Claims
- 1. A unitary heat and pressure consolidated laminated article comprising, in superinposed relationship,
- A. at least one paper sheet impregnated with a substantially completely cured resinous composition, which, in its uncured state, comprises a mixture of (a) and (b), said (a) comprising a polymer of
- 1. from about 75% to about 98%, by weight, based on the total weight of polymer (a), of a polymerizable acrylic monomer and
- 2. from about 2% to about 25%, by weight, based on the total weight of polymer (a), of an acrylic monomer which is different from and copolymerizable with (1) and contains a functional group comprising carboxyl, amide or hydroxyl groups, and said (b) comprising
- 3. a thermosetting melamine/formaldehyde resin having a ratio of melamine to formaldehyde ranging from about 1 : 1.6 to about 1 : 2.5, respectively, the ratio of melamine in said (b) to polymer (a) ranging from about 4 : 1 to about 0.5 : 1, respectively,
- B. a decorative sheet, with its decorative side facing upwardly, impregnated with a substantially completely cured resinous composition which, in its uncured state. comprises a mixture of (c) and (d), said (c) comprising a polymer of
- 4. from about 75% to about 98%, by weight, based on the total weight of polymer (c), of a polymerizable acrylic monomer and
- 5. from about 2% to about 25%, by weight, based on the total weight of polymer (c), of an acrylic monomer which is different from an copolymerizable with (4) and contains a functional group comprising carboxyl, amide or hydroxyl groups, and said (d) comprising
- 6. a thermosetting melamine/formaldehyde resin having a ratio of melamine to formaldehyde ranging from about 1 : 1.6 to about 1 : 2.5, respectively, the ratio of melamine in said (d) to polymer (c) ranging from about 4 : 1 to about 1 : 1, respectively, and
- C. a clear, thermoset cross-linked resinous coating, directly applied to the upward face of said decorative sheet, comprising a composition, which, in its thermosetting, non-cross linked state, comprises a mixture of (e), (f) and (g) said (e) comprising a polymer of,
- 7. from about 75% to about 98%, by weight, based on the total weight of polymer (e), of a polymerizable acrylic monomer and
- 8. from about 2% to about 25%, by weight, based on the total weight of polymer (e), of an acrylic monomer which is different from and copolymerizable with (7) and contains a functional group comprising carboxyl, amide or hydroxyl groups, said (f) comprising
- 9. from about 10% to about 100%, by weight, based on the total weight of said (8), of a highly alkoxymethylated melamine, and said (g) comprising
- 10. from about 5.0% to about 40.0%, by weight, based on the total weight of resin solids in (C), of andalusite, pyrophyllite or mixtures thereof.
- 2. A laminated article according to claim 1 wherein (a) is a polymer acrylonitrile, ethyl acrylate and acrylic acid.
- 3. A laminated article according to claim 1 wherein (a) is a polymer of acrylonitrile, ethyl acrylate and 2-hydroxyethyl acrylate.
- 4. A laminated article according to claim 1 wherein (c) is a polymer of acrylonitrile, ethyl acrylate and acrylic acid.
- 5. A laminated article according to claim 1 wherein (c) is a polymer of acrylonitrile, ethyl acrylate and 2-hydroxyethyl acrylate.
- 6. A laminated article according to claim 1 wherein (e) is a polymer of acrylonitrile, ethyl acrylate and acrylic acid.
- 7. A laminated article according to claim 1 wherein (e) is a polymer of acrylonitrile, ethyl acrylate and 2-hydroxyacrylate.
- 8. A laminated article according to claim 1 wherein (g) is andalusite.
- 9. A laminated article according to claim 1 wherein (a), (c) and (e) are polymers of acrylonitrile, ethyl acrylate acrylic acid.
- 10. A laminated article according to claim 1 wherein (a), (c) and (e) are polymers of acrylonitrile, ethyl acrylate and 2-hydroxyethyl acrylate.
- 11. A laminated article according to claim 1 wherein (g) is pyrophyllite.
- 12. A laminated article according to claim 1 wherein (g) is a mixture of andalusite and pyrophillite.
- 13. A method for the production of the article of claim 1 which comprises heat and pressure consolidating a laminate assembly, consisting essentially of, in superimposed relationship,
- A. at least one paper sheet impregnated with a substantially completely curable resinous composition which comprises a mixture of (a) and (b), said (a) comprising a polymer of
- 1. from about 75% to about 98%, by weight, based on the total weight of polymer (a), of a polymerizable acrylic monomer and
- 2. from about 2% to about 25%, by weight, based on the total weight of polymer (a), of an acrylic monomer which is different from and copolymerizable with (1) and contains a functional group comprising carboxyl, amide or hydroxyl groups, and said (b) comprising
- 3. a thermosetting melamine/formaldehyde resin having a ratio of melamine to formaldehyde ranging from about 1 : 1.6 to about 1 : 2.5, respectively, the ratio of melamine in said (b) to polymer (a) ranging from about 4:1 to about 0.5:1, respectively,
- B. a decorative sheet, with its decorative side facing upwardly, impregnated with a substantially completely curable resinous composition which comprises a mixture of (c) and (d), said (c) comprising a polymer of
- 4. from about 75% to about 98%, by weight, based on the total weight of polymer (c), of a polymerizable acrylic monomer and
- 5. from about 2% to about 25%, by weight, based on the total weight of polymer (c) of an acrylic monomer which is different from and copolymerizable with (4) and contains a functional group comprising carboxyl, amide or hydroxyl groups, and said (d) comprising
- 6. a thermosetting melamine/formaldehyde resin having a ratio of melamine to formaldehyde ranging from about 1 : 1.6 to about 1 : 2.5, respectively, the ratio of melamine in said (d) to polymer (c) ranging from about 4 : 1 to about 1 : 1, respectively, said decorator sheet having
- C. a clear, thermosetting, cross-linkable resinous coating, directly applied to the upward face thereof, said coating comprising a composition which comprises a mixture of (e), (f) and (g), said (e) comprising a polymer of,
- 7. from about 75% to about 98%, by weight, based on the total weight of polymer (e), of a polymerizable acrylic monomer and
- 8. from about 2% to about 25%, by weight, based on the total weight of polymer (e), of an acrylic monomer which is different from and copolymerizable with (7) and contains a functional group comprising carboxyl, amide or hydroxyl groups, said (f) comprising
- 9. from about 10% to about 100%, by weight, based on the total weight of said (8), of a highly alkoxymethylated melamine, and said (g) comprising
- 10. from about 5.0% to about 40.0%, by weight, based on the total resin solids in (C), of andalusite, pyrophyllite or mixtures thereof.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to copending application Ser. No. 617,929, filed Sept. 29, 1975 and entitled Thin, Tough, Stable Laminate.
US Referenced Citations (3)
Number |
Name |
Date |
Kind |
2918452 |
Kun et al. |
Dec 1959 |
|
3220916 |
Petropoulos |
Nov 1965 |
|
3589974 |
Albrinck et al. |
Jun 1971 |
|