WO2016180610A1 - Procédé de préparation d'un substrat revêtu multicouche - Google Patents

Procédé de préparation d'un substrat revêtu multicouche Download PDF

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Publication number
WO2016180610A1
WO2016180610A1 PCT/EP2016/058690 EP2016058690W WO2016180610A1 WO 2016180610 A1 WO2016180610 A1 WO 2016180610A1 EP 2016058690 W EP2016058690 W EP 2016058690W WO 2016180610 A1 WO2016180610 A1 WO 2016180610A1
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WO
WIPO (PCT)
Prior art keywords
wood
substrate
layer
sheet
process according
Prior art date
Application number
PCT/EP2016/058690
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English (en)
Inventor
Matthew Paul Amick
Harmen Jelke Kielstra
Robert Grahn
Peter HÅKANSSON
Original Assignee
Akzo Nobel Coatings International B.V.
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Application filed by Akzo Nobel Coatings International B.V. filed Critical Akzo Nobel Coatings International B.V.
Publication of WO2016180610A1 publication Critical patent/WO2016180610A1/fr

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    • 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
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • 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
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • 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
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin 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
    • 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
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • 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
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
    • 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
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood 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
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    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
    • 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
    • B32B2250/00—Layers arrangement
    • 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
    • B32B2255/00—Coating on the layer surface
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • 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
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    • B32B2255/24—Organic non-macromolecular coating
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    • B32B2255/26—Polymeric coating
    • 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
    • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B32B2307/4026—Coloured within the layer by addition of a colorant, e.g. pigments, dyes
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/41—Opaque
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/412—Transparent
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/514—Oriented
    • B32B2307/518—Oriented bi-axially
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/75—Printability
    • 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
    • B32B2405/00—Adhesive articles, e.g. adhesive tapes
    • 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
    • B32B2479/00—Furniture
    • 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
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B32B27/205—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents the fillers creating voids or cavities, e.g. by stretching
    • 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
    • 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
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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

