Paper-coated laminate, processes for its production and its use

Details Paper-coated laminate, processes for its production and its use Paper-coated laminate, processes for its production and its use

1995-07-11

1997-08-05

Kiliman, Leszek

Stock material or miscellaneous articles

Web or sheet containing structurally defined element or...

Physical dimension specified

428507, 428510, 428511, 428514, 428515, 428520, 4285375, 15624427, 156243, 15624411, 156325, B32B 516, B32B 2308, B29C 4700

Patent

active

056540914

DESCRIPTION:

BRIEF SUMMARY
The present invention relates to a laminate comprising a substrate, a thermoplastic film and a paper layer. The invention also relates to processes for the production of the laminate and its use in the furniture and board industry.
Impregnated papers which, when pressed onto boards, represent preliminary processing in the sense of priming. (primer sheet) or frequently also display a decorative effect (decorative sheet) have long proved their worth in the furniture and board industry. The shortage and increase in cost of genuine veneers have very substantially contributed towards a greater use of the latter sheets. After being pressed onto chipboards or hardboards, the sheets have to be coated because, otherwise, the surface effect is insufficient.
In the course of the simplification of the production procedure, an improved type of impregnated papers, the finish sheet, has been increasingly used. These are impregnated single-colour or printed paper sheets which are provided with a coat by the sheet producer. The resulting finish sheets and continuous edges (continuous edge coating) are delivered on wheels to the furniture and board industry, where they are glued to substrates, such as, for example, chipboards or hardboards, under the action of heat and/or pressure. Surfaces which, as a rule, require no further coating, that is to say are further processed directly from the press, are obtained in this manner.
Known laminate systems are those which are prepared by adhesively bonding a surface-finished paper, i.e., a paper which has been, for example, coated, to a substrate which consists of chipboards or other woodworking materials. The adhesives usually used are urea glues, which have the disadvantage of formaldehyde emission and are therefore ecologically unsafe. When conventional chipboards are used as the substrate, the roughness of the surface is often so great that the substrate first has to be filled. However, this filling involves an additional process step, making the process complicated and the finished product considerably more expensive. The known paper-coated laminate systems therefore require improvement from the ecological and economic point of view.
SU-A-589138 discloses a process for coating woodworking materials with polyethylene films, the woodworking material coated with the polyethylene film being pressed with a decorative layer, in particular with a paper impregnated with a modified melamine/formaldehdye resin. The thickness of the polyethylene films used is 0.05 mm and 0.25 mm.
The disadvantages of the laminates described in SU-A-589138 are the relatively high formaldehyde emissions and the poor adhesion of the polyethylene film to the substrate.
Finally, JP-A-50-87480 relates to decorative laminate systems which are obtained by adhesively bonding an impregnated paper laminate to a thermoplastic PVC film, ethylene/vinyl acetate copolymers being used as adhesives.
It was therefore the object of the present invention to provide paper-coated laminates based on woodworking materials, which should have visually satisfactory surface structures even without the use of a filler. The resistance of the surfaces of the laminates to various reagents, for example foods, such as beer, coffee and the like, and the scratch-resistance of the coatings should be very good; furthermore, the adhesion between the substrate and the surface-finished paper should be excellent. In addition, it should be possible to dispense with impregnation of the papers used in the production of the paper-coated laminates. For ecological reasons, the laminates should have no formaldehyde emission. Furthermore the laminates should be capable of being produced readily and economically, a production process which is as simple as possible being desirable.
The object of the invention is achieved, surprisingly, by laminates comprising a substrate, a thermoplastic film, and a paper layer. The laminates are characterized in that they are composed of adhesion promoter or consists of an adhesion promoter or is bonded to the substrate A)

REFERENCES:
patent: 5243126 (1993-09-01), Chow et al.

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