CN1124941A - 具有耐磨美术表面的层压板 - Google Patents
具有耐磨美术表面的层压板 Download PDFInfo
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
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- B32B27/42—Layered products comprising a layer of synthetic resin comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
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- B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
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- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
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- E04F15/02—Flooring or floor layers composed of a number of similar elements
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Abstract
利用预熟化的浸渍树脂微粒子,以及初始粘合剂物质,最好再加入耐磨的矿物粒子,如此以构成一厚的且具有美术造型的层压板的表面。保护的外层厚度足以构成一耐凿且看起来很深的表面。因为浸渍的树脂以及预熟化的微粒子具有相同的折射率,涂层的透明度以及在下面的装饰纸的总体清晰度非常良好。
Description
本发明是关于装饰层压板,适用于桌子及柜台表面,墙嵌面,地板表面,桌面等等,特别是关于高压装饰层压板及其制造方法。
传统制造装饰用的层压板的方法是,将许多层用合成热固树脂浸泡过的纸张叠加在一起。正常情形下,该组合件是由许多经酚醛树脂浸渍的牛皮纸所制成的塑料贴面板芯所构成,在其上有一装饰纸(decor sheet),通常是一印刷品或单一颜色,且用三聚氰胺树脂浸渍过。在该层压板中,通常在装饰纸之上覆盖有一尽可能透明的贴面层,用以保护装饰纸。
早先美国专利3,373,071及3,135,643中提出例子尝试去除或简化或改良该贴面层。这些专利的技巧是用无色的三聚氰胺浸渍该装饰纸,然后再用2,000-60,000cp(厘泊)较粘的混合液,在该浸渍过的纸张表面涂上一厚涂层。结果该粘性的涂料在该浸透的装饰纸上干固,如此在其表面现场形成一覆盖层。就目前所知,以这种方式做成的层压板从未达到大量商业应用,除了可能用来当铺地板的材料之外,可能是因为所需的费用太高,其中包括了双重处理,也就是,先使浸渍的纸浸透,然后再涂盖表面(这样的处理并未证明比传统使用层层覆盖方式有任何的改善),或者更可能是因为整个层压板的品质未达商业目的的要求,例如,破裂,皱摺,过度的坚硬,贴面的透明度不够等。
利用相同的技术来制造地板用的多叠层瓷砖已有多年了,但单一颜色的清晰度很差,也就是说,象泥土般混浊,因此它们在商业上不理想,并且这种地板用的瓷砖在商业上只适用于地板图案,因为地板离开视线较远,所以人们还可以容忍这种差的清晰度。
在美国专利3,968,291中讨论了另一种后期的尝试,就是在装饰纸上放置一更透明但能完全保护的保护层,其中在覆盖层中所使用的微粒子填充料是硫酸钡,专利所有人测定硫酸钡的折射率,比其他的填充料更接近三聚氰胺树脂的折射率,因此可增加覆盖的透明度,从而改进其下面的装饰纸的清晰度。这个产品也从来没有在商业上被接受,可能是与上述的原因相同。
