Wear-resistant decorative laminates and methods of producing same

Abstract: Wear-resistant, high pressure decorative laminates having scratch, mar, scrape and abrasion resistance and methods of producing the same. More particularly, the laminates employ a decorative sheet saturated with a melamine-formaldehyde resin coating incorporating abrasive materials. An abrasion-resistant coating which contains mineral particles, a coupling agent, a thickening agent and a lubricating agent is disclosed.

Description: Background of the invention This invention generally relates to wear resistant decorative laminates having excellent scratch, mar, scrape and abrasion resistance and methods of producing the same. More particularly, this invention relates to a decorative laminate having improved scratch, mar, scrape and abrasion resistance comprising at least one backing layer sheet and a thermoset resin impregnated decorative paper sheet laminated thereto, said decorative paper sheet having thereon an abrasion resistant resin coating. Moreover, the invention relates to processes for the production of decorative laminates having improved scratch, mar, scrape and abrasion resistance. Conventionally, decorative laminates are made of two essential layers: a core layer and a surface layer. The core layer constitutes a bottom or supporting layer onto which the other layer is bonded. In normal high-pressure laminate manufacture, the core layer consists of a plurality of cellulosic sheets. The core sheets are generally made from a kraft paper impregnated with a laminating resin. Laminating resins commonly used for the core layer include phenolic, amino, epoxy, polyester, silicone, and diallyl phthalate resins to name a few. The industrially preferred laminating resin for decorative laminates is a phenolic resin made from the reaction of phenols with formaldeyhde. Placed above the core layer is a decorative layer which is generally an alpha cellulose pigmented paper containing a print, pattern design or solid color that has been impregnated with a melamine-formaldehyde resin. The cured melamine-formaldehyde resins are colorless and resistant to light; they are resistant to a variety of solvents and stains; and their heat resistance makes them resistant to burning cigarettes, boiling water and heated containers up to about 162,8°C (325°F). Without these melamine-formaldehyde resins, the decorative laminate industry would not exist as it is known today. However, because these resins are extremely brittle, they sometimes require reinforcement. When the decorative layer of the laminate is a printed pattern, it is covered with an overlay as it is commonly referred to, which is a high-quality alpha cellulose paper impregnated with a melamine-formaldehyde resin. This layer protects the decorative print from external abuse such as abrasive wear and tear, harsh chemicals, burns, spills and the like. It is primarily the melamine-formaldehyde resin which accounts for these protective properties. The alpha-cellulose paper acts as a translucent carrier for the water-thin resin, imparts strength to the rather brittle melamine-formaldehyde resin, maintains a uniform resin thickness in the overlay by acting as a shim, and controls resin flow. The core layer, decorative layer and the overlay surface layer (when needed) are stacked in a superimposed relationship, between polished steel plates and subjected to a pressure and temperature for a time sufficiently long enough to cure the laminating resins impregnating the respective layers. The elevated temperature and pressure actually cause the impregnated resins within the sheets to flow, which consolidates the whole into an integral mass known as the laminate. These laminates are used as surfacings for counter tops, table tops, furniture, store fixtures and the like. Abrasive materials have previously been employed in the overlay sheet or solid color decorative sheet in order to improve the abrasion resistance of the laminate. The abrasive materials are generally deposited upon the alpha cellulose matrix or, in other applications, mixed with celluosic fibers or microcrystalline materials replacing the alpha cellulose overlay sheet. Incorporation of abrasive materials in the decorative or overlay sheet can cause severe damage to the delicate, highly polished or intricately etched surfaces of the press plates when the abrasive particles deposited in the decorative or overlay sheet come into contact therewith. Thus, there exists the need for substitution of a resin in the decorative or overlay sheet that will provide excellent surface damage resistance without damaging the delicate plates. Also incorporation of abrasive materials in laminates can cause objectional wear on materials rubbed across them. The provision for such a layer would fulfill a long-felt need and constitute a significant advance in the art. Description of the Prior Art Prior art procedures for the manufacture of abrasion-resistant decorative laminates, such as those taught in U.S. Patent No. 4,255,480, have generally required a multi-step process in which the decorative facing sheet is first coated with a binder/mineral mixture and then dried to bind the abrasion-resistant mineral to the decorative sheet. The dry coated decorative sheet is then impregnated with a thermosetting resin. However, this particular prior art process calls for the utilization of a binding material compatible with the thermosetting resin, namely microcrystalline cellulose, to bind the mineral particles to the decorative sheet. Thus, this prior art process requires a specific binding compound compatible with the thermosetting resin, and separate coating, drying and impregnating steps. Others have attempted production of mar-resistant decorative laminates. For instance, U.S. Patent No. 4,263,081 teaches the production of a mar-resistant laminate but further requires that a second layer of binder/mineral mixture be provided immediately below or above the first binder/mineral layer. U.S. Patent No. 4,305,987 is directed to an abrasion-resistant laminate meeting National Electric Manufacturers' Association (NEMA) standards relating to abrasive