Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
  • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
  • B32B17/04—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments bonded with or embedded in a plastic substance
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B29/00—Layered products comprising a layer of paper or cardboard
  • B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B29/00—Layered products comprising a layer of paper or cardboard
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C5/00—Processes for producing special ornamental bodies
  • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
  • B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C5/00—Processes for producing special ornamental bodies
  • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
  • B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
  • B44C5/0484—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper containing metallic elements
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C5/00—Processes for producing special ornamental bodies
  • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
  • B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
  • B44C5/0492—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper containing wooden elements
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
  • D21H27/30—Multi-ply
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
  • B32B2260/02—Composition of the impregnated, bonded or embedded layer
  • B32B2260/021—Fibrous or filamentary layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
  • B32B2260/04—Impregnation, embedding, or binder material
  • B32B2260/046—Synthetic resin
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/06—Vegetal fibres
  • B32B2262/062—Cellulose fibres, e.g. cotton
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/10—Inorganic fibres
  • B32B2262/101—Glass fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2317/00—Animal or vegetable based
  • B32B2317/12—Paper, e.g. cardboard
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2479/00—Furniture
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2607/00—Walls, panels
  • B32B2607/02—Wall papers, wall coverings
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
  • D21H13/36—Inorganic fibres or flakes
  • D21H13/38—Inorganic fibres or flakes siliceous
  • D21H13/40—Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
  • D21H17/20—Macromolecular organic compounds
  • D21H17/21—Macromolecular organic compounds of natural origin; Derivatives thereof
  • D21H17/24—Polysaccharides
  • D21H17/28—Starch
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
  • Y10T156/10—Methods of surface bonding and/or assembly therefor
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
  • Y10T428/24851—Intermediate layer is discontinuous or differential
  • Y10T428/24868—Translucent outer layer
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
  • Y10T428/24926—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including ceramic, glass, porcelain or quartz layer

Definitions

• the present invention relates to the technical field of laminates.
• the subject of the invention is a decorative laminate, a method of preparing such a laminate and the uses of such a laminate, in the construction and furniture sector, in particular.
• decorative laminates In order to improve the surface appearance of panels that are most often based on wood, it is conventional to use sheets or sheets, called laminated or laminated, with a decorative function, called decorative laminates.
• such decorative laminates are in the form of a plate which generally comprises a part called nucleus, formed of an assembly of superimposed layers or sheets of cellulosic fibrous material, most often made of kraft paper, associated with the one of its large faces, with a decorative layer, most often in the form of a decorated paper.
• the layer (s) constituting the layer (s) decorative have colors or decorative patterns, is (are) impregnated (s) of melamine resins and / or covered with a surface coating impregnated with resin melamine.
• the layers constituting the core are impregnated with phenolic resins.
• the various constituent elements of these decorative laminates are bonded together by a so-called "high pressure” process described below.
• the face of the plate opposite the decorative layer is, in most cases, made suitable for bonding on a support.
• This surface coating is usually made of a sheet of paper, called “overlay”, alpha cellulose fibers impregnated with a thermosetting melamine-formaldehyde resin to achieve a transparent protective coating, after thermocompression.
• Such decorative laminates are, for example, described in US 3,616,021 or FR 2 267 206 in the name of the company FORMICA, to which we can refer for more details.
• Such types of decorative laminates are quite rigid and can not be shaped at room temperature.
• Such laminates are prepared by a batch process at high pressure and generally have a thickness of between 0.5 and 1 mm.
• the high pressure process consists of the simultaneous application of heat (temperature ⁇ 120 ° C.) and a determined high pressure (> 5 MPa), to allow the creep and then the polycondensation of the thermosetting resins in order to obtain a homogeneous material non-porous (density> 1.35 g / cm 3 ), the surface of which has the required appearance.
• the decorative laminates obtained by such a process are thinner (usually 0.25 to 0.6 mm thick), more flexible, but have a surface resistance, especially to external aggressions and chemicals, less performance.
• the present invention proposes to provide decorative laminates much more flexible, which can be implemented at room temperature, for the realization of plating on curved shapes in particular.
• Another object of the invention is to provide a decorative laminate that can be produced in an easy, low cost and easily machinable manner.
