case of embossed film, a film of 6-10 mils gauge is used. This film can be used on ordinary quality wood substrates because a film of this thickness can bridge irregularties in the surface and cover up surface defects. This is an expensive operation because of the weight of film used per square foot of coverage, and also the problem of quality control.
- the laminating operation requires that the film be forced against the substrate by a pressure of some hundreds of lbs. per lineal inch of roll nip, and at fairly high temperatures-critical control of pressure and temperature is essential to avert loss of embossing over portions of the article, or even totally.
- the surface properties of the laminate are identical to those of the plastic film alone.
- An object of the invention is a laminate comprised of a hard substrate, such as wood, and a thermoplastic lamina having a pattern uniformly embossed thereon.
- Another object of the invention is an apparatus and process for making the above-mentioned laminate.
- ⁇ A further object of the invention is such a limaniate which does not require a smooth substrate surface.
- Another further object of the invention is a process for making such a laminate which process does not require a substrate free of surface defects, grain irregularities, irregular adhesive applications, etc.
- a preferred object of the invention is a laminate comprised of a hard substrate, especially wood substrate, and a thermoplastic film, especially a thin film, adhered to said substrate, which film has a pattern uniformly embossed in the outer surface of the film.
- Another preferred object of the invention is a process for making such a plastic film-hard substrate laminate.
- the laminated article of the invention comprises a hard substrate affording structural strength to the article and a lamina of thermoplastic polymeric material adhered to the substrate which lamina has a pattern uniformly embossed in the outer surface thereof, and which embossed pattern is present in the surface of the substrate beneath the embossed lamina.
- the process of the invention comprises introducing into an embossing zone a laminate comprising a hard platelike substrate and a lamina of thermoplastic polymeric material adhered thereto where a uniform pattern is embossed into the outer surface of the lamina; during the embossing operation, the lamina is maintained at a temperature which permits embossing the desired pattern into the surface of the lamina but does not permit strike through; and substantially immediately after the embossing operation, the embossed lamina is cooled rapidly in order to set the embossed pattern.
- the embossing zone comprises an embossing roll and a backup roll where at least one of these rolls is crowned, i.e., a crown roll.
- the embossing roll is straight and the backup roll is crowned.
- the embossing operation is carried out so as to impress into the surface of the substrate, beneath the lamina, the pattern embossed into the surface of the lamina.
- FIGURE 1 shows a schematic representation of conventional cylindrical [embosing] embossing and backup rolls in which pressure (stress) has not as yet been applied to the material to be embossed;
- FIGURE 2 shows the rolls of FIGURE 1 after embossing pressure has been applied with the deflection of the olls being exaggerated to emphasize the embossing probem encountered;
- FIGURE 3 shows a schematic representation of the rnbossing and backup rolls of the present invention unler embossing pressure with the deflection and curvilinear :rown of the rolls being exaggerated to show the present olution of the problem.
- the embossing roll 1 and the backup 011 4 are used to emboss a laminate comprising a hard vood substrate 2 and a thermoplastic .polymer film 3 adlered to the substrate.
- the rolls show no le'flection since they are not under embossing pressure r stress.
- both the embossing roll 1 and he backup roll 4 show deflection (exaggerated) since he rolls are now shown under embossing stress as they lI'GSS upon the Wood substrate 2 and the thermoplastic )olymeric film 3.
- the softened thermoplastic polymeric ilm 3 is thicker at the center of the rolls due to the delection caused by the stress applied to the roll.
- FIG- JRE 3 is shown the present solution to the problem of unevenness of the thermoplatic film during embossing.
- the backup roll 5 contains a curvilinear :rown 6 which compensates for the deflection of both the :mbossing roll 1 and the backup roll 5. Since the deflecion is compensated for, the softened thermoplastic polyneric material 3 on the hard substrate 2 is embossed :venly and uniformly during the embossing operation as .hown. Either the embossing roll, the backup roll or both olls can be crowned to compensate for the deflection. 'f a single roll is crowned, the curvilinear surface is such hat it compensates for the deflection of both rolls.
- the backup roll contains the curvilinear crown ince it is difficult to crown the embossing roll without listorting the pattern to be produced on the thermoplasic polymeric film.
- the size of the curvilinear crown an be calculated by standard engineering procedures vhen the tensile properties of the material of the roll are tnown and the pressure to be applied to the nip is known.
- the laminate introduced into the embossing operation )f the invention comprises a hard, plate-like substrate ll'ld a lamina of thermoplastic polymeric material adrered thereto. While the lamina may be formed of selfldhCSlVC plastic, commonly the substrate and the lamina ire joined by an adhesive. Typical adhesives used in makng the laminates are: natural and synthetic rubber latces, vinyl polymer emulsions, and Neoprene base adhe- :rves.
- the laminate may be completely formed before entry nto the embossing operation of the invention or the sub- .trate and lamina may, in some cases, be brought together and passed into the embossing operation substanially simultaneously.
- the substrate is a hard, plate-like material which af- Tords structural strength to the laminated article.
- the iubstrate may also be described as a hard, plate-like rigid )r semi-rigid material.
- suitable substrates are: vood materials such as plywood, hardboard-particularly lense hardboard, particle board, and chip board.