wear, strain resistance, heat resistance, impact resistance, dimensional stability and the like. The patent discloses a "stabilizing binder material" for the abrasion-resistant mineral. The patent also teaches the use of microcrystalline cellulose as the preferred binder material, acting as a suspending and binding agent and also compatible with melamine and polyester laminating resins. U.S. Patent No. 4,327,141 discloses an abrasion-resistant decorative laminate meeting National Electric Manufacturers Association (NEMA) standards. The abrasion-resistant laminate requires an additional layer of binder material immediately below or above the abrasion resistant coating. U.S. Patent No. 4,395,452 discloses a print sheet for use in the preparation of abrasion-resistant decorative laminates, and requires the presence of binder material "in an amount sufficient to bind and stabilize" the abrasion-resistant mineral to the surface of the paper sheet. U.S. Patent No. 4,400,423 also discloses a print sheet for use in the preparation of abrasion-resistant decorative laminates, however additionally discloses use of an additional layer of binder material immediately above or below the abrasion-resistant coating. U.S. Patent No. 4,430,375 teaches a decorative sheet for use in the preparation of abrasion-resistant decorative laminates and the use of a binder material. Additionally, the process for producing the laminate discloses a separate drying step to enhance the bonding of the abrasion-resistant mineral particles to the decorative sheet. U.S. Patent No. 4,499,137 discloses a scuff-resistant decorative laminate utilizing a wax lubricant having a melt temperature below 127°C (260°F) so as to avoid haze in the laminate. Both U.S. Patent Nos. 4,517,235 and 4,520,062 disclose an abrasion-resistant coating for decorative laminates in which a binder/mineral coating is transferred from a mold surface or flexible tape to the surface of the laminate. Additionally, a transfer carrier containing a non-resinous binder material and mineral abrasive particles is disclosed. U.S. Patent No. 4,532, 170 discloses a facing sheet for a scuff-resistant decorative laminate, comprising a particulate lubricant and binder material for the lubricant particles, but excluding oxidized wax and silicone resin lubricants. U.S. Patent Nos. 4,567,087 teaches a scuff-resistant and abrasion-resistant decorative laminate comprising abrasion-resistant particles, binder material for the particles, and a lubricant which is not an oxidized wax or silicone resin. U.S. Patent No. 4,713,138 discloses a single step method of preparing a facing sheet for use as the uppermost sheet in the manufacture of an abrasion-resistant decorative laminate. The method teaches a binding material for the mineral that (1) withstands the subsequent laminating conditions, (2) is compatible with the thermosetting resin, (3) is present in an amount sufficient to bind the abrasion-resistant mineral to the surface of an unsaturated paper sheet, and (4) suspends the abrasion-resistant mineral particles in the liquid thermosetting resin. U.S. Patent No. 4,741,946 discloses scuff and abrasion-resistant decorative laminates in which finely divided lubricant wax particles are incorporated in or very near the surface of the solid-colored decorative paper. The lubricant is disclosed as not being an oxidized wax or silicone resin. With respect to EP-A-0 219 769, this document discloses a prior wear resistant laminate, but one which does not exhibit the superior wear resistance of the present application. EP-A-0 219 769 utilized a coating process which uses a complex and highly specialized coating formulation that was specifically designed for a reverse roll application to the decorative paper to yield a laminate with a top coating which was several millimeters thick. The coating used in EP-A-0 219 769 is thickened with fully hydrolyzed polyvinyl alcohol and fumed silica to a viscosity of several thousand centipoise so that it may be coated onto the decorative paper and remains as a thick surface coat. In contrast to EP-A-0 219 769, the laminate of the present invention does not utilize either fully hydrolyzed polyvinyl alcohol or fumed silica. In fact, these materials are incompatible with the present invention. The addition of fully hydrolyzed polyvinyl alcohol and fumed silica to the present invention would cause the resin to become so thick that it could not be applied by the sparge pipe or gravure method of the instant invention and the resin would not be able to satisfactorily saturate the decorative sheet of the laminate. Additionally, the laminate disclosed in EP-A-0 219 769 could not have incorporated as high a concentration of abrasion resistant mineral particles as contained in the laminate of the instant invention. If the concentration of mineral particles used in the present invention were also used in EP-A-0 219 769, the laminate of EP-A-0 219 769 would have a hazy finish which would be undesirable. Summary of the invention It is a principal object of this invention to provide laminates having excellent resistance to all known types of physical damage to the surface that cause marring or defacement. This includes scraping by a relatively sharp object of about equal hardness to the laminate resulting in a burnish mark (polished streak) or a chalk mark (transfer of material from the abrading object to the laminate); scratching by a very sharp object of about the same hardness as the grit in the laminate resulting in a groove of plowed away material; and mars such as a series of very closely spaced scratches caused by many very fine particles of about equal hardness to the grit in the laminate such as contained in sandpaper, a scouring pad or air-borne dirt trapped beneath a tool used to fabricate a laminate or an object slid across the installed laminate. It is a further object of this invention to provide the above mentioned excellent scratch, mar, scrape and abrasion resistance in a laminate having a very even, uniformly fine textured matte finish providing a surface gloss of about 14 (Gardener 60)). It is a further object of this invention to provide the above