CA2668891A1 - Laminated panel - Google Patents
Laminated panel Download PDFInfo
- Publication number
- CA2668891A1 CA2668891A1 CA 2668891 CA2668891A CA2668891A1 CA 2668891 A1 CA2668891 A1 CA 2668891A1 CA 2668891 CA2668891 CA 2668891 CA 2668891 A CA2668891 A CA 2668891A CA 2668891 A1 CA2668891 A1 CA 2668891A1
- Authority
- CA
- Canada
- Prior art keywords
- layer
- resin
- particles
- core layer
- decorative layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
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
- B32B29/00—Layered products comprising a layer of paper or 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding 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
- B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
- B32B19/04—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material
-
- 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
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/14—Layered products comprising a layer of synthetic resin next to a particulate layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B82—NANOTECHNOLOGY
- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
-
- 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
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
-
- 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
- Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
- Y10T428/259—Silicic material
-
- 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
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31971—Of carbohydrate
-
- 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
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31971—Of carbohydrate
- Y10T428/31993—Of paper
Abstract
A method for the production of a laminate is provided, comprising the steps of: 1) providing a stack of layers including a decorative layer, a core layer, and optionally an overlayer; 2) impregnating one or both of the decorative layer and overlayer with a resin formulation that includes nanoclay particles disposed within a thermoset resin, wherein the concentration of the nanoclay particles within the thermoset resin is great enough to form a physical barrier within the resin and low enough to avoid a hazy appearance; and 3) subjecting the stack of layers to sufficient heat and pressure to cause the layers to bond to one another. According to an aspect of the present invention, a laminate is provided producible by the above-described method.
Claims (22)
1. A laminated panel, comprising:
a core layer having a first side and a second side, which second side is opposite the first side;
a decorative layer bonded to the first side of the core layer; and an overcoat layer disposed on a side of the decorative layer opposite the core layer, said overcoat layer containing nanoclay particles disposed in a layer of cured thermoset resin, which particles have a mean particle size of about 50 nm or less.
a core layer having a first side and a second side, which second side is opposite the first side;
a decorative layer bonded to the first side of the core layer; and an overcoat layer disposed on a side of the decorative layer opposite the core layer, said overcoat layer containing nanoclay particles disposed in a layer of cured thermoset resin, which particles have a mean particle size of about 50 nm or less.
2. The laminated panel of claim 1, wherein the nanoclay particles comprise a smectite clay mineral.
3. The laminated panel of claim 2, wherein the smectite clay mineral includes montmorillonite.
4. The laminated panel of claim 1, wherein the nanoclay particles comprise synthetic layered silicate particles.
5. The laminated panel of claim 4, wherein the synthetic layered silicate particles are in the range of about 0.01% to 2.00% of the weight of the overcoat layer.
6. The laminated panel of claim 4, wherein the core layer comprises a plurality of sheets of kraft paper.
7. The laminated panel of claim 4, further comprising a backer layer bonded to the second side of the core layer.
8. The laminated panel of claim 4, wherein the overcoat layer includes one or more overlay sheets comprising a cellulose material.
9. The laminated panel of claim 4, wherein the synthetic layered silicate particles are typically wafer-shaped, with an edge disposed between a pair of faces.
10. The laminated panel of claim 9, wherein the edge of each particle has a first electrical charge, and the faces have a second electrical charge which is opposite from the first electrical charge.
11. A laminated panel, comprising:
a core layer;
a decorative layer bonded to the first side of the core layer, and impregnated with a resin containing a concentration of nanoclay particles sufficient to form a physical barrier within the resin, which barrier is resistant to chemical degradation.
a core layer;
a decorative layer bonded to the first side of the core layer, and impregnated with a resin containing a concentration of nanoclay particles sufficient to form a physical barrier within the resin, which barrier is resistant to chemical degradation.
12. The laminated panel of claim 11, wherein the nanoclay particles include synthetic layered silicate particles.
13. The laminated panel of claim 12, wherein the synthetic layered silicate particles are in the range of about 0.01% to 4.00% of the weight of the resin impregnating the decorative layer.