- the substrate need not be flat and smooth as recessarily required for the presently known thi'n' film aminates.
- the surface of the substrate may be mill-finish; )r have grain irregularity, dents or nicks, such as develop n storage and handling; or be made flat, smooth and/ or )urnished before the laminating operation.
- lamina is to be understood to mean a thin ayer of defined plastic lying over a substrate.
- Lamina ncludes films and sheets.
- a film is 1 lamina having a thickness of less than 10 mils and a sheet is a lamina having a thickness of at least 10 mils 1nd typically, a thin sheet is 10-20 mils thick.
- a thin ilm is generally considered to be about 14 mils thick and usually about 1.5-3 mils thick. It is preferred that the lamina be a film, desirably thin film; or a thin sheet.
- the lamina may be formed of any thermoplastic polymeric material which is capable of being formed into a film or sheet. Obviously in a particular situation the specific polymeric material must be capable of being embossed at a temperature not thermally injurious to the substrate.
- Illustrative thermoplastic polymeric materials are: acrylic solid polymer; cellulosics such as cellulose acetate, cellulose triacetate, cellulose butyrate and methyl cellulose; the fluorocarbons such as TFCE and FEP; the polyamides such as nylon; the polyesters such as Mylar, Videne and Scotchpak; the polyolefins such as polyethylene, polypropylene and copolymers thereof; the styrenes such as polystyrene and ABS polymer; and the vinyl polymers. It is to be understood the aforesaid list is not exhaustive of suitable polymers.
- thermoplastic polymeric materials for use with wood substrates are the vinyl polymers.
- the term vinyl polymers as used herein is intended to be understood according to the practice of the plastics arts, i.e., homopolymers of and copolymers including vinyl halides, vinyl esters, and vinylidene halides.
- Typical monomers are vinyl chloride, vinyl fluoride, vinyl acetate, vinyl propionate, vinylidene chloride, and vinylidene fluoride.
- other copo'lymers of interest are ethylene-vinyl chloride and ethylene-vinyl acetate.
- the polymeric materials may be used in the unplasticized or plasticized condition.
- polyvinyl chloride resin and vinyl chloride-vinyl acetate copolymer resin are of especial interest for paneling and furniture usage; it is preferred to use rigid or substantially rigid, i.e., not more than about 10% plasticizer, PVC resin or VC-VAc copolymer resin.
- the lamina may be a smooth finish lamina or an embossed lamina.
- a complex pattern may be obtained by combining an embossed lamina pattern along with the pattern on the embossing means in the embossing operation of the invention.
- the invention is especially adapted to laminates having a smooth finish, thin film lamina.
- the laminate may be any of those currently available on the market or may be a special combination of substrate and polymeric lamina. Illustrative of laminating processes now available is the Continuous Rotary Laminating Process described in Report No. 101, February 1963, The Application of Various Films to Rigid and Semi-Rigid Substrates by the Continuous Rotary Laminating Process, Process Systems, Inc., Cleveland, Ohio.
- the above defined laminate is introduced into an embossing zone wherein a uniform pattern is embossed into the Outer surface of the lamina.
- the term uniform pattern is to be understood to mean essentially the same pattern is on the embossed lamina as is present on the embossing means and the same degree, i.e., there is essentially no variation in depth and clarity of the embossed pattern over the embossed surface of the lamina.
- the embossing zone comprises embossing means for pressing the desired uniform embossed pattern into the surface of the lamina.
- embossed plate and backup plate are designed to provide the distribution of pressure which will result in the uniform pattern.
- the embossing means comprise an embossing roll and a backup roll at least one of these rolls is crowned, i.e., is a crown roll.
- the backup roll is crowned, and the embossing roll is straight.
- the amount of crown needed to afford a uniform embossed pattern is determined by the operating temperature, pressure, length of nip, type of lamina; these factors may be readily correlated by those of ordinary skill in this art.
- An important feature of this invention which is particularly beneficial when the lamina is a thin film, lies in using an embossing means designed to impress the desired pattern not only into the surface of the lamina but also into the surface (skin) of the substrate which is adjacent to the lamina.
- the embossing operation of the invention is carried out at a temperature which permits embossing the pattern therein but does not permit strike throughcreating holes in the lamina.
- the temperature is dependent on the particular lamina and to some extent the pressure being used. Commonly, the embossing temperature will be at least about 150 F.
- the defined laminate may be introduced into the embossing zone at ordinary temperatures and be brought to the desired embossing temperature through the hot embossing means. However, it is more convenient to introduce a heated lamina surface-at about the embossing temperature.
- the embossing operation of the invention will follow substantially immediately after the defined laminate has been produced; the defined laminate while still at about laminating temperature is introduced into the embossing zone.
- the defined laminate is taken from storage at ordinary temperature. preferably it is preheated before introduction into the embossing zone.
- the embossing operation is carried out at a pressure great enough to impress the pattern into the outer surface of the lamina.
- the pressure is great enough to not only emboss the lamina but also to impress the pattern into the surface (skin) of the substrate beneath the lamina. This pressure is dependent on the nature of the substrate, the embossing temperature, and to some extent, the nature of the lamina.
