WO2012065230A1 - Decorative products and building products with improved opacity - Google Patents
Decorative products and building products with improved opacity Download PDFInfo
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- WO2012065230A1 WO2012065230A1 PCT/AU2011/001501 AU2011001501W WO2012065230A1 WO 2012065230 A1 WO2012065230 A1 WO 2012065230A1 AU 2011001501 W AU2011001501 W AU 2011001501W WO 2012065230 A1 WO2012065230 A1 WO 2012065230A1
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- WIPO (PCT)
- Prior art keywords
- melamine cyanurate
- decorative
- paper
- building product
- substrate
- Prior art date
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Classifications
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D5/00—Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
- C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
- C09C1/02—Compounds of alkaline earth metals or magnesium
- C09C1/021—Calcium carbonates
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
- C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
- C09C1/04—Compounds of zinc
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
- C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
- C09C1/36—Compounds of titanium
- C09C1/3607—Titanium dioxide
- C09C1/3653—Treatment with inorganic compounds
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
- C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
- C09C1/36—Compounds of titanium
- C09C1/3692—Combinations of treatments provided for in groups C09C1/3615 - C09C1/3684
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
- C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
- C09C1/40—Compounds of aluminium
- C09C1/402—Satin white, modifications thereof, e.g. carbonated or silicated; Calcium sulfoaluminates; Mixtures thereof, e.g. with calcium carbonate or kaolin
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
- C09C3/00—Treatment in general of inorganic materials, other than fibrous fillers, to enhance their pigmenting or filling properties
- C09C3/006—Combinations of treatments provided for in groups C09C3/04 - C09C3/12
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
- C09C3/00—Treatment in general of inorganic materials, other than fibrous fillers, to enhance their pigmenting or filling properties
- C09C3/06—Treatment with inorganic compounds
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N3/0056—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the compounding ingredients of the macro-molecular coating
- D06N3/0059—Organic ingredients with special effects, e.g. oil- or water-repellent, antimicrobial, flame-resistant, magnetic, bactericidal, odour-influencing agents; perfumes
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- 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
- D21H17/03—Non-macromolecular organic compounds
- D21H17/05—Non-macromolecular organic compounds containing elements other than carbon and hydrogen only
- D21H17/07—Nitrogen-containing compounds
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- 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
- D21H17/63—Inorganic compounds
- D21H17/67—Water-insoluble compounds, e.g. fillers, pigments
- D21H17/675—Oxides, hydroxides or carbonates
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- 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
- D21H19/00—Coated paper; Coating material
- D21H19/36—Coatings with pigments
- D21H19/38—Coatings with pigments characterised by the pigments
- D21H19/385—Oxides, hydroxides or carbonates
-
- 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
- D21H19/00—Coated paper; Coating material
- D21H19/36—Coatings with pigments
- D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
- D21H19/46—Non-macromolecular organic compounds
-
- 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
- D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
- D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
- D21H21/28—Colorants ; Pigments or opacifying agents
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- 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
- D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
- D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
- D21H21/34—Ignifugeants
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- 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
- D21H27/18—Paper- or board-based structures for surface covering
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- 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
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2006/00—Physical properties of inorganic compounds
- C01P2006/60—Optical properties, e.g. expressed in CIELAB-values
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F15/00—Flooring
- E04F15/02—Flooring or floor layers composed of a number of similar elements
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F19/00—Other details of constructional parts for finishing work on buildings
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- 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
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- 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
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2041—Two or more non-extruded coatings or impregnations
-
- 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
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
Definitions
- the invention relates to decorative products and building products, especially but not exclusively to decorative and building product laminates used in the manufacture of furniture, flooring, wall and ceiling components, and to the manufacture of such laminates.
- Decorative laminates and building product laminates used in buildings and for furniture are made with a variety of materials including decor paper, kraft papers, balancing papers, overlay papers and non-woven materials.
- paper or non-woven is used as a carrier of resin, colour, design or any combination of these.
- fibrous nature of the paper or non-woven provides resistance against cracking and or improved impact resistance.
- the paper or non-woven is not required and the building product is only coated.
- Non-woven made with glass or basalt fibres will also improve fire resistance.
- the resin used to impregnate the paper or non- woven is usually clear to avoid interfering with the visual aspects such as desired colour or print.
- the background material may be either a wood panel or one or several kraft papers. Paper or non-woven that does not have opacity would show the colour and structure of the background material thereby interfering with the intended visual appeal of the final product.
- the impregnating resin and coating resin may contain additional Ti0 2 to further improve the visual result.
