WO2007108565A9

WO2007108565A9 - Mulberry paper patterned laminates

Info

Publication number: WO2007108565A9
Application number: PCT/KR2006/000991
Authority: WO
Inventors: Kee Duk Sung
Original assignee: Melatone Ltd; Kee Duk Sung
Priority date: 2006-03-17
Filing date: 2006-03-17
Publication date: 2008-11-13
Also published as: WO2007108565A1

Abstract

For improvement of decoration effects, the present invention provides a mulberry paper patterned laminate, which includes a base plate made from a transparent material; a dry-bond applied to at least one side of the base plate; a mulberry paper adhered to the surface of the dry- bond; and an overlay paper impregnated with a melamine resin provided to the surface of the mulberry paper.

Description

Description MULBERRY PAPER PATTERNED LAMINATES

Technical Field

[I] The present invention relates to a laminate, more specifically, to a mulberry paper patterned laminate with improved decorative beauty.

Background Art [2] In general, laminates (or laminated sheets) are used as decorative materials layered on the surface of furniture or wooden flooring for beautifying their appearances. [3] Fig. 1 is a cross-sectional view of a conventional laminate.

[4] As show in Fig. 1, the laminate has a three-layered structure of a kraft paper 2, a decor paper 3, and an overlay paper 4. The kraft paper, the decor paper, and the overlay paper are made of melamine resin or phenol resin impregnated paper, respectively. [5] Recently, decorative materials with natural beauty have drawn a lot of attention. To keep abreast with this trend, grain or marble shape has been printed on the decor paper

3. [6] However, those printed patterns on the decor paper 3 often look unnatural, and fail to provide more natural, esthetic beauty to the laminate 1. [7] Moreover, since the decor paper is not transparent, that is, since light does not pass through the decor paper when a light is shed from the rear side of the laminate, a soft lighting cannot be created. [8] In addition, because conventional laminates are weak and easily bent, they could be used only as decorative layers on wood or plywood.

Disclosure of Invention

Technical Problem [9] Therefore, the present invention has been made in view of the above problems, and it is an object of the present invention to provide enhanced laminates with decorative beauty.

Technical Solution [10] In accordance with an aspect of the present invention, the above and other objects can be accomplished by the provision of a mulberry paper patterned laminate including: a base plate made from a transparent material; a dry-bond applied to at least one side of the base plate; a mulberry paper adhered to the surface of the dry-bond; and an overlay paper impregnated with a melamine resin provided to the surface of the mulberry paper.

[I I] Preferably, the laminate further includes compressed and dried leaves or wild grasses provided to the mulberry paper for decorative purposes. [12] Also, the mulberry paper is formed of at least one processed mulberry sheets in a layered structure, and compressed and dried leaves or wild grasses provided for decorative purposes are inserted between the mulberry sheets during the layering process. [13] Preferably, the overlay paper is made from a substantially transparent material to show the appearance of the mulberry paper to the outside. [14] The mulberry paper and the overlay paper are compressed and fixed to each other at high temperature and high pressure. [15] The mulberry paper is impregnated with a melamine resin. Moreover, the dry-bond is made of a polyester material, and is heated to be adhered to the mulberry paper. [16] Preferably, the base plate is made from a transparent acryl material or a transparent polycarbonate material. In addition, at least one of the base plate, the mulberry paper and the overlay paper contains a pigment. [17] Preferably, the melamine resin is impregnated after compressed and dried leaves or wild grasses are decorated on the upper surface of the mulberry paper. Furthermore, the dry-bond, the mulberry paper, and the overlay paper are layered on the upper and lower sides of the base plate, respectively. [18] In accordance with another aspect of the present invention, there is provided a mulberry paper patterned laminate, including: a base plate made from a transparent material; a dry-bond applied to the upper and lower sides of the base plate, respectively; and a mulberry paper, which is decorated with compressed and dried leaves or wild grasses, and to which the dry -bond is applied. [19] Preferably, the laminate further includes an overlay paper impregnated with a melamine resin provided to the surfaces of the mulberry paper, respectively. Also, the mulberry paper is impregnated with a melamine resin. [20] Preferably, at least one of the base plate, the mulberry paper and the overlay paper contains a pigment, and the base plate is made from a transparent polycarbonate material.

