Stock material or miscellaneous articles – Two dimensionally sectional layer
Reexamination Certificate
1999-10-09
2003-04-22
Beck, Shrive P. (Department: 1772)
Stock material or miscellaneous articles
Two dimensionally sectional layer
C428S045000, C428S156000, C428S161000, C428S163000, C428S167000
Reexamination Certificate
active
06551678
ABSTRACT:
FIELD OF THE INVENTION
This invention relates generally to high pressure decorative laminates and methods for producing same, and more specifically, laminates having a deeply textured surface displaying a tile design.
BACKGROUND OF THE INVENTION
Typically deeply textured embossed high pressure decorative laminates are produced with an overall thickness greater than those with more planar textures, such that the areas of deepest embossment have a thickness about the same as that for conventionally textured high pressure decorative laminates. While this avoids the problem of texture embossment punch-through and weakening of the laminate structure, with associated breakage, etc., the necessary increased thickness of such laminates detracts from their postformability. As such, it is often not possible to postform these laminates to the relatively tight radii of conventional kitchen countertop profiles, or other demanding postforming applications, and therefore restricting their use to either general purpose flatstock applications, or postforming applications with less aesthetically pleasing larger radii bends. For the aforementioned reasons, a deeply embossed tile design high pressure decorative laminate, with commercially acceptable physical properties and postforming characteristics, has been heretofore precluded.
High pressure decorative laminates have been used as a surfacing material for many years, in commercial and residential applications, where pleasing aesthetic effects, in conjunction with functional behavior, such as superior wear, heat and stain resistance compared to alternative surfacing materials, have been desired. Typical applications include, but are not limited to, furniture, kitchen countertops, table tops, store fixtures, bathroom vanity tops, cabinets, wall paneling, partitions, and the like. However, historically, high pressure decorative laminates have not been successfully used to replace “natural” ceramic tile for applications such as kitchen countertops, bathroom vanity tops, or shower and tub surrounds, where the “real” tile look is desired, even though high pressure decorative laminate offers several distinct advantages over ceramic tile, including a naturally antibacterial, antifungal and mold resistant surface, ease of installation, ease of cleaning, lower cost, warmth to the touch, and more forgiveness with breakable objects such as glassware and dinnerware. A natural ceramic tile installation consists of 5% or more porous grout area, which is easily stained and readily promotes bacterial, fungal and mold growth, which is becoming ever more of a household and business concern. Therefore, the need exists for a postformable, high pressure decorative laminate with a pleasing, deep textured tile design simulating the look and feel of natural ceramic tile without the deficiencies noted above.
High pressure decorative laminates can generally be classified by their decorative surface design as being either a uniform solid color, or a printed pattern, whether a woodgrain, stone-like or abstract design. Each type of high pressure decorative laminate can also be classified as to its surface finish, which in conjunction with its color or pattern, contributes to the overall decorative surface design, structure and aesthetics, as will be discussed in more detail below. High pressure decorative laminates can also be classified by their intended application as defined by the industry's governing body, the National Electrical Manufacturers Association (NEMA) in there standards publication LD 3-1995. Of particular interest is the “postforming type”, which is defined as “a high pressure decorative laminate (HPDL) similar to the general-purpose type, but is capable of being thermoformed under controlled temperature and pressure” after its initial manufacture, which is well understood by those versed in the art.
High pressure decorative laminates are generally comprised of a decorative sheet layer, which is either a solid color or a printed pattern, over which is optionally placed a translucent overlay sheet, typically employed in conjunction with a print sheet to protect the print's ink line and enhance abrasion resistance, although an overlay can also be used to improve abrasion resistance of a solid color as well. A solid color sheet typically consists of alpha cellulose paper containing various pigments, fillers and opacifiers, generally with a basis weight of about 50 to 120 pounds per 3000 square foot ream. Similarly, print base papers are also pigmented and otherwise filled alpha cellulose sheets, usually lightly calendered and denser than solid color papers, and lower in basis weight at about 40-75 pounds per ream, onto which surface is rotogravure or otherwise printed a design using one or more inks. Conversely, overlay papers are typically composed of highly pure alpha cellulose fibers without any pigments or fillers, although they can optionally be slightly dyed or “tinted”, and are normally lighter in weight than the opaque decorative papers, in the range of 10-25 pounds per ream.
Typically, these overlay and decorative print and solid color surface papers are impregnated, or “treated”, with a melamine-formaldehyde thermosetting resin, which is a condensation polymerization reaction product of melamine and formaldehyde, to which can be added a variety of modifiers, including plasticizers, flow promoters, catalysts, surfactants, release agents, or other materials to improve certain desirable properties, as will be understood by those versed in the art. As with melamine-formaldehyde resin preparation and additives thereto, those versed in the art will also appreciate that other polyfunctional amino and aldehydic compounds can be used to prepare the base resin, and other thermosetting polymers, such as polyesters, may be useful as the surface resin for certain applications, but use of a melamine-formaldehyde resin is preferred. Optionally, an untreated decorative paper can be used in conjunction with a treated overlay, if the overlay contains sufficient resin, such that during the laminating process heat and pressure consolidation, there is adequate flow of the resin from the overlay to contribute to the adjacent decorative layer, so as to effect sufficient interlaminar bonding of the two, as well as bonding of the decorative layer to the core. The equipment used to treat these various surface papers is well known to those versed in the art. The papers are normally treated to controlled, predetermined resin contents and volatile contents; the optimum levels will be well understood by those versed in the art, with typical resin contents in the ranges of 64-80%, 45-55% and 35-45% for overlay, solid color and print (unless used untreated) papers respectively, and all with volatile contents of about 5-10%.
The surface paper of a high pressure decorative laminate is simultaneously bonded to the core, which usually is comprised of a plurality of saturating grade kraft paper “filler” sheets, which have been treated or impregnated with a phenol-formaldehyde resin, which also simultaneously fuse and bond together during the laminating process, forming a consolidated, multi-lamina integral assembly. Again, those versed in the art will appreciate that a variety of modifiers such as plasticizers, extenders and flow promoters can be added to the phenol-formaldehyde resin, that other phenolic and aldehydic compounds can be used to prepare the base resin, or other types of thermosetting resins such as epoxies or polyesters may be used, although a phenol-formaldehyde resin is preferred. In addition, other materials such as linerboard, fabric, glass, or carbon fiber may be used for the filler plies, but a saturating grade kraft paper and other modified kraft papers are presently preferred, typically with a basis weight of about 70-150 pounds per ream. The resin preparation and filler treating methodologies are also well known to those versed in the art.
During the laminating or pressing operation, the various surface and filler sheets are cured under heat and press
Fairbanks Robert Paul
Nilsson Kenneth Allan
O'Brien Kevin Francis
Beck Shrive P.
Formica Corporation
Meyer Brown Rowe & Maw
Tsoy Elena
LandOfFree
Deep embossed tile design postformable high pressure... does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Deep embossed tile design postformable high pressure..., we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Deep embossed tile design postformable high pressure... will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-3088874