- T1O 2 is the leading inorganic white opacifying agent, being supplied in either rutile or anatase form.
- the light refraction index (LRI) of Ti0 2 is better than any known substitute, being in the order of 2.7 for rutile and 2.5 for anatase.
- LRIs of alternative materials that are used to provide opacity are in the order of ZnS 2.37, ZnO 2, PCC 1.6, kaolin 1.56, talc 1.57.
- melamine cyanurate is an industrial chemical normally manufactured from melamine and cyanuric acid or isocyanuric acid, known in industry as a flame retardant additive for polyamide (e.g. nylon), polyurethane and epoxy resins: It is not strictly a salt but a crystalline complex of melamine and cyanuric acid.
- the inclusion of MC into or on a decorative laminate or building product laminate may arise from addition of the MC during the papermaking process, for example at the wet- end of the paper machine, or during the non-woven manufacturing process, for example when a binder is applied to the glass fibres, or from application as a coating to the paper or non-woven after formation of the continuous web, whether in-line or as an off-line application.
- Various methods are available for applying a coating, for example by size press, roll coater, spraying, air knife,, curtain coater or blade coater.
- MC may be applied by sublimation, or as a solid reaction between melamine and cyanuric acid. The method of applying the coating is not limited to the examples as any number of factors can influence the decision of which coating method to use.
- the MC may be provided in a coating on the decorative or building product, or in a surface layer of the product.
- the product may be a substrate having a coating containing melamine cyanurate in a sufficient amount to provide or enhance opacity.
- the inclusion of the MC may arise from addition of the MC in the process of impregnating a paper or non-woven for later use in creating a decorative laminate or building product laminate.
- the MC may also be added directly to the surface of a substrate such as a wood panel or gypsumboard to provide opacity whether or not as part of a coating.
- the MC may be added to the impregnating resin, or the MC may be applied as a coating, or the MC may be applied using both impregnation and coating.
- the coating containing the MC may include a binder, for example PVA, or may be mixed into a resin, for example UF or MF resin.
- the coating may also be a different polymer to that of the impregnating resin, of which non-limiting examples are an acrylic, epoxy, urethane, melamine, urea, phenol, or polyester type.
- the MC coating may also include other materials such as but not limited to Ti0 2 , ZnS, CaC0 3 , kaolin, talcum, antistatic additives, antibacterial additives or abrasive resistant or scratch resistant additives.
- the MC coating may be combined with a binder, or may be mixed into a resin.
- the MC may be pre-mixed with one or more other materials to enhance dispersion, or to encapsulate the other materials.
- the MC may be mixed with pigments to provide colour as well as opacity.
- the invention provides 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.
- the invention provides a a method of manufacturing a decorative or building product including providing one of more constituents of the product with melamine cyanurate in an amount effective to provide or enhance opacity in the product.
- the product is preferably a laminate, and typically includes an impregnated paper or non-woven component and optionally a substrate supporting the impregnated paper or non-woven component.
- the impregnating substance is typically but not necessarily a resin.
- the one or more constituents that include melamine cyanurate then comprise one or more constituents of the laminate or substrate comprising a paper or non-woven component, a coating, an impregnating resin, and the substrate.
- the melamine cyanurate is present in conjunction with one or more other opacifying additives selected from T1O2, ZnS, CaCC>3, talcum and Kaolin.
- T1O2 opacifying additives
- a combination of MC and T1O2 has proven especially effective.
- the form in which the melamine cyanurate is present may be one or more of a coating, a coating that includes MC in admixture, an MC phase distributed through the respective constituent of the laminate, and a distributed constituent of a mixed phase comprising the constituent.
- the laminate of the invention can exhibit improved postformability and/or fire resistance relative to the same laminate without MC.
- the MC may be added to paper or non-woven materials suitable for use in the manufacture of decorative laminates and building product laminates, during the paper or non-woven manufacturing process.
- the invention extends to a paper or non-woven that includes melamine cyanurate in or on the paper or non-woven in a form effective to enhance the opacity of the paper or non-woven in a subsequent laminate in which the paper or non- woven is incorporated.
- the decorative or building product may be a panel or moulding.
- the MC may be included in a substance that is coated directly onto the product.
- the substance may be a resin in particular embodiments.
- melamine and cyanuric acid components of MC may be added to a paper furnish (A).
- a downstream furnish (B) consisting of water, cellulose, melamine and cyanuric acid is stirred, allowing the melamine and cyanuric acid to solubilise and react to form MC, then a paper sheet is formed.
