# US 11,077,639 B2 · Surfacing materials and method of manufacture

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- Number: US 11,077,639 B2
- Document ID: US11077639B2
- Status: Granted
- Kind: B2
- Application number: 16/438,904
- Filed: 2019-06-12
- Published: 2019-11-07
- Granted: 2021-08-03
- Earliest claimed: 2016-08-19
- Assignees: Wilsonart LLC
- Applicants: Wilsonart LLC
- Inventors: Muyuan M Ma; Rajesh Ramamurthy; Jin Chao; Mahesh Subramanian
- Web page: https://patentgrep.com/patent/US11077639B2

## CPC

- B32B 3/26: characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids {(foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205); characterised by an apertured layer}
- B05D 3/002: {Pretreatement}
- B05D 3/0254: {After-treatment}
- B05D 3/065: {After-treatment}
- B05D 3/068: {using ionising radiations (gamma, X, electrons)}
- B05D 5/02: to obtain a matt or rough surface
- B32B 7/06: permitting easy separation
- B32B 27/10: of paper or cardboard
- B32B 27/16: specially treated, e.g. irradiated
- B32B 27/36: comprising polyesters
- B32B 29/005: {next to another layer of paper or cardboard layer}
- B32B 38/06: Embossing
- B44B 5/0052: {by pressing (B44B5/0061 and B44B5/0076 take precedence)}
- B44B 5/026: {Dies (B44B5/028 takes precedence)}
- B44C 1/24: Pressing or stamping ornamental designs on surfaces
- B44C 5/0469: {comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper}
- B44C 5/0476: {with abrasion resistant properties}
- C08J 3/244: {Stepwise homogeneous crosslinking of one polymer with one crosslinking system, e.g. partial curing}
- C08J 3/28: Treatment by wave energy or particle radiation
- C08J 7/0427: {with only one layer of a composition containing a polymer binder (with more layers C08J7/042)}
- C08J 7/043: Improving the adhesiveness of the coatings per se, e.g. forming primers (adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50)
- C08J 7/046: Forming abrasion-resistant coatings; Forming surface-hardening coatings
- C08J 7/123: {Treatment by wave energy or particle radiation (C08J7/18 takes precedence)}
- C09D 4/00: Coating compositions, e.g. paints, varnishes or lacquers, based on organic non-macromolecular compounds having at least one polymerisable carbon-to-carbon unsaturated bond {; Coating compositions, based on monomers of macromolecular compounds of groups C09D183/00 - C09D183/16}
- C09D 5/28: for wrinkle, crackle, orange-peel, or similar decorative effects
- C09D 133/06: of esters containing only carbon, hydrogen and oxygen, the oxygen atom being present only as part of the carboxyl radical
- C09D 133/08: Homopolymers or copolymers of acrylic acid esters
- B29C 33/424: {Moulding surfaces provided with means for marking or patterning (for injection moulding B29C45/372)}
- B29C 33/56: Coatings {, e.g. enameled or galvanised}; Releasing, lubricating or separating agents {(in-mould coating B29C37/0028; using or applying separating agents B29C37/0067)}
- B29C 33/68: Release sheets
- B29C 59/026: {of layered or coated substantially flat surfaces}
- B29C 59/16: by wave energy or particle radiation {, e.g. infrared heating (B29C59/007 takes precedence)}
- B29C 2033/426: {Stampers}
- B29L 2031/722: {Decorative or ornamental articles}
- B32B 29/06: specially treated, e.g. surfaced, parchmentised
- B32B 2037/268: {Release layers}
- B32B 2038/0076: {Curing, vulcanising, cross-linking}
- B32B 2038/008: {Sewing, stitching}
- B32B 2255/02: on fibrous or filamentary layer
- B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer
- B32B 2255/26: Polymeric coating
- B32B 2260/028: Paper layer
- B32B 2260/046: Synthetic resin
- B32B 2305/72: Cured, e.g. vulcanised, cross-linked
- B32B 2307/408: Matt, dull surface
- B32B 2307/728: Hydrophilic
- B32B 2310/0881: using ion-radiation, e.g. alpha-rays
- B32B 2451/00: Decorative or ornamental articles
- C08J 2367/02: Polyesters derived from dicarboxylic acids and dihydroxy compounds; (C08J2367/06 takes precedence)
- C08J 2433/14: of esters containing halogen, nitrogen, sulfur, or oxygen atoms in addition to the carboxy oxygen
- D21H 19/66: Coatings characterised by a special visual effect, e.g. patterned, textured (marbled paper D21H27/04)
- D21H 25/06: of impregnated or coated paper (D21H25/08 takes precedence)
- Y10T 156/1039: Surface deformation only of sandwich or lamina [e.g., embossed panels]
- Y10T 156/1994: Means for delaminating from release surface
- Y10T 428/24446: Wrinkled, creased, crinkled or creped
- Y10T 428/24479: including variation in thickness
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02)
- B44B: MACHINES, APPARATUS OR TOOLS FOR ARTISTIC WORK, e.g. FOR SCULPTURING, GUILLOCHING, CARVING, BRANDING, INLAYING (processes for producing decorative effects B44C; embossing leather C14B)
- B44C: PRODUCING DECORATIVE EFFECTS (processes for applying liquids or other fluent materials to surfaces, in general B05D; shaping of plastics or substances in a plastic state B29C; printing processes to produce transfer pictures B41M3/12; thermographic duplication or marking methods B41M5/00); MOSAICS; TARSIA WORK (imitation of mosaic or tarsia work patterns B44F11/04); PAPERHANGING {(labels G09F; multi-step processes for making paper labels or tags B31D1/02)}
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- D21H: PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A textured release sheet includes a substrate, which has been electron beam treated, including a top side and a bottom side. A matte surface is formed on the bottom side thereof, wherein the matte surface of the surfacing material is a coating of an radiation curable material applied to the bottom side of the substrate. The coating is an UV curable acrylate mixture applied to the substrate, wherein the UV curable acrylate mixture is irradiated with UV-radiation via an excimer laser emitter to produce a UV-irradiated layer wherein the UV curable acrylate mixture is only crosslinked on the surface thereof, which produces a matting surface through the effects of a micro-convolution.