更近期,本技术因为NEVAMAR ARP技术的发展而有革命性的突破,请参考Scher等人的美国专利4,255,480;4,395,452;4,430,375;Re32,152;4,263,081;4,327,141;4,400,423;Ungar等人的美国专利4,713,138;4,517,235;4,520,062;5,037,694;5,093,185;Lex等人的美国专利4,971,855;及0′Dell等人的美国专利4,499,137;4,532,170;以及4,567,087。在ARP技术中,用以保护该装饰层避免其磨损的覆盖层的厚度大大地减少,因此可提供高浓度耐磨粒子层,附着在上纸层的上层表面,通常是该装饰层。此项技术不仅改良了早期技术中的抗耐磨性质,而且因为保护层的超薄结构,而可增加其透明度。
此ARP的技术已为工业界及公众提供了良好的服务,依照这项技术所制造的层压板被公认为是上等产品而且需求量很大。即使如此,仍需要寻求一种具有超级清晰且视觉很深,具有良好耐凿性及NEMA的抗磨性装饰层压板,特别是具有一清晰且明亮的装饰外表的层压板,但它看起来象在该层压板上表面以下。此外,即使是较薄的保护涂层,人们也希望它能有优良的耐耗损及抗磨损性,而另一方面也能降低用来切割层压板工具的磨损程度以及压板模具的耗损度。
因此,本发明的目的是克服那些如上述所指出的现有技术中的缺点。
本发明的另一目的是提供一超清晰且视深度良好,具有NEMA抗耐磨性质的层压板。
本发明的又一目的是提供一改进的装饰层压板,特别是一符合所有NEMA要求的高压装饰层压板,其在装饰纸的表层覆盖有一厚的保护涂层,它具有比任何已知的厚层保护涂层更良好的透明度,并且其耐磨性及清晰度及透明度与ARP超薄保护层压板的相同。
本发明的又进一步目的是提供一改进的层压板产品,它具有传统覆盖层以及APR层压板所有的优点。
本发明的又进一步目的是提供一改进的装饰层压板产品,它具有APR层压板的所有优点,而且更具有另外的优点,即减少了工具的耗损,以及能够提供符合NEMA要求的视深高光泽木纹,以及具有改进的亮度及清晰度的花纹或单色地板砖、改进的耐凿性,以及防止压板模过度磨损。
这些及其他的目的可以利用一含丰富树脂的厚保护层,也就是比ARP保护层最大10倍厚的一保护层达到,也就是与传统的覆盖层以及早期美国专利′071及′643中现场铸造的涂层的厚度大约相同,典型的重量是每令25-30lbs或更多的固体物质,其中采用一微粒材料,由一预熟化的热固树脂颗粒所构成,该树脂具有与层压树脂本身相同或大致相同的折射率。
与美国专利′643及′291比较,该两件专利皆尝试在它们的保护层中寻找和使用填充料,该填充料的折射率尽可能的与层压树脂的折射率相近,本发明使用的原则是与熟化的层压树脂折射率最近的材料是熟化层压树脂本身。因此,假如用在装饰纸上的层压树脂是三聚氰胺甲醛树脂(本文以下称为蜜胺树脂),此为典型所使用的材料,则主要构成保护层的微粒子的材料是预熟化的蜜胺树脂微粒子。
本发明以上及其它的目的、特性及优点,由下面各种实施例的详细说明会更清楚。
本发明的主要特征之一是在层压过程中,使用由具有与应用在层压过程中的未熟化或部分熟化的层压树脂(在后者热固之后使用)具有相同或大致相同的折射率的树脂形成的预熟化热固树脂微粒。其中“预熟化”一词是指,树脂粒子的熟化或固化已经先被处理至最大可能的程度,或至少到一种熟化的阶段,在此时它的熔体粘度高到足以防止这些粒子在液体的层压树脂中溶解,和/或在一般层压条件下熔化并且流动,如此在高压/层压制造层压板的过程中不良地渗透到下层纸中,例如,该装饰纸。
如上所指,在制造符合NEMA标准的高压力装饰层压板的过程中,在正常情况下用以浸透/浸渍该装饰及覆盖层的典型层压树脂是蜜胺树脂,因而蜜胺树脂是应用在上层或本发明中的各层的优选层压树脂。因此,预熟化的热固树脂的微粒子最好同样采用蜜胺树脂。但是,其他的树脂体系也可能被使用,例如,聚酯,脲甲醛,双氰胺甲醛,环氧物,聚氨基甲酸酯,可熟化的丙烯酸以及这些树脂的混合物。预熟化的聚合物粒子因此可以选自蜜胺树脂,聚酯,环氧树脂,可熟化丙烯酸等或它们的混合物。
在某些情况下以及为了得到特别的效果,也可能使用某些不能共存的混合物,例如,预熟化的聚酯树脂粒子或聚氨基甲酸酯树脂粒子以及熟化的蜜胺树脂粒子及液态的蜜胺层压树脂;但是,通常,熟化的树脂与液体的层压树脂相同,而且任何不能共存的熟化树脂粒子只以小量的存在。
也可能将几种不同程度预熟化的树脂粒子混合在一起使用,而且甚至可能使用少量的树脂粒子,这些树脂粒子仍然可以部分地在液态的蜜胺树脂中溶解,如此可以熔化并且流入下层纸中,但是这种熟化较浅的粒子的量必须不能大到失去所要产品,也就是说,最后的层压板必须有一大部分由预熟化的树脂构成的透明保护覆盖层。假如该透明的覆盖层非常薄,但是其中有50%或以上的成分含有耐磨的矿物粒子。
