US4532170A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Scuff-resistant laminates
Assignee: General Electric Co
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Filing: 1984-07-25
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Granted: 1985-07-30
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Expires: 2004-07-25
Abstract
Abstract The scuff resistance of a high-pressure laminate is improved by incorporating in or very near the surface thereof, finely divided polyethylene wax preferably having a particle size of about 1-25 microns and a melting point of 220 DEG -230 DEG F. The wax is incorporated as part of a coating mixture applied to the face of an unimpregnated decor paper sheet in an ultra-thin layer, which layer is dried at a temperature below the wax melting point and then impregnated with conventional melamine-formaldehyde resin. The impregnated sheet is placed onto a sheet of convention phenolic resin impregnated core sheets and consolidated in the conventional way under heat and pressure. During consolidation, the wax particles "bloom", or migrate to the surface. The finished laminate surface has greatly improved scuff resistance.
Inventors
- 👤 Robin D. O'Dell
- 👤 Israel S. Ungar
- 👤 Herbert I. Scher
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 02:27
CPC Classifications
B; B32; B32B; B32B29/00; D; D21; D21H; D21H27/00; D21H27/18; D21H27/22; D21H27/26; D21H27/28; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24355; Y10T428/24372; Y10T428/24405; Y10T428/24802; Y10T428/24851; Y10T428/24868; Y10T428/24876; Y10T428/249921; Y10T428/249994; Y10T428/249998; Y10T428/25; Y10T428/254; Y10T428/31504; Y10T428/31801; Y10T428/31804; Y10T428/31808
Claims Analysis
Total Claims: 15
Claim 1
Independent Claim
119 words
A facing sheet for use in the manufacture of stain- and scuff-resistant decorative laminates, said facing sheet having thereon an ultra-thin facing layer comprising (1) a solid, finely particulate lubricant in an amount sufficient such that, during use of the facing sheet to make decorative laminate, the particulate lubricant melts and blooms to the surface thereby providing a decorative laminate having simultaneously good clarity and improved scuff resistance, with the proviso that said solid lubricant is not an oxidized wax or a silicone resin, and (2) sufficient binder material for said particles of lubricant to bind said particles to the surface of said facing sheet, said facing sheet being impregnated with a thermosetting resin compatible with said binder material.
Claim 2
Dependent Claim
119 words
A facing sheet for use in the manufacture of stain- and scuff-resistant decorative laminates, said facing sheet having thereon an ultra-thin facing layer comprising (1) a solid, finely particulate lubricant in an amount sufficient such that, during use of the facing sheet to make decorative laminate, the particulate lubricant melts and blooms to the surface thereby providing a decorative laminate having simultaneously good clarity and improved scuff resistance, with the proviso that said solid lubricant is not an oxidized wax or a silicone resin, and (2) sufficient binder material for said particles of lubricant to bind said particles to the surface of said facing sheet, said facing sheet being impregnated with a thermosetting resin compatible with said binder material.
Claim 3
Dependent Claim
26 words
A facing sheet according to claim 1 wherein said lubricant has a particle size of about 1-25 microns and a melting point of about 220°-230° F.
Claim 4
Dependent Claim
23 words
A facing sheet in accordance with claim 1 wherein said lubricant is a polymer wax having a particle size of about 1-25 microns.
Claim 5
Dependent Claim
57 words
A facing sheet in accordance with claim 1, wherein said lubricant is a micronized polyethylene wax present in said ultra-thin facing layer in an amount of 0.175 to 0.5 pounds per ream of facing paper; said thermosetting resin is polyester resin or melamine-formaldehyde resin; and said binder material is microcrystalline cellulose, carboxymethylcellulose, sodium alginate or mixtures thereof.
Claim 6
Dependent Claim
27 words
A facing sheet according to claim 1 wherein said lubricant has a particle size of less than 30 microns and a melting point of about 180°-285° F.
Claim 7
Dependent Claim
14 words
A facing sheet according to claim 5 wherein said lubricant is micronized polyethylene wax.