• Another object of the invention is to provide decorative laminates which have improved dimensional stability, especially in the event of a change in temperature, or in the event of a change in humidity conditions.
• the decorative laminates according to the invention must therefore be able to be used, not only on conventionally wood based supports, but innovatively on plaster or metal supports.
• the present invention therefore relates to a flexible decorative laminate comprising a core obtained by impregnation of a support with a thermosetting resin associated with a decorative layer, optionally covered with a protective coating, characterized in that the support comprises cellulosic fibers and glass fibers bonded together by a plasticizer.
• the decorative laminate according to the invention preferably has one or the other of the following characteristics, or any combination of these characteristics, when they do not exclude each other:
• the core is monolayer
• thermosetting resin is a phenolic resin, preferably a phenol / formaldehyde mixture, obtained in a basic reaction medium.
• the resin mass is advantageously 34 to 40%, preferably 36 to 38% of the total weight of the impregnated core.
• the glass fibers have a length greater than or equal to 4 mm
• the glass fibers represent from 10 to 20%, preferably from 16 to 17%, of the total mass of the support,
• the cellulosic fibers are cellulose fibers, bleached, unbleached or recycled, optionally in a mixture,
• the cellulosic fibers represent at least 60%, preferably at least 67% of the total mass of the support, the plasticizing agent is starch,
• the plasticizing agent represents from 10 to 20%, preferably from 14 to 16%, of the total mass of the support,
• the decorative laminate has a thickness of between 0.2 and 0.4 mm, advantageously of the order of 0.3 mm, its density is preferably greater than or equal to 1.35,
• the present invention also relates to a process for preparing a decorative laminate as defined above, in which a core is prepared by impregnating a support comprising cellulosic fibers and glass fibers bonded together by an agent plasticizer, with a thermosetting resin and a stack of the impregnated core obtained and a decorative layer, optionally covered with a protective coating, is assembled under pressure.
• a core is prepared by impregnating a support comprising cellulosic fibers and glass fibers bonded together by an agent plasticizer, with a thermosetting resin and a stack of the impregnated core obtained and a decorative layer, optionally covered with a protective coating, is assembled under pressure.
• the assembly is carried out at a temperature of between 115 ° C. and 195 ° C.
• the applied pressure is between 2 and 10 MPa.
• the present invention also relates to the use of a decorative laminate as defined above, as a coating material for a support of wood, plaster, concrete, cellular concrete or metal.
• Fig. 1 is a schematic sectional view of the various constituents of a laminate according to the invention.
• Fig. 2 shows a schematic sectional view of a device for preparing, simultaneously, several decorative laminates.
• the decorative laminates I according to the invention are composed of a core 1, a decorative layer 2, most often covered with a protective coating 3, as illustrated in FIG. 1.
• the originality of the decorative laminates according to the invention is directly related to the core 1, and the materials that constitute it.
• This core 1 has an atypical composition for a decorative laminate. It contains not only cellulose fibers, but also glass fibers and a plasticizer, most often in the form of an organic polymer.
• the glass fibers are preferably longer than or equal to 4 mm. Their proportion advantageously represents from 10 to 20%, and preferably from 16 to 17%, of the total mass of the support. These glass fibers give its rigidity and stability to the new laminate obtained.
• These glass fibers are mixed with cellulose fibers, which may be of different qualities, in particular bleached, unbleached or recycled, optionally mixed.
• the proportion of these fibers in the support advantageously represents at least 60%, preferably at least 67% of the total mass of the impregnating support.
• the presence of the glass fibers makes it possible to obtain good dimensional stability of the laminate and gives it good rigidity.
• a plasticizer is used.
• the plasticizer represents from 10 to 20%, and preferably from 14 to 16%, of the total mass of the core before impregnation.
• this plasticizer is vegetable starch.
• plasticizers can be used such as polyvinyl alcohol, sugar, acetoguanamine (6-methyl 1,3,5-triazine 2,4-diyldiamine), caprolactam, thioureas.
• This plasticizing agent contributes to obtaining the flexibility characteristics of the decorative laminate obtained. But above all, the plasticizer improves the behavior of the laminate, thermal expansion in a temperature range of about 20 to 100 ° C.