- the hot embossed pattern is set by rapidly cooling the embossed lamina substantially immediately after the embossing operation. It is preferred to cool by flooding, e.g. by a shower spray, the embossed surface with a liquid which is inert to the lamina. Liquid water is a suitable coolant. For many uses, a protective wax film is desirable over the embossed lamina. A wax finish is easily imparted to the embossed lamina by using as the coolant a water base-wax emulsion. The water is evaporated leaving a wax finish on the surface of the embossed pattern.
- the substrate is a wood material, such as plywood, hardboard, particle board or chip board
- the lamina is a smooth surface vinyl polymer film.
- the embossing means comprises an embossing roll and a backup roll, at least one of which rolls in a crown roll; it is convenient to use a straight embossing roll and a crowned backup roll.
- the film is introduced into the embossing zone at the embossing temperature of about 200250 F.
- the pattern is embossed into the film and pressed into the surface (skin) of the substrate beneath the fihn by applying an embossing pressure of about 40006000 lbs. per lineal inch of nip of said rolls.
- the hot embossed lamina is rapidly cooled to set the pattern by flooding the embossed lamina after it leaves the rolls with a water basewax emulsion. Water is sucked from the surface to leave a wax finish embossed lamina where the pattern is uniformly embossed into the lamina surface and the skin of the substrate beneath the lamina.
- the embossing roll was heavy wall construction, approximately 12 inches in diameter and the roll was run at laminate speeds of 1020 feet per minute.
- the pressure varied somewhat with the density of the hardboard but was around 5,000 lbs. per lineal inch of nip.
- the backup roll was a heavy wall steel cushion roll, 12 inches in diameter.
- the backup roll was crowned 22 mils (0.022) in a 48 inch nip; this is twice the calculated deflection of the embossing roll. This pressure and crown provided a nembossing nip of uniform opening during production of the embossed laminate and gave a uniform pattern over the nip of the laminate.
- the hot embossed laminate was quenched to set the pattern with water base-wax emulsion, applied at room temperature.
- the laminates produced as above had a finished wood grain appearance, closely resembling quarter-cut oak; the film was tough and very resistant to scoring and scratching; none of the surface characteristics present in the substrate and visible in the smooth laminate were evident in the embossed laminate. Tests run with chip board gave the same high quality surface appearance of the laminate.
- a process for making an embossed laminate which comprises:
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Abstract
AN APPARATUS AND PROCESS FOR FORMING A UNIFORM EMBOSSED LAMINATE. A UNIFORM PATTERN IS APPLIED TO THE PLASTIC LAMINA OF A LAMINATE BY UTILIZING A CURVILINEAR CROWN ON THE ROLL TO COMPENSATE FOR THE DEFLECTION OF THE EMBOSSING AND BACKUP ROLLS. THE LAMINATING PROCESS INCLUDES THE STEPS OF EMBOSSING A UNIFORM PATTERN INTO THE OUTER SURFACE OF A FILM OF THERMOPLASTIC POLYMRIC MATERIAL ADHERED
TO A HARD PLATE-LIKE SUBSTRATE BY MEANS OF THE EMBOSSING ROLL AND A BACKUP ROLL WHILE THE FILM IS AT AN EMBOSSING TEMPERATUE. AFTER EMBOSSING, THE FILM IS RAPIDLY COOLED TO SET THE EMBOSSED PATTERN.
TO A HARD PLATE-LIKE SUBSTRATE BY MEANS OF THE EMBOSSING ROLL AND A BACKUP ROLL WHILE THE FILM IS AT AN EMBOSSING TEMPERATUE. AFTER EMBOSSING, THE FILM IS RAPIDLY COOLED TO SET THE EMBOSSED PATTERN.
Description
0d. 26, 1971 MH'TMAN Re. 27,201
APPARATUS AND PROCESS FOR PRODUCING AN EMBOSSED PLASTIC LAMINATE Original Filed Dec. 27. 1967 mw mw W WW INVENTOR 6 EMANUEL MITTMAN BY fw 7&4
United States Patent 27,201 APPARATUS AND PROCESS FOR PRODUCING AN EMBOSSED PLASTIC LAMINATE Emanuel Mittman, Forest Hills, N.Y., assignor to W. R. Grace & Co., New York, N.Y. Original No. 3,483,057, dated Dec. 9, 1969, Ser. No. 693,774, Dec. 27, 1967, which is a continuation-in-part of Ser. No. 354,797, Mar. 25, 1964. Application for reissue Apr. 23, 1970, Ser. No. 31,396
Int. Cl. B31f 1/10 US. Cl. 156-209 Claims Matter enclosed in heavy brackets II] appears in the original patent but forms no part of this reissue specification; matter printed in italics indicates the additions made by reissue.
ABSTRACT OF THE DISCLOSURE An apparatus and process for formng a uniform embossed laminate. A uniform pattern is applied to the plastic lamina of a laminate by utilizing a curvilinear crown on the roll to compensate for the deflection of the embossing and backup rolls. The laminating process includes the steps of embossing a uniform pattern into the outer surface of a film of thermoplastic polymeric material adhered to a hard plate-like substrate by means of the embossing roll and a backup roll while the film is at an embossing temperature. After embossing, the film is rapidly cooled to set the embossed pattern.