除了在装饰纸上覆盖该透明的保护层外,本发明的层压板合适地以标准的方式制造,并且最好有一传统的结构,例如,它包含有2至8个用苯酚浸渍的牛皮纸的塑料贴面板芯,其上具有一层以蜜胺树脂浸渍过的装饰纸,在装饰纸之上,加上本发明的保护层。最后的层压板是用典型的方法制造,例如将塑料贴面板芯叠放在一合适的压力机上,并且将覆盖有保护层的装饰纸叠放其上,然后将此组合件放在两块压板模之间,加热及加压力一段足够长的时间,以便制造所要的装饰用的层压板。用于高压层压板及低压层压板的加压条件是标准化的并且是众所皆知的。
该厚的透明保护涂层主要包括预熟化的热固树脂粒子以及一种最初始的粘合剂物质,以及(可选择使用和优选)少量相对细小微粒的耐磨矿物质,合乎要求的平均粒子大小范围为0.5-50μm,最好是1-30μm,而最理想平均粒子大小是1微米。这类典型的保护层包括有15-20lbs/ream预熟化胺树脂粒子,以及6lbs/ream的Al2O3粒子。耐磨矿物质粒子最好是有足够的量以便将较大的预熟化树脂粒子部分地包住,该种粒子可能大到250μm,但是最大值以100μm较佳。矿物质粒子的硬度至少应该为7级(莫氏硬度)而且这种粒子最好是氧化铝或氧化铝及二氧化硅的混合物,虽然矿物粒子可包括氧化锆,氧化铈,硬玻璃珠,碳化矽及钻石粉。有许多其他物质,例如纤维屑等,应该避免使用,因为它们会减少透明度。
初始的粘合材料可以是任何可与体系共存的物质,它可将保护涂层在层压过程结束前现场固定在装饰层的上表面,包括许多种以树脂为基础的粘合物质,它们可以与所选用的层压树脂体系统共存,高粘性或粘稠的部分熟化树脂,或任何依照ARP技术可以当作粘合剂的物质,例如藻酸钠,气相二氧化矽,微晶纤维素,或混合物,例如Avicel,它是由大部分微晶纤维素与少量的羧甲基纤维素(CMC)混合而成。
另外一个依照本发明制作的典型产品有薄得多的保护覆盖层,其相对的厚度是每令6-8lbs固体物质,包括大约相同量的预熟化树脂粒子及矿物粒子。这是一种类似ARP的产品,而其中所含的矿物粒子的数量大约只是ARP层压板的一半,但是确有相同的耐磨及耐耗损性,并且改进了工具耗损度及降低了压板模具耗损度。
保护涂层可以许多方式应用到装饰纸上,简单地说,这些是一种与美国专利US4,255,480中ARP方法相似的两步骤过程;一种与美国专利4,713,138相似的单步骤过程;一种与美国专利US4,517,235及US4,517,235及US4,520,062相似的转换过程;以及一光漆过程,其中,保护覆盖层组分是直接涂在一木质板层或类似材料上,接着施力压紧。
在两步骤方法优选的使用形式中,涂料的成分是由氧化铝的小粒子或其他最好平均粒子大小大约在1到30μm耐磨粒子,以及最大粒子大小为250μm,优选最大粒子大小是100μm的预熟化树脂粒子及很少量的微晶纤维素粒子的混合物,所有组分皆分散在一稳定的,含水的淤浆中。氧化铝的粒子是如此小以致在最后产品中并不干扰视觉效果,它可用以当作耐磨物质,而微晶纤维素粒子当作优选的初始粘合剂物质。如众所知,初始粘合剂必须与层压过程中所使用的树脂系统能共存,通常为蜜胺树脂或在某些低压层压板的情况下为聚酯树脂体系,而微晶纤维素不仅有此功能并且可稳定在装饰纸表面的氧化铝的小粒子及预熟化树脂。
如此,优选的淤浆组分包含氧化铝的小粒子及预熟化树脂微粒子以及很少量的微晶纤维素粒子的混合物,所有的物质皆分散在水中。其中,预熟化树脂微粒子数量及最佳的小矿物粒子的量必须足够能制造最终产品,使其具有如上所述需要的耐磨性,并且初始粘合剂的量必须足够将矿物粒子及预熟化树脂粒子现场固定在装饰纸正表面。通常,发现2到10份(重量)的微晶纤维素配20-120份(重量)的氧化铝及预熟化树脂微粒子能得到满意的结果;然而,有可能在此范围之外制造。预熟化树脂的量是,每1份(重量)的矿物粒子配1到6份(重量)的预熟树脂粒子,如众所知,不仅可以在此范围之外制造,同时也可以不使用任何的矿物粒子来生产具有较厚透明保护覆盖层的适当产品。
在淤浆中含水量也必须考虑实用的情况,因为假如水太少,淤浆会变得太稠而很难应用;相反,若水太多,则在涂抹的过程中将因淤浆的流挂而使涂层的厚度很难保持一致。因此,含2.0%(wt)的微晶纤维素及大约24%(wt)氧化铝及预熟化树脂粒子(以水的重量为基准)的淤浆很稳定,也就是说,氧化铝及预熟化树脂粒子不会沉底;但是如果使用超过大约3.5%(wt)的微晶纤维素,以及大约24%(wt)氧化铝及预熟化树脂粒子(以水的重量为基准),则淤浆变得非常粘而很难应用。