- the components of MC are added to a paper furnish (C), the components being melamine and cyanuric acid.
- the downstream furnish (D) consisting of water, cellulose, T1O2, melamine and cyanuric acid is stirred, allowing the melamine and cyanuric acid to solubilise and react to form MC, then a paper sheet is formed.
- the melamine and cyanuric acid are separately dissolved in water and the 2 solutions are mixed together and stirred for 30 minutes at room temperature (23°C), enabling the formation of MC.
- the solution containing MC is added to the paper furnish (D) and a paper sheet is formed.
- the MC may be added to paper or non-woven materials subsequent to their manufacture, e.g. during further processes in the add value manufacturing chain.
- the MC may be added to the already formed paper web or non-woven web via a size press or any other coating method.
- the addition of MC as a coating to the already formed paper may be done in-line or may be done offline.
- the MC is added to an impregnation resin and the resin containing MC is impregnated into the paper or non-woven.
- the paper or non-woven is impregnated and the MC is applied to the first impregnated paper or non- woven as a coating.
- the MC may be added via both the impregnation and coating stages.
- the MC may be added directly to a building product laminate substrate (e.g. a wood based panel or gypsum board) to improve the opacity of a coating on the surface of the substrate.
- the MC may be combined with a binder and applied directly to the surface of a substrate.
- the binder may be, as a non- limiting example, PVA or UF resin or MF resin.
- the substrate may then be further improved with a protective or decorative coating.'
- the protective or decorative coating may be an impregnated paper or non-woven.
- the MC coated substrate may be printed before a protective coating is applied.
- the MC is applied to the paper, non-woven or substrate by a dry coating method such as electrostatic coating.
- the MC used in the present invention may be purchased ready to use. Alternatively the MC may be manufactured in situ.
- a simple method for producing melamine cyanurate in situ in an embodiment where MC is added during the paper manufacturing process entails adding melamine and cyanuric acid to the watery paper furnish and stirring until the melamine and cyanuric acid have dissolved and formed in situ MC.
- this method may impact on the yield of MC.
- the melamine and cyanuric acid are dissolved into separate watery solutions that are later combined and stirred to allow the formation of MC in situ.
- a method for producing MC in situ in an embodiment where MC is added downstream to paper or non-woven materials entails dissolving melamine and cyanuric acid in water and later combining and stirring the two solutions to allow for the formation of MC in situ.
- the MC does not need to be fully de-watered as it can be added to a watery impregnating resin, or a watery coating resin and applied to a paper or non-woven. Examples
- Example 1 report the opacity achieved using MC alone or in combination with another opacifying agent.
- a paper disc was formed from the following furnish mixture, designated Mixture 1 :-
- the paper was formed into a high pressure laminate in a hot press.
- the opacity measured as % reflection over a black standard was 43.1 %.
- a paper disc was formed from the following furnish mixture, designated Mixture 2:-
- the reaction between the components took place at 23°C for 30 minutes.
- the paper disc which weighed 2.73g and had an ash content of 11.4%, was thereafter impregnated with melamine formaldehyde resin, dried to b-stage and manufactured as a high pressure laminate as in Example 1.
- the MC and Ti0 2 were present in equal proportions by weight.
- the opacity was measured as 84.2%, indicating that a combination of MC and T1O2 was more effective in enhancing opacity than MC alone (example 1). Comparative Example 3
- a paper disc was formed from the following furnish mixture, designated Mixture 3:
- the paper disc which weighed 2.76g and had an the ash content of 14.4%, was thereafter impregnated with melamine formaldehyde resin, dried to b-stage and manufactured as a high pressure laminate as in Example 1.
- the opacity was measured as 83.9%, indicating that a combination of MC and T1O2 was similarly as effective in enhancing opacity as T1O2 alone. This has the benefit that the less abrasive and commercially more attractive MC being less expensive and more readily available, can be used to substitute Ti0 2 .
- a paper was formed from furnish Mixture 2 above. On this occasion, the melamine and cyanuric acid were first separately dissolved each in 5 litres of water then added to the furnish of water, cellulose and Ti0 2 in a separate flask and mixed at 23°C for 30 minutes. The paper disc thus formed was impregnated with melamine formaldehyde resin, dried to b-stage and manufactured as a high pressure laminate as in Example 1.
- a paper was formed from furnish Mixture 2 above. On this occasion, the mixture was stirred at 80°C for 30 minutes, before the paper was formed.