This application is a continnation-in-part of US. Ser. No. 354,797, filed Mar. 25, 1964, now abandoned.
This invention relative to embossed plastic laminates such as wood substrate-plastic lamina, and toa method of making such embossed laminates.
Laminates made up of a substrate, such as wood, metal, paper, and cloth, and a thermoplastic film or sheet are in common use. In recent years lamination has been used in the wood and Wood products industry with materials, such as plywood and hardboard to upgrade these materials by improving durability and appearance, and thereby widen their area of usefulness.
While clear films and sheets have been laminated to furniture quality wood for protective purposes, the plastic film or sheet is normally used to impart a decorative appearance, as well as a more durable surface. The decoration may be simple pigmentation or grain printing or embossed patterns, such as wood grain or fabric.
In the case of embossed film, a film of 6-10 mils gauge is used. This film can be used on ordinary quality wood substrates because a film of this thickness can bridge irregularties in the surface and cover up surface defects. This is an expensive operation because of the weight of film used per square foot of coverage, and also the problem of quality control. The laminating operation requires that the film be forced against the substrate by a pressure of some hundreds of lbs. per lineal inch of roll nip, and at fairly high temperatures-critical control of pressure and temperature is essential to avert loss of embossing over portions of the article, or even totally. In these thick film embossed laminates, the surface properties of the laminate are identical to those of the plastic film alone.
Efforts have been made to use thin films of 1-3 mils gauge in wood substrate lamination. Because of the thinness of the film, even with pigmented film or printed, the surface defects of the substrate are visible. It has been necessary with thin film laminates to use only the highest quality wood substrates. Substrate defects such as chatter marks, irrgular fiber patterns, surface defects, etc. must be removed by abrasion and polishing or burnishing im- Re. 27,201 Reissuecl Oct. 26, 1971 mediately before lamination. The thin film laminates have been limited to smooth films because the laminating nip remove any embossing pressed into the film before the lamination operation.
Efforts have been made to emboss the thin film after lamination but these have been unsuccessful. It has not been possible to produce a laminate having a uniformly embossed pattern over the surface of the film. The conventional cylindrical embossing rolls give irregular distribution of the pattern and depth of the embossing.
In architectural and furniture use of these plastic laminates, the appearance of an actual wood grain in the embossed surface has made the thick film laminates preeminent. The smooth surfaced, printed grain, thin film laminates have been relegated to secondary and lower grade uses.
An object of the invention is a laminate comprised of a hard substrate, such as wood, and a thermoplastic lamina having a pattern uniformly embossed thereon. Another object of the invention is an apparatus and process for making the above-mentioned laminate.
\A further object of the invention is such a limaniate which does not require a smooth substrate surface. Another further object of the invention is a process for making such a laminate which process does not require a substrate free of surface defects, grain irregularities, irregular adhesive applications, etc.
A preferred object of the invention is a laminate comprised of a hard substrate, especially wood substrate, and a thermoplastic film, especially a thin film, adhered to said substrate, which film has a pattern uniformly embossed in the outer surface of the film. Another preferred object of the invention is a process for making such a plastic film-hard substrate laminate.
Other objects of the invention will become apparent in the course of the detailed description of the invention.
The laminated article of the invention comprises a hard substrate affording structural strength to the article and a lamina of thermoplastic polymeric material adhered to the substrate which lamina has a pattern uniformly embossed in the outer surface thereof, and which embossed pattern is present in the surface of the substrate beneath the embossed lamina.
The process of the invention comprises introducing into an embossing zone a laminate comprising a hard platelike substrate and a lamina of thermoplastic polymeric material adhered thereto where a uniform pattern is embossed into the outer surface of the lamina; during the embossing operation, the lamina is maintained at a temperature which permits embossing the desired pattern into the surface of the lamina but does not permit strike through; and substantially immediately after the embossing operation, the embossed lamina is cooled rapidly in order to set the embossed pattern.
In the preferred embodiment of the process invention, the embossing zone comprises an embossing roll and a backup roll where at least one of these rolls is crowned, i.e., a crown roll. Desirably the embossing roll is straight and the backup roll is crowned.
In another preferred embodiment, the embossing operation is carried out so as to impress into the surface of the substrate, beneath the lamina, the pattern embossed into the surface of the lamina.
The invention will now be more specifically described with reference to the drawings in which:
FIGURE 1 shows a schematic representation of conventional cylindrical [embosing] embossing and backup rolls in which pressure (stress) has not as yet been applied to the material to be embossed;
FIGURE 2 shows the rolls of FIGURE 1 after embossing pressure has been applied with the deflection of the olls being exaggerated to emphasize the embossing probem encountered; and
FIGURE 3 shows a schematic representation of the rnbossing and backup rolls of the present invention unler embossing pressure with the deflection and curvilinear :rown of the rolls being exaggerated to show the present olution of the problem.
' In each of the figures, the center line of each roll shows he amount of the deflection of the roll.