Claim 8
Dependent Claim
40 words
A facing sheet according to claim 5 wherein said solid, particulate lubricant is present in an amount, based on the total weight of the components of the ultra-thin facing layer, exclusive of said thermosetting resin, of at least 2.5 percent.
Claim 9
Dependent Claim
25 words
A facing sheet according to claim 7 wherein the maximum quantity of said solid, particulate lubricant in said ultra-thin facing layer is about 20 percent.
Claim 10
Dependent Claim
32 words
A facing sheet according to claim 7 wherein said solid, particulate lubricant is present in said ultra-thin facing layer in an amount of 0.175 to 0.5 pounds per ream of facing paper.
Claim 11
Dependent Claim
17 words
A facing sheet according to claim 5 wherein said thermosetting resin is polyester resin or melamine-formaldehyde resin.
Claim 12
Dependent Claim
20 words
A facing sheet according to claim 5 wherein said binder material is microcrystalline cellulose, carboxymethylcellulose, sodium alginate or mixtures thereof.
Claim 13
Independent Claim
217 words
A method of producing a scuff-resistant decorative laminate from at least one backing layer and a thermosetting resin impregnated facing sheet, comprising coating an overlay or decor facing sheet with an ultra-thin wet layer of (1) a solid, particulate lubricant in an amount sufficient such that during a subsequent consolidation step, the particulate lubricant melts and blooms to the surface thereby providing a laminate having simultaneously good clarity and improved scuff resistance; and (2) sufficient binder material for said lubricant particles to bind said particles to the surface of said facing sheet; drying said mixture on said facing sheet at a temperature of at least 140° F. and sufficient to enhance the bonding of said particles by said binder material to the surface of said decor sheet, to provide an ultra-thin dry layer of said mixture thereon, said drying being carried out at a temperature less than the melting temperature of said solid, particulate lubricant; impregnating said coated facing sheet with a polyester or melamine-formaldehyde thermosetting resin; assembling said resin-impregnated and coated facing sheet over at least said backing layer; and subjecting said assembly to heat and pressure at a temperature greater than the melting temperature of said solid, particulate lubricant to consolidate said backing layer and said facing sheet to thereby provide said scuff-resistant devorative laminate.
Claim 14
Independent Claim
217 words
A method of producing a scuff-resistant decorative laminate from at least one backing layer and a thermosetting resin impregnated facing sheet, comprising coating an overlay or decor facing sheet with an ultra-thin wet layer of (1) a solid, particulate lubricant in an amount sufficient such that during a subsequent consolidation step, the particulate lubricant melts and blooms to the surface thereby providing a laminate having simultaneously good clarity and improved scuff resistance; and (2) sufficient binder material for said lubricant particles to bind said particles to the surface of said facing sheet; drying said mixture on said facing sheet at a temperature of at least 140° F. and sufficient to enhance the bonding of said particles by said binder material to the surface of said decor sheet, to provide an ultra-thin dry layer of said mixture thereon, said drying being carried out at a temperature less than the melting temperature of said solid, particulate lubricant; impregnating said coated facing sheet with a polyester or melamine-formaldehyde thermosetting resin; assembling said resin-impregnated and coated facing sheet over at least said backing layer; and subjecting said assembly to heat and pressure at a temperature greater than the melting temperature of said solid, particulate lubricant to consolidate said backing layer and said facing sheet to thereby provide said scuff-resistant devorative laminate.
Claim 15
Dependent Claim
49 words
A method according to claim 12 wherein said solid, particulate lubricant is a polyethylene wax having a particle size less than 30 microns, a melting temperature of less than 260° F. and preferably 220°-230° F.; and the temperature at which said drying is carried out is approximately 170°-190° F.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1988-07-29 | 1989-01-28 | 1989-07-30 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-07-29 | 1993-01-28 | 1993-07-30 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-07-29 | 1997-01-28 | 1997-07-30 | $7700.00 | Window Closed / Lapsed |