Definitions

  • the invention relates to a process of preparing a multi-layer coated wood or wood-based material substrate.
  • the invention also relates to a multi-layer coated substrate obtainable by the process.
  • US 8506742 B2 describes a method for laminating a plastic film with a wood- base substrate, in particular for producing a high-gloss surface on a wood-base substrate, in which a plastic film is laminated by means of a laminating agent, preferably an adhesive, with a wood-base substrate and permanently bonded to the wood-base substrate, the plastic film being formed so as to be transparent on its top, and the products obtainable in this manner and their use, in particular in the area of the wood and furniture industry, for example for the production of pieces of furniture and fitments of all kinds.
  • a laminating agent preferably an adhesive
  • WO 2009/103847 describes a self-adhesive material for a wood board.
  • the self-adhesive material is formed of polyolefin film containing reactive groups with -OH groups of the wood for forming self-adhesive properties.
  • the invention relates to a wood board in which the self-adhesive material is used as a coating and/or as a glue-line material.
  • WO 2008/002360 describes the preparation of a laminated composite structure having a base layer comprising a base substrate; at least one polymeric layer laminated onto a surface of the base substrate.
  • the polymeric layer is preferably bonded to the base substrate using a thermosetting adhesive interposed between the substrate surface and the polymeric layer.
  • a drawback of the methods described in these documents is that the gloss grade, colour and structure of the surface of the substrate is determined by the type of plastic film used, which limits the types of surface appearances which can be realized. Further, there is an interest in the wood industry, in particular in the furniture industry, to use low-density wood-base substrates to reduce the costs of the final products. A problem with low density wood-based substrates is that coatings cannot be directly applied onto such substrates in a satisfactory manner, generally leading to unsatisfactory finishes.
  • the application of plastic films on such profiled substrates can lead to equally unsatisfactory finishes.
  • the present invention seeks to provide a process which is very flexible in the type of surface to be achieved, and which is in particular suitable for creating a high quality finish on low density wood-based substrates and/or 3D-shaped substrates (e.g. profiled or milled substrates).
  • the invention now provides a process of preparing a multi-layer coated substrate comprising the steps, in any suitable order, of
  • a substrate which is a wooden substrate, or which is a wood-based material.
  • suitable substrates include fiberboard of low, medium, or high density, particle board, oriented strand board, plywood, or natural woods such as pine or poplar.
  • the process is of particular use for wood based substrates which are difficult to coat with liquid primer compositions, or which have a pronounced tendency to absorb liquid primer compositions.
  • the preferred wood based substrates are fiberboard and particle board.
  • the process according to the invention allows for the easy formation of high quality primers and top coats on inexpensive wood-based substrates, in particular on fiber board or particle board having a low density, such as a density in the range of 520 to 750 kg/m 3 , in particular 550 to 650 kg/m 3 .
  • Low density board is typically used for low end finishes and cheaper products. With the process of the invention it is possible to eliminate primer painting steps and also reduce the quantity of topcoat used and still achieve an excellent appearance.
  • the primer film serves as a leveling layer which covers surface imperfections in lower quality board and allows high quality finishes to be achieved on inexpensive wood-based substrates.
  • the process of the invention allows a furniture manufacturer to use lower density and inexpensive wood-based substrates for furniture making which gives them a cheaper and lower weight product that is better for transportation costs and easier to handle by consumers.
  • the process of the invention also comprises the step of providing a primer sheet comprising at least two layers, i.e. polymeric top layer and an adhesive bottom layer.
  • suitable polymers for the polymeric top layer of the primer sheet include polyester, such as polyethylene terephthalate, polyolefin, such as polypropylene (e.g. cavitated biaxially oriented polypropylene (BOPP)), polyurethane, polyvinylchloride, fluoropolymers (e.g. polyvinylidene fluoride), acrylics or other suitable resins. Also mixtures or hybrids of the afore-mentioned polymers can be used. Polyurethanes, fluoropolymers, polypropylenes, or polyesters, may be particularly preferred. It is preferred that the polymeric top layer has good moisture barrier properties and the ability to cover or level any surface irregularities of the wood-based substrate.
  • polymers which allow for satisfactory lamination even on 3-D shaped substrates (e.g. profiled or milled substrates).
  • monolayer or multilayer films comprising polypropylene, modified polyethylene terephthalate (e.g. with isophthalic acid (PEI) or modified with cyclohexanedimethanol, CHDM, (PET-G)), thermoplastic polyurethanes (e.g.
  • aromatic polyether or aromatic polyester urethanes based on aromatic polyether or aromatic polyester urethanes
  • acrylates such as polymethyl methacrylate, acrylonitrile butadiene styrene
  • fluoropolymers such as polyvinyl fluoride, polyvinylidene fluoride, fluorinated ethylene propylene, perfluoroalkoxy alkane, ethylene tetrafluoroethylene, or ethylene chlorotrifluoroethylene, or combination thereof.
