Decorative laminates having a thick chemical resistant outer layer
AssigneeWestinghouse Electric Corp.
InventorsDaniel L. Cannady, Jr., Lenon G. Brooker
Life of this patent
Estimating the term…
Abstract
A resin impregnated and resin coated has a decorative portion coated at least 1 mil thick with a vinyl ester terminated bisphenol A epoxy resin matrix, containing hollow plastic microspheres through its thickness.
Claims12
A resin impregnated and resin coated, chemical resistant laminate comprising a core, and a top decorative layer containing a decorative sheet having a top exterior coating thereon, at least 1 mil thick and covering the entire decorative layer, the coating comprising a vinyl ester terminated bisphenol A epoxy resin matrix, containing hollow, transparent, microspheres made from a thermoplastic selected from the group consisting of vinylidene chloride polymers, vinylidene chloride-acrylonitrile copolymers, vinyl chloride-acrylonitrile copolymers, styrene-acrylonitrile copolymers, and vinyl chloride-vinylidene chloride copolymers having a diameter of up to about 80 microns, said laminate being heat and pressure consolidated, where said microspheres are substantially uniformly distributed through and support the epoxy resin matrix, and are effective to help support the epoxy resin coating during consolidation.
A method of making a coated decorative laminate comprising the steps:
- (1) admixing a vinyl ester terminated bisphenol A epoxy resin with about 0.5 weight percent to about 10 weight percent, based on epoxy resin solids, of hollow, transparent, microspheres made from a thermoplastic selected from the group consisting of vinylidene chloride polymers, vinylidene chloride-acrylonitrile copolymers, vinyl chloride-acrylonitrile copolymers, styrene-acrylonitrile copolymers, and vinyl chloride-vinylidene chloride copolymers and having a diameter of from about 2 microns to about 40 microns, to provide a homogeneous composition having a viscosity of from about 850 cps. to about 3500 cps. at 25.degree. C.,
- (2) providing a decorative layer, containing a decorative sheet,
- (3) coating the microsphere containing epoxy composition at least 1 mil thick over the entire top of the decorative sheet, to provide an outer epoxy resin matrix containing supporting microspheres,
- (4) drying the coated decorative sheet,
- (5) placing the dried, coated, decorative sheet on a resin impregnated core, and
- (6) heat and pressure consolidating the decorative sheet and core, where said microspheres expand during steps (4) and (6), are substantially uniformly distributed through the epoxy resin matrix after step (6), and are effective to help support the coating of epoxy resin during consolidation.
A resin impregnated and resin coated, chemical resistant laminate comprising a core, and a top decorative layer containing a decorative sheet having a top exterior coating thereon, at least 1 mil thick and covering the entire decorative layer, the coating comprising a vinyl ester terminated bisphenol A epoxy resin matrix, containing hollow, transparent, microspheres made from a thermoplastic containing the ##STR4## and having a diameter of up to about 80 microns, said laminate being heat and pressure consolidated, where said microspheres comprise from about 1.5 volume % to about 20 volume % of the exterior coating, are substantially uniformly distributed through and support the epoxy resin matrix, and are effective to help support the epoxy resin coating during consolidation.
Dependencies are inferred from the claim text.