US3897589A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Fast curing, water-resistant laminate made with accelerated melamine-aldehyde resin and accelerated phenol-aldehyde resin and method of making it
Assignee: Westinghouse Electric Corp
•
Filing: 1973-05-24
•
Granted: 1975-07-29
•
Expires: 1993-05-24
Abstract
Abstract A laminate and a method of making it are disclosed. The laminate is made with a phenol-aldehyde resin composition containing a water-soluble carbonate or bicarbonate catalyst, the presence of which accelerates the cure time of the resin. A substrate is coated with the composition, stacked with at least one sheet of substrate coated with an accelerated melamine-aldehyde resin and cured. The resulting laminate is not only made in less time than an unaccelerated control but also exhibits superior water-boil resistance.
Inventors
- 👤 Joseph F Meier
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-06 04:11
CPC Classifications
B; B32; B32B; B32B29/00; B32B29/002; B32B29/005; D; D21; D21H; D21H17/00; D21H17/20; D21H17/33; D21H17/46; D21H17/47; D21H17/48; B32B2317/00; B32B2317/12; B32B2317/125; B32B2451/00; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1089; Y10T156/1092; Y10T156/1093; Y10T428/00; Y10T428/31504; Y10T428/31942; Y10T428/31946; Y10T428/31949; Y10T428/31964; Y10T428/31967
Claims Analysis
Total Claims: 37
Claim 1
Independent Claim
7 words
A METHOD OF MAKING A LAMINATE COMPRISING:
Claim 2
Independent Claim
7 words
A METHOD OF MAKING A LAMINATE COMPRISING:
Claim 3
Dependent Claim
71 words
PREPARING A COMPOSITION WHICH COMPRISES: A. A PHENOL AND AN ALDEHYDE IN A MOLAR RATIO OF ABOUT 1.15 TO ABOUT 2.0, B. ABOUT 0.0002 TO ABOUT 0.01 PHR OF A CATALYST SELECTED FROM THE GROUP CONSISTING OF WATER-SOLUBLE CARBONATES, WATER-SOLUBLE BICARVONATES, AND MIXTURES THEREOF, AND C. ABOUT 5 TO ABOUT 100 PHR OF A SOLVENT FOR SAID CATALYST AND FOR THE RESIN PRODUCED BY REACTION OF SAID PHENOL WITH SAID ALDEHYDE,
Claim 4
Dependent Claim
71 words
PREPARING A COMPOSITION WHICH COMPRISES: A. A PHENOL AND AN ALDEHYDE IN A MOLAR RATIO OF ABOUT 1.15 TO ABOUT 2.0, B. ABOUT 0.0002 TO ABOUT 0.01 PHR OF A CATALYST SELECTED FROM THE GROUP CONSISTING OF WATER-SOLUBLE CARBONATES, WATER-SOLUBLE BICARVONATES, AND MIXTURES THEREOF, AND C. ABOUT 5 TO ABOUT 100 PHR OF A SOLVENT FOR SAID CATALYST AND FOR THE RESIN PRODUCED BY REACTION OF SAID PHENOL WITH SAID ALDEHYDE,
Claim 5
Dependent Claim
15 words
HEATINGG SAID COMPOSITION TO CONVERT SAID COMPOSITION TO AT LEAST ABOUT 95% OF THEORETICAL SOLIDS,
Claim 6
Dependent Claim
15 words
HEATINGG SAID COMPOSITION TO CONVERT SAID COMPOSITION TO AT LEAST ABOUT 95% OF THEORETICAL SOLIDS,
Claim 7
Dependent Claim
12 words
A method according to claim 1 wherein said catalyst is sodium carbonate.
Claim 8
Dependent Claim
15 words
heating said composition to convert said composition to at least about 95% of theoretical solids;
Claim 9
Dependent Claim
15 words
heating said composition to convert said composition to at least about 95% of theoretical solids;
Claim 10
Dependent Claim
36 words
A method according to claim 1 wherein said solvent is about 1 to about 25% methanol and about 75 to about 99% water and the amount of said solvent is about 15 to about 50 phr.