14. A laminated panel, comprising:
a core layer having a first side and a second side, which second side is opposite the first side;
a decorative layer bonded to the first side of the core layer; and an overcoat layer disposed on a side of the decorative layer opposite the core layer, said overcoat layer containing a chemical resistance barrier disposed in a layer of cured thermoset resin, which barrier is formed from synthetic layered silicate particles at least some of which are electrically attracted to one another.
a core layer having a first side and a second side, which second side is opposite the first side;
a decorative layer bonded to the first side of the core layer; and an overcoat layer disposed on a side of the decorative layer opposite the core layer, said overcoat layer containing a chemical resistance barrier disposed in a layer of cured thermoset resin, which barrier is formed from synthetic layered silicate particles at least some of which are electrically attracted to one another.
15. A method for the production of a laminate, comprising the steps of:
providing a decorative layer and a core layer, said decorative layer including at least one paper sheet;
impregnating the decorative layer with a resin formulation that includes electrostatically charged synthetic particles disposed within a thermoset resin, wherein the charged synthetic layered particles attract to one another upon application of the resin formulation and are in sufficient concentration to form a barrier within the resin; and subjecting a stack of the decorative layer and core layer to sufficient heat and pressure to cause the layers to bond to one another.
providing a decorative layer and a core layer, said decorative layer including at least one paper sheet;
impregnating the decorative layer with a resin formulation that includes electrostatically charged synthetic particles disposed within a thermoset resin, wherein the charged synthetic layered particles attract to one another upon application of the resin formulation and are in sufficient concentration to form a barrier within the resin; and subjecting a stack of the decorative layer and core layer to sufficient heat and pressure to cause the layers to bond to one another.
16. The method of claim 15, wherein the barrier within the resin is operable to provide resistance to chemical degradation.
17. The method of claim 15, wherein the synthetic layered silicate particles are in the range of about 0.005% to 2.00% of the weight of the resin formulation.
18. The method of claim 15, comprising the further step of providing a backer layer and wherein the core layer is disposed between the decorative layer and the backer layer within the stack.
19. The method of claim 15, further comprising the step of providing an overcoat layer disposed on a side of the decorative layer opposite the core layer, which overcoat layer includes the resin formulation.
20. The method of claim 15, further comprising the step of drying the decorative sheet to a volatile content in the range of about 5.0% to 15.0%, prior to subjecting the stack to heat and pressure.
21. A method for the production of a laminate, comprising the steps of:
providing a decorative layer having at least one paper sheet, a first side and a second side;
providing a core layer comprising one or more materials selected from the group consisting of plywood, medium density fiberboard, high density fiberboard, particleboard, plastic and nylon;
impregnating the decorative layer with a resin formulation that includes electrostatically charged synthetic particles disposed within a thermoset resin, wherein the charged synthetic layered particles attract to one another upon application of the resin formulation and are in sufficient concentration to form a barrier within the resin; and stacking the core layer and the decorative layer such that the core layer is disposed in contact with the second side of the decorative layer;
subjecting the stack of layers to heat in the range of about 180°C to 210°C and pressure in the range of about 300 psi to 400 psi for a sufficient amount of time to cause the layers to bond to one another.
providing a decorative layer having at least one paper sheet, a first side and a second side;
providing a core layer comprising one or more materials selected from the group consisting of plywood, medium density fiberboard, high density fiberboard, particleboard, plastic and nylon;
impregnating the decorative layer with a resin formulation that includes electrostatically charged synthetic particles disposed within a thermoset resin, wherein the charged synthetic layered particles attract to one another upon application of the resin formulation and are in sufficient concentration to form a barrier within the resin; and stacking the core layer and the decorative layer such that the core layer is disposed in contact with the second side of the decorative layer;
subjecting the stack of layers to heat in the range of about 180°C to 210°C and pressure in the range of about 300 psi to 400 psi for a sufficient amount of time to cause the layers to bond to one another.
22. A method for the production of a laminate, comprising the steps of:
providing a decorative layer having at least one paper sheet, a first side and a second side;
providing a core layer comprising one or more materials selected from the group consisting of plywood, medium density fiberboard, high density fiberboard, particleboard, plastic and nylon;
applying an overcoat layer to the first side of the decorative layer, which overcoat layer includes a resin formulation having electrostatically charged synthetic particles disposed within a thermoset resin, wherein the charged synthetic layered particles attract to one another upon application of the resin formulation to the decorative layer, and which particles are in sufficient concentration within the overcoat layer to form a barrier within the resin; and stacking the core layer and the decorative layer such that the core layer is disposed in contact with the second side of the decorative layer;
subjecting the stack of layers to sufficient heat and pressure to cause the layers to bond to one another.
