Search

BR-102024017994-A2 - Thermocast laminate, process for producing a thermocast laminate, press, and use of a thermocast laminate and a press.

BR102024017994A2BR 102024017994 A2BR102024017994 A2BR 102024017994A2BR-102024017994-A2

Abstract

The present invention relates to a thermo-fused laminate with high strength and gloss and its use in furniture making, construction, and various other applications. In order to achieve the desired characteristics of the laminate, a manufacturing process for a thermo-fused laminate (TFL) was also determined using the same manufacturing process as a high-pressure laminate (HPL). The present invention also relates to a modified press for the production of the laminate and its use.

Inventors

  • ALÍPIO JOSÉ GUSMÃO DOS SANTOS

Assignees

  • FORMILINE INDÚSTRIA DE LAMINADOS LTDA

Dates

Publication Date
20260317
Application Date
20240830

Claims (20)

  1. 1. Thermocast laminate (20), characterized in that it comprises: - at least one inner layer (26) of substrate; and - at least one outer layer (22) impregnated with melamine resin or derivatives on the upper face of the inner layer.
  2. 2. Thermocast laminate (20) according to claim 1, characterized in that it further comprises a second outer layer (24) of melamine resin on the underside of the inner layer.
  3. 3. Thermocast laminate (20) according to claim 1 or 2, characterized in that the substrate of the inner layer (26) is selected from MDF, particleboard, MDP (Medium Density Particleboard) and the like, preferably MDF and particleboard.
  4. 4. Thermocast laminate (20) according to any one of claims 1 to 3, characterized in that one face or both faces of the outer layer (22, 24) comprise(s) one or more melamine resin impregnated decoratives, preferably 1 layer of melamine resin impregnated decorative per face totaling 2 layers.
  5. 5. Process for producing a thermoformed laminate, characterized in that it comprises the following steps: I. Supply of raw materials; II. Catalysis of melamine resin; III. Impregnation of decorative paper with melamine resin; IV. Laminate assembly; and V. Pressing.
  6. 6. Process according to claim 5, characterized in that water, melamine, formaldehyde and additives are added during step II.
  7. 7. Process according to claim 5 or 6, characterized in that the catalysis time of step II, in seconds, is about 120% to about 150% of the catalysis time of high-pressure laminates, preferably about 135% to about 150% of the time.
  8. 8. Process according to any one of claims 5 to 7, characterized in that in step II, the resin comprises by mass: - from about 20% to about 60% melamine relative to the total mass of the resin, preferably from about 25% to about 55% melamine relative to the total mass of the resin, more preferably from about 35% to about 45% melamine relative to the total mass of the resin; - from about 15% to about 45% formaldehyde relative to the total mass of the resin, preferably from about 20% to about 40% formaldehyde relative to the total mass of the resin, more preferably from about 25% to about 35% formaldehyde relative to the total mass of the resin; - from about 10% to about 40% water relative to the total mass of the resin, preferably from about 15% to about 35% water relative to the total mass of the resin, more preferably from about 20% to about 30% water relative to the total mass of the resin; and from about 0.5% to about 10% additives relative to the total mass of the resin, preferably from about 1% to about 9% additives relative to the total mass of the resin, more preferably from about 4% to about 6% additives relative to the total mass of the resin.
  9. 9. Process according to any one of claims 5 to 8, characterized in that in step III, one or more of the decorative elements are impregnated with melamine resin.
  10. 10. Process according to any one of claims 5 to 9, characterized in that in step V, the pressing is done at a pressure greater than or equal to about 10 kgf/cm2 to about 90 kgf/cm2.
  11. 11. Process according to any one of claims 5 to 10, characterized in that in step V the press is applied in cycles of equal to or less than about 40 minutes, preferably cycles of equal to or less than about 30 minutes, even more preferably cycles of about 5 to about 20 minutes, wherein the temperature of the press varies between about 80 °C and about 200 °C, preferably from about 100 °C to 180 °C.
  12. 12. Process according to any one of claims 5 to 11, characterized in that it further comprises the steps of: V. cutting and trimming; VI. inspection and shipping.
  13. 13. Press (30), characterized in that it comprises a set of pressure regulating valves in the hydraulic system (34) and an electronic press limiting hydraulic valve (33), wherein the pressure has a minimum control rate of about 1 Kgf/cm2 and wherein the control range varies from about 10 to about 120 Kgf/cm2.
  14. 14. Press (30) according to claim 13, characterized in that it comprises press actuator cylinders (31), electronic press limiting hydraulic valve (33), hydraulic system pressure regulating valve (34), pressure measuring gauge (35), filtering system with BYPASS valve (36), hydraulic pump (37) and electric motor (38).
  15. 15. Press (30) according to claim 13, characterized in that it is for the production of laminates.
  16. 16. Press (30) according to any one of claims 13 to 16, characterized in that it is for the production of low-pressure laminates (TFL) and high-pressure laminates (HPL).
  17. 17. Press (30) according to claim 16, characterized in that the range above 90Kgf/cm2 produces high-pressure laminate (HPL).
  18. 18. Press (30) according to claim 16, characterized in that the range equal to or below 90Kgf/cm2 produces low-pressure laminate (TFL).
  19. 19. Thermocast laminate (20), characterized in that it is produced by the press (30) as defined in claim 13.
  20. 20. Use of a laminate, characterized by being used in furniture making, civil construction, architectural carpentry, among others, where the laminate comprises: - at least one inner substrate layer; and - at least one outer layer impregnated with melamine resin or derivatives on the upper face of the inner layer.