含矿物的粒子组合最好包含少量的润湿剂,优选非离子的润湿剂,以及硅烷。润湿剂的量不重要,但是只需要非常少量,并且过量的润湿剂没有任何的益处。依照传统的做法,保湿剂,脱模剂,催化剂和/或消沫剂皆可使用。
假如使用硅烷作为一种偶合剂,它可以用化学方式将氧化铝或其他的非有机物粒子与浸渍后及熟化的预熟化蜜胺粒子及/或蜜胺结合和固化,而这样可提供更好的启始耐磨性,因为氧化铝粒子除了以机械方式之外,还以化学方式与蜜胺结合,因此可以在磨耗的情况下有更长的使用期限。硅烷应选自那些可与所使用的特定热固层压树脂相容的物质;在这方面,具有一氨基基团的硅烷,例如γ-1氨基丙基三甲氧基硅烷,与蜜胺树脂使用时特别有效。所使用硅烷的量不必很大,而事实上其量只有所使用的微粒矿物重量的0.5%,就能有效地增加最后层压板的耐磨性能;所建议的最大的量为氧化铝或其他坚硬粒子重量的2%,因为量再大也不能得到更好的效果,而只是增加原材料的成本。
装饰纸在涂上前述的涂料组合物之后就进行干燥,然后以一般正常方式用适当的热固树脂浸渍,例如,蜜胺树脂或聚酯。在装饰纸以蜜胺树脂浸渍之前,利用微晶纤维素当作粘合剂涂层必须以高温干燥。如此,最低干燥温度大约是140°F,而最好的干燥温度是240-270°F。在干燥之后,经过浸渍并涂层处理过的装饰纸上就堆上许多以树脂浸渍过的塑料贴面板芯或其他的背材,并且,在加热及压力下以一般方式进行层压。
另外一种达到本发明目的方法是以一种单步骤过程将一层预熟化树脂微粒子涂在装饰纸的表面,而同时在单步操作中可使装饰纸达到完全的树脂饱和,在此程序中未熟化的液态树脂是预熟化树脂粒子及耐磨矿物粒子的载体。实施本发明所采用的方法最佳如下方式说明:
(1)制备液态可热固的浸渍树脂以及涂层组合物的混合物,其中,涂层组合物包括预熟化的合成树脂微粒子,其浓度足够在层压表面形成一有预定厚度的树脂沉积层,以及供预熟化树脂粒子使用的一种初始粘合剂,例如,微晶纤维素或更粘的部分熟化的蜜胺树脂粒子,该初始粘合材料可以与可热固浸渍树脂可相容,并且经得起后来的层压条件,初始粘合物质的量应足以将预熟化树脂微粒子固定在未饱和的纸张的表面,而初始粘合物质也同样用来将预熟树脂微粒悬浮在液态的可热固的浸渍树脂中;
(2)在单一操作中沉积保护层和浸渍,其方法是将液态可热固浸渍树脂与涂料组分的混合物,最好其粘度不大于200-250厘泊,涂在一未饱和的纸张的正面上,涂抹的速度必须可以使未饱和的纸张中液态可热固浸渍树脂达成饱和,而且该涂料组合物在正表面上沉积;和
(3)将涂抹及浸渍好的纸装饰层干燥后可以得到可用于层压的装饰层。
另一种选择,如上面所指,一种细小坚硬矿物粒子,其浓度足够增加耐磨性而不会干扰可见度,可以在步骤(1)中加在预熟化的树脂微粒中,在此情况下涂层的厚度可以减小而不会失去耐磨性。
可以用在熟化聚合物微粒子组合物中的坚硬矿物为如上所述精细粒子大小的矿物,最好平均粒子大小在0.5-0.9μm之间,虽然如上所指,可以采用更大尺寸的粒子,其数量足够提供一耐磨层而不会影响可见度。必须了解的一点是,液体的粘度要足够维持矿物粒子与预熟化树脂粒子一起悬浮在其中。
该单一操作涂层/浸渍步骤可以在一阶段或多个阶段中进行,也就是说,完全的浸渍可以在该涂层布置好的同一阶段完成,或另一种方式,部分浸渍可以在一连续过程中的第一阶段中与该涂层一起进行,紧接着由下方进行第二次在线树脂溶液浸渍。
如上面所指,预熟化的合成树脂微粒是选自蜜胺,聚酯,环氧及可熟化丙烯酸或类似的树脂或其混合物。粘合物质最好是“Avi-cel”,上市的成分是含大约89%的微晶纤维素及11%的羧甲基纤维素(CMC)的混合物。也可能,但也不是最理想,可以采用层压树脂本身当作粘合剂,在这种情况下所用的层压树脂必须比较粘,其性质像浆状物或类似物。
最好的组合物适当含有1份(重量)Avicel对4-60份(重量)的矿物粒子及预熟化树脂微粒组合物。如上述所指,预熟化树脂微粒对矿物粒子的比例可以有很大的变化,适合的范围是1-6∶1。也可能加入少量额外的CMC(或不加)及少量的硅烷。最好是加入少量的表面活性剂,如美国专利4,255,480中所述,以及少量的固体润滑剂以加强其耐擦伤性,如美国专利4,567,087中所述。