## Claims

### Claim 1

A laminate lay-up, comprising:
a texture-imparting release sheet composed of a release sheet substrate, which has been electron beam treated to prepare a surface of the release sheet substrate for coating with a UV curable acrylate mixture to improve wettability of the substrate, the release sheet substrate including a top side and a bottom side; and
a matte surface formed on the bottom side thereof, wherein the matte surface is a coating of a radiation curable material applied to the bottom side of the release sheet substrate, the coating being the UV curable acrylate mixture applied to the release sheet substrate, wherein the UV curable acrylate mixture is irradiated with UV-radiation via an excimer laser emitter to produce a UV-irradiated layer wherein the UV curable acrylate mixture is only crosslinked on the surface thereof, which produces a matting surface through the effects of a micro-convolution, wherein the coating is applied to the substrate and partially cured via UV-radiation to a create UV-irradiated layer and subsequently subjected to electron beam irradiation to crosslink and harden the entire layer;
a decorative layer including a decorative sheet substrate and a coating comprised of a UV and thermal curable epoxy acrylic or urethane acrylic, wherein the decorative sheet substrate is electron beam treated prior to application of coating and the coating is partially cured to create an irradiated layer, the irradiated layer being subsequently fully cured via thermal curing when the laminate lay-up is pressed and heated;
a core layer composed of one or more sheets of paper impregnated with resin.

### Claim 2 (depends on 1)

The laminate lay-up according to claim 1, wherein the UV curable acrylate mixture is applied to the release sheet substrate with a layer thickness of not more than 150 microns.

### Claim 3 (depends on 2)

The laminate lay-up according to claim 2, wherein the epoxy acrylic or urethane acrylic is applied to the release sheet substrate with a layer thickness in the range between 30 and 100 microns.

### Claim 4 (depends on 1)

The laminate lay-up according to claim 1, wherein the release sheet substrate is a PET film.