  • polymeric primer top layer films include cavitated biaxially oriented polypropylene (BOPP), such as those commercialized under the designation Torayfan®), thermoplastic polyurethane such as those commercialized under the designation Dureflex®, polymethylmethacrylate such as those commercialized under the designation Acrylite®, and polyvinylidene fluoride / acrylic alloys such as those commercialized under the designation Fluorex®.
  • BOPP biaxially oriented polypropylene
  • Dureflex® thermoplastic polyurethane
  • Dureflex® polymethylmethacrylate
  • Acrylite® polymethylmethacrylate
  • polyvinylidene fluoride / acrylic alloys such as those commercialized under the designation Fluorex®.
  • cavitated film such as cavitated BOPP
  • An advantage of using a cavitated film is its good results for 3D-shaped substrates and in particular its conformance to small radius curves upon 3D pressing (e.g. for profiled or milled substrates such as a profiled kitchen front).
  • the polymeric top layer may be a clear layer or an opaque layer containing pigments.
  • a white or gray pigmented polymeric top layer has been found very suitable for most top coats to be applied on the polymeric top layer of the primer sheet. If so desired, the pigmentation of the polymeric top layer of the primer sheet can be adapted to match the color of the top coat to be applied. In this case irregularities in the hiding power of the top coat will be less visible. Also minor damages or scratches occurring during use of a piece of furniture will be less visible if the color of the polymeric top layer matches the color of the top coat.
  • a polymeric top layer which has undergone an adhesion improving surface treatment.
  • adhesion improving surface treatments include corona treatment, plasma treatment, flame treatment, or chemical treatments.
  • one or both surface of the polymeric top layer may be subjected to the afore-mentioned adhesion improving surface treatment.
  • adhesion improving surface treatment is of particular importance in cases wherein the polymer used for the polymeric top layer has a low surface energy or a low surface polarity, or otherwise a surface with insufficient adhesion properties.
  • Polymeric top layers based on polypropylene, polyethylene terephthalate or fluoropolymers have preferably undergone an adhesion improving surface treatment.
  • the thickness of the polymeric top layer is suitably in the range of 20 to 200 ⁇ , preferably in the range of 25 to 75 ⁇ .
  • the primer sheet further comprises an adhesive bottom layer.
  • the adhesive bottom layer suitably comprises a hot melt or pressure sensitive adhesive composition.
  • Non-reactive adhesives may be preferred.
  • a non-reactive adhesive means and adhesive which does not contain groups that chemically react with -OH groups of the wood substrate.
  • Advantages of non-reactive adhesives include low to no toxicity, excellent gap filling, high initial tack or green strength, and reprocess-ability. In particular, it is advantageous in a production environment to be able to re-process wood substrates, e.g., when they show certain coating defects.
  • the adhesive composition may be a reactive, or a thermoplastic hot melt adhesive composition, a non-reactive hot melt adhesive composition may be preferred.
  • the adhesive composition is suitably selected to allow sufficient melt-flow of the adhesive at the lamination temperature to allow the adhesive to flow into any surface irregularities of the substrate surface.
  • Non-reactive hot melt adhesive materials that are useful may contain as a major constituent an adhesive polymer such as an acrylic-type polymer; block copolymer; natural rubber, reclaimed rubber, or synthetic rubber (e.g. styrene- butadiene rubber); tackified natural or synthetic rubber; a copolymer of ethylene and vinyl acetate; an ethylene-vinyl-acrylic terpolymer; polyisobutylene; poly (vinyl ether); aromatic polyether urethane; polyolefin (e.g. poly-alpha-olefins); and crystallizable polyesters (e.g. crystallizable thermoplastic copolyesters).
  • Other materials may be included in the adhesive such as tackifying resins, plasticizers, antioxidants, fillers, waxes, etc.
  • Pressure sensitive adhesive materials that are useful may be an acrylate or methacrylate based composition typified by low glass transition temperature acrylic esters.
  • useful acrylic esters include methyl acrylate, ethyl acrylate, n-propyl acrylate, isopropyl acrylate, n-butyl acrylate, isobutylacrylate, tert-butyl acrylate, amyl acrylate, hexyl acrylate, octyl acrylate, 2-ethylhexyl acrylate, undecyl acrylate, or lauryl acrylate. Glass transition temperatures of such acrylic esters may generally be in the range of 0 to about -80 °C.
  • Particularly preferred adhesive materials for flat line or 3D press lamination include acrylic pressure sensitive adhesives such as those commercialized under the designation Aroset®, aromatic polyether urethanes such as those commercialized under the designation Macroplast®, crystallizable thermoplastic copolyesters such as those commercialized under the designation Dynacoll® S, and poly-alpha-olefins (APAO) such as those commercialized under the designation Vestoplast®.
  • acrylic pressure sensitive adhesives such as those commercialized under the designation Aroset®
  • aromatic polyether urethanes such as those commercialized under the designation Macroplast®
  • crystallizable thermoplastic copolyesters such as those commercialized under the designation Dynacoll® S
  • APAO poly-alpha-olefins
  • the adhesive composition can be applied to the polymeric top layer as an organic solvent-based composition, a water-based composition, or as a composition without volatile diluents.
  • the adhesive layer is a non-pigmented clear layer. If so desired, the adhesive comprises pigments or filler particles to adapt color and opacity properties.