Description

FIELD OF APPLICATION [001] The present invention relates to a thermally fused laminate (TFL) and its use in furniture making, construction and various other applications. The present invention also relates to the process of producing a thermally fused laminate. [002] Furthermore, the present invention describes a press modified in its pressure actuation system, capable of serving both the production of hot-melt laminates and high-pressure laminates and laminates produced by the press. FUNDAMENTALS OF THE INVENTION [003] Wood composites are used in different laminates and can vary in size, thickness, density, and durability. Initially, wood composites were mostly used indoors. However, their use in harsher environments, such as outdoors, has necessitated efforts to improve the characteristics of the composites. These different characteristics are achieved through changes in the composition of the composites, the combination and composition of the layers, and the manufacturing processes. [004] Medium-density fiberboard (MDF) panels are commonly used, with or without outer layers of melamine, phenolic, or other materials. These outer layers provide a better finish to the product, allowing for overlays and coatings, as well as different colors and designs (or prints). [005] Currently, wood composites can visually mimic materials such as solid wood and even some types of stone cladding, such as marble. [006] Among the types of laminates, high-pressure laminates can be mentioned, which have high resistance to impact, heat, wear and moisture. Another widely used laminate is thermoformable laminate. [007] It is noteworthy that the niche for low-pressure laminates (TFL and MDF) is vast and allows for the application of its products in various fields, such as civil construction, furniture manufacturing, among others. [008] However, these laminates often require specific presses for their production, making high-pressure laminate production plants more difficult and expensive. The same press may not be able to produce both high and low-pressure laminates, making a new press necessary and therefore a larger production facility. [009] Document US4365547A refers to the production of decorative laminates, laminated assemblies composed of Kraft paper core sheets impregnated with thermosetting phenolic resin, a decorative sheet impregnated with thermosetting melamine resin and, optionally, an overlay sheet impregnated with thermosetting melamine resin. The laminate is made by pressing the sheets together in a hydraulic press heated by steam, hot water or other suitable heating medium with a curing temperature between 130 °C and 150 °C. The document does not mention pressing solutions or press cycles. [0010] Document US4474841A refers to a self-supporting, rigid, high-pressure, easily parkable, thermally radiant decorative paper laminate panel comprising a thermosetting resin. The production process for this laminate panel occurs at temperatures between 135 °C and 180 °C and pressures between 700 and 1400 psi. However, the document does not specify the press cycles, and uses medium to high pressures. [0011] As demonstrated, high-pressure laminates (HPL) have high resistance to abrasion, moisture, and high temperatures. Low-pressure laminates (TFL and MDF) are versatile, have a wider supply, and a lower manufacturing cost compared to high-pressure laminates, but are less resistant to abrasion, water vapor, and high temperatures. [0012] In view of this limitation of low-pressure laminates, and in order to produce laminates with better characteristics, the present invention describes a modified production process to overcome the aforementioned technical problem. [0013] Unlike the high-pressure laminates (HPL) of the FORMICA® line, where the panel is pressed with two sides of decorative papers impregnated with melamine resin and the substrate is formed by layers of kraft paper impregnated with phenolic resin, efforts have been made to produce a low-pressure thermoformed panel pressed with decorative papers with a melamine resin on both sides of the panel on a substrate of MDF or particleboard, replacing the impregnated kraft paper. [0014] Thus, the press initially used only in the production of high-pressure laminates was modified with regard to pressure limiters, control valves and new inverter configurations, allowing the same press to produce both high and low-pressure laminates. SUMMARY OF THE INVENTION [0015] A primary objective of the invention is to provide a thermo-fused laminate with improved resistance to abrasion, water vapor, and high temperatures. [0016] A second objective of the invention is to provide a process for producing a thermo-fused laminate. [0017] A third objective of the invention is to provide a pressure actuation system. [0018] A fourth objective is to provide a modified press with a pressure actuation system for the production of laminates. [0019] A fifth objective refers to the laminates produced by