In FIGURE 1 the embossing roll 1 and the backup 011 4 are used to emboss a laminate comprising a hard vood substrate 2 and a thermoplastic .polymer film 3 adlered to the substrate. In FIGURE 1 the rolls show no le'flection since they are not under embossing pressure r stress. In FIGURE 2 both the embossing roll 1 and he backup roll 4 show deflection (exaggerated) since he rolls are now shown under embossing stress as they lI'GSS upon the Wood substrate 2 and the thermoplastic )olymeric film 3. The softened thermoplastic polymeric ilm 3 is thicker at the center of the rolls due to the delection caused by the stress applied to the roll. In FIG- JRE 3 is shown the present solution to the problem of unevenness of the thermoplatic film during embossing.
In FIGURE 3 the backup roll 5 contains a curvilinear :rown 6 which compensates for the deflection of both the :mbossing roll 1 and the backup roll 5. Since the deflecion is compensated for, the softened thermoplastic polyneric material 3 on the hard substrate 2 is embossed :venly and uniformly during the embossing operation as .hown. Either the embossing roll, the backup roll or both olls can be crowned to compensate for the deflection. 'f a single roll is crowned, the curvilinear surface is such hat it compensates for the deflection of both rolls. Pref- :rably, the backup roll contains the curvilinear crown ince it is difficult to crown the embossing roll without listorting the pattern to be produced on the thermoplasic polymeric film. The size of the curvilinear crown :an be calculated by standard engineering procedures vhen the tensile properties of the material of the roll are tnown and the pressure to be applied to the nip is known.
The laminate introduced into the embossing operation )f the invention comprises a hard, plate-like substrate ll'ld a lamina of thermoplastic polymeric material adrered thereto. While the lamina may be formed of selfldhCSlVC plastic, commonly the substrate and the lamina ire joined by an adhesive. Typical adhesives used in makng the laminates are: natural and synthetic rubber latces, vinyl polymer emulsions, and Neoprene base adhe- :rves.
The laminate may be completely formed before entry nto the embossing operation of the invention or the sub- .trate and lamina may, in some cases, be brought together and passed into the embossing operation substanially simultaneously.
The substrate is a hard, plate-like material which af- Tords structural strength to the laminated article. The iubstrate may also be described as a hard, plate-like rigid )r semi-rigid material. Especially suitable substrates are: vood materials such as plywood, hardboard-particularly lense hardboard, particle board, and chip board.
An important advantage of the process of the invenion is that the substrate need not be flat and smooth as recessarily required for the presently known thi'n' film aminates. The surface of the substrate may be mill-finish; )r have grain irregularity, dents or nicks, such as develop n storage and handling; or be made flat, smooth and/ or )urnished before the laminating operation.
The term lamina is to be understood to mean a thin ayer of defined plastic lying over a substrate. Lamina ncludes films and sheets. In the plastics art, a film is 1 lamina having a thickness of less than 10 mils and a sheet is a lamina having a thickness of at least 10 mils 1nd typically, a thin sheet is 10-20 mils thick. A thin ilm is generally considered to be about 14 mils thick and usually about 1.5-3 mils thick. It is preferred that the lamina be a film, desirably thin film; or a thin sheet.
The lamina may be formed of any thermoplastic polymeric material which is capable of being formed into a film or sheet. Obviously in a particular situation the specific polymeric material must be capable of being embossed at a temperature not thermally injurious to the substrate. Illustrative thermoplastic polymeric materials are: acrylic solid polymer; cellulosics such as cellulose acetate, cellulose triacetate, cellulose butyrate and methyl cellulose; the fluorocarbons such as TFCE and FEP; the polyamides such as nylon; the polyesters such as Mylar, Videne and Scotchpak; the polyolefins such as polyethylene, polypropylene and copolymers thereof; the styrenes such as polystyrene and ABS polymer; and the vinyl polymers. It is to be understood the aforesaid list is not exhaustive of suitable polymers.
An especially suitable class of thermoplastic polymeric materials for use with wood substrates are the vinyl polymers. The term vinyl polymers as used herein is intended to be understood according to the practice of the plastics arts, i.e., homopolymers of and copolymers including vinyl halides, vinyl esters, and vinylidene halides. Typical monomers are vinyl chloride, vinyl fluoride, vinyl acetate, vinyl propionate, vinylidene chloride, and vinylidene fluoride. In addition to the copolymers of these monomers other copo'lymers of interest are ethylene-vinyl chloride and ethylene-vinyl acetate.
In general, the polymeric materials may be used in the unplasticized or plasticized condition. In the case of the vinyl polymers, polyvinyl chloride resin and vinyl chloride-vinyl acetate copolymer resin are of especial interest for paneling and furniture usage; it is preferred to use rigid or substantially rigid, i.e., not more than about 10% plasticizer, PVC resin or VC-VAc copolymer resin.
The lamina may be a smooth finish lamina or an embossed lamina. A complex pattern may be obtained by combining an embossed lamina pattern along with the pattern on the embossing means in the embossing operation of the invention. The invention is especially adapted to laminates having a smooth finish, thin film lamina.
The laminate may be any of those currently available on the market or may be a special combination of substrate and polymeric lamina. Illustrative of laminating processes now available is the Continuous Rotary Laminating Process described in Report No. 101, February 1963, The Application of Various Films to Rigid and Semi-Rigid Substrates by the Continuous Rotary Laminating Process, Process Systems, Inc., Cleveland, Ohio.
