WO2000061385A1

WO2000061385A1 - Improvement in decoration plate and its manufacturing process

Info

Publication number: WO2000061385A1
Application number: PCT/BR2000/000012
Authority: WO
Inventors: Flavio Maluf
Original assignee: Eucatex S/A Industria E Comercio
Priority date: 1999-04-07
Filing date: 2000-02-10
Publication date: 2000-10-19
Also published as: AR022902A1; BR9901043A

Abstract

Improvement in decoration plate and its manufacturing process, involving a central part defined as plate itself (1) in any thickness, which top and bottom surfaces are flat, where the top one is coated by a decorative paper (2) impregnated with a melamine resin and, on the top of this layer, is placed another coating of pure cellulose film (3), while the opposite face or bottom surface of the plate (1) is covered by a paper of high thickness/weight (4), equally impregnated with melamine resin.

Description

Descriptive report related to the invention patent "IMPROVEMENT IN DECORATION PLATE AND ITS MANUFACTURING PROCESS", or most particularly the invention hereof is related to technical and functional enhancements specially developed in the view of the characterization of means to form wooden decorating plates and its similar thereof, in a way that at least one of its surfaces can, in the end of the process, have an appearance perfectly finished and with a greater surface resistance, becoming an ideal product for different commercial, residential or industrial applications, such as, for example in the manufacture of table plates, counters and others, that for one reason or other, demand a greater superficial resistance.

This way, one objective of the present invention is to provide a product in the shape of a plate formed by various layers of different materials, matching elements with proper characteristics that, in the set, result in different technical and functional effects, namely related to the surface resistance, as well as it presents itself in the shape of a finished product, related to use and, in its application, few industrial operations are performed, just executing trims or smaller details for the plate to be in a shape and size fitted to its final application.

One of the main characteristics of the plate subjects of the invention is the fact that it can be formed by a substrate in the shape of a plate of mass, compensated and similar, which finished surface is defined by a paper previously decorated in patterned with different textures, drawings or other various ornamental motives, such as: wood, rocks, and/or others, so that, such paper is impregnated with a melanin resin without aluminum oxide and covered by a film of pure cellulose also impregnated with melanin resin, finalizing this way, a flat and highly resistant surface.

For a better comprehension of the present invention, it is further made a detailed description of the invention, referring to the enclosed drawings, where:

FIGURA 1 : represents a view schematically showing the cross section of the referred plate.

According to the illustration above, and in its details, the present inventive DECORATING PLATE, is characterized by the fact that it embodies a central part defined as the plate itself (1 ) in any thickness, which top and bottom surfaces are flat, where the superior is coated by a decorative paper (2) impregnated with a melanin resin and, on top of this layer, is placed another coating of pure cellulose film (3), while the opposite face or the bottom side of the plate (1 ) is coated with a paper of high thickness (4), in the same way impregnated with melanin resin.

The plate (1 ) is constituted by an structural substrate of mass, hard wood, compensated or similar, including all those materials resulting from the processes involving wood. The MANUFACTURING PROCESS OF THE

DECORATIVE PLATE, above is characterized by the fact that it involves the following steps: a) preparation of an intermediate structural layer in the shape of the plate itself (1 ), that constitutes a mass substrate, a wooden sheet or other kind of material resulting from the process involving wood; b) preparation of a decorative paper (2); c) preparation of a pure cellulose coating film (3); d) preparation of a balance bottom coating (4); e) impregnation of the decorative paper (2) with a proper melanin resin; f) application of the impregnated decorative paper (2) on the top surface of the plate (1 ); g) application of a pure cellulose film (3), also impregnated with melanin resin, over the decorative paper layer (2); e h) application of the high thickness paper (4) also impregnated with melanin resin on the bottom surface of the plate (1 ), for the formation of a coating to counter balance the stress on the said plate (1 ).

The applications of the different layers are obtained by stages of quick cycle pressing, where through a pressure that can vary from 18 to 30 Kg/cm², with a temperature between 170 and 200°C and 20 to 45 seconds cycle, in presses of single or multi steps.

The weight of the decorative paper varies from 50 to 120 g/m², containing, according to its high absorption capacity, from 75 to 150% by weight of resin over the paper original weight. The decorative paper (2) can be an overlay paper, which weight may vary from 27 to 67 g/m², containing from 150 to 400% by weight of resin over its original weight.