mentioned excellent scratch, mar, scrape and abrasion resistance in a laminate having a very even, uniform glossy surface finish. It is still a further object of this invention to protect the expensive and delicate plates, used to produce high pressure decorative laminates, from undue or premature wear caused by the inclusion in the laminate surface of hard abrasive particles and to prevent an objectionable deposit of worn metal fragments on the surfaces of light colored laminates. The foregoing objects and others are accomplished in accordance with the present invention by employing the preferred embodiments of the invention. These and other objects of the present invention will be apparent from the detailed description given hereinafter. In accordance with these objectives of the present invention, a new high pressure decorative laminate has been developed which has excellent resistance to scratching, marring, scraping and abrasion. According to the present invention, a decorative laminate is provided that has improved scratch, mar, scrape and abrasion resistance, comprising at least one backing layer sheet and a thermoset resin impregnated decorative paper sheet laminated thereto, said decorative paper sheet having thereon an abrasion resistant resin coating comprising: abrasion resistant mineral particles having a particle size of about 3 µm (microns) and abrasion resistant mineral particles having a particle size of about 25 µm (microns), in a concentration sufficient to provide for abrasion resistance, the ratio of the larger particles to the smaller particles being 2 to 1, said abrasion resistant mineral particles being applied concurrently with said thermoset resin to said decorative sheet to simultaneously coat and impregnate said decorative sheet; a coupling agent; a thickening agent in an amount sufficient to suspend said abrasion resistant mineral particles; and a lubricating agent in a concentration sufficient to provide for scrape resistance. Processes for the production of decorative laminates according to the present invention are indicated in the independent claims 11, 20, 21, 22, 31 and 32. Detailed description of the Embodiments The preferred embodiment for the decorative laminates having excellent scratch, mar, scrape and abrasion resistance utilize a coating formulation mixture comprising melamine-formaldeyhde resin to which the following is added: 1.6 percent Al₂O₃ (alumina) grit particles having a particle size of at least 25 µm (microns); 0.8 percent Al₂O₃ (alumina) grit particles having a particle size of at least 3 µm (microns); from about 0.3 percent to about 1.2 percent polyvinyl alcohol; 0.25 percent silane coupling agent based upon the amount of grit used; 0.075 percent xanthan gum thickener; and 0.1 percent PEG 6000 distearate. The melamine-formaldehyde resin may also be modified with a plasticizer and/or an acid catalyst if a more flexible wear-resistant laminate is desired. The preferred catalyst is paratoluene sulfonic acid; however, any kind of acid such as magnesium bromide, hydrochloric acid, sulfuric acid or the like may be utilized as a catalyst. The melamine formaldehyde resin coating formulation additionally contains polyvinyl alcohol as an auxiliary slip agent. A polyethylene wax known by the tradename AC316 from Allied Chemical Company was evaluated as an auxiliary slip agent, however was found to impart haze and blur to the resulting decorative laminate. The polyvinyl alcohol functions to impart resistance to marks from sliding objects (sometimes referred to as "scuff": resistance) to the resulting laminate. The melamine-formaldehyde resin coating formulation additionally contains a silane coupling agent, the amount based upon the desired amount of grit utilized in the laminate; an alginate thickener such as xanthan gum to suspend the grit particles and protect the plates used in the laminate production process from undue wear causing metal mar marks on light colored laminates; and PEG 6000 distearate to enhance surface slip and improve scrape resistance of the laminate. The PEG 6000 distearate used in the resin coating formulation is the preferred lubricating agent, as it provides scrape resistance. Zinc stearate and other lubricating compounds were evaluated for scrape resistance, but were found less effective. The coating formulation may also contain a small amount (0.01-0.1 percent) of a surfactant designed to reduce surface tension of the coating to provide a smooth and a uniform deposition of the coating. An example of such agent is Silwet® L-77 from Union Carbide Co. L-77 is a dimethylpolyoloxane. The resulting decorative laminate utilizing the melamine formaldehyde resin coating formulation as described above has excellent scratch resistance imparted by the 25 µm (microns) alumina grit. The laminate additionally has excellent mar resistance imparted by the 3 µm (microns) alumina grit. The 3 µm (microns) alumina grit, being smaller, has much more surface area and thus provides more complete coverage of the laminate surface. However, the larger, 25 µm (microns) alumina grit particles are necessary to provide scratch resistance to the laminate. This is because mar is produced by many very small, closely spaced particles covering a broad area of the abrading object and, because of the broad coverage, pressure is very low. In contrast, a scratch is produced by a single larger hard, sharp object that is under greater pressure as a result of its small contact area with the laminate surface. Two processes may be used to produce the wear-resistant laminates having either a matte finish or glossy finish. It is well understood in the art that the surface finish of the resulting decorative laminate, whether a matte finish or glossy finish laminate is achieved, is dependent upon the surface texture of the pressing plates used in the consolidation of the laminate. One process which may be used to produce the wear resistant decorative laminate is the sparge pipe process. With the sparge pipe process, the resin coating formulation is applied to a decorative paper sheet using a sparge pipe having many holes to spread the resin coating formulation uniformly