Method for preparing resin-reinforced decorative board

• US 5,405,705 A
• Filed: 12/11/1992
• Issued: 04/11/1995
• Est. Priority Date: 12/13/1991
• Status: Expired due to Fees

• Current Assignee: Kuraray Company Limited, Oshika Shinko Company Limited
• Original Assignee: Kuraray Company Limited, Oshika Shinko Company Limited
• Inventors: Kondo, Masami, Fujimoto, Masaru, Tsuchiya, Tadayuki, Chatani, Michio
• Primary Examiner(s): Gallagher, John J.
• Application Number:
  US07/989,803
• Time in Patent Office: 851 Days
• Field of Search: 156/307.5, 156/306.9, 156/313, 428/537.1
• US Class Current: 428/537.1
• CPC Class Codes: B32B 21/042 of wood B32B21/13 takes precedence
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles wall paper B32B2607/02
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B44C 5/043 containing wooden elements
• CPC Class Codes: B44C 5/0469 comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
• CPC Class Codes: Y10T 428/31989 Of wood

Abstract

There is disclosed a method for preparing a resin-reinforced decorative board which comprises the steps of interposing a polymerizable gelatinous substance between a decorative veneer and a base board, pressurizing and heating the materials to permeate at least part of components constituting the gelatinous substance to the decorative veneer or both of the decorative veneer and the base board, and polymerizing the substance to laminate the decorative veneer and the base board through an adhesive layer.

Claims

1. A method for preparing a resin-reinforced decorative board which comprises the steps of interposing an acrylic partially cross-linked polymer gel between a decorative veneer and a base board, pressurizing and heating the materials to permeate at least part of components constituting said polymer gel into the decorative veneer or both the decorative veneer and the base board, and polymerizing the substance to laminate the decorative veneer and the base board through an adhesive layer formed from said polymer gel.

2. The method of claim 1, wherein the acrylic partially cross-linked polymer gel has a composition obtained by subjecting to partial polymerization of a mixture composed of 3 to 60% by weight of a cross-linking monomer principally composed of a di(meth)acrylate containing at least two urethane linkages and 97 to 40% by weight of an unsaturated monomer principally composed of methyl methacrylate which may contain its polymer dissolved therein, and containing a polymer in an amount not exceeding the range of 80% by weight and increasing a polymer content 4 to 62% by weight than that in the above mixture.

3. The method of claim 1, wherein the partially cross-linked polymer gel is pulverized or kneaded.

4. The method of claim 1, wherein the partially cross-linked polymer gel is further mixed dispersively and kneaded after adding 1 to 100 parts by weight of an unsaturated monomer principally comprising an alkyl methacrylate which may contain a cross-linking monomer, or syrup principally comprising an alkyl methacrylate which contain its polymer dissolved therein and may contain a cross-linking monomer based on 100 parts by weight of the partially cross-linked polymer gel.

5. The method of claim 1, wherein the adhesive layer has a thickness of 0.2 to 3 mm.

6. The method of claim 1, wherein tensile breakage elongation after polymerizing the partially cross-linked polymer gel is 5 to 100%.

7. A method for preparing a resin-reinforced decorative board according to claim 1 wherein said acrylic partially cross-linked polymer gel has a viscosity in the range of 3×

10³ to 5×

10⁶ poise at 50°

C.

8. A resin-reinforced decorative board prepared by the method as claimed in any preceding claim.