EP0329154A1
Expired / Lapsed
EP
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Process for the production of a decorative thermosetting laminate
Assignee: Unilin Nordic AB
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Filing: 1989-02-17
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Granted: —
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Expires: 2009-02-17
Abstract
Abstract Process for the production of a decorative thermosetting laminate with an abrasion-resistant surface layer, which laminate comprises paper sheets impregnated with a thermosetting resin. In the process a continuous paper is impregnated with a noble thermosetting resin such as melamine-formaldehyde resin. At least one side of the paper is coated with 2 - 20 g/m², preferably 3 - 12 g/m² of small, dry and hard particles evenly distributed over the whole wet surface of the resin on the continuous paper. The resin is dried, whereupon the particle coated impregnated paper, so-called prepreg is possibly cut to sheets. At least one such sheet or continuous paper is placed as a surface layer on a base layer and bonded thereto.
Inventors
- 👤 Kent O. Lindgren
- 👤 Sven E. Danielsson
- 👤 Tommy M. Johnsson
- 👤 Nils-Joel A. Nilsson
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-11-08 23:08
CPC Classifications
B; B32; B32B; B32B29/00; B32B29/06; B32B27/00; B32B27/04; B32B21/00; B32B21/02; B32B21/04; B32B21/06; B44; B44C; B44C5/00; B44C5/04; B44C5/0469; B44C5/0476; B32B2307/00; B32B2307/50; B32B2307/554; B32B2451/00; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24802; Y10T428/24893; Y10T428/24909
Claims Analysis
Total Claims: 16
Claim 1
Independent Claim
119 words
Process for the production of a decorative thermosetting laminate with an abrasion-resistant surface layer, which laminate comprises paper sheets impregnated with a thermosetting resin wherein a continuous paper is impregnated with a noble thermosetting resin such as melamine-formaldehyde resin, that at least one side of the continuous paper is coated with 2 - 20 g/m², preferably 3 - 12 g/m² of small, dry and hard particles evenly distributed over the whole wet surface of resin on the continuous paper, that the resin is dried, that the particle coated, impregnated paper so-called prepreg is possibly cut to sheets, that at least one such sheet or continuous paper is placed as a surface layer on a base layer and bonded thereto.
Claim 2
Dependent Claim
119 words
Process for the production of a decorative thermosetting laminate with an abrasion-resistant surface layer, which laminate comprises paper sheets impregnated with a thermosetting resin wherein a continuous paper is impregnated with a noble thermosetting resin such as melamine-formaldehyde resin, that at least one side of the continuous paper is coated with 2 - 20 g/m², preferably 3 - 12 g/m² of small, dry and hard particles evenly distributed over the whole wet surface of resin on the continuous paper, that the resin is dried, that the particle coated, impregnated paper so-called prepreg is possibly cut to sheets, that at least one such sheet or continuous paper is placed as a surface layer on a base layer and bonded thereto.
Claim 3
Dependent Claim
107 words
Process according to claim 1, wherein the base layer consists of a plurality of conventional dry prepregs of continuous paper or paper sheets respectively which are not coated with particles, that the resin in the uppermost of these continuous papers or paper sheets possibly consists of a noble thermosetting resin such as melamine-formaldehyde resin, while the rest of the continuous paper or paper sheets preferably contain a less noble thermosetting resin such as phenol-formaldehyde resin or phenol-urea-formaldehyde resin, and that the continuous papers or a pile of paper sheets are laminated continuously or discontinuously respectively with the surface layer at a high pressure and an increased temperature.
Claim 4
Dependent Claim
18 words
Process according to claim 1, wherein the base layer consists of a particle board or a fibre board.
Claim 5
Dependent Claim
34 words
Process according to any one of claims 1 - 3, wherein the particle coated continuous paper or paper sheet consists of a so-called overlay paper, preferably of α-cellulose and/or of a so-called decor sheet.
Claim 6
Dependent Claim
28 words
Process according to claim 3, wherein the particle coated continuous paper or paper sheet is bonded to the base layer by gluing or laminating under heat and pressure.
Claim 7
Dependent Claim
22 words
Process according to any one of claims 1 - 5, wherein the hard particles consist of silica, aluminium oxide and/or silicon carbide.
Claim 8
Dependent Claim
30 words
Process according to any one of claims 1 - 6, wherein the particles have an average particle size of about 1 - 80 µm, preferably about 5 - 60 µm.
Claim 9
Dependent Claim
41 words
Process according to any one of claims 1 - 7, wherein the particle coated continuous paper or paper sheet is a decor sheet and said sheet is also coated with pulverized α-cellulose impregnated with a thermosetting resin, such as melamine resin.
Claim 10
Dependent Claim
18 words
Process according to any one of claims 1 - 8, wherein two particle coated overlay sheets are used.
Claim 11
Dependent Claim
31 words
Process according to any one of claims 1 - 9 wherein the particle coated side of the continuous paper or the sheet is directed towards the upper side of the laminate.
Claim 12
Dependent Claim
97 words
Process according to any one of claims 1 - 10 wherein the dry, hard particles 2 are applied by means of a device comprising a container 1 containing the hard particles 2, and a rotating doctor-roll 3 with uneven surface placed under the container 1, whereby the particles 2 are intended to fall down from the container 1 to the doctor-roll 3 and then be evenly distributed on a paper web 4 continuously fed under the doctor-roll 3, said paper web being impregnated with a thermosetting resin but not dried before the application of the particles 2.
Claim 13
Dependent Claim
39 words
Process according to claim 11, wherein the device used also comprises a scraper plate 5 under the container 1, which plate is intended to give an even feeding of the particles 2 along the surface of the doctor-roll 3.
Claim 14
Dependent Claim
40 words
Process according to claim 11 or 12, wherein the device used comprises an air knife or the like 6 intended to get the particles 2 to come loose from the doctor-roll 3 at a constant amount per unit of time.
Claim 15
Dependent Claim
19 words
Process according to any one of claims 1 - 10, wherein the hard particles are applied by electrostatic coating.
Claim 16
Dependent Claim
27 words
Process according to any one of claims 1 - 10, wherein the hard particles are charged by means of friction and then applied to the paper web.
References Cited (Backward Citations)
EP0122396A2
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EP0136577A2
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