across the top side of the decorative paper. A first sparge coating supplies nearly all of the required resin, about 80 percent of the requirement. In a second step, the wet resin-coated decorative paper is further dipped into an identically formulated resin coating mixture which supplies the remainder of the required resin. The total resin pick-up by the decorative sheet is regulated by metering-squeeze rollers. It has been found that inferior scratch and mar resistance is obtained if the decorative paper is dipped only into the resin coating formulation without the prior sparge process. The resin coated decorative paper and at least one backing sheet is dried and then heat and pressure consolidated using conventional techniques into a high pressure decorative laminate having excellent scratch, mar, scrape and abrasion resistance. It is well understood that more than one sheet of backing paper may be used to produce laminates of varying thicknesses. The second process which may be used to produce the wear-resistant high pressure decorative laminates is the gravure pad coating process. With this process, the resin coating formulation is first applied to the surface of the raw decorative paper sheet using a gravure pad coating cylinder. When applied in this manner, the decorative paper sheet picks up only about 20 percent of the required amount of resin, so the percentage of grit in the coating formulation must be increased to about 15 percent so that a sufficient amount of the abrasive grit is imparted to the decorative sheet. In a second step subsequent to the gravure coating, either with or without an intermediate drying step, the decorative paper sheet is dipped into the resin coating formulation containing neat melamine-formaldehyde resin, which is resin which has not been modified with the abrasive grit, to supply the remainder of the required amount of resin to saturate the sheet. The resin pick-up by the decorative sheet is regulated by metering squeeze rollers. Coating the decorative sheet with a coating formulation which uses a neat melamine-formaldehyde resin has been found to render the coating process less damaging to the highly polished stainless steel plates used for producing high gloss laminates. The coated decorative paper and at least one backing sheet is dried and then heat and pressure consolidated using conventional techniques into a high pressure decorative laminate having excellent scratch, mar, scrape and abrasion resistance. It is well understood that more than one backing sheet may be used to produce laminates of varying thicknesses. In order to further define the specifics of the present invention, the following examples are provided and intended to illustrate the high pressure decorative laminate having improved scratch, mar, scrape and abrasion resistance and the process for producing the laminate, and not to limit the particulars of the present invention: EXAMPLE 1 Laminate samples having a matte finish were subjected to four different testing procedures to measure scratch, mar, scrape and abrasion resistance. The matte laminate samples tested included: (1) Standard FORMICA® brand high pressure decorative laminate having a matte finish; (2) FORMICA® brand high pressure decorative laminate having a matte finish which additionally contained PEG 6000 distearate in the resin coating; (3) FORMICA® brand high pressure decorative laminate having a matte finish which additionally contained 0.8 percent of 6 µm (microns) alumina grit particles in the resin coating, the resin coating being applied to the decorative sheet by dip and squeeze application; (4) a high pressure decorative matte finish laminate produced by the sparge pipe process and having a decorative sheet impregnated with a resin coating formulation containing 1.5 percent 6 µm (microns) alumina particle grit, xanthan gum and PEG 6000 distearate; (5) a high pressure decorative matte finish laminate produced by the sparge pipe process and having a decorative sheet impregnated with a resin coat formulation containing 1.6 percent 25 µm (microns) alumina particle grit, 0.8 percent 3 µm (microns) alumina particle grit, xanthan gum, and PEG 6000 distearate; and (6) a matte finish wear-resistant laminate known as NEVAMAR ARP®. Each of the above-described laminate samples was subjected to the following four test procedures: I. GLASS SCRATCH TEST This test was designed to measure the ease with which a laminate could be scratched using a material of similar sharpness and hardness to ordinary silica, the usual scratching component in air-borne dirt. Scratches are very thin lines, usually several 2,54 cm (inches) long and widely spaced one from another. Material is plowed out by the scratch-inducing agent and the indentation in the laminate surface can usually be felt by running a fingernail over it. Each of the 6 laminate samples described above were scratched four times with the edge of a glass microscope slide (Fisher brand Cat. No. 12-550A 75 x 25 mm - non-frosted) held in a device to which loads of 25, 50, 100 and 200 grams could be applied. The laminate surfaces were observed visually and the resulting surface scratches were rated as follows: 0 = no mark visible under these conditions 1 = very, very faint scratch visible if tilted to a critical angle 2 = very faint scratch - easier to see than a #1 3 = faint scratch - fairly easy to see at most angles 4 = easily visible scratch that will disappear at a critical angle 5 = a scratch easily visible at any angle under good light. The results were then totalled for all scratches on the particular laminate sample. The results appear in TABLE I below. II. MAR-TEST The mar resistance of each of the laminate samples was determined by rubbing the laminate surface under controlled conditions with an abrasive cloth (blue grit utility cloth grade 280J type 311T, by 3M Company) and then measuring the change in surface gloss of the marred area as compared to the original surface gloss. The change in surface gloss was measured by a 60) glossmeter manufactured by Gardner Laboratory Division, Bethesda, Maryland. The mar resistance for each laminate sample was calculated as