在此配方中有6个重要的可变量,其中有3个是独立变量而另外3个是因变量,在美国专利4,713,138中所有的变量皆有解释。装饰纸张的重量,液体树脂含量及耐磨组分的重量都与配方无关。对这些变量的要求是由外在因素,例如颜色,最后饱和的程度,及耐磨性所决定。单位表面积的浸渍树脂重量(干的)是由纸的基本重量及树脂成分两者组合所决定。粘度是由整个液体体积对微粒物质含量所决定。因此,加到液态树脂中水的量由粘度和额外加入的水量所决定,该粘度是由耐磨组分及未切割树脂混合而得到,所加的额外的水是为了容易同时进行涂层及浸渍而使粘度降低到所希望的值,粘度通常是小于250cp,最好大约是100cp。
第三种方法,如上面所指,是一种与Ungar等人的美国专利4,517,235及4,520,062相似的转换法。在这种形式的过程中,本发明的涂层是涂布在一转换基层并且在其上干燥。然后,在一般的层压加压的操作中将此转换基层的面朝下抵住一完全或部分饱和的装饰纸或抵住另一合适的基层,例如一木质夹板。在足够热量,时间及压力下完成层压的操作后,该层压板从转换基层剥离,或反之亦然,而本发明的保护层将会被转换到装饰纸或基层的上表面。
实施本发明的第四种方法是采用一种上光漆的过程。其中,组合物直接涂在基层上,例如一木质夹板,然后干燥,最后加压及加热挤压。
本发明的优选方案中主要使用完全熟化的蜜胺树脂,它被磨成细粉并在挤压过程中在压板及装饰层间充当为一种填充材料。通过选择与浸渍树脂相同材料的粒子,在最后层压板成品中的保护涂层的折射率将会一样,在挤压之后可在层压板上制成免于模糊不清,高透明的表面。如此得到的透明度足够清楚,因此可以采用一单色装饰纸而不会失去其亮度及色泽。
除了清晰的厚表面涂层之外,通过改变采用的预熟化树脂微粒及其微粒大小可得到其它许多的装饰外表。这类装饰外表包括不同的纹理。也可以利用着色的预熟微粒子来制造有趣的视觉效果。可以预知的是,外表的变化是多样的,而且是由粒子大小,预熟化树脂微粒,数量,涂层厚度及着色来决定。实际所需要的外表可以由本案内容配合例行实验来决定。
下面的实施例是用来解说:
实施例1
在300°F下,加热蜜胺树脂直到其熟化,得到蜜胺树脂微粒。一旦熟化后,该物质被磨成微粒,其大小分布如下:
250μ + 0.02%
180μ + 0.04%
106μ + 0.47%
45μ + 70.60%
25μ + 22.45%
25μ以下 - 6.40%
淤浆成分包括60份上述的预熟蜜胺粒子及60份平均粒子大小为1μm的氧化铝,在一如下所示的韦林搅拌器(Waring blender)中制备。7.5份的微晶纤维素(Avicel RC 581)及2.5份的CMC加入到搅拌的水中。在2到3分钟之后,在搅拌器中,Avicel完全分散使氧化铝及预熟化树脂粒子被混入其中。
最后所成的淤浆分别被涂布到50lbs/今及65lbs/今未浸渍具有木纹及万花筒碎花款式的印刷纸张表面。此涂层在265°F下干燥大约3分钟。接着,该纸张利用蜜胺甲醛树脂以一般正常方式浸透,并且以正常程序干燥。树脂的含量是51-55.6%,挥发性成分是4.6-5.2%。层压板采用传统的一般操作来制造和挤压,即,大约290°F,1000psi,大约25分钟。
实施例2
液态的蜜胺树脂(1575lbs.)依照标准的方式制备供装饰纸浸渍用。在每192.8lbs液态树脂中加入0.001份(重量)的表面活性剂TRITON CF 21。以高速度在一具有低切力的混合器中混合5分钟。11磅Avicel以一种快速的方式加入其中以避免聚在一起或成块。紧接其后,快速加入47lbs预熟化蜜胺树脂粒子及47lbs的30μm的氧化铝。
在加入70加仑的水后测量其粘度以便提供粘度不超过150厘泊的产品(Brookfield粘度计#3,以12rpm速度旋转)。
重量为65lbs/令的印刷过的装饰纸以196.1lbs/令的速度被涂上一层。该纸张在高温干燥,如一般的方式将此纸张用来制造层压板。
磨损结果如下:
款式 MR-51 MR-12
启始点 (循环) 650 750
最终点 (循环) 1300 750
磨损速率 975 1138
速率/100转 0.015g 0.012g
实施例3
为了得到两个额外的样品,上面的例2对每一情况采用20μm及25μm氧化铝。
磨损结果如下:
纸张款式 MR-12 MR-51
粒子大小 20μm 25μm 20μm 25μm
启始点(循环) 150 650 275 800
最终点(循环) 1000 1550 550 1600
磨损速率 575 1100 413 1200
速率/100转 0.017g 0.012g 0.031g 0.017g
实施例4-中重量保护层
下面的配方是用于过量涂层以及同时使一印制的装饰纸浸透之用:
150加仑未切割的蜜胺树脂(1,575lbs)
70加仑水
11磅Avicel
92磅30μm(平均粒子大小)氧化铝
92磅预熟化蜜胺树脂粒子(最大100μm)
0.27磅Infirnol脱模剂
6.2磅Nacure 3525蜜胺树脂熟化催化剂
32磅二甘醇保湿剂(humectant)
1.36磅Bubrake消沫剂
涂层/浸渍以每令57.8磅的未切割蜜胺树脂固体的速度进行,而Avicel以每令0.66磅的速度被涂布,氧化铝以每令5.62磅的速度,预熟化蜜胺树脂微粒以每令5.62磅的速度,保湿剂以每令1.64磅的速度。通过干燥器之后,装饰纸树脂含量为52%,以及挥发性含量为6%。
以通常的方式将装饰纸压成高压装饰层压板,最后的层压板符合所有的NEMMA标准,而且具有优异的耐磨性及抗滑动耗损性。
实施例5-高视深,高耐凿性的实验室的配方
制备一种实验室浸渍/涂层组合物,并以每今58.31磅的未切割树脂固体的速度涂到装饰纸上,而Avicel以每令0.67磅的速度,预熟化蜜胺固体以每令26.1磅的速度(其中最大粒子大小为100μm)以及氧化铝以每令5.63磅的速度涂布。通过干燥器之后,该纸的树脂含量为60%,以及挥发性含量为6%。透明的保护涂层有一相同每令20磅固体的厚度。将装饰纸与一些以酚醛树脂浸渍过的塑料贴面板芯压合后,可以得到一完全符合NEMA标准的层压板,而且其有额外绝佳的耐凿性,其中,装饰纸可以清晰且明亮可见,但是它在层压板中看起来很深。
实施例6-替换ARP
下面的配方是用于同时涂层及浸渍一单色装饰纸:
195加仑未切割蜜胺树脂(2,047.5磅)
50加仑水
15磅Avicel
2.9磅蜡
44磅15μm氧化铝
44磅预化熟蜜胺树脂粒子(最大尺寸100μm)
0.35磅Emerest 2652润湿剂
0.32磅Infirnol脱模剂
8.2磅Nacure 3525催化剂
1.1磅Bubrake消沫剂
以上的组合物以下列的速率涂布,每令60.93磅的未熟化固体树脂,每令0.74 Avicel;每令0.13磅蜡;每令2.17磅氧化铝及每令2.17磅预熟化蜜胺树脂粒子。如此涂层及浸渍过的单色装饰纸接着通过以正常方式通过一干燥烤箱。当它取出时,其树脂含量为52%,以及挥发性含量为6%。该装饰纸依一般方法用来制作层压板。最后所得的层压板具有优异的耐磨性及滑动耐耗损性,并且完全符合所有NEMA标准。因为有相对少量的氧化铝的存在,在切割该层压板时工具的耗损可以降低。
实施例7
下述配方是用于同时涂层和浸渍装饰纸(实验室量);
447克 蜜胺树脂(268.2克分子固体)
166克 水
3.12克 Avicel
0.87克 消泡润湿剂(31滴)
26.1克 氧化铝(平均粒子大小30μm)
26.1克 预熟化蜜胺树脂粒子
(按照实施例1)
0.09克 Infirnol脱模剂(3滴)
9.08克 甘二醇
1.78克 Nacure催化剂(88滴)
0.31克 Bubrake消泡剂(10滴)
上述组合物固体总量范围为56-58%,固体树脂总量(除预熟化树脂粒子外)范围为51-53%,将其以下述速度涂布到装饰纸上:
未熟化的蜜胺树胺 62.69-68.02磅/令
(3000平方英尺)
Avicel 0.72-0.78磅/令
预熟化蜜胺树脂微粒 6.09-6.61磅/令
氧化铝粒子 6.09-6.61磅/令
甘二醇 2.12-2.30磅/令
实施例8
采用下述配方,重复实施例7:
蜜胺树脂 361.0克(216.6克固体)
水 201.0克
Avicel 3.12克
防沫润湿剂 0.87克(31滴)
氧化铝(平均粒子 26.1克
大小30μm)
实施例1的预熟化 26.1克
蜜胺粒子
Infirnol脱模剂 0.09克(3滴)
甘二醇 9.08克
Nacure催化剂 1.78克(88滴)
Bubrake消泡剂 0.31克(10滴)
