Fabric (woven – knitted – or nonwoven textile or cloth – etc.) – Coated or impregnated woven – knit – or nonwoven fabric which... – Two or more non-extruded coatings or impregnations
Reexamination Certificate
2002-08-28
2004-12-28
Morris, Terrel (Department: 1771)
Fabric (woven, knitted, or nonwoven textile or cloth, etc.)
Coated or impregnated woven, knit, or nonwoven fabric which...
Two or more non-extruded coatings or impregnations
C442S136000, C442S172000, C442S180000, C442S181000, C442S247000, C442S252000, C442S255000, C442S268000, C428S328000, C428S340000, C428S920000, C428S921000
Reexamination Certificate
active
06835676
ABSTRACT:
BACKGROUND OF THE INVENTION
(a) Field of the Invention
The present invention relates to a fire-resistant composite panel, and more particularly, to a fire-resistant composite panel that can be used in various applications such as for interior finishing materials for passenger cars, interior materials for ships and automobiles, materials for walls of subway stations, washrooms and kitchens, building interior or exterior materials for ceilings and floors, and for furniture, the fire-resistant composite panel having excellent fire-resistance and impact-resistance, a low dimensional change, and good workability to form a curvature. The present invention also relates to a fire-resistant decorative composite panel using the fire-resistant composite panel.
(b) Description of the Related Art
A common melamine-based decorative panel is generally formed by pressing a plurality of layers consisting of a surface protective layer and a decoration layer both impregnated by a melamine resin, and a core layer impregnated by a phenol resin onto kraft paper, using a multi-stage press at an elevated temperature under a high pressure. However, these decorative panels have drawbacks of being thermally weak due to their high content of resins and pulp layers.
Therefore, in order to meet the requirement of fire-resistance for materials used as building interior and exterior materials, furniture, and the like, ground stone or processed metals are used, and alternately, tiles made of ceramics or porcelain are attached to the surface. Though these materials have good durability and fire-resistance, they have drawbacks of a high manufacturing cost, a heavy weight, and low workability; and furthermore there is limitation for their use as colorful decoration.
In order to solve the above-mentioned problems, fire-resistant melamine-based decorative materials comprising a specific inorganic compound in their substrate layer have been proposed, examples of which can be found in Japanese Patent Pub. Nos. 03-253342 (FIG.
1
), 11-268186 (FIG.
2
), 10-305527 (FIGS.
2
and
3
), 10-305525 (FIGS.
2
and
3
), etc. These decorative panels have a multi-layered configuration consisting of, from top to bottom, a sheet for a decorative layer using a patterned substrate and a melamine resin, a basic material layer made by blending an inorganic filler such as a nonwoven glass fabric and aluminum hydroxide with a melamine resin or a phenol resin and by impregnating or coating, a reinforcing layer made by blending and impregnating a nonwoven glass fabric with a melamine resin or a phenol resin, another basic material layer and another decorative layer. These layers are molded with a multi-stage press at a high temperature under a high pressure.
However, although such conventional fire-resistant melamine-based decorative panels exhibit improved fire-resistance compared with common melamine-based decorative panels, there are still problems in that their fire-resistance and dimensional stability are insufficient because a large amount of resin is used in order to improve strength and processability of the decorative panels and their manufacturing cost is increased due to the use of inorganic filler such as aluminum hydroxide.
Moreover, the conventional fire-resistant melamine-based decorative panel does not have enough impact resistance to be used alone when its thickness is not more than 2 mm, and it can not be used to construct a curved surface.
SUMMARY OF THE INVENTION
Taking into consideration of the problems of the prior arts, an object of the present invention is to provide a fire-resistant composite panel having excellent fire-resistance, impact-resistance and dimensional stability; and also to provide a fire-resistant decorative composite panel using the same.
Another object of the present invention is to provide a fire-resistant composite panel comprising a rear layer that imparts superior flexibility to the panel itself thereby enabling working it to a curved shape, and to provide a fire-resistant decorative composite panel using the same.
Yet another object of the present invention is to provide a fire-resistant composite panel comprising an inorganic filler that imparts superior strength to the decorative panel, and to provide a fire-resistant decorative composite panel using the same.
In order to achieve these objects and others, the present invention provides a fire-resistant composite panel comprising:
a) a substrate layer formed by impregnating or coating a substrate material of a woven or nonwoven fabric of inorganic fiber, or a paper, with a resin compound which contains an inorganic filler having loess as a main component and a thermosetting resin selected from the group consisting of a phenol resin a modified phenol resin, a modified phenol-urea resin, a melamine resin, and a modified melamine resin; and
b) a rear layer of an aluminum sheet or a galvanized steel plate.
Further, the present invention provides a fire-resistant decorative composite panel comprising:
a) a decoration layer formed by impregnating or coating a thermosetting resin onto a patterned substrate;
b) a substrate layer formed by impregnating or coating a substrate material of a woven or nonwoven fabric of inorganic fiber, or a paper, with a resin compound which contains an inorganic filler having loess as a main component and a thermosetting resin selected from the group consisting of a phenol resin, a modified phenol resin, a modified phenol-urea resin, a melamine resin, and a modified melamine resin; and
c) a rear layer of an aluminum sheet or a galvanized steel plate.
REFERENCES:
patent: 6333280 (2001-12-01), Hashimoto et al.
patent: 6410122 (2002-06-01), Tono et al.
patent: 1998-66205 (1998-10-01), None
patent: 2001-69165 (2001-07-01), None
patent: 2001-246513 (2001-10-01), None
patent: WO 98/09816 (1998-03-01), None
Kim Hyoung-Yool
Kim Kwang-Min
Song Wan-Ho
Alston & Bird LLP
LG Chem Ltd.
Morris Terrel
Piziali Andrew T
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