A decorative and/or functional laminate using a nonwoven glass fibre material impregnated and or coated with a novel mixture of at least styrene maleic anhydride copolymer amic acid and cyanuric acid and melamine to provide opacity and a laminate surface suitable for printing or painting and/or sealing.
B32B 21/10 - Next to a fibrous or filamentary layer
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
B32B 33/00 - Layered products characterised by particular properties or particular surface features, e.g. particular surface coatingsLayered products designed for particular purposes not covered by another single class
B32B 38/00 - Ancillary operations in connection with laminating processes
A mixture comprising styrene maleic anhydride copolymer amic acid, cyanuric acid, and melamine that can be used as an opacifier, surface coating material or replacement material, and in laminate components.
C09D 135/06 - Copolymers with vinyl aromatic monomers
C09D 161/28 - Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds with melamine
C08L 35/06 - Copolymers with vinyl aromatic monomers
D21H 19/38 - Coatings with pigments characterised by the pigments
D21H 19/62 - Macromolecular organic compounds or oligomers thereof obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
The present invention provides a decorative and/or functional laminate using a nonwoven glass fibre material impregnated and or coated with a novel mixture of at least styrene maleic anhydride copolymer amic acid and cyanuric acid and melamine to provide opacity and a laminate surface suitable for printing or painting and/or sealing.
B32B 21/02 - Layered products essentially comprising wood, e.g. wood board, veneer, wood particle board in the form of fibres, chips, or particles
B32B 21/10 - Next to a fibrous or filamentary layer
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 17/06 - Layered products essentially comprising sheet glass, or fibres of glass, slag or the like comprising glass as the main or only constituent of a layer, next to another layer of a specific substance
C08L 35/06 - Copolymers with vinyl aromatic monomers
C09D 135/06 - Copolymers with vinyl aromatic monomers
C09D 161/28 - Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds with melamine
C08F 8/32 - Introducing nitrogen atoms or nitrogen-containing groups by reaction with amines
A decorative or building product in which one or more constituents of the product include melamine cyanurate in an amount effective to provide or enhance opacity in the product.
A method of manufacturing a decorative laminate includes applying one or more UV curable printing inks to a substrate, applying over the UV curable printing inks on the substrate a coating that is compatible with the inks, partially curing the compatible coating, placing the coated substrate in a hot press and completing curing at elevated temperature and pressure. Also disclosed is a decorative laminate comprising a substrate (11) having thereon printing (12) comprising one or more UV cured printing inks, and a coating (13) over the printing on the substrate which is compatible with the UV cured printing inks.
A method for manufacturing a laminate includes applying a first coating to a surface of a substrate, placing an overlaying material onto the first coating, and thereafter partially curing at least part of the first coating. A second coating may be applied to the overlaying material, and initial partial curing effected after the second coating has been applied to the combination of the first coating and the overlaying material. Typically, the substrate, the first coating, the second coating if applied and the overlaying material are pressed as an assembly in a hot press to form a laminate.
A method of manufacturing a resin-impregnated printed paper includes applying printed indicia to a paper substrate, impregnating the printed paper with resin and thereafter treating the resin-impregnated printed paper to reduce its water content and to at least partially cure the impregnating resin, whereby to produce a further cured resin-impregnated printed paper. The reduction of water is effected by irradiation with near infrared (NIR) radiation. The paper and/or printed indicia contain one or more pigments selected for their relatively low absorption of NIR radiation and/or a plurality of pigments selected for their mutual relatively low differences in absorption of NIR radiation whereby to minimize localised blistering of the resin arising from any NIR absorption by the pigments. Also disclosed is a décor paper and a laminate.
A method of manufacturing a highly transparent abrasion and scratch resistant overlay, or a highly transparent abrasion and scratch resistant décor paper surface, includes impregnating a paper with a first resin to produce a first stage impregnated paper substrate, and partially drying the first stage impregnated paper substrate. Applied to the partially dried first stage substrate is at least one coating of a second resin compatible with the first resin. The method further includes applying to the at least one coating, in a wet on wet process, a liquid resin layer containing hard particles for abrasion resistance, whereby to produce a composite paper, and drying and at least partially curing the composite paper to the required b-stage. Also disclosed is a highly transparent abrasion and scratch resistant overlay, or a highly transparent abrasion and scratch resistant décor paper surface.
