Nevamar Corporation, Llp

Exxon Research and Engineering Company

Herbert I Scher

Israel S Ungar

Robin D O'Dell

Joseph A Lex

Nelson L O'Neill

Richard R Baehr, Jr

Delbert A Williams

A method and apparatus for continuous casting of polymerizable thermosetting materials comprises mixing the materials with controlled amounts of two or more catalyst groups and passing said mixture through two or more series of heating stages. The initially gelled mixture which has not yet undergone excessive shrinkage is mechanically isolated from the ungelled mixture.

Method and apparatus for continuous casting of polymerizable

A method and apparatus for continuous casting of polymerizable materials that shrink during polymerization includes rapidly heating a moving matrix substantially uniformly throughout its cross section by radio frequency energy to initiate polymerization and maintaining the matrix thereafter in substantial thermal isolation such that substantially adiabatic polymerization occurs.

Method and apparatus for continuous casting of polymerizable material

A glossy laminate is made using highly polished caul plates, the laminate having superior sliding can wear resistance, and without damaging the plates. This result is effected by use of the technology of Scher et al. U.S. Pat. No. 4,255,480; O'Dell et al. U.S. Pat. No. 4,491,137 and 4,567,087; and/or Ungar et al. U.S. Pat. No. 4,713,138, except that the particles size of the grit is maintained at less than 9 micrometers. In this way a glossy laminate is obtained which retains its glossy appearance under normal wear conditions, and without rapid destruction of the expensive polished caul plates.

Wear-resistant glossy laminates

An improved process of making abrasion-resistant decorative laminate without overlay comprises simultaneously impregnating and coating a laminate decor sheet with a mixture of the liquid impregnating resin and an abrasion-resistant composition of microcrystalline cellulose and abrasion-resistant mineral particles such as alumina. The microcrystalline cellulose functions not only as a binder material in the product, but also serves to maintain the mineral particles in suspension in the liquid resin. The mixture is deposited onto the top surface of the decor sheet which absorbs the liquid resin leaving on the upper surface thereof an ultra-thin layer of the abrasion-resistant composition plus a small amount of resin. After drying, the decor sheet is ready for use in the manufacture of high and low pressure decorative laminates.

Method of producing abrasion-resistant decorative laminate

The scuff resistance of high-pressure laminated plastic is improved by incorporating in or very near the surface thereof, finely divided polyethylene wax having a particle size of about 1-25 microns and a melting point of preferably 220.degree.-230.degree. F. The wax is incorporated as part of an abrasion-resistant coating mixture applied to the face of an unimpregnated decor paper sheet in an ultra-thin layer, which layer is dried at a temperature below the wax melting point and then impregnated with conventional melamine-formaldehyde resin. The impregnated sheet is placed onto a sheet of convention phenolic resin impregnated core sheets and consolidated in the conventional way under heat and pressure. During consolidation, the wax particles 'bloom', or migrate to the surface. The finished laminate surface has greatly improved scuff resistance.

Scuff resistance in abrasion-resistant laminates

The scuff resistance of a high-pressure laminate is improved by incorporating in or very near the surface thereof, finely divided polyethylene wax preferably having a particle size of about 1-25 microns and a melting point of 220.degree.-230.degree. F. The wax is incorporated as part of a coating mixture applied to the face of an unimpregnated decor paper sheet in an ultra-thin layer, which layer is dried at a temperature below the wax melting point and then impregnated with conventional melamine-formaldehyde resin. The impregnated sheet is placed onto a sheet of convention phenolic resin impregnated core sheets and consolidated in the conventional way under heat and pressure. During consolidation, the wax particles 'bloom', or migrate to the surface. The finished laminate surface has greatly improved scuff resistance.

Scuff-resistant laminates

Highly abrasion-resistant transfer coatings are provided on a wide variety of substrates, thermoplastic or thermosetting, by transfer coating from a mold surface or a flexible web, such as by use of a heat transfer tape, an ultra-thin coating consisting essentially of a non-resinous binder material such as microcrystalline cellulose together with mineral abrasive particles, preferably alumina or a mixture of silica and alumina which have been heated together at a temperature of at least 140.degree. F., the ultra-thin coating also preferably containing a silane and a small quantity of a sticking agent such as a thermoplastic or thermosetting resin.

Transfer coating of abrasion-resistant layers

An abrasion-resistant laminate is prepared by providing an ultra thin coating of mineral particles and micro crystalline cellulose on the surface of conventional printed paper, followed by impregnating the paper with a conventional laminating resin, and then using the print paper so obtained in a laminating process without the necessity of using an overlay sheet.

Abrasion-resistant laminate

An abrasion-resistant laminate is prepared by providing an ultra thin coating of micro-crystalline cellulose overcoated with an ultra thin layer of mineral particles and micro crystalline cellulose on the surface of conventional printed paper, followed by impregnating the paper with a conventional laminating resin, and then using the print paper so obtained in a laminating process without the necessity of using an overlay sheet.

Growing community of inventors

Randallstown, MD, United States of America

Herbert I Scher