The balance coating (4) is preferably a high weight/thickness paper, as an absorbing Kraft paper with a weight varying between 100 and 180 g/m² with a content of melanin, urea or phenol resin in the order of 75 to 150% by weight.

The melanin resin used is of the kind produced by the condensation of melanin and added phormaldeide with productsd that conferees characteristics to the press process, as well as its elasticity, flow rate and hardening level are obtained through these adds.

According to what is noticed, further to what has been shown and illustrated, we note that the main characteristic of the product in question is its surface resistance with any of the used substrates.

Other important factor of the present invention related to the products known by the art, is the advantage of having the final product stratified in only one phase of short press cycles.

The plate in question, as already cited, presents itself in its finished shape, being a great product for the furniture manufactures, since this producer has the availability of a plate to assemble different products, eliminating the intermediate phases of different coatings sticking and pressing on the substrate and consequently, the furniture manufacturing process is simplified.

On the other hand, the plate before mentioned can also be used to coat vertical surfaces.

It shall be mentioned that the present process can be performed for the configuration of plates of various wideness.

Claims

CLAIMSWhat is claimed is:

1. IMPROVEMENT IN DECORATION PLATE AND ITS MANUFACTURING PROCESS, characterized by embodying a central part defined as plate itself (1 ) of any thickness, which top an bottom surfaces are flat, where the top surface is coated by a decorative paper (2) impregnated with a melamine resin and on top of this cover is placed another pure cellulose film coating (3), while its opposite face or bottom surface of the plate (1 ) is coated with a high weight/thickness paper (4), in the same way impregnated with melamine resin.

2. IMPROVEMENT IN DECORATION PLATE AND ITS MANUFACTURING PROCESS, according to claim 1 , characterized by the fact that the plate (1 ) is construed by a mass structural substrate, hard wood, compensated, or similar, including al those materials resulting from the processes involving wood.

3. IMPROVEMENT IN DECORATION PLATE AND ITS MANUFACTURING PROCESS, characterized by comprehending the following steps: a) preparation of an intermediate structural layer in the shape of the plate itself (1 ), that constitutes a mass substrate, a wooden sheet or other kind of material resulting from the process involving wood; b) preparation of a decorative paper (2); c) preparation of a pure cellulose coating film (3); d) preparation of a balance bottom coating (4); e) impregnation of the decorative paper (2) with a proper melamine resin; f) application of the impregnated decorative paper (2) on the top surface of the plate (1); g) application of a pure cellulose film (3), also impregnated with melamine resin, over the decorative paper layer (2); and h) application of the high thickness paper (4) also impregnated with melamine resin on the bottom surface of the plate (1 ), for the formation of a coating to counter balance the stress on the said plate (1).

4. IMPROVEMENT IN DECORATION PLATE AND ITS

MANUFACTURING PROCESS, characterized by the fact that the application of the different layers are obtained through the steps of quick cycle type pressing, where by pressures that can vary from 18 to 30 Kg/cm², with temperatures between 170 and 200°C and cycles of 20 to 45 seconds, in single or multi phases presses.

5. IMPROVEMENT IN DECORATION PLATE AND ITS MANUFACTURING PROCESS, characterized by the fact that the weight of the decorative paper varies from 50 to 120 g/m², that can, according to its high absorption capacity, contain 75 to 150% by weight of resin over the paper original weight.

6. IMPROVEMENT IN DECORATION PLATE AND ITS MANUFACTURING PROCESS, characterized by the fact that the decorative paper (2) is of overlay kind, which weight can vary from 27 to 67 g/m², containing a quantity of 150 to 400% by weight of resin over its original weight.

7. IMPROVEMENT IN DECORATION PLATE AND ITS MANUFACTURING PROCESS, according to claim 1 , characterized by the fact that the balance coating (4) is preferably a high weight/thickness paper such as absorbing Kraft paper with a weight varying between 100 and 180 g/m² with a content of melamine, urea or phenolic resin of 75 to 150% by weight over its original weight.

8. IMPROVEMENT IN DECORATION PLATE AND ITS MANUFACTURING PROCESS, characterized by the fact that the melamine resin used is preferably of the kind produced by condensation of added melamine and phormaldeide with products that confers characteristics to the press process, as well as its elasticity, flow rate and hardening level are obtained through such adds.