• the decorative laminate according to the invention has advantageous plastic properties .
• the presence of this plasticizer also influences the mechanical strength characteristics, such as the stiffness and the tensile strength of the core 1 and the decorative laminate I obtained with such a core 1.
• the support of impregnation has a basis weight of 100 to 150 g / m 2 , preferably of the order of 130 g / m 2 .
• the total mass of the glass fibers, the cellulose fibers and the plasticizer agent represents at least 98% of the total mass of the impregnating support.
• the maximum 2% remaining can, for example, correspond to retention agents or flocculants, typically present in paper sheets.
• the core 1 is obtained by impregnation of an impregnating support as defined above with a thermosetting resin.
• the impregnating support is in the form of a sheet whose porosity or air permeability characteristics are advantageously chosen to allow the thermosetting resin, and in particular the phenolic resin, to penetrate the entire surface of the sheet. thickness of the support and soak it.
• the values of porosity or resistance to the penetration of the air of the impregnating support according to the GURLEY test are preferably from 1 to 15 seconds with a preference for the values of 3 to 6 seconds.
• Good impregnation of the support with the phenolic resin allows, in particular to ensure the characteristics required by the standard decorative laminates EN438 -1 & 2.
• thermosetting resin used gives the decorative laminates I obtained mechanical strength characteristics, according to the different mechanical stresses to which they are subjected.
• the impregnating resin of the core 1 is preferably a thermosetting phenolic resin, preferably a phenol / formaldehyde mixture, obtained in a basic reaction medium. This resin also contributes to the possible shaping of the finished laminate.
• the impregnation of the support is carried out with a mixture of formaldehyde and phenol which has one or more of the following characteristics:
• the pH at 20 ° C. of the resin is from 7.0 to 12, preferably from 7 to 8,
• the amount of dry matter present in the resin is in the range of 35 to 65%, preferably 50 to 55%; the measurement is by means of an apparatus which simultaneously makes it possible to heat and weigh the loss of mass, and thus to determine the loss of volatile matter during the heating time. Heating is performed at 180 0 C until stabilization of the mass loss.
• the impregnation of the support is, for example, carried out by dipping the impregnating support in the form of a sheet in a bath of the thermosetting resin. At the outlet of the bath, the support is soaked thoroughly with the thermosetting resin.
• the amount of resin that impregnates the support can be adjusted, according to any technique well known to those skilled in the art, for example by calibration or dosage.
• the degree of impregnation of the core with the thermosetting resin is such that the resin mass advantageously represents from 34 to 40%, preferably from 36 to 38% of the total weight of the impregnated core, on the laminate obtained (c. that is to say after removal of the volatiles present in the impregnation bath, elimination which takes place during the thermocompression step).
• the impregnated core generally contains, prior to lamination, a mass percentage of 6-8% volatiles (volatile mass / impregnated core weight x 100), preferably 6.5 to 7.5%. These volatiles are removed during the subsequent lamination step. These volatiles come in particular from the solvent contained in the impregnating resin, which are generally water and / or an alcohol.
• the core 1 is associated on its large face Ii with a decorative layer 2.
• the decoration can be united in color or correspond to a pattern or design. Any type of decorative layer used in the prior art can be implemented.
• the decorative layer comprises several sheets, with for example a plain sheet, acting as a screen, to opacify the decor .
• This decorative layer may be impregnated with a thermosetting resin, advantageously with a melamine resin.
• the printed paper is, for example, made in rotogravure and its basis weight is preferably between 65 and 100 g / m 2 .
• the decorative layer may be covered with a surface coating. This is particularly the case, when it is not impregnated with a thermosetting resin, it is then, the surface coating which provides the protection.
• the surface coating can be either a weak paper basis, called “overlay”, or directly a layer of transparent thermosetting resin, melamine type.
• An overlay paper is generally made of alpha cellulose fibers impregnated with a thermosetting melamine-formaldehyde resin. Such paper preferably has a basis weight of 14 to 50 g / m 2 , and provides sufficient amount of melamine resin to the surface of the laminate to achieve the desired strength characteristics in accordance with EN438.