Advantageous Effects

[21] The present invention is capable of providing laminates with a markedly enhanced decorative beauty. Brief Description of the Drawings

[22] The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[23] Fig. 1 is a cross-sectional view of a conventional laminate; [24] Fig. 2 is a cross-sectional view of a mulberry paper patterned laminate according to one embodiment of the present invention;

[25] Fig. 3 is an exploded, cross-sectional view of a mulberry paper patterned laminate according to one embodiment of the present invention; and

[26] Fig. 4 is a flow chart explaining the method for manufacturing a mulberry paper applied to the present invention.

[27] <Descriptions of Reference Numerals>

[28] 10: laminate 11: base plate

[29] 12: dry-bond 15: mulberry paper

[30] 20: overlay paper

Best Mode for Carrying Out the Invention

[31] A mulberry paper patterned laminate according to a preferred embodiment of the present invention will now be described with reference to the accompanying drawings. In the following description, same drawing reference numerals are used for the same elements even in different drawings. Also, well-known functions or constructions are not described in details since they would obscure the invention in unnecessary detail.

[32] Fig. 2 is a cross-sectional view of a mulberry paper patterned laminate according to one embodiment of the present invention, and Fig. 3 is an exploded, cross-sectional view of the mulberry paper patterned laminate according to one embodiment of the present invention.

[33] As shown in Figs. 2 and 3, the mulberry paper patterned laminate 10 includes a base plate 11 having a dry-bond 12 formed on the surface, a mulberry paper 11, and an overlay paper 20.

[34] The base plate 11 is made from transparent synthetic resin materials including acryl or glass. Desirably, it is made from polycarbonate materials which have excellent durability and excellent heat resistance during high-temperature press processing. It is also possible to manufacture the base plate 11 by combining or mixing transparent acryl, polycarbonate and glass.

[35] The dry-bond 12 is used as an adhesive when heated. A desirable example of the dry-bond 12 is a polyester resin because it serves to maintain a good appearance of the object to which it is applied. Therefore, the mulberry paper 12 can be adhered to the surface of the dry-bond 12 in the melted state.

[36] Moreover, it is desirable that the mulberry paper 12 should further include compressed dried leaves or wild grasses for decorative purposes. The mulberry paper 12 is constituted by at least 15-layered mulberry sheets, and the compressed dried leaves or wild grasses provided for decoration are inserted between the mulberry sheets. [37] The following will now describe the method for manufacturing the mulberry paper

15. [38] Fig. 4 is a flow chart explaining the method for manufacturing the mulberry paper by an automatic production process. [39] The method for automatically producing the mulberry paper 15 is explained with reference to Fig. 4 as follows. The mulberry paper used in the present invention is desirably made from the trunk of a tree like mulberry. [40] At first, twigs are removed from the trunk of mulberry, and the trunk is steamed and peeled off (SlO). The peel is dried and then dipped in cold water to be swollen up

(S20). [41] Later, a grass called uramine is added (S30). Optionally, banana peel or rice straw may be added. In addition, during the paper processing in an automatic machine, dried leaves or wild grasses may be dropped or sprayed on a moving wire (S40). [42] Here, the uramine is a kind of grasses called Nori that grows naturally in Japan. It may be used in combination of the leaves or wild grasses, or separately from the leaves or wild grasses. The uramine, dried leaves or wild grasses serve to increase the natural beauty of the mulberry paper. [43] Next, the mulberry paper passes through rolls that remove moisture, and is dried in a drying steam line at about 80°C for 40-60 seconds (S50). In this manner, manufacturing the mulberry paper is completed. [44] Thusly manufactured mulberry paper 15 with natural beauty can be used for decorative purposes as it is. [45] Moreover, compressed and dried leaves or wild grasses may be placed on the upper surface of the mulberry paper 15 for decorative purposes. In addition, the mulberry paper 15 is formed of at least one processed mulberry sheet, and the compressed and dried laves or wild grasses may be inserted between the mulberry sheets during the layering process. [46] In this way, natural beauty of the mulberry paper patterned laminate can be increased even more. [47] Meanwhile, as shown in Figs. 2 and 3, the overlay paper 20 impregnated with melamine resin is applied to the surface of the mulberry paper 15. The mulberry paper

15 and the overlay paper 20 are fixed to each other by HPL (high pressure and high temperature laminated) method or LPL (low pressure laminated) method. [48] Desirably, the heating adhesion process of the mulberry paper 15 by the dry -bond

12 and the mutual fixing process between the overlay paper 20 and the mulberry paper

15 may be carried out at the same time during one process. [49] In result, the mulberry paper 15 and the overlay paper 20 are united substantially as one body, and a resin laminate having high strength can be provided. [50] The melamine resin is a thermosetting resin obtained by a condensation reaction between melamine and formaldehyde. Since the melamine is colorless and transparent, it is easily colored. Also, the melamine resin has high heat resistance and great hardness.