  • a suitable manufacturing process for the primer sheet is to solvent cast the adhesive onto one surface of a pre-formed polymeric sheet in a web process or roll to roll process and force dry the applied adhesive layer in a multistage continuous oven.
  • Suitable application methods include slot die, roll coating, reverse roll coating, gravure coating, or other roll casting methods well known to the art.
  • a preferred application method is slot die or roll coating.
  • the dry thickness of the adhesive layer is suitably in the range of 5 to 50 ⁇ , preferably in the range of 12 to 40 ⁇ .
  • the layer thickness of the polymeric top layer and the adhesive bottom layer may be adapted so as to achieve the required quality of lamination and adhesive flow during the lamination process. It is preferred to select a hot-melt adhesive which is sufficiently non-tacky at ambient temperature to allow winding up the primer sheet in a roll without blocking for storage and transportation of the primer sheet. Adhesives which are sufficiently non-tacky can be selected by testing. Generally, suitable adhesives are those having a softening point or the beginning of the melt range above a temperature of 60°C, preferably above 80°C. When adhesives are used which can crystallize or partly crystallize, it is generally beneficial to allow the adhesive to crystallize or partly crystallize after application in order to minimize tackiness.
  • the process further comprises the step of laminating the adhesive bottom layer of the primer sheet to at least a part of the surface of the substrate of wood or wood-based material.
  • a suitable lamination process of the primer sheet to wood substrate involves heat laminating the sheet to the substrate.
  • the substrate may be an essentially flat or board like substrate.
  • the substrate may be a 3D-shaped substrate such as a substrate having three dimensional surface contours (e.g. a profiled or milled substrate) to which the primer sheet is laminated such that the primer sheet adopts the surface contour of the substrate. If so desired, the primer sheet may be wrapped around the edges of the substrate where needed.
  • Lamination temperature and pressure required depend on line speed and wood substrate type.
  • the lamination can be done on a flat surface profile or a 3D surface profile such as a milled or profiled surface profile of the wood substrate, e.g., by 3D-pressing.
  • the primer sheet is laminated to a flat and formable wood based substrate, and subsequently the wood based substrates and the layers already applied to it are together subjected to a shaping process so as to create a three-dimensional shape.
  • the shaping process can be carried out before or after application of the top coat on the polymeric top layer of the primer sheet.
  • the process further comprises the step of applying a top coat on the polymeric top layer of the primer sheet.
  • the top coat is applied as a liquid coating composition to the polymeric top layer of the primer sheet.
  • suitable application methods for the liquid top coat are well known to the skilled person and include roller coating and spray coating. Spray coating may be preferred, e.g., for 3D-shaped substrates after lamination of the primer sheet.
  • the liquid coating composition may be a water-based coating composition, and organic solvent-based coating composition, or a solvent-free liquid coating composition. After application, the liquid coating composition is solidified by evaporation of volatile diluent or chemical curing, or a combination thereof.
  • the coating composition may be thermally curable or curable by actinic radiation, such as UV light or electron beam radiation.
  • suitable coating compositions include polyesters (e.g.
  • thermosetting polyesters free radical curing unsaturated polyesters, and acid curing saturated polyesters
  • fluoropolymers e.g. polyvinylidene fluoride
  • acrylates e.g. UV-curing acrylates
  • polyurethanes including crosslinkable aliphatic polyurethane dispersions, in particular acid or hydroxyl functional polyurethane dispersions
  • mixtures thereof e.g. polyvinylidene fluoride / acrylic alloys.
  • Particularly useful coating compositions include free radical curing unsaturated polyester compositions such as AkzoNobel Wood Finishes IC301 and crosslinkable aliphatic polyurethane dispersions such as those commercialized under the designations Sancure®, Bayhydrol®, Daotan®, or Hauthane.
  • the liquid top coat is applied to the polymeric top layer after the primer sheet has been laminated to the wood-based substrate.
  • the liquid top coat may also be applied to the polymeric top layer before the primer sheet is laminated to the wood-based substrate.
  • the top coat should have sufficient flexibility to withstand the lamination process, such as coatings based on aliphatic polyurethane dispersions (crosslinkable aliphatic polyurethane dispersions in particular), acrylic latexes, high molecular weight (>150,000 MW) thermoplastic acrylics, or coatings based on polyvinylidene fluoride / acrylic alloys.
  • Such coatings are generally applied to the polymeric top layer and cured or dried before laminating (e.g. 3D pressing) the wood based substrate.
  • the top coat is applied to the polymeric top layer of the primer sheet as a polymer based top coat sheet.
  • the polymer based top coat sheet may be laminated to the polymeric top layer of the primer sheet after the primer sheet has been laminated to the substrate. If so desired, the polymer based top coat sheet may be laminated to the polymeric top layer of the primer sheet before the primer sheet is laminated to the substrate. In that case, the top coat sheet and the primer sheet are laminated to the wood or wood-based substrate as a multilayer coating sheet.