- This paper disc was impregnated with melamine formaldehyde resin, dried to b-stage and manufactured as a high pressure laminate as in Example 1. The opacity was measured as 86.2%, marginally the best result. This is attributed to higher dissolution expressed as g/l of melamine and cyanuric acid at elevated temperature enabling increased formation of MC.
- Example 6 To form a mixture similar to paper mixture 2, the melamine and cyanuric acid were first mixed in a separate flask at 80°C (substantially higher than in Example 4) for 30 minutes, then filtered and washed with water, then added to the furnish of water, cellulose and Ti0 2 . The paper was impregnated with melamine formaldehyde resin, dried to b-stage and manufactured as a high pressure laminate as in Example 1. The opacity was measured as 86%
- a 75 g/m 2 white decor paper with Ti0 2 content ca 36% was impregnated with clear melamine formaldehyde (MF) resin, then a paper from the same production was impregnated with a mix of MF resin and melamine cyanurate (MC). Similar end weights (ca. 168glm 2 ) were achieved with 21.5g MC replacing a similar amount of MF resin.
- MF clear melamine formaldehyde
- MC may be partly substituted for resin, say up to 10% or perhaps up to 20% or even up to 30%, to thus allow total Ti0 2 in the system (in the resin and in the paper) to be reduced without any material reduction of opacity.
- a 60g/m 2 white decor paper with Ti0 2 content ca. 30% was impregnated with a MF resin containing 13% Ti0 2 ( MF resin 30 kg + Ti0 2 4.5 kg ).
- the end weight of the impregnated paper was ca. 140g/m 2 .
- the impregnated paper was pressed onto a piece of particleboard.
- the colour characteristics according to CIELab system were measured as L * 92.03, a * -0.92, b* 1.28.
- solubility of melamine and cyanuric acid are well known and should be taken into account when preparing water based mixtures used in papermaking. Accordingly the abovementioned mixtures and the amount and ratio of melamine and cyanuric acid are only described as non-limiting examples. Increasing the water temperature results in faster dissolution of melamine and cyanuric acid and as well the increased solubility of melamine and cyanuric acid provides a higher yield of MC per litre of water.
- MC acts as a lubricant
- the postformability of a laminate is improved both by the MC acting as a lubricant and because the MC has been used to substitute for T1O2.
- the presence of MC to enhance opacity is likely to improve the fire resistance of a decorative laminate, building product laminate, or a wood based panel or gypsumboard.
- MC as described in the present specification is of commercial value in the manufacture of decorative laminates or building product laminates based on paper or non-woven or applied directly to a building product substrate such as a wood based panels or gypsumboard, that finds application in the manufacture of furniture or construction products such as flooring, wall or ceiling articles.
- MC in paper not further utilised in a value-adding procedure
- the amount of MC applied to paper, non-woven or building product laminate substrate will vary with regard to the opacity desired due to the colour intensity or colour variation of background material and commercial attractiveness of MC as a substitute in existing opacifying systems. It is therefore forseen that papers, non-wovens or building product laminates may achieve the desired opacity with 100% MC and no other opacifying agent, or that MC may be used in combination with existing opacifying agents at a substitution rate of between 1 - 99%.
Landscapes
- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Inorganic Chemistry (AREA)
- Life Sciences & Earth Sciences (AREA)
- Materials Engineering (AREA)
- Wood Science & Technology (AREA)
- Textile Engineering (AREA)
- Laminated Bodies (AREA)
- Paper (AREA)
Abstract
Description
Claims
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2011331919A AU2011331919B2 (en) | 2010-11-19 | 2011-11-21 | Decorative products and building products with improved opacity |
US13/885,937 US20130244517A1 (en) | 2010-11-19 | 2011-11-21 | Decorative products and building products with improved opacity |
ES11841060.4T ES2644495T3 (en) | 2010-11-19 | 2011-11-21 | Decorative products and building products with enhanced opacity |
