Cold punchable cresylic laminates

Claim 2

A sheetlike member of claim 1 which has been heated to temperatures in the range of from about 30* to 180* C. for a time sufficient to advance said composition to an extent such that said member has a flow of from about 3 to 20 percent.

Claim 3

evaporates below about 150* C. at atmospheric pressures, and

Claim 4

being produced by reacting under aqueous liquid phase conditions formaldehyde and a cresol-phenol-mixture in the presence of an organic basic catalyst,

Claim 5

evaporates below about 150* C. at atmospheric pressure, and

Claim 6

evaporates below about 150* C. at atmospheric pressures, and

Claim 7

being produced by reacting under aqueous liquid phase conditions formaldehyde and a cresol-phenol mixture in the presence of an organic basic catalyst,

Claim 8

said cresol-phenol mixture comprising from about 20 to 100 weight percent of cresol with the balance up to 100 weight percent of any given such mixture being phenol,

Claim 9

is a mutual solvent for said second resole resin and for said water (if present), to an extent such that the resulting so-impregnated substrate contains from about 30 to 70 weight percent of said second composition (dry weight basis), C. said second dissolved resole resin being derived from cresol, phenol, and formaldehyde and being characterized by:

Claim 10

is a mutual solvent for said first resole resin and said water, said mixture comprising (dry weight basis) from about 35 to 65 weight percent of said first resole resin and the balance up to 100 weight percent of a given mixture being said carboxylated alkadiene interpolymer to an extent such that the resulting so impregnated substrate contains from about 5 to 40 weight percent of said first composition (dry weight basis), B. secondly impregnating a said so-first-impregnated laminate with a second composition comprising from about 30 to 70 weight percent (total composition basis) of a second dissolved resole resin, from about 0.5 to 15 weight percent (total composition basis) of dissolved water, and the balance up to 100 weight percent (total composition basis) being an organic liquid which:

Claim 11

said cresol-phenol mixture comprising from about 20 to 100 weight percent of cresol with the balance up to 100 weight percent of any given such mixture being phenol,

Claim 12

is a mutual solvent for said cresol-phenol-formaldehyde resole resin and for said water, to an extent such that the resulting so-impregnated substrate contains from about 30 to 70 weight percent of said second composition (dry weight basis), B. said cresol-phenol-formaldehyde resole resin being characterized by:

Claim 13

A cold punchable laminate construction prepared by the stEps of: A. forming at least one sheetlike member of claim 2 into a layered configuration which is at least two layers thick with adjoining layers being substantially in face-to-face engagement, and B. subjecting the so-resulting layered configuration to pressures in the range of from about 50 to 2,000 p.s.i. while maintaining temperatures in the range of from about 120* to 180* C. for a time sufficient to substantially completely thermoset both said first composition and said second composition and thereby produce a desired laminate.

Claim 14

said cresol-phenol mixture comprising from about 20 to 100 weight percent of cresol with the balance up to 100 weight percent of any given such mixture being phenol,

Claim 15

being substantially insoluble in water but having an acetone solubility such that a 55 weight percent solution thereof in acetone can be prepared, and

Claim 16

In a process for making an intermediate sheetlike member adapted for use in the manufacture of cold punchable laminates using as a starting material a substrate of cellulosic fibers arranged into a generally integral sheetlike form which has been first impregnated with a first composition comprising (dry weight basis) from about 35 to 65 weight percent of a water-soluble phenol-formaldehyde resole resin and the balance up to 100 weight percent of said first composition being a carboxylated alkadiene interpolymer comprising a polymerized monomer mixture of from about 3 to 8 weight percent acrylic acid, from about 35 to 60 weight percent of a conjugated alkadiene monomer, and the balance up to 100 weight percent comprising at least one material selected from the group consisting of monovinyl aromatic compounds and alkene nitrile compounds such that said so-first-impregnated substrate contains from about 5 to 40 weight percent of said first composition, the improvement which comprises the steps of: A. secondly impregnating a said so-first-impregnated laminate with a second composition comprising from about 30 to 70 weight percent (total composition basis) of a dissolved cresol-phenol-formaldehyde resole resin from about 0.5 to 15 weight percent (total composition basis) of dissolved water, and the balance up to 100 weight percent (total composition basis) being an organic liquid which:

Claim 17

being substantially insoluble in water but having an acetone solubility such that a 55 weight percent solution thereof in acetone can be prepared, and

Claim 18

being substantially insoluble in water but having an acetone solubility such that a 55 weight percent solution thereof in acetone can be prepared, and

Claim 19

having a free formaldehyde content which is less than about 5 weight percent.

Claim 20

having a free formaldehyde content which is less than about 5 weight percent.

Claim 21

A process for making an intermediate sheetlike member adapted for use in the manufacture of cold punchable laminates comprising the steps of: A. first impregnating a substrate comprising cellulosic fibers arranged into a generally integral sheetlike form, with a first composition comprising from about 5 to 40 weight percent (total composition basis) of a mixture comprising a first dissolved water soluble phenol-formaldehyde resole resin and an aqueous phase colloidially dispersed carboxylated alkadiene interpolymer comprising a polymerized monomer mixture of from about 3 to 8 weight percent acrylic acid, from about 35 to 60 weight percent of a conjugated alkadiene monomer, and the balAnce up to 100 weight percent comprising at least one material selected from the group consisting of monovinyl aromatic compounds and alkene nitrile compounds, from about 5 to 100 weight percent water, and the balance up to 100 weight percent of any given first composition being an organic liquid which:

Claim 22

having a free formaldehyde content which is less than about 5 weight percent.

Claim 23

In a process for making a laminate construction using a sheetlike member of the type described in claim 1, the improvement which comprises the steps of A. heating at least one such sheetlike member at temperatures in the range of from about 30* to 180* C. for a time to advance some to an extent such that the resulting sheetlike member has a flow of from about 3 to 20 percent, B. forming at least one such so-advanced sheetmember into a layered configuration at least two layers thick with adjoining layers being substantially in face-to-face engagement, C. subjecting the resulting layered configuration to pressures in the range of from about 50 to 2,000 p.s.i. while maintaining temperatures in the range of from about 120* to 180* C. for a time sufficient to substantially completely thermoset said composition and thereby produce a desired laminate construction.

Claim 24

A process for making a laminate construction using a sheetlike member of the type described in claim 2 comprising the steps of A. forming at least one such sheetlike member into a layered configuration at least two layers thick with adjoining layers being substantially in face-to-face engagement, and B. subjecting the resulting layered configuration to pressures in the range of from 50 to 2,000 p.s.i. while maintaining temperatures in the range of from about 120* to 180* C. for a time sufficient to substantially completely thermoset said composition and thereby produce a desired laminate construction.