[51] The overlay paper 20 is made from a transparent material so that the shape or appearance of the mulberry paper 15 may be shown to the outside. Desirably, the mulberry paper 15 is also impregnated with melamine resin.

[52] Therefore, by the overlay paper 20 and the melamine resin, the mulberry paper 15 is not exposed directly to the outside but protected and any damages or deterioration on the mulberry paper 15 can be prevented more effectively.

[53] In addition, at least one of the base plate 11, the mulberry paper 15 and the overlay paper 20 contains a predetermined pigment.

[54] Although the mulberry paper 15 and the overlay paper 20 may be formed only one side of the base plate 11, it is more desirable that the dry -bond 12, the mulberry paper 15 and the overlay paper 20 are all layered on both sides of the base plate 11.

[55] According to another embodiment of the present invention, melamine resin may be impregnated with the mulberry paper 15 even after compressed and dried leaves or wild grasses are decorated on the upper surface of the mulberry paper 15. In this case, since the melamine resin functions as the overlay paper 20, a separate overlay paper is not needed.

[56] As described above, the laminate of the present invention has a substantially improved natural beauty and strength.

[57] In addition, since the base plate is made from a transparent resin material, when a light is shed from the rear side of the laminate, a soft lighting can be created.

[58] And, in case that the base plate is formed of a polycarbonate plate, the laminate has a sufficient strength not to be easily bent. Thus, instead of attaching the laminate to separate plywood, it can be utilized as an independent decorative panel. Industrial Applicability

[59] As explained so far, the mulberry paper patterned laminate of the present invention provides a substantially improved decorative appearance by comprising the natural mulberry paper.

[60] In addition, since the laminate has a sufficient strength not to be easily bent, it can be utilized as an independent decorative panel. Also, the base plate made from a transparent material transmits a light, creating a soft lighting and decorative beauty.

[61] Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.

Claims

[I] A mulberry paper patterned laminate, comprising: a base plate made from a transparent material; a dry-bond applied to at least one side of the base plate; a mulberry paper adhered to the surface of the dry-bond; and an overlay paper impregnated with a melamine resin provided to the surface of the mulberry paper. [2] The laminate of claim 1, wherein the mulberry paper further comprises compressed and dried leaves or wild grasses provided for decorative purposes. [3] The laminate of claim 1, wherein the mulberry paper is formed of at least one processed mulberry sheets in a layered structure, and compressed and dried leaves or wild grasses provided for decorative purposes are inserted between the mulberry sheets during the layering process. [4] The laminate of claim 1, wherein the overlay paper is made from a substantially transparent material to show the appearance of the mulberry paper to the outside. [5] The laminate of claim 1, wherein the mulberry paper and the overlay paper are compressed and fixed to each other at high temperature and high pressure. [6] The laminate of claim 1, wherein the mulberry paper is impregnated with a melamine resin. [7] The laminate of claim 1, wherein the dry -bond is made of a polyester material, and is heated to be adhered to the mulberry paper. [8] The laminate of claim 1, wherein the base plate is made from a transparent acryl material.

[9] The laminate of claim 1, wherein the base plate is made from a transparent polycarbonate material. [10] The laminate of claim 1, wherein at least one of the base plate, the mulberry paper and the overlay paper contains a pigment.

[I I] The laminate of claim 1, wherein the melamine resin is impregnated after compressed and dried leaves or wild grasses are decorated on the upper surface of the mulberry paper.

[12] The laminate of claim 1, wherein the dry -bond, the mulberry paper, and the overlay paper are layered on the upper and lower sides of the base plate, respectively.

[13] A mulberry paper patterned laminate, comprising: a base plate made from a transparent material; a dry-bond applied to the upper and lower sides of the base plate, respectively; and a mulberry paper, which is decorated with compressed and dried leaves or wild grasses, and to which the dry-bond is applied. [14] The laminate of claim 13, further comprising: an overlay paper impregnated with a melamine resin provided to the surfaces of the mulberry paper, respectively. [15] The laminate of claim 13, wherein the mulberry paper is impregnated with a melamine resin. [16] The laminate of claim 13, wherein at least one of the base plate, the mulberry paper and the overlay paper contains a pigment. [17] The laminate of claim 13, wherein the base plate is made from a transparent polycarbonate material.