US4503115A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Plate-shaped molded article and process for its preparation and use
Assignee: Trespa International BV
•
Filing: 1982-11-23
•
Granted: 1985-03-05
•
Expires: 2002-11-23
Abstract
Abstract Disclosed is a decorative molded article, for example, in the form of a flat plate for structural application such as constructional panels, which comprises a core of wood and/or cellulose fibers, pressed together with a thermosetting synthetic resin under conditions suitable for hardening the resin. The resin content amounts to more than 150 and up to 900 g per 1000 g of dry fibers, and the density of the molded article is between 900 to 1600 kg/m3. A decorative layer is placed onto one or both surfaces of the molded article, for example, a decorative foil or a coating. A process for producing and also using the molded article is also described.
Inventors
- 👤 Martinus H. Hemels
- 👤 Gerardus W. Schuren
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 20:19
CPC Classifications
B; B32; B32B; B32B21/00; B32B21/04; B32B21/08; B32B21/02; B32B27/00; B32B27/06; B32B27/18; B44; B44C; B44C5/00; B44C5/04; B44C5/0469; C; C08; C08L; C08L97/00; C08L97/02; B32B2272/00; B32B2305/00; B32B2305/72; B32B2307/00; B32B2307/30; B32B2307/306; B32B2307/3065; B32B2451/00; B32B2607/00; Y; Y10; Y10S; Y10S428/00; Y10S428/92; Y10T; Y10T428/00; Y10T428/25; Y10T428/252; Y10T428/253; Y10T428/254; Y10T428/29; Y10T428/2982; Y10T428/2991; Y10T428/2993; Y10T428/2996; Y10T428/2998; Y10T428/31504; Y10T428/31971; Y10T428/31975; Y10T428/31978; Y10T428/31982; Y10T428/31989; Y10T442/00; Y10T442/20; Y10T442/2762; Y10T442/277; Y10T442/2828; Y10T442/2836; Y10T442/60; Y10T442/659; Y10T442/664; Y10T442/693
Claims Analysis
Total Claims: 28
Claim 1
Independent Claim
99 words
A decorative molded article, comprising: a core of a fiber containing material comprised of wood or cellulose fibers which are coated with a thermosetting synthetic resin, said resin having been added to said fibers as an aqueous solution prior to heat-hardening of said resin, the content of said resin being between at least about 150 g and not more than about 900 g of resin per 1000 g of dry fibers; and a decorative layer on at least one surface of said core, wherein the density of the molded article is between about 900 and 1600 kg/m 3 .
Claim 2
Dependent Claim
99 words
A decorative molded article, comprising: a core of a fiber containing material comprised of wood or cellulose fibers which are coated with a thermosetting synthetic resin, said resin having been added to said fibers as an aqueous solution prior to heat-hardening of said resin, the content of said resin being between at least about 150 g and not more than about 900 g of resin per 1000 g of dry fibers; and a decorative layer on at least one surface of said core, wherein the density of the molded article is between about 900 and 1600 kg/m 3 .
Claim 3
Dependent Claim
42 words
A molded article according to claim 1, wherein the resin content is between about 150 and 600 g of resin per 1000 g of dry fibers, and the density of the molded article is between about 1100 and 1500 kg/m 3 .
Claim 4
Dependent Claim
21 words
A molded article according to claim 1, wherein said core contains up to about 50% by weight of organic synthetic fibers.
Claim 5
Dependent Claim
41 words
A molded article according to claim 1, wherein said thermosetting synthetic resin comprises a phenol-formaldehyde resin, a melamine-formaldehyde resin, an epoxy resin, a urea-formaldehyde resin, a cross-linkable acrylic resin, a polyurethane resin, an epichlorohydrin-polyaminopolyamide resin, an epichlorohydrin-polyamine-resin or an epichlorohydrin-polyamide resin.
Claim 6
Dependent Claim
25 words
A molded article according to claim 4, wherein said synthetic resin has a B-time of more than about 5 minutes (130° C.) prior to thermosetting.
Claim 7
Dependent Claim
36 words
A molded article according to claim 5, wherein said synthetic resin comprises a phenol-formaldehyde resin with a predominantly low molecular weight component, in combination with a phenol-formaldehyde resin with a high molecular weight proportion of polycondensate.
Claim 8
Dependent Claim
19 words
A molded article according to claim 1, wherein the thermosetting resin comprises a synthetic resin with a non-flammable additive.
Claim 9
Dependent Claim
26 words
A molded article according to claim 1, wherein said thermosetting resin comprises a synthetic resin which due to modifications in the molecular chain exhibits non-flammable properties.
Claim 10
Dependent Claim
53 words
A molded article according to claim 8, wherein said synthetic resin is a phosphoric acid-phenol-amino-resin, prepared by the heat-hardening of a mixture of a precondensed, not yet hardened resin comprising melamine-formaldehyde-phosphoric acid, di-cyandiamide-formaldehyde-phosphoric acid or urea-formaldehyde-phosphoric acid as the first component and a precondensed, not yet hardened phenol-formaldehyde resin as the second component.
