Stock material or miscellaneous articles – Structurally defined web or sheet – Discontinuous or differential coating – impregnation or bond
Patent
1987-12-14
1990-05-22
Weston, Caleb
Stock material or miscellaneous articles
Structurally defined web or sheet
Discontinuous or differential coating, impregnation or bond
156242, 156243, 156246, 428204, 428480, 428483, 428511, 428515, 428516, B32B 2710
Patent
active
049276999
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL DOMAIN
The invention is concerned with a process for producing a decorative foil or sheet containing a polymer plastic, in which at least one flat, porous and possibly a fibrous carrier is used, and which comprises a transparent protective layer on the decorative surface of the foil of a polymer plastic protecting a decorative layer at least at one of its surfaces. It furthermore concerns a foil or sheet produced by this process.
STATE OF THE ART
A process for producing a foil of this type is known from Austrian Pat. No. 312 472. By this process, a carrier foil is initially produced from a fibrous carrier material impregnated with synthetic resin, and it is then provided at one surface side with a decorative pattern and/or imprint. The carrier foil is then bonded at this decorative surface side with a transparent surface foil which may consist, e.g., also of an acrylate plastic.
Production of such carrier foils is generally effected by impregnating fibrous carrier materials, such as paper, fleece, glass matting and similar, with synthetic resins, such as aminoplastics, phenolic plastics, polyesters, epoxy resins or acrylic resins in the form of solutions or dispersions, and through subsequent drying and/or curing. The impregnating agent must display so low a viscosity that the carrier material is able to absorb the quantity of impregnating agent that will be sufficient to produce a closed foil surface, while already at the beginning of the curing of the thusly impregnated carrier material, usually done in a heated press, the viscosity of the impregnating agent must already be high enough--through precondensation or pre-polymerization--that the impregnating agent cannot flow out or be squeezed out laterally from the carrier material.
For many polymer plastics, such as polymethyl methacrylate or polystyrene, monomers do indeed have a sufficiently low viscosity for impregnating fibrous carrier materials, but at room temperature or at a somewhat higher temperature that is advantageous for impregnating purposes they are so highly volatile that they would evaporate after the carrier material is impregnated, before the pre-polymerization has fully set in.
PRESENTATION OF THE INVENTION
It is the initial object of the invention to make known a process for producing a polymer plastic containing foil or sheet of the type known from Austrian Pat. No. 312 472, in which the polymerizable plastic to be contained in the pores of the flat carrier material may also be one on a monomer basis that at room temperature or at a slightly increased temperature is highly volatile and/or with regard to which air oxygen has a disturbing effect on the polymerization.
This problem is solved according to a first variant of the invention by a process which is characterized by that a polymer plastic in solid or highly viscous form with a viscosity higher than 10,000 mPa.s is applied to an appropriately flat support inside a separating layer, whereby eventually, regions of the support surface arranged in the manner of a surface pattern remain free of plastic, by that to this layer of solid or highly viscous plastic a low-viscosity polymerizable monomer and/or pre-polymer with a viscosity of less than 100 mPa.s is applied, which will fill any still free regions in the separating layer and form over it a liquid layer, by that the porous carrier material is then applied onto this liquid layer, which sinks or is pressed into the liquid layer, by that eventually, thereupon a highly-viscous plastic with a viscosity of higher than 10,000 mPa.s is applied to form a second separating layer, and by that the thusly produced compound material is transferred to the foil or thin sheet under polymerization of the plastics contained in it. Advantageously, regions of highly-viscous plastic arranged in the manner of a surface pattern in the second separating layer can remain free.
According to a second variant of the invention, the problem set to the invention is solved in a process, characterized by that on an eventually, flat support ther
REFERENCES:
patent: 2345013 (1944-03-01), Soday
patent: 2769742 (1956-11-01), Helbiny
patent: 3639202 (1972-02-01), Simon
patent: 4543145 (1985-09-01), Schnell
Isovolta Osterreichische Isolierstoffwerke Aktiengesellschaft
Weston Caleb
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