providing a decorative layer having at least one paper sheet, a first side and a second side;
providing a core layer comprising one or more materials selected from the group consisting of plywood, medium density fiberboard, high density fiberboard, particleboard, plastic and nylon;
applying an overcoat layer to the first side of the decorative layer, which overcoat layer includes a resin formulation having electrostatically charged synthetic particles disposed within a thermoset resin, wherein the charged synthetic layered particles attract to one another upon application of the resin formulation to the decorative layer, and which particles are in sufficient concentration within the overcoat layer to form a barrier within the resin; and stacking the core layer and the decorative layer such that the core layer is disposed in contact with the second side of the decorative layer;
subjecting the stack of layers to sufficient heat and pressure to cause the layers to bond to one another.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US86447706P | 2006-11-06 | 2006-11-06 | |
| US60/864,477 | 2006-11-06 | ||
| US11/564,094 US7807263B2 (en) | 2006-11-06 | 2006-11-28 | Laminated panel |
| US11/564,094 | 2006-11-28 | ||
| PCT/US2007/083635 WO2008058075A1 (en) | 2006-11-06 | 2007-11-05 | Laminated panel |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2668891A1 true CA2668891A1 (en) | 2008-05-15 |
| CA2668891C CA2668891C (en) | 2012-03-27 |
Family
ID=39110590
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2668891 Active CA2668891C (en) | 2006-11-06 | 2007-11-05 | Laminated panel |
Country Status (9)
| Country | Link |
|---|---|
| US (2) | US7807263B2 (en) |
| EP (1) | EP2091732B1 (en) |
| JP (1) | JP5562032B2 (en) |
| KR (1) | KR101121959B1 (en) |
| AU (1) | AU2007316459B2 (en) |
| CA (1) | CA2668891C (en) |
| IL (1) | IL198566A (en) |
| NZ (1) | NZ577158A (en) |
| WO (1) | WO2008058075A1 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20080234423A1 (en) * | 2007-03-21 | 2008-09-25 | Alberta Research Council Inc. | Phyllosilicate modified resins for lignocellulosic fiber based composite panels |
| DE102007026170A1 (en) * | 2007-06-04 | 2008-12-11 | Akzenta Paneele + Profile Gmbh | Laminated decorative plate and method for its production |
| US20190016008A1 (en) * | 2015-08-07 | 2019-01-17 | Basf Se | Method for coating wood-based materials without abrading the surface |
Family Cites Families (29)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2219843B1 (en) | 1973-03-02 | 1975-08-22 | Formica Sa | |
| US3928706A (en) | 1973-06-25 | 1975-12-23 | Formica Int | Wear-resistant decorative laminates and methods for producing same |
| US3927140A (en) * | 1973-10-24 | 1975-12-16 | Research Corp | Adhesive composition |
| JPS6357232A (en) * | 1986-08-28 | 1988-03-11 | イビデン株式会社 | Decorative board with metallic gloss surface and manufacture thereof |
| JP2809313B2 (en) * | 1989-10-04 | 1998-10-08 | イビデン株式会社 | Thermosetting resin decorative board |
| US5429867A (en) * | 1993-01-11 | 1995-07-04 | James River Corporation Of Virginia | Synthetic hectorite coated flexible film |
| US5344704A (en) | 1993-04-07 | 1994-09-06 | Nevamar Corporation | Abrasion-resistant, aesthetic surface layer laminate |
| US5989696A (en) | 1996-02-13 | 1999-11-23 | Fort James Corporation | Antistatic coated substrates and method of making same |
| US5952093A (en) | 1997-02-20 | 1999-09-14 | The Dow Chemical Company | Polymer composite comprising a inorganic layered material and a polymer matrix and a method for its preparation |
| JP4028061B2 (en) * | 1998-01-16 | 2007-12-26 | 大日本印刷株式会社 | Inorganic decorative board and method for producing the same |
