Decorative laminate and corresponding production method
A method is described for producing a decorative laminate including: providing a decorative layer, applying a mixture of a thermohardening synthetic resin and hard particles to said layer, pressing the decorative layer and the mixture in a hot press at a press temperature in order to obtain a laminate, the mixture also containing a wax whose melting point is less than approximately 140° C. and/or by more than approximately 50° C. lower than the press temperature. A decorative laminate, a decorative laminate board and a method for producing a decorative prepreg sheet are also disclosed.
1. A method for producing a decorative laminate, comprising:
providing a decorative layer,
applying a mixture comprising a thermohardening synthetic resin and hard particles to the decorative layer,
applying at least one wax to the decorative layer or to the mixture,
pressing a supporting substrate, the decorative layer, the mixture and the wax in a hot press at a press temperature to form a decorative laminate board,
wherein a melting range of the at least one wax is at least one of below a temperature of about 140° C. and by more than 50° C. below the press temperature, and
drying the applied mixture at a drying temperature above the melting range of the wax.
2. The method according to claim 1 , wherein the melting range is by more than 60° C. lower than the press temperature.
3. The method according to claim 1 , wherein a dwell time in the press is from about 4 to 60 seconds.
4. The method according to claim 1 , wherein a pressure of the press is less than 50 bars.
5. The method according to claim 1 , wherein the press temperature is at least equal to or higher than a hardening temperature suitable for hardening the at least one synthetic resin.
6. The method according to claim 1 , wherein the at least one wax has a melting viscosity of less than 75 mPa·s at the press temperature.
7. The method according to claim 1 , further comprising drying the decorative layer with the applied mixture before the pressing, and at a drying temperature within a drying temperature range below the press temperature.
8. The method according to claim 7 , wherein the drying is carried out until a remaining water content is 7% or less.
9. The method according to claim 7 , wherein the drying temperature range is about 140° C. to 190° C.
10. The method according to claim 7 , wherein during the drying, the drying temperature initially has an increasing temperature profile and thereafter a decreasing temperature profile.
11. The method according to claim 7 , wherein a drying time is from 1 to 3 minutes.
12. The method according to claim 1 , wherein the application of the wax is carried out together with the application of the mixture.
13. The method according to claim 12 , wherein the wax is a component of the mixture.
14. The method according to claim 1 , wherein the melting range of the wax is above 60° C.
15. The method according to claim 1 , wherein at least 90% of the hard particles have a size below 80 μm.
16. The method according to claim 1 , wherein the thermohardening synthetic resin is a melamine resin.
17. The method according to claim 1 , wherein the hard particles are aluminium oxide particles.
18. The method according to claim 1 , wherein the wax is a Fischer-Tropsch-Wax.
19. The method according to claim 1 , wherein the at least one wax is comprised in the mixture in an amount of from 0.1 to 5 weight percent of the mixture.
20. The method of claim 1 , further comprising arranging the decorative layer on a supporting substrate.
21. The method of claim 7 , wherein the drying is carried out until a remaining water content is 6% or less.
22. A method for producing a decorative laminate, comprising:
providing a decorative layer,
applying a mixture comprising a thermohardening synthetic resin and hard particles to the decorative layer,
applying at least one wax to the decorative layer or to the mixture,
drying the decorative layer with the applied mixture before the pressing, and at a drying temperature within a drying temperature range below the press temperature,
wherein a drying time is from 1 to 3 minutes; and
pressing a supporting substrate, the decorative layer, the mixture and the wax in a hot press at a press temperature to form a decorative laminate board,
wherein a melting range of the at least one wax is at least one of below a temperature of about 140° C. and by more than 50° C. below the press temperature.
23. The method according to claim 22 , wherein the melting range is by more than 60° C. lower than the press temperature.
24. The method according to claim 22 , wherein a dwell time in the press is from about 4 to 60 seconds.
25. The method according to claim 22 , wherein a pressure of the press is less than 50 bars.
26. The method according to claim 22 , wherein the press temperature is at least equal to or higher than a hardening temperature suitable for hardening the at least one synthetic resin.
27. The method according to claim 22 , wherein the at least one wax has a melting viscosity of less than 75 mPa·s at the press temperature.
28. The method according to claim 22 , further comprising drying the decorative layer with the applied mixture before the pressing, and at a drying temperature within a drying temperature range below the press temperature.
29. The method according to claim 28 , wherein the drying is carried out until a remaining water content is 7% or less.
30. The method according to claim 28 , wherein the melting range of the wax is below the drying temperature.
31. The method according to claim 28 , wherein the drying temperature range is about 140° C. to 190° C.
32. The method according to claim 28 , wherein during the drying, the drying temperature initially has an increasing temperature profile and thereafter a decreasing temperature profile.
33. The method according to claim 22 , wherein the application of the wax is carried out together with the application of the mixture.
34. The method according to claim 33 , wherein the wax is a component of the mixture.
35. The method according to claim 22 , wherein the melting range of the wax is above 60° C.
36. The method according to claim 22 , wherein at least 90% of the hard particles have a size below 80 μm.
37. The method according to claim 22 , wherein the thermohardening synthetic resin is a melamine resin.
38. The method according to claim 22 , wherein the hard particles are aluminium oxide particles.
39. The method according to claim 22 , wherein the wax is a Fischer-Tropsch-Wax.
40. The method according to claim 22 , wherein the at least one wax is comprised in the mixture in an amount of from 0.1 to 5 weight percent of the mixture.
41. The method of claim 22 , further comprising arranging the decorative layer on a supporting substrate.
42. The method of claim 22 , further comprising drying the applied mixture at a drying temperature above the melting range of the wax.
43. The method according to claim 28 , wherein the drying is carried out until a remaining water content is 6% or less.