The above defined laminate is introduced into an embossing zone wherein a uniform pattern is embossed into the Outer surface of the lamina. The term uniform pattern is to be understood to mean essentially the same pattern is on the embossed lamina as is present on the embossing means and the same degree, i.e., there is essentially no variation in depth and clarity of the embossed pattern over the embossed surface of the lamina.
The embossing zone comprises embossing means for pressing the desired uniform embossed pattern into the surface of the lamina. In a plate press, the embossed plate and backup plate are designed to provide the distribution of pressure which will result in the uniform pattern.
It is preferred that the embossing means comprise an embossing roll and a backup roll at least one of these rolls is crowned, i.e., is a crown roll. Conveniently, the backup roll is crowned, and the embossing roll is straight. The amount of crown needed to afford a uniform embossed pattern is determined by the operating temperature, pressure, length of nip, type of lamina; these factors may be readily correlated by those of ordinary skill in this art.
An important feature of this invention which is particularly beneficial when the lamina is a thin film, lies in using an embossing means designed to impress the desired pattern not only into the surface of the lamina but also into the surface (skin) of the substrate which is adjacent to the lamina.
This impressing of the embossed pattern into the skin of the substrate results in several unexpected benefits, among which are: A far stronger bond between the substrate and the embossed lamina than existed in defined laminate. A reorientation of the skin of the substrate that eliminates grain irregularities and other surface defects; the appearance of the laminate is equally as good with ordinary wood material substrate as with a smooth, burnished substrate. A hardening of the lamina, i.e., the embossed lamina is much more resistant to scuffing and scoruing than the defined adhered lamina or the lamina before adhesion to the substrate. In the case of a wood grain embossed pattern, this film-hard board laminate of the invention, a more realistic appearance and feel are present than in a conventional thick fihn embossed laminate. The advantages make this particular embodiment of the laminate of the invention especially suitable for furniture.
The embossing operation of the invention is carried out at a temperature which permits embossing the pattern therein but does not permit strike throughcreating holes in the lamina. The temperature is dependent on the particular lamina and to some extent the pressure being used. Commonly, the embossing temperature will be at least about 150 F.
The defined laminate may be introduced into the embossing zone at ordinary temperatures and be brought to the desired embossing temperature through the hot embossing means. However, it is more convenient to introduce a heated lamina surface-at about the embossing temperature.
In a preferred embodiment of the process the embossing operation of the invention will follow substantially immediately after the defined laminate has been produced; the defined laminate while still at about laminating temperature is introduced into the embossing zone.
If the defined laminate is taken from storage at ordinary temperature. preferably it is preheated before introduction into the embossing zone.
The embossing operation is carried out at a pressure great enough to impress the pattern into the outer surface of the lamina. In the preferred operation the pressure is great enough to not only emboss the lamina but also to impress the pattern into the surface (skin) of the substrate beneath the lamina. This pressure is dependent on the nature of the substrate, the embossing temperature, and to some extent, the nature of the lamina.
The hot embossed pattern is set by rapidly cooling the embossed lamina substantially immediately after the embossing operation. It is preferred to cool by flooding, e.g. by a shower spray, the embossed surface with a liquid which is inert to the lamina. Liquid water is a suitable coolant. For many uses, a protective wax film is desirable over the embossed lamina. A wax finish is easily imparted to the embossed lamina by using as the coolant a water base-wax emulsion. The water is evaporated leaving a wax finish on the surface of the embossed pattern.
In a preferred embodiment of the invention, the substrate is a wood material, such as plywood, hardboard, particle board or chip board, and the lamina is a smooth surface vinyl polymer film. The embossing means comprises an embossing roll and a backup roll, at least one of which rolls in a crown roll; it is convenient to use a straight embossing roll and a crowned backup roll. Desirably the film is introduced into the embossing zone at the embossing temperature of about 200250 F. The pattern is embossed into the film and pressed into the surface (skin) of the substrate beneath the fihn by applying an embossing pressure of about 40006000 lbs. per lineal inch of nip of said rolls. The hot embossed lamina is rapidly cooled to set the pattern by flooding the embossed lamina after it leaves the rolls with a water basewax emulsion. Water is sucked from the surface to leave a wax finish embossed lamina where the pattern is uniformly embossed into the lamina surface and the skin of the substrate beneath the lamina.
ILLUSTRATION Smooth, rigid polyvinyl chloride resin film, standard 2 mils gauge printed to resemble stained wood laminated to a dense hardboard substrate was embossed with patterns such as, quarter cut oak grain and coarse woven fabric, like monks cloth. The embossing temperature was around 225 F. and the smooth laminate was preheated to in the region 200-250 F.
The embossing roll was heavy wall construction, approximately 12 inches in diameter and the roll was run at laminate speeds of 1020 feet per minute. The pressure varied somewhat with the density of the hardboard but was around 5,000 lbs. per lineal inch of nip.
The backup roll was a heavy wall steel cushion roll, 12 inches in diameter. The backup roll was crowned 22 mils (0.022) in a 48 inch nip; this is twice the calculated deflection of the embossing roll. This pressure and crown provided a nembossing nip of uniform opening during production of the embossed laminate and gave a uniform pattern over the nip of the laminate.
The hot embossed laminate was quenched to set the pattern with water base-wax emulsion, applied at room temperature.
