Stock material or miscellaneous articles – Composite – Of addition polymer from unsaturated monomers
Patent
1991-07-25
1993-07-20
Buffalow, Edith
Stock material or miscellaneous articles
Composite
Of addition polymer from unsaturated monomers
428525, 428530, 4285375, 427411, 427214, B32B 2708
Patent
active
052292177
DESCRIPTION:
BRIEF SUMMARY
This invention relates to a decorative laminated panel that consists of several layers of core papers impregnated with phenolic resin and a surface layer of decorative paper or overlay paper impregnated in melamine resin.
Decorative laminated panels according to DIN 16 926, also referred to as high-pressure laminates (HPL), present on the top side of the core made-up of core papers a surface layer that consists of a single-color or printed decorative paper and possibly a transparent overlay paper; this surface layer is impregnated with melamine resin or a similar amino plastic resin and then pressed together with the core papers.
An essential and important feature for the use of the laminated panels is the resistance of the melamine resin surfaces to the effects of many chemicals. It is disadvantageous, however, that lacquers of the various lacquer systems adhere very poorly to the melamine resin surface. However, because of the relatively great hardness and vitreous structure of the melamine resin surface it would be desirable to apply a somewhat softer and viscous coating of lacquer but not as brittle. The fields of applications of the decorative laminated panels would be greatly expanded by such a surface configuration.
In fact, it is known (from DE-A-36 30 315) that a wear resistant acrylic coating can be applied to the surface of a decorative laminated panel. But this acrylic coating must harden together with the melamine resin during the pressing process and for this reason cannot be applied subsequently. Thus, in this manner it is not possible to produce decorative laminated panels to which a lacquer coating suited to the particular field of application can be applied in any subsequent stage of production. An acrylic lacquer that is applied to the melamine resin surface after the melamine resin has hardened would not be sufficiently adhesive.
It is also known (from GB-A-1 452 858) that polyvinyl butyral is applied as adhesive layer to the back of a decorative backing paper not impregnated with melamine resin. This adhesive layer shall effect in the subsequent pressing process the bonding of the untreated decorative paper with the phenolic-resin impregnated core of the laminated panel which at this time is not yet completed.
The polyvinyl butyral does not constitute in this process an adhesive primer layer to which a lacquer coating that is applied at any subsequent time would adhere better but it is directly an adhesive. Therefore, polyvinyl butyral is mentioned herein merely as an example of one of the several thermosetting resins. It is only through the thermosetting of this resin that the adhesive effect is obtained by means of which the not impregnated decorative paper is bonded to the resin-impregnated core of the laminated panel in the subsequent pressing process.
It is known ("Pioloform B" brochure of the Wacker Company) that melamine resins can be combined with polyvinyl butyral in order to obtain stoving lacquers or resin systems that harden at room temperature. This admixture of polyvinyl butyral to the melamine resin with which is impregnated the paper web for the surface layer is unsuitable production of surface layers for decorative laminated panels because the melamine resin used to impregnate the decorative papers is present in an aqueous solution while polyvinyl butyral is not sufficiently soluble in water.
Thus, it is task of this invention to produce a decorative laminated panel of the initially described type with a surface that can be lacquered.
According to the invention, this task has been solved in that the surface of the surface layer has a polyvinyl butyral adhesive primer layer.
An excellent adhesive layer for lacquers is obtained by the adhesive layer of polyvinyl butyral applied to the outer surface of the surface layer; this does not affect in any manner the structure and the visual properties of the laminated panel itself. The lacquer coating can be then applied to the thus prepared surface of the laminated panel at any time during the manufacturing process. The appeara
REFERENCES:
patent: 2413931 (1947-01-01), Stamatoff
patent: 3345248 (1967-10-01), Pounds et al.
patent: 4765858 (1988-08-01), Vankerckhoven et al.
Buffalow Edith
Resopal GmbH
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