| JPH11207877A (en) * | 1998-01-20 | 1999-08-03 | Dainippon Printing Co Ltd | Decorative plate and its manufacture |
| JP4205241B2 (en) * | 1999-03-04 | 2009-01-07 | 住友化学株式会社 | Laminated body |
| JP2001030436A (en) * | 1999-07-22 | 2001-02-06 | Showa Denko Kk | Decorative plate and its laminate |
| JP2001199016A (en) * | 1999-11-08 | 2001-07-24 | Oji Paper Co Ltd | Gas barrier laminate |
| SE516696C2 (en) | 1999-12-23 | 2002-02-12 | Perstorp Flooring Ab | Process for producing surface elements comprising an upper decorative layer as well as surface elements produced according to the method |
| US6403231B1 (en) * | 2000-05-12 | 2002-06-11 | Pechiney Emballage Flexible Europe | Thermoplastic film structures having improved barrier and mechanical properties |
| EP1328554A2 (en) * | 2000-09-21 | 2003-07-23 | Rohm And Haas Company | Improved nanocomposite compositions and methods for making and using same |
| JP2002117741A (en) * | 2000-10-10 | 2002-04-19 | Shin Etsu Polymer Co Ltd | Laser marked key top member |
| JP2002192065A (en) * | 2000-12-22 | 2002-07-10 | Inax Corp | Weather resistant coated article |
| US7026038B2 (en) | 2001-04-04 | 2006-04-11 | Nevamar Company, Llc | Wear resistant laminates |
| US6702967B2 (en) | 2001-07-27 | 2004-03-09 | E. I. Du Pont De Nemours And Company | Process for preparing decorative surface materials having a decorative pattern |
| JP2003326651A (en) * | 2002-05-15 | 2003-11-19 | Toray Ind Inc | Mat-like gas-barrier laminated film |
| US7745012B2 (en) * | 2003-01-22 | 2010-06-29 | Panolam Industries International, Inc. | Leather decorative laminate |
| JP2005162868A (en) * | 2003-12-02 | 2005-06-23 | Sekisui Chem Co Ltd | Resin composition for use in protective layer |
| JP4074608B2 (en) * | 2004-04-23 | 2008-04-09 | 三洲男 藤原 | Coating method for interior materials |
| US7438972B2 (en) | 2004-06-24 | 2008-10-21 | Ppg Industries Ohio, Inc. | Nanoparticle coatings for flexible and/or drawable substrates |
| US7736836B2 (en) * | 2004-09-22 | 2010-06-15 | Jonghan Choi | Slip film compositions containing layered silicates |
| US8309230B2 (en) | 2004-11-12 | 2012-11-13 | Inmat, Inc. | Multilayer nanocomposite barrier structures |
| JP5058542B2 (en) * | 2006-09-21 | 2012-10-24 | アイカ工業株式会社 | Flame retardant prepreg and incombustible decorative board |
-
2006
- 2006-11-28 US US11/564,094 patent/US7807263B2/en active Active
-
2007
- 2007-11-05 KR KR1020097011549A patent/KR101121959B1/en active IP Right Grant
- 2007-11-05 WO PCT/US2007/083635 patent/WO2008058075A1/en active Application Filing
- 2007-11-05 CA CA 2668891 patent/CA2668891C/en active Active
- 2007-11-05 JP JP2009536420A patent/JP5562032B2/en not_active Expired - Fee Related
- 2007-11-05 NZ NZ577158A patent/NZ577158A/en unknown
- 2007-11-05 AU AU2007316459A patent/AU2007316459B2/en active Active
- 2007-11-05 EP EP07844868.5A patent/EP2091732B1/en active Active
-
2009
- 2009-05-05 IL IL198566A patent/IL198566A/en active IP Right Grant
-
2010
- 2010-09-30 US US12/894,304 patent/US20110017399A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| IL198566A (en) | 2015-07-30 |
| IL198566A0 (en) | 2010-02-17 |
| KR20090075890A (en) | 2009-07-09 |
| EP2091732A1 (en) | 2009-08-26 |
| US20110017399A1 (en) | 2011-01-27 |
| US7807263B2 (en) | 2010-10-05 |
| EP2091732B1 (en) | 2018-08-08 |
| AU2007316459B2 (en) | 2011-02-03 |
| WO2008058075A1 (en) | 2008-05-15 |
| JP5562032B2 (en) | 2014-07-30 |
| AU2007316459A1 (en) | 2008-05-15 |
| CA2668891C (en) | 2012-03-27 |
| NZ577158A (en) | 2012-05-25 |
| KR101121959B1 (en) | 2012-03-09 |
| JP2010509102A (en) | 2010-03-25 |
| US20080107891A1 (en) | 2008-05-08 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request |