Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
2005-01-11
2005-01-11
Yao, Sam Chuan (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S078000, C156S245000, C156S250000, C156S583500, C264S122000, C264S128000
Reexamination Certificate
active
06841023
ABSTRACT:
A process for the manufacturing of a core forming a carrying structure for decorative laminates. The core comprises particles of cured, and optionally foamed, rigid, polyurethane, polyisocyanurate and/or phenolic resin. The particles are bonded to each other in a pressing procedure with a bonding agent comprising an adhesive such as a polymerizing monomer.i) The particles are achieved by grinding cured, and optionally foamed, rigid, polyurethane, polyisocyanurate and/or phenolic resin so that it passes through a 2 mm screen, preferably a 1 mm screen,ii) 100 parts per weight of particles is mixed with 1-100 parts per weight of fiber, the fiber additive having an average length in the range 1-15 mm.iii) The particle-fiber mixture is allowed to absorb a selected amount of water, the amount of water being in the range 1-15% by weight, The water is either added at any stage before the adding of bonding agent, and/or being used as a solvent in the bonding agent, and that,iv) 85 parts per weight of the particle mixture is mixed with 2-15 parts per weight of a bonding agent, the bonding agent selected from the group consisting of,a) A mixture of polyols, such as polyester or polyether, crude methylene diphenyl diisocyanate and possibly a small amount of blowing agent in a ratio forming a polymeric resin with a density in the range 600-1400 kg/m3.b) A formaldehyde based resin such as phenol-formaldehyde resin, urea-formaldehyde resin, melamine-urea-formaldehyde resin, melamine-urea-phenol-formaldehyde resin or phenol-resorcinol-formaldehyde resin, orc) Polyvinyl acetate resin.v)The mixture is applied between the belts of the continuos belt press or the press plates of a static press, optionally with at least one intermediate carrier web, the belts or press plates allowing a mainly uniform and specified material thickness to form. A slightly porous and preconditioned core with a selected water content in the range 0.8-12% is hereby achieved. The invention also relates to a decorative laminate achieved through the process.
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U.S. application No. 10/839,204, filed May 6, 2004.
Pergo (Europe) AB
Stevens Davis Miller & Mosher L.L.P.
Yao Sam Chuan
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