• the "overlay" is a transparent layer and makes it possible to obtain a very good reflection of the impression of the decor present on the decorative sheet.
• the support impregnated with thermosetting resin, the decorative layer optionally covered with a surface coating are stacked and associated by thermocompression. During this lamination step, a crosslinking of the thermosetting resin and a bond between the core 1 obtained and the decorative layer are obtained, this bond being produced by virtue of the thermosetting resin.
• the decorative laminate I according to the invention is therefore different by the nature of the core which is no longer made of several sheets of kraft paper, but a core of specific paper based on cellulose fibers, glass fibers and plasticizer.
• This core advantageously consists of a single sheet.
• the decorative laminate according to the invention preferably has a thickness of between 0.2 and 0.4 mm, advantageously of the order of 0.3 mm. Its density is preferably greater than or equal to 1.35.
• the decorative laminates according to the invention can be prepared by high pressure lamination. In general, their preparation process is carried out in four steps:
• Impregnation consists in introducing into the different layers to be impregnated, namely the constituent support of the core, the decorative layer and the coating overlay, the corresponding resin.
• the impregnator consists of a head called reel for unwinding the paper reels, an impregnation head which comprises a resin receiving tank and a system for quantifying the amount of resin that is desired introduce by m 2 , a dryer that eliminates the amount of solvent provided by the resin and a system that puts the impregnated support in the form of sheets or coils.
• Stacking consists in superimposing the various constituent elements of the laminate: the impregnated support (corresponding to the core 1), then the decorative layer 2 and the coating 3, so that the decorative layer is positioned between the core 1 and the coating 3.
• the stratification makes it possible to assemble the various layers and is carried out by thermocompression, most often in a press.
• the stratification is advantageously carried out at a temperature of 115.degree.
• the pressure applied is preferably between 2 and 10
• a finishing step consisting of a cutting operation of the edges of the laminate obtained, is most often performed to put the decorative laminate in the final format.
• the decorative laminates according to the invention are preferably obtained under high pressure pressing, but their mechanical characteristics differ from high pressure laminates (HPL) and continuous laminates (CPL). that we find on the market.
• HPL high pressure laminates
• CPL continuous laminates
• a decorative laminate according to the invention releases, by its combustion, a caloric potential measured according to the ISO5660 method which is at values below 4.5 MJ / m 2 , - they are very easy to put into operation. and easy machining, they can be cut with conventional tools, such as cutter or chisel,
• the decorative laminates according to the invention can be used as coating material for different types of wood-based supports, but also in plasterboard, plaster, cellular concrete (SIPOREX), metal, etc.
• the decorative laminates according to the invention exhibit a thermal expansion in the direction of the length and also in the cross direction, much higher than that of the laminates of the prior art.
• ISO 11359-1 1999 October 1999 Plastics-Thermomechanical Analysis (TMA) - partial: general principles. It is located, over a temperature range of 20 to 100 0 C, between 0 and 500 ppm (10 ⁇ 6 meter)
• decorative laminates allow a wide range of uses for the layout and decoration of the building, including the realization of partitions, doors, furniture, bathroom, office.
• the decorative laminates of the invention can be implemented, in particular in the construction of high-rise buildings, establishments receiving the public, thanks to these performance of fire behavior.
• Example of embodiment of a decorative laminate according to the invention A sheet of paper of 130 g / m 2 (SISD130 from Cascades, Sainte Marie, France) is used, intended to form the core of the laminate.
• This sheet of paper is composed of 68% by weight of bleached cellulose fibers, 14% by weight of starch and 17% by weight of glass fibers with a minimum length of 4 mm.
• This sheet of paper is impregnated with phenolic resin, so that after impregnation, the resin mass corresponds to 36-38% of the total mass of the impregnated paper.
• the total mass of the impregnated paper comprises 6.5-7.5% volatiles.
• the phenolic resin used is prepared in the following manner: the molar ratio of formaldehyde to phenol used is 1.35 and is also used in the potash liquor, at a molar ratio on the phenol of 0.045.
• an aqueous solution of formaldehyde at 50% by weight, an aqueous solution of phenol at 99.9% by weight, reduced to 92% by addition of water and a potassium hydroxide solution at 50% by weight are used.