  • suitable polymer based top coat sheet materials include polyurethanes, acrylics, polyesters, fluoropolymers, and their combinations (e.g.
  • polyvinylidene fluoride / acrylic alloys in single layer or multilayer solution cast or extruded films.
  • the polymer based top coat sheets may be clear or pigmented or printed with high quality graphics by a suitable print method such as gravure or digital print.
  • the polymer based top coat sheets may also be embossed with a texture such as for the tactile sensation of wood grain.
  • Suitable polymer based top coat sheet films are available from AkzoNobel under the designation Soliant®.
  • the invention also relates to a multi-layer coated substrate obtainable by a process as described above.
  • the multi-layer coated substrate comprises
  • a primer sheet comprising a polymeric top layer and an adhesive bottom layer, laminated to at least a part of the surface of the wood- based substrate via the adhesive bottom-layer, and
  • multi-layer coated substrates are, e.g., 3D-shaped substrates, in particular 3D-shaped substrates with low density such as medium density fiberboard (MDF), comprising an acrylic sheet or a cavitated BOPP as polymeric top layer of the primer sheet, a hotmelt polyurethane as adhesive bottom-layer of the primer sheet and a thermosetting polyester-based top coat or a polyvinylidene fluoride (PVDF)/acrylic alloy top coat sheet.
  • MDF medium density fiberboard
  • PVDF polyvinylidene fluoride
  • a white opaque polyethylene terephthalate sheet with chemical adhesion promoting surface coating treatment on both surfaces was used.
  • the layer thickness was 25 or 50 ⁇ .
  • Suitable sheets are available from Mitsubishi Polyester under the trade designation Hostaphan® W54B or from SKC Films under the trade designation Skyrol® SW84G.
  • a polyurethane hot melt adhesive from Chase Corporation available under the trade designation Macroplast® QA4849, was applied in a dry film thickness of 13 or 25 ⁇ . These sheets served as primer sheets and were heat laminated to a flat, low density wood-based substrate. Subsequently a liquid top coat was applied to the top layer of the primer sheet.
  • the top coat was a thermosetting polyester- based top coat composition available from Akzo Nobel Wood Finishes under the trade designation IC301 .
  • the topcoated primer sheet showed exemplary appearance and moisture resistance when compared to low density wood- based substrate coated with liquid primer and liquid topcoat.
  • a 175 ⁇ clear acrylic primer sheet available from Evonik under the trade designation Acrylite® was coated with 50 ⁇ of the polyurethane hot melt adhesive Macroplast® QA4849 that had been pigmented white.
  • the hot melt adhesive was first coated and dried on a 50 ⁇ BOPP release carrier and then thermally transfer laminated to the clear acrylic sheet.
  • the primer sheet with hot melt adhesive was thermoformed (3D-pressed) over a MDF substrate that had been 3D profiled as in a kitchen front.
  • the pressing temperature was 160 °C and the pressure was less than 5 Bar.
  • the 3D wrapped MDF substrate was subsequently coated with the thermosetting polyester-based top coat composition IC301 .
  • the resulting coated profiled board show exemplary appearance in the profiled areas and the A side radius of the board.
  • a laminated wood sample was prepared according to the process set forth in Example 2 except using a 75 ⁇ white acrylic primer sheet and a clear hot melt adhesive with similar results.
  • Example 4
  • a laminated wood sample was prepared according to the process set forth in Example 2 except using a 50 ⁇ clear, surface treated cavitated BOPP primer sheet available from Toray Plastics under the trade designation Torayfan®. The conformance of the primer sheet in the areas of small profile radius was excellent.
  • PVDF polyvinylidene fluoride
  • Acrylic top coat sheet with a wood grain pattern gravure print available from AkzoNobel under the trade designation Fluorex® was thermally laminated to a clear 50 ⁇ corona treated polyester based primer sheet available from Mitsubishi Polyester under the trade designation Hostaphan® MG47.
  • the polyurethane hot melt adhesive Macroplast® QA4849 was coated and dried on a 50 ⁇ BOPP release liner and then thermally transfer laminated to the polyester primer sheet on the side opposite the PVDF/acrylic top coat sheet.
  • the multilayer coating sheet was then thermally laminated to a flat MDF substrate to transfer the wood grain pattern appearance to the wood-based substrate with good results.
  • a laminated wood sample was prepared according to the process set forth in Example 5 except an additional transparent, low gloss 38 ⁇ top coat sheet containing a soft touch tactile sensation was thermally laminated on top of the clear PVDF/acrylic top coat sheet with the wood grain pattern. This multilayer top coat sheet was then thermally laminated to the polyester primer sheet. The resulting laminated MDF substrate has the appearance and tactile sensation of soft, stained real wood.
  • Example 7
  • a laminated wood sample was prepared according to the process set forth in Example 3. After application of the topcoat, the laminated wood sample was reprocessed by heating the sample with IR heat to 120 °C in order to sufficiently soften the hot melt adhesive allowing the primer sheet with topcoat to be removed from the wood substrate. The wood substrate was lightly sanded and brushed and then prepared again with primer sheet and topcoat as above. It is advantageous in a production environment if wood substrates can be reprocessed when they show certain coating defects. With heat reactive hot melt adhesives it is difficult to remove the laminated primer sheet without significant destruction of the surface of the wood substrate making reprocessing impossible.