D21H 27/28 - Structures being applied on the surface by special manufacturing processes, e.g. in presses characterised by the overlay sheet or the top layers of the structures treated to obtain specific resistance properties, e.g. against wear or weather
B32B 27/10 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance of paper or cardboard
D21H 19/66 - Coatings characterised by a special visual effect, e.g. patterned or textured
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 29/00 - Layered products essentially comprising paper or cardboard
D21H 19/80 - Paper comprising more than one coating
B32B 5/16 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer formed of particles, e.g. chips, chopped fibres, powder
B32B 33/00 - Layered products characterised by particular properties or particular surface features, e.g. particular surface coatingsLayered products designed for particular purposes not covered by another single class
D21H 19/82 - Paper comprising more than one coating superposed
B32B 27/04 - Layered products essentially comprising synthetic resin as impregnant, bonding, or embedding substance
B32B 27/06 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance
B32B 27/08 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance of synthetic resin of a different kind
D21H 17/68 - Water-insoluble compounds, e.g. fillers or pigments siliceous, e.g. clays
A heat reflective laminate comprises a substrate board (12), an intermediate carrier layer (22) comprising paper or non-woven fabric overlaying the substrate board, and a metal layer (24) on and adhered to the intermediate carrier layer. The intermediate carrier layer and the substrate board are bonded by a thermosetting resin at least partially impregnating the intermediate layer and an adjacent surface portion (13) of the board. Also disclosed is a method of manufacturing the laminate by combining the aforesaid layers (12, 22, 24) in a hot press.
B32B 15/00 - Layered products essentially comprising metal
B32B 15/18 - Layered products essentially comprising metal comprising iron or steel
B32B 37/10 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using direct action of vacuum or fluid pressure
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B32B 15/20 - Layered products essentially comprising metal comprising aluminium or copper
B32B 37/14 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
B32B 15/08 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance of synthetic resin
B32B 37/06 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
B32B 15/16 - Layered products essentially comprising metal next to a particulate layer
B32B 37/08 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the cooling method
10.
IMPROVEMENTS IN THE MANUFACTURE OF B-STAGE RESIN IMPREGNATED PAPERS OR NON-WOVENS
A method of manufacturing a b-stage resin impregnated décor paper that is suitable for inclusion in a decorative or industrial laminate, includes impregnating a décor print base paper with a resin carried by a solvent, which resin includes one or more of melamine formaldehyde, urea formaldehyde, and phenol formaldehyde or any combination of these. Thereafter the resin impregnated paper is irradiated with near infra-red (NIR) radiation selected to partially remove solvent by evaporation of the solvent, whereby to produce a partially dried and partially cured printable b-stage resin impregnated paper. The partially dried and partially cured printable b-stage resin impregnated paper is then printed to obtain a décor paper suitable for subsequent final curing in the formation of a decorative or industrial laminate. Apparatus is also disclosed, as is a method that entails impregnating a paper with an aqueous urea solution and irradiating the wet impregnated paper with near infra-red (NIR) radiation.
A method of, and apparatus for, manufacturing a decorative or industrial laminate in which one or more resin-impregnated papers (8a,8b) and a substrate (5) are combined in a press zone (26) in which heat and pressure are applied, whereby to form the laminate (10). In different aspects, the one or more resin-impregnated papers, the substrate and/or the laminate are pre- and/or post-treated (30,40,50,60) by being heated, preferably utilising near infra-red (NIR) irradiators (34,35,36).
B32B 27/04 - Layered products essentially comprising synthetic resin as impregnant, bonding, or embedding substance
B32B 29/06 - Layered products essentially comprising paper or cardboard specially treated, e.g. surfaced, parchmentised
B27N 3/18 - Auxiliary operations, e.g. preheating, humidifying, cutting-off
B32B 7/10 - Interconnection of layers at least one layer having inter-reactive properties
B44C 5/04 - Ornamental plaques, e.g. decorative panels, decorative veneers
B27N 3/06 - Making particle boards or fibreboards, with preformed covering layers, the particles or fibres being compressed with the layers to a board in one single pressing operation
A method and apparatus for manufacturing a b-stage pre-preg of resin impregnated paper or non-woven. The method includes irradiating a resin impregnated paper or non-woven with near infra-red (NIR) radiation to at least partially remove solvent by evaporation of the solvent, and to advance cure of the resin, whereby to produce an at least partially dried and at least partially cured b-stage pre-preg. The apparatus includes a resin impregnation station (10) for impregnating a paper or non-woven (5) with resin carried by a solvent, and a heating and curing station (20) having irradiation means (24, 25) to irradiate the impregnated paper or non-woven (5') with near infra-red (NIR) radiation.
D06M 15/00 - Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials with macromolecular compoundsSuch treatment combined with mechanical treatment
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