follows: Mar resistance tends to depend disproportionately on the original background gloss of the laminate. The glossier the laminate, the higher the WG value. WG = the percent change in gloss (mar resistance) NOTE: Burnishing (surface gloss increase), will be a negative value. The results of the mar resistance for each laminate sample are set forth below in TABLE I. III. SCRAPE TEST This test was intended to measure the likelihood of the surface of one laminate to be scraped by the sharp corner of the surface of another laminate being dragged across it. Scrape is a long, narrow streak that may appear as a burnish (higher gloss) or as a whitish, chalky mark. Each of the laminate samples were scraped five times using neutral gray, solid color FORMICA® brand laminate chips, grade 1058. The laminate surfaces of the samples were then visually observed and the surface scrapes were rated as follows: 0 = no visible mark 1 = a burnish (higher gloss) mark that disappears as the sample is rotated to various angles. 2 = a burnish mark visible at all viewing angles. 3 = a chalk mark that disappears as the sample is rotated at various angles. 4 = a chalk mark visible at all viewing angles. NOTE : If the scrape appeared to "skip" such as burnish to chalk or burnish to nothing, the scrape was graded according to the greatest severity of the scrape. The results of the test were totalled and averaged for all scrapes on the particular laminate sample. The results appear in TABLE I below. IV. ABRASION TEST This test measured the ability of the surface of a high pressure decorative laminate to maintain its design and color when subjected to abrasive wear. Each of the laminate samples were uniformly abraded for 750 cycles using 180 grit alumina oxide sandpaper strips 1/2 inch (12.7 mm) wide by 6 inches (152.4 mm) long. After 750 cycles, the resulting groove depth in the laminate surface was measured to determine abrasion resistance. The results of the abrasion resistance test are summarized below in TABLE I. SAMPLE SCRATCH (0-20 scale) MAR (%ΔG) SCRAPE (0-4 scale) ABRASION (Groove Depth at 750 cycles) 1 (Control) 14 34 1-2 -- 2 14 34 1 -- 3 11 9 2-3 60,96 µm (2.4 mils) 4 6.4 -4.7 1.8 38,1 µm (1.5 mils) 5 3.7 -7.5 1.9 20,32 µm (0.8 mils) 6 5 -8.2 2 20,32 µm (0.8 mils) TABLE I shows that the standard FORMICA® brand laminate product having a matte finish had poor scratch and mar resistance and fair scrape resistance. The addition of small microgrit slightly improved scratch and substantially improved mar, but was detrimental to scrape resistance. Increasing the level of small grit, applying it to the decorative sheet surface with a sparge pipe and including the PEG distearate, substantially improved scratch and mar resistance (a negative value means the sample burnished or became glossier when abraded) and the PEG distearate improved scrape resistance in spite of the presence of grit. This higher level of surface applied grit also reduced the groove depth resulting from 750 cycles of abrasion. Finally the mixed grit including the larger size 25 µm (microns) particles and the smaller size 3 µm (microns) particles, brought about a further improvement in scratch resistance and reduced the abrasion groove depth by half. The PEG distearate continued to maintain good scrape resistance EXAMPLE 2 The purpose of this example was to test scratch, abrasion and mar resistance in wear-resistant high pressure decorative laminates having a glossy finish produced by either the sparge pipe process or gravure process and having varying amounts and particle sizes of alumina grit in the resin coating formulation impregnated in the decorative sheet. The following eight laminate samples were tested: (1) A control sample of glossy finish standard FORMICA® brand laminate having no alumina grit particles; (2) A glossy finish laminate produced by the sparge pipe process and having 2.5 percent 3 µm (microns) alumina particle grit in the resin coating; (3) A glossy finish laminate produced by the sparge pipe process and having 0.8 percent 9 µm (microns) alumina grit particles in the resin coating; (4) A glossy finish laminate produced by the sparge pipe process and having 1.5 percent 9 µm (microns) alumina grit particles in the resin coating; (5) A glossy finish laminate produced by the gravure process and having 10 percent 9 µm (microns) alumina grit particles in the resin coating; (6) A glossy finish laminate produced by the gravure process and having 15 percent 9 µm (microns) alumina grit particles in the resin coating; (7) A glossy finish laminate produced by the sparge pipe process and having a mixture of 1.6 percent 25 µm (microns) Al₂O₃ grit particles and 0.8 percent 3 µm (microns) Al₂O₃ grit particles in the resin coating; (8) Nevamar® "Glossie" wear-resistant decorative laminate. Each of the above laminates was tested for scratch resistance, abrasion resistance and mar resistance using the testing procedures previously described in EXAMPLE 1. The results of the testing are set forth below in TABLE II. Sample Scratch Improvement (times better than control) Abrasive Improvement (times better than control) Mar Resistance Improvement (% improvement over control) 1 (Control) 1 1 0 2 1 0.9 94.3 3 1.4 1.3 93.7 4 2 1.4 98.0 5 2 2.8 99.2 6 7 3.6 99.8 7 14 ∞ 99.4 8 3.7 1.5 88.5 The data in TABLE II shows that virtually any inclusion of microgrit substantially improves mar resistance because all samples improved 93.7% to 99.8% in this property as compared to the control. This is a very narrow range and all experimental samples would be considered to have good mar resistance. However, when considering scratch resistance, only the samples with very high grit levels or the larger particle size grit have good values. The best sample (Sample 7) (mixed grit) is 14 times better than the control. The next best sample (Sample 6) is 7 times better, meaning that only half as good scratch resistance was achievable with the 9 µm (microns) particle size grit as compared to the 25 µm (microns) particle size grit. Finally, in abrasive wear, only Sample 7 made with 25 µm (microns) particle size grit showed an immeasurable groove depth after 500 abrasion cycles.