将该组合物以每令51.01磅未熟化蜜胺的速度涂布到装饰纸上。假若整个施工速度为55.23磅/令,其它组分速度为4.22磅/令。
额外的例子
制备一个与上面实施例5相似的例子,只是在其中没有任何的氧化铝存在。可以得到一个符合NEMA标准的产品,它有优异的清晰度及耐凿性。预熟化粒子涂布的速度是每令35磅。
另一个与实施例4相似的例子,只是其中的Avicel以藻酸钠取代。结果令人满意。
另一个实施例采用与实施例1相似的配方进行,此配方直接被涂在木质夹板的上表面。在涂层及干燥之后,该板面在热及压力下挤压以在木板上形成一保护涂层。
另外,采用聚酯树脂进行一种制造低压力板的尝试。其中,底层采用Masonite板。采用一木纹理的装饰纸,而且涂层/浸渍配方与实施例5的相同,只是预熟化树脂粒子是使用聚酯树脂粒子,而浸渍树脂是相同的未熟化的聚酯树脂。最后的产品有优良的耐磨性。
前面对特别实施例的描述揭露了本发明的总的特性,因此,其他人可以利用目前的知识轻易修改和/或为了不同的应用而改良那些实施例,并不会脱离其一般性的概念,而且,因此,这类的修改或改良应该在本公开方案相同的意义及范围之内作为解释。必须了解的是,在本说明中的述语或专有名词是为了叙述而非限定之用。以上所提到的专利并入作为参考。
Claims (20)
1、在一符合NEMA耐磨标准的装饰层压板中,包括一上层有一装饰层及在装饰层上面有一保护涂层的基底,其改进在于:
该保护涂层是透明的,且主要包括有熟化的热固树脂,它由预熟化树脂粒子及可选择性地加入的细小矿物粒子构成,该矿物粒子在热固树脂基体中所具有的莫氏硬度至少是7,该预熟树脂粒子的光折射率与该热固基体的光折射率大体上相同。
2、根据权利要求1所述的层压板,其中该基体由木材所构成,而该装饰上层是一树脂浸渍过的装饰纸。
3、根据权利要求1所述的层压板,其中的基体是一本质夹板。
4、根据权利要求1所述的层压板,其中该装饰层包括有一由热固树脂浸渍过的装饰纸层,而且其中该装饰层的上述树脂及该保护层的上述树脂是相同的树脂。
5、根据权利要求4所述的层压板,它是一低压层压板,而且其中该树脂是选自聚酯树脂及蜜胺树脂。
6、根据权利要求4所述的层压板,其中该层压板是一符合NEMA标准的高压装饰层压板,而且该树脂是选自蜜胺树脂,尿素树脂及二氰胺树脂。
7、根据权利要求1所述的层压板,其中该透明保护层进一步包括有该细小矿物粒子,其平均粒子尺寸不超过50μm。
8、根据权利要求7所述的层压板,其中该矿物粒子选自氧化铝,硅石及其混合物。
9、根据权利要求1所述的层压板,其中该透明保护层进一步包括有一初始粘合物质。
10、根据权利要求9的层压板,其中该初始粘合物选自微晶纤维素,羧甲基纤维素,藻酸钠及其混合物。
11、根据权利要求4的层压板,其中该透明保护层进一步包括细小粒子尺寸的矿物粒子及初始粘合物质,该粒子具有的莫氏硬度值至少为7。
12、根据权利要求11的层压板,其中该透明保护层厚度大约为2-3密耳。
13、一种耐磨装饰层压板包括有一核芯,其上放置有单一的表面薄层,该表面薄层包括有一经热固层压树脂浸渍过并涂有一保护层的装饰纸,主要包含有:
(1)以重量计从5到大约30份的微粒矿物,该矿物选自有氧化铝,硅石及其混合物;
(2)以重量计从1到大约5份的初始粘合剂物质,它选自微晶纤维素,藻酸钠,羧甲基纤维素及其混合物;
(3)预熟树脂粒子的量至少等于或最大为该矿物微粒量的6倍;而且
(4)具有与该预熟树脂微粒大致相同光折射率的足够量的该热固层压树脂,为该微小矿物粒子及该预熟化树脂粒子构成一永久基体,该保护层是清晰且透明的。
14、在一装饰的强化层压板中包含有一坚硬的核心层,一固定在该核心层上以华丽热固树脂浸渍过的装饰纸张,以及一置于装饰层上的保护层,该装饰层可经由保护层清楚地看见,该改进在于:
该保护层主要包含有一热固华丽树脂基体,与该华丽热固树脂有相同光折射率的预熟化树脂粒子,而且其中大致所有该预熟化树脂粒子尺寸皆小于250μm,而且可选择性地加入最大上限为,以重量计算每100份预熟树脂粒子,100份莫氏硬度至少是7而平均粒子尺寸不大于50μm的磨碎无色耐磨矿物粒子,而且当该磨碎耐磨矿物微粒物质存在时,该保护层同样也包括足够量的一种初始粘合物质,以便将矿物粒子及预熟树脂微粒现场固定在该装饰纸层的表面。
15、根据权利要求11所述的层压板,其中所述树脂是蜜胺树脂。
16、根据权利要求15所述的层压板,其中所述的覆盖涂层包括大约每令15-20磅的所述预熟化蜜胺树脂微粒。
