Method of Manufacture of Direct Pressure Laminates
Using a method of direct-pressure laminating employing short cycle presses (low pressure process), one or more impregnated overlays and a non-impregnated decor sheet are laminated to a base material.
1 . A method of direct-pressure laminating at least one impregnated overlay and a non-impregnated decor sheet to a base material employing short cycle presses (low pressure process).
2 . A method as claimed in claim 1 using a resin/overlay composition with a flow value larger than 8%.
3 . A method as claimed in claim 2 , wherein the resin comprises at least one modifier for adjusting a flow value selected from the group consisting of di- or polyols, polyether dials and alkoxylated alcohols, and a mixture thereof.
4 . A method as claimed in claim 3 , wherein the modifier is selected from the group consisting of C 2 to C 12 diols.
5 . A method as claimed in claim 2 , wherein the resin is an aminoplast resin.
6 . A method as claimed in claim 5 , wherein the resin is a melamine resin.
7 . A method as claimed in claim 2 , wherein the resin comprises at least one additive selected from the group consisting of hardeners, surface-active agents, separating agents and anti-foaming agents.
8 . A method as claimed in claim 1 , wherein the base material is a material selected from the group consisting of high density fibre board (HDF), a medium density fibre board (MDF), a chipboard, a gypsum board, and a glass fibre board.
9 . A method as claimed in claim 1 , wherein at least one kraft paper is laminated to the base material.
10 . A method as claimed in claim 1 , wherein the at least one overlay is first impregnated with a standard resin and then with another resin to yield a resin/overlay composition with a flow value larger than 8%.
11 . A method as claimed in claim 1 , wherein the overlay has a paper weight of less than 50 g/m 2 , and/or is impregnated with resin by weight percentages of 300 and 500%, in relation to the paper weight.
12 . A method as claimed in claim 1 , wherein the overlay is cured to a prepreg before being laminated to the decor sheet and the base material.
13 . A method as claimed in claim 1 , wherein a structure is imprinted in the laminating process.
14 . A method as claimed in claim 1 , employing a pressure of less than 40 bar.
15 . A method as claimed in claim 1 , employing a temperature lower than 220° C.
16 . A laminate produced by a method as set forth in claim 1 .
17 . A method as claimed in claim 1 using a resin/overlay composition with a flow value from larger than 8% to 30%.
18 . A method as claimed in claim 1 using a resin/overlay composition with a flow value of 10 to 20%.
19 . A method as claimed in claim 4 , wherein the modifier is selected from the group consisting of 1,4-butane diol, 1,5-pentane diol, and 1,6-hexane diol.
20 . A method as claimed in claim 1 , employing a pressure of less of 20 to 35 bar.
21 . A method as claimed in claim 1 , employing a temperature of 140 to 200° C.
22 . A method as claimed in claim 2 , wherein the resin/overlay composition have a content of volatile components between 6 and 8%.
23 . A method as claimed in claim 2 , wherein the resin/overlay composition have a content of volatile components between 6.9 and 7.4%.
24 . A method as claimed in claim 3 , wherein the modifier is added in an amount of 8 to 20 weight parts per 100 parts resin.