EP11841060.4A EP2640910B1 (en) | 2010-11-19 | 2011-11-21 | Decorative products and building products with improved opacity |
PL11841060T PL2640910T3 (en) | 2010-11-19 | 2011-11-21 | Decorative products and building products with improved opacity |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2010905133A AU2010905133A0 (en) | 2010-11-19 | Decorative and building product laminates with improved opacity | |
AU2010905133 | 2010-11-19 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2012065230A1 true WO2012065230A1 (en) | 2012-05-24 |
Family
ID=46083430
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/AU2011/001501 WO2012065230A1 (en) | 2010-11-19 | 2011-11-21 | Decorative products and building products with improved opacity |
Country Status (6)
Country | Link |
---|---|
US (1) | US20130244517A1 (en) |
EP (1) | EP2640910B1 (en) |
ES (1) | ES2644495T3 (en) |
PL (1) | PL2640910T3 (en) |
PT (1) | PT2640910T (en) |
WO (1) | WO2012065230A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3896044A1 (en) | 2020-04-17 | 2021-10-20 | Depco-Trh Pty Ltd | Mixture for enhancing opacity |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH06306313A (en) | 1993-04-21 | 1994-11-01 | Hajime Okazaki | Fine particle for coating or printing and decorative laminate |
US20040025749A1 (en) * | 2002-08-08 | 2004-02-12 | Kronos International Inc. | Method for the surface treatment of a titanium dioxide pigment |
US6709764B1 (en) | 1997-12-02 | 2004-03-23 | Arjo Wiggins | Decorative paper sheet and decorative laminate comprising same |
WO2006111458A1 (en) | 2005-04-18 | 2006-10-26 | Owens-Corning Intellectual Capital, Llc | Fire retardant laminate |
WO2006130907A1 (en) | 2005-06-06 | 2006-12-14 | Depco-Ppg Pty Ltd | Manufacture of an impregnated paper or non-woven |
US20070071989A1 (en) | 2005-09-27 | 2007-03-29 | Thiele Erik S | Paper laminates |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP2694501B2 (en) * | 1993-08-09 | 1997-12-24 | 一 岡崎 | Synthetic resin composition |
JP2006289942A (en) * | 2005-04-14 | 2006-10-26 | Taisei Shin | Decorative material treated with metallic paint |
JP4783070B2 (en) * | 2005-06-24 | 2011-09-28 | シャープ株式会社 | Semiconductor memory device and manufacturing method thereof |
BRPI0710146A2 (en) * | 2006-04-13 | 2011-08-02 | Dsm Ip Assets Bv | paper substrate comprising steam deposited triazine, and process and apparatus for making a laminate comprising the substrate |
-
2011
- 2011-11-21 EP EP11841060.4A patent/EP2640910B1/en active Active
- 2011-11-21 ES ES11841060.4T patent/ES2644495T3/en active Active
- 2011-11-21 PT PT118410604T patent/PT2640910T/en unknown
- 2011-11-21 WO PCT/AU2011/001501 patent/WO2012065230A1/en active Application Filing
- 2011-11-21 PL PL11841060T patent/PL2640910T3/en unknown
- 2011-11-21 US US13/885,937 patent/US20130244517A1/en not_active Abandoned
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH06306313A (en) | 1993-04-21 | 1994-11-01 | Hajime Okazaki | Fine particle for coating or printing and decorative laminate |
US6709764B1 (en) | 1997-12-02 | 2004-03-23 | Arjo Wiggins | Decorative paper sheet and decorative laminate comprising same |
US20040025749A1 (en) * | 2002-08-08 | 2004-02-12 | Kronos International Inc. | Method for the surface treatment of a titanium dioxide pigment |
WO2006111458A1 (en) | 2005-04-18 | 2006-10-26 | Owens-Corning Intellectual Capital, Llc | Fire retardant laminate |
WO2006130907A1 (en) | 2005-06-06 | 2006-12-14 | Depco-Ppg Pty Ltd | Manufacture of an impregnated paper or non-woven |
US20070071989A1 (en) | 2005-09-27 | 2007-03-29 | Thiele Erik S | Paper laminates |
Non-Patent Citations (1)
Title |
---|
See also references of EP2640910A4 |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3896044A1 (en) | 2020-04-17 | 2021-10-20 | Depco-Trh Pty Ltd | Mixture for enhancing opacity |
EP3896043A1 (en) | 2020-04-17 | 2021-10-20 | Depco-Trh Pty Ltd | High opacity laminate surface |
WO2021209812A1 (en) * | 2020-04-17 | 2021-10-21 | Depco-Trh Pty Ltd | High opacity laminate surface |
Also Published As
Publication number | Publication date |
---|---|
EP2640910A4 (en) | 2015-06-17 |
PL2640910T3 (en) | 2018-02-28 |
US20130244517A1 (en) | 2013-09-19 |
EP2640910B1 (en) | 2017-07-26 |
ES2644495T3 (en) | 2017-11-29 |
AU2011331919A1 (en) | 2013-07-04 |
PT2640910T (en) | 2017-11-03 |
EP2640910A1 (en) | 2013-09-25 |
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