Claims: A decorative laminate having improved scratch, mar, scrape and abrasion resistance comprising at least one backing layer sheet and a thermoset resin impregnated decorative paper sheet laminated thereto, said decorative paper sheet having thereon an abrasion resistant resin coating comprising: abrasion resistant mineral particles having a particle size of about 3 µm (microns) and abrasion resistant mineral particles having a particle size of about 25 µm (microns), in a concentration sufficient to provide for abrasion resistance, the ratio of the larger particles to the smaller particles being 2 to 1, said abrasion resistant mineral particles being applied concurrently with said thermoset resin to said decorative sheet to simultaneously coat and impregnate said decorative sheet; a coupling agent; a thickening agent in an amount sufficient to suspend said abrasion resistant mineral particles; and a lubricating agent in a concentration sufficient to provide for scrape resistance. A decorative laminate having improved scratch, mar, scrape and abrasion resistance according to claim 1, wherein said thermoset resin is melamine-formaldehyde resin. A decorative laminate having improved scratch, mar, scrape and abrasion resistance according to claim 1, wherein said abrasion resistant mineral particles comprise about 15 percent w./w. wet resin of the abrasion resistant resin coating. A decorative laminate having improved scratch, mar, scrape and abrasion resistance according to claim 1, wherein said abrasion resistant mineral particles are alumina. A decorative laminate having improved scratch, mar, scrape and abrasion resistance according to claim 1, wherein said coupling agent is a silane. A decorative laminate having improved scratch, mar, scrape and abrasion resistance according to claim 1, wherein said thickening agent is a xanthan gum. A decorative laminate having improved scratch, mar, scrape and abrasion resistance according to claim 1, wherein said lubricating agent is polyvinyl alcohol or polyethylene glycol distearate having a molecular weight of about 6000. A decorative laminate having improved scratch, mar, scrape and abrasion resistance according to claim 2, wherein said melamine-formaldehyde resin is modified with a plasticizer and a catalyst. A decorative laminate having improved scratch, mar, scrape and abrasion resistance comprising at least one backing layer sheet and a melamine-formaldehyde resin impregnated decorative paper sheet having thereon an abrasion resistant resin coating comprising: abrasion resistant alumina particles having a particle size of about 3 µm (microns) and abrasion resistant alumina particles having a particle size of about 25 µm (microns), the ratio of the larger particles to the smaller particles being 2 to 1, wherein the entire amount of said abrasion resistant alumina particles comprises about 15 percent w./w. wet resin of the abrasion resistant resin coating; silane, wherein said silane comprises about 0.25 percent w./w. wet resin of the abrasion resistant resin coating; xanthan gum, wherein said xanthan gum comprises about 0.075 percent w./w. wet resin of the abrasion resistant resin coating; polyvinyl alcohol or polyethylene glycol distearate having a molecular weight of about 6000, wherein said polyvinyl alcohol comprises about 0.3 percent w./w. wet resin to about 1.2 percent w./w. wet resin of the abrasion resistant resin coating and said polyethylene glycol distearate comprises about 0.1 percent w./w. wet resin of the abrasion resistant resin coating. A decorative laminate having improved scratch, mar, scrape and abrasion resistance according to claim 9, wherein said decorative laminate has a surface gloss of about 14. A process for the production of decorative laminates having improved scratch, mar, scrape and abrasion resistance comprising the steps of: preparing a mixture of a liquid thermosetting, impregnating resin and an abrasion resistant coating, wherein said mixture comprises: (1) abrasion resistant mineral particles having a particle size of about 3 µm (microns) and abrasion resistant mineral particles having a particle size of about 25 µm (microns) in a concentration sufficient to provide for abrasion resistance, the ratio of the larger particles to the smaller particles being 2 to 1; (2) a coupling agent; (3) a thickening agent in an amount sufficient to suspend said abrasion resistant mineral particles; and (4) lubricating agents in a concentration sufficient to provide for scrape resistance; simultaneously coating and impregnating a decorative paper sheet with said abrasion resistant mineral particles and said resin by uniformly coating said decorative sheet with said mixture of thermosetting resin and abrasion resistant coating, whereby about 80 percent of the amount of resin required for saturation of said decorative sheet is impregnated into said decorative sheet; dipping said resin impregnated decorative sheet into an identically formulated mixture of thermosetting resin and abrasion resistant coating, whereby the remaining amount of resin required for saturation of said decorative sheet is impregnated into said resin impregnated decorative sheet; metering the total amount of resin impregnated into the decorative sheet by metering means; and drying and consolidating said resin impregnated decorative sheet exposing it heat and pressure, thereby obtaining a high pressure decorative laminate having improved scratch, mar, scrape and abrasion resistance. The process according to claim 11, wherein said liquid thermosetting, impregnating resin is melamine-formaldehyde resin. The process according to claim 11, wherein said abrasion resistant mineral particles are