Claim 11
Dependent Claim
24 words
COATING SHEETS OF A FIRST SUBSTRATE WITH SAID COMPOSITION TO A RATIO OF COATED SUBSTRATE TO UNCOATED SUBSTRATE OF ABOUT 1.1 TO ABOUT 2.5,
Claim 12
Dependent Claim
24 words
COATING SHEETS OF A FIRST SUBSTRATE WITH SAID COMPOSITION TO A RATIO OF COATED SUBSTRATE TO UNCOATED SUBSTRATE OF ABOUT 1.1 TO ABOUT 2.5,
Claim 13
Dependent Claim
24 words
coating sheets of a first substrate with said composition to a ratio of coated substrate to uncoated substrate of about 1.1 to about 2.5;
Claim 14
Dependent Claim
24 words
coating sheets of a first substrate with said composition to a ratio of coated substrate to uncoated substrate of about 1.1 to about 2.5;
Claim 15
Dependent Claim
5 words
partially drying said coated substrate;
Claim 16
Dependent Claim
5 words
partially drying said coated substrate;
Claim 17
Dependent Claim
5 words
PARTIALLY DRYING SAID COATED SUBSTRATE,
Claim 18
Dependent Claim
5 words
PARTIALLY DRYING SAID COATED SUBSTRATE,
Claim 19
Dependent Claim
19 words
A method according to claim 1 wherein the amount of said catalyst is about 0.004 to about 0.008 phr.
Claim 20
Dependent Claim
16 words
A method according to claim 1 wherein said phenol is hydroxybenzene and said aldehyde is formaldehyde.
Claim 21
Dependent Claim
7 words
FORMING A STACK OF SAID COATED SUBSTRATES,
Claim 22
Dependent Claim
7 words
FORMING A STACK OF SAID COATED SUBSTRATES,
Claim 23
Dependent Claim
7 words
forming a stack of said coated substrates;
Claim 24
Dependent Claim
7 words
forming a stack of said coated substrates;
Claim 25
Dependent Claim
52 words
placing on said stack at least one sheet of a second substrate coated with an accelerated resin consisting essentially of melamine and an aldehyde and containing about 0.001 to about 2% (based on resin solids) of a free-radical generator, said resin having about the same cure time as said phenol-aldehyde resin; and
Claim 26
Dependent Claim
52 words
placing on said stack at least one sheet of a second substrate coated with an accelerated resin consisting essentially of melamine and an aldehyde and containing about 0.001 to about 2% (based on resin solids) of a free-radical generator, said resin having about the same cure time as said phenol-aldehyde resin; and
Claim 27
Dependent Claim
52 words
PLACING ON SAID STACK AT LEAST ONE SHEET OF A SECOND SUBSTRATE COATED WITH AN ACCELERATED RESIN CONSISTING ESSENTIALLY OF MELAMINE AND AN ALDEHYDE AND CONTAINING ABOUT 0.001 TO ABOUT 2% (BASED ON RESIN SOLIDS) OF A FREE-RADICAL GENERATOR, SAID RESIN HAVING ABOUT THE SAME CURE TIME AS SAID PHENOL-ALDEHYDE RESIN, AND
Claim 28
Dependent Claim
52 words
PLACING ON SAID STACK AT LEAST ONE SHEET OF A SECOND SUBSTRATE COATED WITH AN ACCELERATED RESIN CONSISTING ESSENTIALLY OF MELAMINE AND AN ALDEHYDE AND CONTAINING ABOUT 0.001 TO ABOUT 2% (BASED ON RESIN SOLIDS) OF A FREE-RADICAL GENERATOR, SAID RESIN HAVING ABOUT THE SAME CURE TIME AS SAID PHENOL-ALDEHYDE RESIN, AND
Claim 29
Dependent Claim
15 words
A method according to claim 5 wherein said formaldehyde is in the form of formalin.
Claim 30
Dependent Claim
84 words
A method according to claim 1 wherein prior to curing, sheets of said first substrate which are next to a sheet of said second substrate have a resin to substrate ratio of about 1.1 to about 1.5 and a volatile content of about 3.5 to about 7.0% and sheets of said first substrate farther away from said sheet of said second substrate have a resin to substrate ratio of about 1.3 to about 2.5 and a volatile content of about 7.0% to about 10.5%.
Claim 31
Dependent Claim
16 words
curing the resins in said stack at an accelerated rate by heating said stack under pressure.
Claim 32
Dependent Claim
16 words
curing the resins in said stack at an accelerated rate by heating said stack under pressure.
Claim 33
Dependent Claim
16 words
CURING THE RESINS IN SAID STACK AT AN ACCELERATED RATE BY HEATING SAID STACK UNDER PRESSURE.
Claim 34
Dependent Claim
16 words
CURING THE RESINS IN SAID STACK AT AN ACCELERATED RATE BY HEATING SAID STACK UNDER PRESSURE.
Claim 35
Dependent Claim
13 words
A method according to claim 1 wherein said first substrate is kraft paper.
Claim 36
Dependent Claim
31 words
A method according to claim 1 wherein said curing is done at about 250* to about 330*F and about 800 to about 1200 psi for about 25 to about 60 minutes.
Claim 37
Dependent Claim
10 words
A laminate made according to the method of claim 1.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-07-28 | 1979-01-27 | 1979-07-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-07-28 | 1983-01-27 | 1983-07-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-07-28 | 1987-01-27 | 1987-07-29 | $7700.00 | Window Closed / Lapsed |