Warp resistant laminates having a core impregnated with a mixture of phenolix resin and alkyl substituted phenol

• US 4,514,462 A
• Filed: 04/14/1983
• Issued: 04/30/1985
• Est. Priority Date: 04/14/1983
• Status: Expired due to Term

• Current Assignee: Nevamar Co. LLC (International Paper Company)
• Original Assignee: Westinghouse Electric Company LLC (Brookfield Asset Management Incorporated)
• Inventors: Brooker, Lenon G.
• Primary Examiner(s): Ives, Patricia C.
• Application Number:
  US06/485,089
• Time in Patent Office: 747 Days
• Field of Search: 428/525, 428/526, 428/530, 428/531, 428/285, 428/286
• US Class Current: 442/252
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2305/026 Porous
• CPC Class Codes: B32B 2315/085 Glass fiber cloth or fabric
• CPC Class Codes: B32B 2317/10 Natural fibres, e.g. wool, cotton
• CPC Class Codes: B32B 2317/122 Kraft paper
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles wall paper B32B2607/02
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 29/005 next to another layer of paper or cardboard layer
• CPC Class Codes: B32B 29/02 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: C08G 8/24 with mixtures of two or more phenols which are not covered by only one of the groups C08G8/10 - C08G8/20
• CPC Class Codes: D21H 17/48 with phenols
• CPC Class Codes: D21H 27/26 characterised by the overlay sheet or the top layers of the structures decorative panels B44C5/04; wood grain effects B44F9/02
• CPC Class Codes: D21H 5/0087 Aspect concerning the core layer(s)
• CPC Class Codes: Y10T 156/1093 with covering of discrete laminae with additional lamina
• CPC Class Codes: Y10T 428/31946 Next to second aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31949 Next to cellulosic
• CPC Class Codes: Y10T 428/31967 : Phenoplast
• CPC Class Codes: Y10T 442/3577 : Phenolic resin
• CPC Class Codes: Y10T 442/3927 : Including a paper or wood pulp layer
• CPC Class Codes: Y10T 442/3943 : Plural paper or wood pulp layers

Abstract

An impregnating composition for warp free laminates, is made from the diluted reaction mixture of: a phenolic component selected from at least one of phenol, resol, xylenol, resorcinol, naphthol; alkyl substituted phenol, where alkyl contains from 4 to 13 carbon atoms; and aldehyde.

Claims

1. A sheet material, impregnated with a reaction mixture composition consisting essentially of:

(1) a phenolic component selected from the group consisting of phenol, cresol, xylenol, resorcinol, naphthol, and mixtures thereof,

(2) alkyl substituted phenol, where alkyl contains from 4 to 13 carbon atoms, and

(3) aldehyde;

where the mole ratio of phenolic component;

alkyl substituted phenol is from about 1;

0.0035 to 0.5, said composition being in the dried "B"-stage.

2. The impregnated sheet of claim 1, where the sheet material is selected from the group consisting of Kraft paper, cotton cloth, cotton linter paper, and glass cloth.

3. The impregnated sheet of claim 1, where the phenolic component is phenol, the alkyl substituted phenol is nonyl phenol, the alkyl of the alkyl substituted phenol is in the para position, the alkyl substituted phenol is single alkyl substituted phenol, and the aldehyde is selected from the group consisting of formaldehyde and uninhibited formaldehyde.

4. The impregnated sheet of claim 1, where the mole ratio of phenolic component+alkyl substituted phenol:

aldehyde is from about 1;

1 to 3.

5. A cured, bonded, unitary, warp resistant comprising:

(1) a melamine resin impregnated sheet, and

(2) at least one core sheet disposed next to the melamine impregnated sheet, said core sheet impregnated with a reaction mixture composition consisting essentially of;

(1) a phenolic component selected from the group consisting of phenol, cresol, xylenol, resorcinol, naphthol, and mixtures thereof,

(2) alkyl substituted phenol, where alkyl contains from 4 to 13 carbon atoms, and

(3) aldehyde;

where the mole ratio of phenolic component;

alkyl substituted phenol is from about 1;

0.0035 to 0.5,

said melamine resin and reaction mixture composition being in the cured state.

6. The laminate of claim 5, where the core sheet is selected from the group consisting of Kraft paper, cotton cloth, cotton linter paper, and glass cloth, the sheet impregnated with melamine resin is alpha-cellulose paper, the alkyl of the alkyl substituted phenol is in the para position, and the alkyl substituted phenol is single alkyl substituted phenol.

7. The laminate of claim 5, where the mole ratio of phenolic component+alkyl substituted phenol:

aldehyde in the resin of this invention is from about 1;

1 to 3.

8. The laminate of claim 5, containing a melamine resin impregnated decorative print sheet, and where, in the alkyl substituted phenol, alkyl contains from 7 to 11 carbons.

9. The laminate of claim 8, containing a melamine resin impregnated protective overlay sheet covering the print sheet, and where the phenolic component is phenol, the alkyl substituted phenol is nonyl phenol, and the aldehyde is selected from the group consisting of formaldehyde and uninhibited formaldehyde.