alumina. The process according to claim 11, wherein said coupling agent is silane. The process according to claim 11, wherein said thickening agent is xanthan gum. The process according to claim 11, wherein said lubricating agent is polyvinyl alcohol or polyethylene glycol distearate having a molecular weight of about 6000. The process according to claim 12, wherein said melamine-formaldehyde resin is modified with a plasticizer and a catalyst. The process according to claim 11, wherein said coating and impregnating step is accomplished by a sparge pipe containing holes to allow for the uniform application of the thermosetting resin and abrasion resistant coating mixture onto the top surface of said decorative sheet. The process according to claim 11, wherein said metering means are metering-squeeze rollers. A process for the production of decorative laminates having improved scratch, mar, scrape and abrasion resistance comprising the steps of: preparing a mixture of a melamine-formaldehyde resin and an abrasion resistant coating, wherein said mixture comprises: (1) 0.8 percent w./w. wet resin abrasion resistant alumina particles having a particles size of about 3 µm (microns) and 1.6 percent w./w. wet resin abrasion resistant alumina particles having a particle size of about 25 µm (microns); (2) about 0.25 percent w./w. wet resin silane; (3) about 0.075 percent w./w. wet resin xanthan gum; and (4) about 0.3 percent w./w. wet resin to about 1.2 percent w./w. wet resin polyvinyl alcohol or about 0.1 percent w./w. wet resin polyethylene glycol distearate having a molecular weight of about 6000; simultaneously coating and impregnating a decorative paper sheet with said abrasion resistant alumina particles and said melamine-formaldehyde resin by uniformly coating said decorative sheet with said mixture of melamine-formaldehyde resin and abrasion resistant coating, whereby about 80 percent of the amount of melamine-formaldehyde resin required for saturation of said decorative sheet is impregnated into said decorative sheet; dipping said melamine-formaldehyde resin impregnated decorative sheet into an identically formulated mixture of melamine-formaldehyde resin and abrasion resistant coating, whereby the remaining amount of melamine-formaldehyde resin required for saturation of said decorative sheet is impregnated into said resin impregnated decorative sheet; metering the total amount of melamine-formaldehyde resin impregnated into the decorative sheet by metering-squeeze rollers; and drying and consolidating said melamine-formaldehyde resin impregnated decorative sheet exposing it heat and pressure, thereby obtaining a high pressure decorative laminate having improved scratch, mar, scrape and abrasion resistance. A process for the production of decorative laminates having improved scratch, mar, scrape and abrasion resistance comprising the steps of: preparing a mixture of a liquid thermosetting, impregnating resin and an abrasion resistant coating, wherein said mixture comprises: (1) abrasion resistant mineral particles having a particle size of about 3 µm (microns) and abrasion resistant mineral particles having a particle size of about 25 µm (microns) in a concentration sufficient to provide for abrasion resistance, the ratio of the larger particles to the smaller particles being 2 to 1; (2) a coupling agent; (3) a thickening agent in an amount sufficient to suspend said abrasion resistant mineral particles; and (4) lubricating agents in a concentration sufficient to provide for scrape resistance; simultaneously coating and impregnating a decorative paper sheet with said abrasion resistant mineral particles and said resin by uniformly coating said decorative sheet with said mixture of thermosetting resin and abrasion resistant coating whereby up to about 20 percent of the amount of resin required for saturation of said decorative sheet is impregnated into the decorative sheet; dipping said resin impregnated decorative sheet into an identically formulated mixture of thermosetting resin and abrasion resistant coating, whereby the remaining amount of resin required for saturation of said decorative sheet is impregnated into the resin impregnated decorative sheet; metering the total resin impregnated into the resin impregnated decorative sheet by metering means; and drying and consolidating said resin impregnated decorative sheet exposing it heat and pressure, thereby obtaining a high pressure decorative laminate having improved scratch, mar, scrape and abrasion resistance. A process for the production of decorative laminates having improved scratch, mar, scrape and abrasion resistance comprising the steps of: preparing a mixture of a liquid thermosetting, impregnating resin and an abrasion resistant coating, wherein said mixture comprises: (1) abrasion resistant mineral particles having a particle size of about 3 µm (microns) and abrasion resistant mineral particles having a particle size of about 25 µm (microns) in a concentration sufficient to provide for abrasion resistance, the ratio of the larger particles to the smaller particles being 2 to 1; (2) a coupling agent; (3) a thickening agent in an amount sufficient to suspend said abrasion resistant mineral particles; and (4) lubricating agents in a concentration sufficient to provide for scrape resistance; simultaneously coating and impregnating a decorative paper sheet with said abrasion resistant mineral particles and said resin by uniformly coating said decorative sheet with said mixture of thermosetting resin and abrasion resistant coating whereby about 20 percent of the amount of resin required for saturation of said decorative sheet is impregnated into said decorative