The laminates produced as above had a finished wood grain appearance, closely resembling quarter-cut oak; the film was tough and very resistant to scoring and scratching; none of the surface characteristics present in the substrate and visible in the smooth laminate were evident in the embossed laminate. Tests run with chip board gave the same high quality surface appearance of the laminate.
These embossed thin film laminates are suitable for the most exacting structural and furniture usages.
What is claimed is:
1. A process for making an embossed laminate which comprises:
(A) adhesively applying to a surface of as substrate formed of a wood material, a smooth surfaced vinyl polymer film to form a laminate of polymer film to wood;
(B) passing said laminate into an embossing means having an. embossing roll and a backup roll, at least one of said rolls having a curvilinear crown;
(C) embossing the film portion of the laminate while said film is at a temperature of at least about F. and less than the strike through temperature by contacting said film with said embossing roll under an embossing pressure of about 4000-6000 pounds per linear inch of nip of said rolls, said pressure sufficient to impress into the surface of said substrate the pattern embossed into the film;
(D) substantially immediately after embossing, cooling said embossed film with water or a water base-wax emulsion to set the pattern embossed in said film.
2. The process of claim 1 wherein the film temperature is about 200 F.25 0 F.
3. The process of claim 1 wherein the film has a thickness of 2 mils gauge.
4. The process of claim 1 wherein the wood material is plywood.
5. The process of claim 1 wherein the wood material is hardboard.
6. The process of claim 1 wherein the vinyl :film is polyvinyl chloride resin film.
7. The process of claim 1 wherein the vinyl film has a printed surface to resemble stained wood.
8. The process of claim 1 wherein the backup roll has a 12 inch diameter, and a crowned surface of 22 mils in a 48 inch nip.
9. The process of claim 1 wherein the backup r011 has :laim 1.
10. A process for making an embossed laminate which -mprises:
(A) adhesively applying to a surface of a substrate formed of a wood material, a smooth surfaced vinyl polymer lamina to form a laminate of polymer lamina to wood; 7
(B) passing said laminate into an embossing means having an embossing roll and backup roll, at least one of said rolls having a curvilinear crown,
(C) embossing the film portion of the laminate while said film is at a temperature of at last about 150 F. and less than the strike through temperature by contacting said film with said embossing roll under an embossing pressure of about 4000-6000 pounds per linear inch of nip of said rolls, said pressure sufficient to impress into the surface of said substrate the pattern embossed into the film;
(D) substantially immediately after embossing, cooling said embossed film to set the pattern embossed in said film.
1]. A process for making an embossed laminate which romprises:
(A) adhesively applying to a surface of a substrate formed of a wood material, a smooth surfaced vinyl polymer film to form a laminate of polymer film to wood;
(B) passing said laminate into an embossing means having an embossing roll and a backup roll, at least one of said rolls having a curvilinear crown;
(C) embossing the film portion of the laminate while said film is at a temperature less than the strike through temperature by contacting said film with said embossing roll under an embossing pressure of about 40006000 pounds per linear inch of nip of said rolls, said pressure sufiicient to impress into the surface of said substrate the pattern embossed into the film; and
(D) substantially immediately after embossing, cooling said embossed film to set the pattern embossed in said film.
12. The process of claim 11 wherein the film temperature is about 200 F.Z F.
13. The process of claim 11 wherein the film has a thickness of 2 mils gauge.
14. The process of claim 11 wherein the vinyl film is polyvinyl chloride resin film.
15. The process of claim 11 wherein the backup roll has a 12 inch diameter, and a crowned surface of 22 mils in a 48-inch nip.
References Cited The following references, cited by the Examiner, are of record in the patented file of this patent or the original patent.
UNITED STATES PATENTS OTHER REFERENCES Waldron Embossing Machines, John Waldron Corp., pp. 3, 5, 7, 8 and 9, received U.S. Patent Office May 13, 1952.