17、根据权利要求15所述的层压板,其中该透明保护层的厚度相当于大约每令6-8磅的该预熟树脂及该矿物粒子。
18、用以制造装饰层压板的装饰纸,包括有一经过可热固树脂浸渍过且其上有一保护层的纸,该保护层大致是透明的而且主要含有预熟化热固树脂微粒,及可选择加入的细小矿物粒子,该矿物粒子在一可热固树脂基体中的莫氏硬度值至少是7,该预熟树脂粒子的折射率大致与该可热固树脂的折射率相同,以及可选择性的包含有一初始粘合物质。
19、在一制造符合NEMA耐磨标准的层压板的方法中包括将一基体及一装饰上层组合成一体,该装饰上层以可热固的树脂浸渍过并且其上有一保护涂层,该组合件经过热及压力处理,如此可使该可热固树脂流动或至少部分熟化,其改进在于:
该保护层是透明的而且主要含有一由预熟化树脂粒子及选择性加入的细小矿物粒子形成的熟化热固树脂及可选择性加入的一种初始粘合物质,且矿物粒子在可热固树脂基体中莫氏硬度值至少是7,其与该装饰上表层的可热固树脂浸渍液相互匹配,该预熟化树脂粒子的光折射率大致与至少部分熟化形式的该基体中上述可热固树脂的光折射率相同。
20、在一制备用于生产装饰层压板的装饰纸的方法中,包括将装饰纸上涂一保护层并将该装饰纸以可热固树脂浸渍,其改进在于:
该保护层主要包括有预熟化热固树脂粒子及选择性加入的细小且莫氏硬度值至少是7的矿物粒子及与该细小矿物粒子同时使用的初始粘合剂物质,该预熟树脂的光折射率大致与该可热固树脂基体的光折射率相同。
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1995
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Also Published As
Publication number | Publication date |
---|---|
BR9405959A (pt) | 1996-01-30 |
US5545476A (en) | 1996-08-13 |
FI954772A0 (fi) | 1995-10-06 |
JP3693297B2 (ja) | 2005-09-07 |
NO953934D0 (no) | 1995-10-03 |
IL109222A (en) | 2000-02-17 |
EP0693030B1 (en) | 1999-01-13 |
EP0693030A1 (en) | 1996-01-24 |
NO307506B1 (no) | 2000-04-17 |
US5344704A (en) | 1994-09-06 |
ES2129635T3 (es) | 1999-06-16 |
ZA942123B (en) | 1995-09-05 |
KR100312599B1 (ko) | 2002-02-19 |
AU678462B2 (en) | 1997-05-29 |
FI954772A (fi) | 1995-10-06 |
IL109222A0 (en) | 1994-07-31 |
DK0693030T3 (da) | 1999-09-06 |
DE69415970T2 (de) | 1999-08-12 |
CN1104327C (zh) | 2003-04-02 |
KR960701753A (ko) | 1996-03-28 |
CA2160149C (en) | 2004-07-13 |
WO1994022678A1 (en) | 1994-10-13 |
NZ260147A (en) | 1995-12-21 |
JPH08511212A (ja) | 1996-11-26 |
ATE175630T1 (de) | 1999-01-15 |
IN191782B (zh) | 2004-01-03 |
NO953934L (no) | 1995-10-03 |
DE69415970D1 (de) | 1999-02-25 |
AU6554694A (en) | 1994-10-24 |
CA2160149A1 (en) | 1994-10-13 |
PL311125A1 (en) | 1996-02-05 |
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