Claim 11
Dependent Claim
23 words
A molded article according to claim 9, wherein 1 to 2% by weight of phosphorus, relative to the total resin content, are contained.
Claim 12
Dependent Claim
23 words
A molded article according to claim 1, wherein said core contains 100% to 40% by weight wood fibers, and the balance cellulose fibers.
Claim 13
Dependent Claim
25 words
A molded article according to claim 1, having the configuration of an essentially flat plate with a thickness of between about 0.5 to 30 mm.
Claim 14
Dependent Claim
32 words
A molded article according to claim 1, wherein said decorative layer comprises a fabric, formed fleece, a synthetic resin overlay, a paper overlay, a wood overlay or a layer of a coating.
Claim 15
Dependent Claim
39 words
A molded article according to claim 13, wherein said decorative layer comprises a decorative foil impregnated with a thermosetting resin comprising a melamine-formaldehyde resin applied with weight per unit area of from about 80 to 400 g/m 2 .
Claim 16
Dependent Claim
28 words
A molded article according to claim 13, wherein said decorative layer comprises a cross-linked acrylic resin, a urethane resin, an epoxy resin, a melamine resin, or water glass.
Claim 17
Dependent Claim
22 words
A molded article according to claim 1, wherein said core contains up to about 50% by weight of pressed synthetic resin particles.
Claim 18
Dependent Claim
24 words
A construction panel suitable for exterior application comprising a molded article as defined in claim 1 in the form of a substantially flat plate.
Claim 19
Dependent Claim
18 words
A molded article according to claim 1, wherein said aqueous solution of said resin is an alkaline solution.
Claim 20
Dependent Claim
40 words
A molded article according to claim 1, wherein said molded article has a thickness between about 2 and 40 mm, a degree of water uptake of approximately 0.8% or less, and a degree of swelling of approximately 2.5% or less.
Claim 21
Dependent Claim
40 words
A construction panel according to claim 17, wherein said molded article has a thickness between about 2 and 40 mm, a degree of water uptake of approximately 0.8% or less, and a degree of swelling of approximately 2.5% or less.
Claim 22
Dependent Claim
83 words
A process for producing a molded article according to claim 1, comprising the steps of: adding said wood or cellulose fibers to an aqueous solution of said thermosetting synthetic resin to coat said wood or cellulose fibers with from about 15 to 90% by weight of said thermosetting synthetic resin in an uncured state; forming the coated fibers into a randomly deposited non-woven web-like mat; predensifying the web-like mat; and heating and pressing the predensified mat under conditions sufficient to harden said resin.
Claim 23
Dependent Claim
51 words
A process according to claim 21 further comprising the steps of softening wood chips with steam at a pressure of from about 1 to 10 bar, and comminuting the chips into fibers, and wherein said coating step comprises spraying said fibers with a resin solution or dispersion of the thermosetting resin.
Claim 24
Dependent Claim
59 words
A process according to claim 22, further comprising the step of treating the wood chips during or after the comminuting step with an alkaline formaldehyde solution under a pressure of from about 3 to 10 bar and at a temperature of from about 80° to 180° C., to produce a chemical reaction of the formaldehyde with the wood fibers.
Claim 25
Dependent Claim
28 words
A process according to claim 21, wherein said forming step comprises laying down the fibers provided with the resin in a tangled layer onto a moving conveyor belt.
Claim 26
Dependent Claim
42 words
A process according to claim 21, wherein said heating and compressing step comprises pressing the mat together with at least one decorative foil at a temperature between about 130° to 180° C. and a pressure of between about 30 to 100 bar.
Claim 27
Dependent Claim
30 words
A process according to claim 21, further comprising the step of applying at least one decorative layer to the surface of the molded article after said heating and pressing step.
Claim 28
Dependent Claim
17 words
A process according to claim 21, wherein said aqueous solution of said resin is an alkaline solution.
References Cited (Backward Citations)
US2464301A
Cited
US2537126A
Cited
US2573956A
Cited
US2582961A
Cited
US2926154A
Cited
GB865727A
Cited
GB908205A
Cited
GB984170A
Cited
GB1015803A
Cited
US3372131A
Cited
GB1052667A
Cited
US3673020A
Cited
US3887511A
Cited
US3832316A
Cited
GB1433464A
Cited
US4010296A
Cited
US4154882A
Cited
US4158713A
Cited
DE2657924A1
Cited
US4271221A
Cited
US4379193A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1988-03-04 | 1988-09-03 | 1989-03-05 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-03-04 | 1992-09-03 | 1993-03-05 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-03-04 | 1996-09-03 | 1997-03-05 | $7700.00 | Window Closed / Lapsed |