BENJAMIN A. BORCHELT, Primary Examiner G. E. MONTO'NE, Assistant Examiner U.S. Cl. X.R.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US69377467A | 1967-12-27 | 1967-12-27 | |
US3139670A | 1970-04-23 | 1970-04-23 |
Publications (1)
Publication Number | Publication Date |
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USRE27201E true USRE27201E (en) | 1971-10-26 |
Family
ID=26707191
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US693774A Expired - Lifetime US3483057A (en) | 1967-12-27 | 1967-12-27 | Apparatus and process for producing an embossed plastic laminate |
US27201D Expired USRE27201E (en) | 1967-12-27 | 1970-04-23 | Apparatus and process for producing an embossed plastic laminate |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US693774A Expired - Lifetime US3483057A (en) | 1967-12-27 | 1967-12-27 | Apparatus and process for producing an embossed plastic laminate |
Country Status (1)
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US (2) | US3483057A (en) |
Cited By (4)
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US20030159600A1 (en) * | 2001-12-21 | 2003-08-28 | Ruthven Paul J. | Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength |
US20050092195A1 (en) * | 2001-12-21 | 2005-05-05 | Fort James Corporation | Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength |
US20050173085A1 (en) * | 2004-02-11 | 2005-08-11 | Schulz Galyn A. | Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength |
US8178025B2 (en) | 2004-12-03 | 2012-05-15 | Georgia-Pacific Consumer Products Lp | Embossing system and product made thereby with both perforate bosses in the cross machine direction and a macro pattern |
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DE3900294A1 (en) * | 1989-01-07 | 1990-07-12 | Kuesters Eduard Maschf | PRINT CALENDAR |
NL9401818A (en) * | 1994-11-02 | 1996-06-03 | Houthandel Lambert Van Den Bos | Method, device and embossing roller to pattern a fiberboard surface. |
DE19718771A1 (en) * | 1997-05-03 | 1998-11-05 | Dieffenbacher Gmbh Maschf | Procedure for manufacture of derived timber product board, such as chip board and fibre board |
DE19718770A1 (en) * | 1997-05-03 | 1998-11-05 | Dieffenbacher Gmbh Maschf | Procedure for manufacture of structured surfaces of cold derived timber product board |
BE1013553A3 (en) | 2000-06-13 | 2002-03-05 | Unilin Beheer Bv | Floor covering. |
BE1018753A3 (en) * | 2009-05-11 | 2011-08-02 | Flooring Ind Ltd Sarl | LAMINATE PANEL AND METHODS FOR MANUFACTURING LAMINATE PANELS. |
LT2339092T (en) | 2009-12-22 | 2019-07-25 | Flooring Industries Limited, Sarl | Method for producing covering panels |
BE1019331A5 (en) | 2010-05-10 | 2012-06-05 | Flooring Ind Ltd Sarl | FLOOR PANEL AND METHODS FOR MANUFACTURING FLOOR PANELS. |
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Family Cites Families (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2306046A (en) * | 1939-05-12 | 1942-12-22 | Carbide & Carbon Chem Corp | Composite structure |
US2551005A (en) * | 1946-12-04 | 1951-05-01 | Goodrich Co B F | Surface finishing thermoplastic materials |
US2662002A (en) * | 1951-02-14 | 1953-12-08 | Frederick A Sunderhauf | Method of embossing rolls |
US2666726A (en) * | 1951-04-21 | 1954-01-19 | Crown Zellerbach Corp | Method of making masked lignocellulosic material |
US2759866A (en) * | 1952-12-17 | 1956-08-21 | Gen Tire & Rubber Co | Method of making wall covering |
US3150031A (en) * | 1960-07-13 | 1964-09-22 | Congoleum Nairn Inc | Article and method of making resilient floor covering having air pockets |
US3022207A (en) * | 1961-02-08 | 1962-02-20 | Abiti Power & Paper Company Lt | Method of producing decorative wall panels with prefinished score lines |
US3121642A (en) * | 1961-09-29 | 1964-02-18 | Congoleum Nairn Inc | Process for producing decorative surface covering |
US3305419A (en) * | 1962-03-28 | 1967-02-21 | Allied Chem | Method of producing an embossed panel |
US3180779A (en) * | 1962-11-14 | 1965-04-27 | Congoleum Nairn Inc | Decorative surface coverings and process for producing them |
US3239365A (en) * | 1963-04-29 | 1966-03-08 | Congoleum Nairn Inc | Resilient decorative surface covering and method of making same |
-
1967
- 1967-12-27 US US693774A patent/US3483057A/en not_active Expired - Lifetime
-
1970
- 1970-04-23 US US27201D patent/USRE27201E/en not_active Expired
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US8142617B2 (en) | 1999-11-12 | 2012-03-27 | Georgia-Pacific Consumer Products Lp | Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength |
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US20050092195A1 (en) * | 2001-12-21 | 2005-05-05 | Fort James Corporation | Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength |
US7182838B2 (en) | 2001-12-21 | 2007-02-27 | Georgia Pacific Corporation | Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength |
US20030159600A1 (en) * | 2001-12-21 | 2003-08-28 | Ruthven Paul J. | Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength |
US7857941B2 (en) | 2001-12-21 | 2010-12-28 | Georgia-Pacific Consumer Products Lp | Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength |
US6887349B2 (en) * | 2001-12-21 | 2005-05-03 | Fort James Corporation | Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength |
US20050173085A1 (en) * | 2004-02-11 | 2005-08-11 | Schulz Galyn A. | Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength |
US7297226B2 (en) | 2004-02-11 | 2007-11-20 | Georgia-Pacific Consumer Products Lp | Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength |
US7799176B2 (en) | 2004-02-11 | 2010-09-21 | Georgia-Pacific Consumer Products Lp | Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength |
US8287694B2 (en) | 2004-02-11 | 2012-10-16 | Georgia-Pacific Consumer Products Lp | Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength |
US8535481B2 (en) | 2004-02-11 | 2013-09-17 | Georgia-Pacific Consumer Products Lp | Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength |
US8178025B2 (en) | 2004-12-03 | 2012-05-15 | Georgia-Pacific Consumer Products Lp | Embossing system and product made thereby with both perforate bosses in the cross machine direction and a macro pattern |
US8647105B2 (en) | 2004-12-03 | 2014-02-11 | Georgia-Pacific Consumer Products Lp | Embossing system and product made thereby with both perforate bosses in the cross machine direction and a macro pattern |
Also Published As
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US3483057A (en) | 1969-12-09 |
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