Stock material or miscellaneous articles – Structurally defined web or sheet – Discontinuous or differential coating – impregnation or bond
Reexamination Certificate
1999-09-17
2001-12-25
Chen, Vivian (Department: 1773)
Stock material or miscellaneous articles
Structurally defined web or sheet
Discontinuous or differential coating, impregnation or bond
C428S195100, C428S200000, C428S203000, C428S212000, C428S213000, C428S214000, C428S215000, C428S354000, C428S3550EN, C428S3550EN, C428S3550AC, C428S337000, C428S480000, C428S483000, C428S515000, C428S516000, C428S519000, C428S520000, C428S521000, C428S522000, C428S523000, C525S088000, C525S09200D, C525S090000, C525S095000, C525S098000, C525S191000, C525S240000
Reexamination Certificate
active
06333094
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to a thermoformable composite synthetic veneer film having more than one layer and to furniture parts produced therewith, as well as to a process for production and for use of the film.
The film comprises: at least one base film or base layer comprised at least partly of polyolefin and having a thickness of 100 to 500 &mgr;m, which comprises, based on 100 parts by weight of polyolefin, from 0 to 90 parts by weight of at least one inorganic and/or organic filler, pigment or filler-pigment mixture and at least one UV stabilizer, and also the customary processing aids (antioxidants, phosphites, lubricants); at least one intermediate layer in the form of at least one primer layer, bonding layer or bonding film; and, arranged directly thereupon or onto a printing layer, coloring layer or color-printing layer arranged over part or all of the surface and, arranged directly thereupon or onto a bonding layer, at least one polyester-containing single- or multiple-layer-structure layer or film, where at least one bonding layer, adhesion-promoting layer or reactant layer has been arranged (on the side facing the working material) below the base film or base layer. According to the invention, the intermediate layers and the polyester-containing layers or films have a particular composition or, respectively, a particular structure.
EP 0 522 240 B1 discloses a composite synthetic-polymer film having more than one layer and comprising at least one base layer or base film based on at least one polyolefin, and, arranged below the base film or base layer, at least one bonding layer, bonding film, adhesion-promoting layer and/or reactant layer, and comprising, arranged above the base layer or base film, at least one upper layer or film. According to EP 0522240 the base film or base layer of polyolefin or comprising polyolefin is from 60 to 700 &mgr;m in thickness and comprises, based on 100 parts by weight of polyolefin, from 5 to 150 parts by weight of at least one inorganic and/or organic filler, pigment or filler-pigment mixture, and at least one UV stabilizer and/or a heat stabilizer and/or an antioxidant, and has, arranged thereupon, at least one intermediate layer in the form of at least one primer bonding layer or bonding film and, arranged over part or all of the surface thereof, at least one printing layer, coloring layer or color-printing layer, and, arranged directly thereupon or onto one or more intermediate layers, at least one polymethyl methacrylate-containing, polyamide-containing and/or polyester-containing single- or multiple-layer-structure protective layer or protective film. The film can be used outdoors or else as a veneer film. However, it is thermoformable only at very high temperatures (150° C.) and, in addition, it has a very narrow processing range (±2.5° C.).
SUMMARY OF THE INVENTION
One objective of the present invention is to develop an improved composite synthetic-polymer film for furniture. This should, inter alia, have good thermoformability even at low temperatures (100° C.) and a significantly broader processing range (from 90 to 130° C.). The film should also have improved surface properties (scratch resistance, chemical resistance) and good adhesion properties on wood materials, wood parts, plasterboard or metal.
In accomplishing these and other objects, there has been provided according to one aspect of the present invention a multilayer thermoformable composite synthetic film, comprising:
(1) at least one base layer comprising polyolefin and having a thickness of 100 to 500 &mgr;m, which comprises, based on 100 parts by weight of polyolefin, from 0 to 90 parts by weight of (i) at least one inorganic and/or organic filler, pigment or filler-pigment mixture, (ii) at least one UV stabilizer and/or (iii) heat stabilizer and/or (iv) antioxidant, wherein the base layer comprises (a) at least one propylene copolymer with moderate or high ethylene content sufficient to provide a Vicat softening point VST/A/50 of from 110 to 130° C. and a melt index MFR (230/2.16) of from 1 to 10 g/10 min, (b) at least one polyethylene, and (c) at least one polyethylene elastomer or polyethylene-containing elastomer;
(2) at least one first intermediate bonding layer;
(3) at least one polyester-containing layer comprising an amorphous polyester having a Vicat softening point VST/A/50 of from 60 to 90° C.;
(4) at least one bonding layer, adhesion-promoting layer or reactant layer arranged on the underside of the base layer; and
(5) a surface-covering layer arranged on top of the film.
According to another aspect of the invention, there has been provided a process for producing a multilayer thermoformable composite synthetic veneer film as defined above, comprising extruding at least one layer of said film, including the base layer, wherein the base layer is adjusted to a Vicat softening point VST/A/50 of from 70 to 80° C., and/or the melt index MFR (230° C./2.16) of the propylene copolymer is selected at 20 to 8 g/10 min, prior to the extrusion.
According to still another aspect of the invention, there is provided a process for producing furniture parts using the above film, which comprises applying, in a thermoforming process and at temperatures of from 80 to 140° C. the veneer film to a previously produced part of wood or of wood materials, or boards of wood or of wood materials or comprising wood fibers, using the bonding layer, adhesion-promoting layer or reactant layer arranged below the base layer, and bonding to the parts or boards of wood or of wood materials.
Finally, there has also been provided according to the invention a laminated article comprising a base part made from wood or from wood materials, a board made from wood or wood materials, plasterboard, metal, or a part or sheet made from metal, laminated with a film as defined above.
Further objects, features and advantages of the present invention will become apparent from the detailed description of preferred embodiments set forth below, when considered in conjunction with the accompanying figures of drawing.
REFERENCES:
patent: 4087485 (1978-05-01), Huff
patent: 4701496 (1987-10-01), Yoshimura et al.
patent: 4778697 (1988-10-01), Genske et al.
patent: 5273797 (1993-12-01), Hazelton et al.
patent: 522 240 (1993-01-01), None
Ewald Egon
Schneider Manfred
Alkor GmbH Kunststoffe
Chen Vivian
Foley & Lardner
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