• a light and translucent paper sheet of 24 g / m 2 of paper material (TVONA 25 from Schoeller) is also used, which is impregnated with melamine resin, so that after impregnation, the mass of resin corresponds to at 76-78 of the total mass of the impregnated paper.
• the total mass of the impregnated paper comprises 7 - 8% volatiles.
• This sheet of paper is commonly called: overlay.
• the melamine resin used is prepared as follows: a molar ratio of formaldehyde to melamine of 1.65 and a proportion of water of 2.58 mol% are used.
• the total amount of melamine is introduced and the reaction mixture is very rapidly heated to 95 ° C +/- 1 and maintained until a volume dilutability of 1.6 +/- 0.1 based on resin volume taken from the reactor and reduced to 20 ° C.
• This dilutability is determined by taking 30 ml of resin brought to a temperature of 20 ° C. at which 48 ml of water at 20 ° C.: when a turbidity is obtained, the temperature is lowered.
• magnesium sulphamate an accelerator for melamine resin, is added.
• the melamine resin obtained has the following characteristics:
• the impregnation steps of the papers, with either the phenolic resin or the melamine resin are carried out by dipping in the bath of phenolic resin or melamine, then the amount of resin is set by calibrating rollers and the impregnated paper is dried in a blown hot air dryer. Finally, the sheet obtained is cooled using a cooling roll and formatted using a rotary type cutter.
• the parameters of the impregnator used are as follows:> Resin bath temperature: 35 ° C +/- 2> Temperature of the dryer zones 5 successive zones are at 120 ° C.,
• the decorative laminate is then made manually by stacking the sheets below according to the desired format and in the order below, as illustrated in FIG. 1: a surface coating 3, corresponding to the overlay sheet, impregnated with melamine resin,
• a core 1 (or more precisely a support impregnated with phenolic resin), corresponding to the sheet of paper impregnated with phenolic resin,
• the surface coating 3, the decorated paper 2, and the core 1 constitutes a stack II.
• the lamination is then carried out by thermal conduction obtained using metal trays 5 and 6 perforated, to allow the passage of a coil of superheated water, these two trays acting as a press.
• the firing cycle of the laminate is then carried out by heating to a maximum temperature of less than 130 ° C., and then cooling of the laminate is carried out up to 65 ° C. This thermal cycle is carried out under an isobar of 6 to 8 MPa, or even 4 to 5 MPa.
• the following firing cycle is used: a) Raising the so-called bearing temperature to 110 0 C of the panel located in the middle of the stage b) Maximum temperature of the inner panel: 128-130 0 C c) Bearing duration at 110 0 C is 16 minutes +/- 2 ° d) cooling to 60 0 C at the inner panel.
• the separator sheet 4 is removed.
• the next step is finishing, which involves removing burrs on each side of the laminate. This is done using a saw, knife or router. There is no step of sanding the laminate on the face I 2 of the core 1, opposite to the decorative layer 2.
• the fij. 2 illustrates a stack in a press between two plates 5 and 6, allowing the production of several laminates I, simultaneously, which improves productivity.
• the mattress sheets 7 serve to partially limit the lamination defects.
• Sheet 8 stainless steel structured or not are positioned in front of the decorated face, so that each overlay is in contact with a sheet.
• a support plate can be inserted between the plate 6 and the mattress 7 and thus allow the movement of the various elements from top to bottom.

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• Life Sciences & Earth Sciences (AREA)
• Engineering & Computer Science (AREA)
• Wood Science & Technology (AREA)
• Laminated Bodies (AREA)

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• 2005
  • 2005-10-27 FR FR0510972A patent/FR2892658B1/fr not_active Expired - Fee Related
• 2006
  • 2006-10-26 WO PCT/FR2006/051107 patent/WO2007048977A1/fr not_active Ceased
  • 2006-10-26 US US12/083,889 patent/US7964270B2/en not_active Expired - Fee Related
  • 2006-10-26 EP EP06831299A patent/EP1940634A1/de not_active Withdrawn
• 2008
  • 2008-04-01 NO NO20081579A patent/NO20081579L/no not_active Application Discontinuation

Non-Patent Citations (1)

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