Landscapes

  • Laminated Bodies (AREA)

Abstract

L'invention concerne un procédé de préparation d'un substrat revêtu multicouche comprenant les étapes, dans n'importe quel ordre approprié, consistant à a) fournir un substrat de bois ou un matériau à base de bois, b) fournir une feuille d'apprêt comprenant une couche supérieure polymère et une couche inférieure adhésive, c) stratifier la couche inférieure adhésive de la feuille d'apprêt sur au moins une partie de la surface du substrat de bois ou du matériau à base de bois, et d) appliquer un revêtement supérieur sur la couche supérieure polymère de la feuille d'apprêt.
PCT/EP2016/058690 2015-05-08 2016-04-20 Procédé de préparation d'un substrat revêtu multicouche WO2016180610A1 (fr)

Applications Claiming Priority (4)

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US201562158651P 2015-05-08 2015-05-08
US62/158,651 2015-05-08
EP15171871.5 2015-06-12
EP15171871 2015-06-12

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Cited By (1)

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CN111808540A (zh) * 2020-01-15 2020-10-23 广东新纪源复合材料股份有限公司 一种高粘性磨砂预涂膜及其制备方法

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Publication number Priority date Publication date Assignee Title
WO2008002360A1 (fr) 2006-06-28 2008-01-03 Exxonmobil Oil Corporation Préparation de substrats composites stratifiés à l'aide d'un film polymère orienté revêtu
WO2009103847A1 (fr) 2008-02-18 2009-08-27 Upm-Kymmene Wood Oy Matériau autoadhésif pour panneau en bois et panneau en bois
US8506742B2 (en) 2006-02-17 2013-08-13 Jowat Ag Method for laminating plastic films with wood-base substrates, in particular for producing high-gloss surfaces

Patent Citations (3)

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Publication number Priority date Publication date Assignee Title
US8506742B2 (en) 2006-02-17 2013-08-13 Jowat Ag Method for laminating plastic films with wood-base substrates, in particular for producing high-gloss surfaces
WO2008002360A1 (fr) 2006-06-28 2008-01-03 Exxonmobil Oil Corporation Préparation de substrats composites stratifiés à l'aide d'un film polymère orienté revêtu
WO2009103847A1 (fr) 2008-02-18 2009-08-27 Upm-Kymmene Wood Oy Matériau autoadhésif pour panneau en bois et panneau en bois

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111808540A (zh) * 2020-01-15 2020-10-23 广东新纪源复合材料股份有限公司 一种高粘性磨砂预涂膜及其制备方法

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