sheet; drying said resin impregnated decorative sheet; dipping said resin impregnated decorative sheet into a neat thermosetting resin, whereby the remaining required amount of resin is impregnated into the resin impregnated decorative sheet; metering the total resin impregnated into the resin impregnated decorative sheet by metering means; and drying and consolidating said resin impregnated decorative sheet exposing it heat and pressure, thereby obtaining a high pressure decorative laminate having improved scratch, mar, scrape and abrasion resistance. The process according to claim 21 or 22, wherein said liquid thermosetting, impregnating resin is melamine-formaldehyde resin. The process according to claim 21 or 22, wherein said abrasion resistant mineral particles comprise about 15 percent w./w. wet resin of said mixture. The process according to claim 21 or 22, wherein said abrasion resistant mineral particles are alumina. The process according to claim 21 or 22, wherein said coupling agent is silane. The process according to claim 21 or 22, wherein said thickening agent is xanthan gum. The process according to claim 21 or 22, wherein said lubricating agent is polyvinyl alcohol or polyethylene glycol distearate having a molecular weight of about 6000. The process according to claim 21 or 22, wherein said coating and impregnating step is accomplished by a gravure pad coating cylinder. The process according to claim 21 or 22, wherein said metering means are metering-squeeze rollers. A process for the production of decorative laminates having improved scratch, mar and abrasion resistance comprising the steps of: preparing a mixture of melamine-formaldehyde impregnating resin and an abrasion resistant coating, wherein said mixture comprises: (1) abrasion resistant alumina particles having a particle size of about 3 µm (microns) and abrasion resistant alumina particles having particle size of about 25 µm (microns), the ratio of the larger particles to the smaller particles being 2 to 1, wherein the entire amount of said abrasion resistant alumina particles comprise about 15 percent w./w. wet resin of said mixture; (2) about 0.25 percent w./w. wet resin silane; (3) about 0.075 percent xanthan gum w./w. wet resin; and (4) about 0.3 percent w./w. wet resin to about 1.2 percent w./w. wet resin polyvinyl alcohol or about 0.1 percent w./w. wet resin polyethylene glycol distearate having a molecular weight of about 6000; simultaneously coating and impregnating a decorative paper sheet with said abrasion resistant particles and said resin by uniformly coating said decorative sheet with said mixture of melamine-formaldehyde resin and abrasion resistant coating whereby about 20 percent of the amount of melamine-formaldehyde resin required for saturation of said decorative sheet is impregnated into said decorative sheet; dipping said resin impregnated decorative sheet into an identically formulated mixture of melamine-formaldehyde resin and abrasion resistant coating, whereby the remaining amount of melamine-formaldehyde resin required for saturation of said decorative sheet is impregnated into said resin impregnated decorative sheet; metering the total melamine-formaldehyde resin impregnated into the resin impregnated decorative sheet by metering squeeze rollers; and drying and consolidating said resin impregnated decorative sheet exposing it heat and pressure, thereby obtaining a high pressure decorative laminate having improved scratch, mar, scrape and abrasion resistance. A process for the production of decorative laminates having improved scratch, mar and abrasion resistance comprising the steps of: preparing a mixture of a melamine-formaldehyde impregnating resin and an abrasion resistant coating, wherein said mixture comprises: (1) abrasion resistant alumina particles having a particle size of about 3 µm (microns) and abrasion resistant alumina particles having a particle size of about 25 µm (microns), the ratio of the larger particles to the smaller particles being 2 to 1, wherein the entire amount of said abrasion resistant alumina particles comprises about 15 percent w./w. wet resin of said mixture; (2) about 0.25 percent w./w. wet resin silane; (3) about 0.075 percent w./w. wet resin xanthan gum; and (4) about 0.3 percent w./w. wet resin to about 1.2 percent w./w. wet resin polyvinyl alcohol or about 0.1 percent w./w. wet resin polyethylene glycol distearate having a molecular weight of about 6000; simultaneously coating and impregnating a decorative paper sheet with said abrasion resistant particles and said resin by uniformly coating said decorative sheet with said mixture of melamine-formaldehyde resin and abrasion resistant coating whereby about 20 percent of the amount of melamine-formaldehyde resin required for saturation of said decorative sheet is impregnated into said decorative sheet; drying said resin impregnated decorative sheet; dipping said resin impregnated decorative sheet into a neat melamine-formaldehyde resin, whereby the remaining amount of resin required for saturation of said decorative sheet is impregnated into resin impregnated decorative sheet; metering the total melamine-formaldehyde resin impregnated into the resin impregnated decorative sheet by metering-squeeze rollers; and drying and consolidating said resin impregnated decorative sheet exposing it heat and pressure, thereby obtaining a high pressure decorative laminate having improved scratch, mar, scrape and abrasion, resistance.

Inventors: ALBRINCK DONALD JOSEPH, MASCAVAGE JOHN JOSEPH, ALBRINCK, DONALD JOSEPH, MASCAVAGE, JOHN JOSEPH
Applicants: FORMICA CORP, FORMICA CORPORATION
Application year: 1991
Main classification: B44C5
IPC codes: B32B27, B44C5