Surface layer material and melamine decorative laminate

Patent metadata

Field	Value
Publication number	US-9511570-B2
Application number	US-201013995782-A
Country	US
Kind code	B2
Filing date	Dec 22, 2010
Priority date	Dec 22, 2010
Publication date	Dec 6, 2016
Grant date	Dec 6, 2016

Abstract

The present invention provides a surface layer material for a melamine decorative laminate having an aluminum layer, allowing 3R or less bending while maintaining the surface hardness of the melamine decorative laminate, and a melamine decorative laminate comprising the surface layer material. Disclosed is a surface layer material for a decorative laminate comprising a surface layer and an aluminum layer, the material comprising a surface layer substrate having a first surface being a design surface and a second surface being a surface on an opposite side of the design surface, wherein a melamine resin composition comprising a melamine resin is carried on the first surface, and a urethane-acrylic resin composition comprising a urethane-acrylic resin is carried on the second surface.

First claim

The invention claimed is:

1. A melamine decorative laminate, comprising:
a surface layer material comprising a surface layer substrate having a first surface and a second surface opposite to the first surface, the first surface becoming a design surface of the decorative laminate and being coated with a melamine resin composition comprising a melamine resin, and the second surface being coated with a water-soluble clear resin composition comprising a urethane-acrylic resin emulsion having an average particle diameter of 100 nm or less, and
an aluminum layer having a surface coated with an epoxy resin,
wherein the surface coated with the epoxy resin of the aluminum layer directly adheres to the second surface coated with the urethane-acrylic resin emulsion of the surface layer material.

2. The melamine decorative laminate according to claim 1 , wherein the aluminum layer has a thickness of 0.1 to 0.3 mm.

3. The melamine decorative laminate according to claim 1 , wherein the melamine decorative laminate has a 3R outward bendability in accordance with a bending test (Method A) of JIS K6902.

4. A method for preparing a melamine decorative laminate, comprising:
providing a surface layer material, wherein the surface layer material comprises:
a surface layer substrate having a first surface and a second surface opposite to the first surface, the first surface becoming a design surface of the decorative laminate, and the second surface becoming a surface for adhering to an aluminum layer;
wherein the first surface is coated with a melamine resin composition comprising a melamine resin, and the second surface is coated with a water-soluble clear resin composition which comprises a urethane-acrylic resin emulsion having an average particle diameter of 100 nm or less;

providing an aluminum layer, wherein the aluminum layer has a surface coated with an epoxy resin; and
adhering the surface coated with the epoxy resin of the aluminum layer directly to the second surface of the surface layer material.

Assignees

• Nakagawa Hiroshige
• Kifuku Toshinori
• Sumitomo Bakelite Co

Inventors

• Nakagawa Hiroshige
• Kifuku Toshinori

Classifications

• B32B15/20

  comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)} · CPC title

• B44C5/0415

  containing metallic elements · CPC title

• B32B2255/28

  Multiple coating on one surface · CPC title

• B32B15/12 Primary

  of paper or cardboard · CPC title

• Y10T428/31594

  Next to aldehyde or ketone condensation product [phenol-aldehyde, etc.] · CPC title