High pressure decorative laminate suitable for use as postforming

using polyurethane resins

Ana Henriques1, João M. Ferra2, Jorge Manuel Martins3, Ângela Dias, Fernão Magalhães1 and Luísa Carvalho1,3

1 LEPABE - Faculdade de Engenharia, Universidade do Porto, Rua Dr. Roberto Frias, Porto, Portugal

2 EuroResinas – Industrias Químicas, S.A., Sines, Portugal

3 DEMad - Departamento de Engenharia de Madeiras, Escola Superior de Tecnologia de Viseu, Instituto Politécnico de

Viseu, Campus Politécnico de Repeses, Viseu, Portugal

4 ARCP – Associação Rede de Competências em Polímeros, Porto, Portugal

Introduction

High Pressure Laminates (HPL) – Industrial Process

IMPREGNATION PROCESS

• 1 - Raw paper after unwinding are immersed in a

bath with resin

• 2- After impregnation, the paper is sent to a set

of dryers to evaporate the volatile compound

present in the resin

1

2

COST Action FP1006 at Aristotle University of Thessaloniki, Thessaloniki, Greece, April 7 - 9, 2015

PRESSING PROCESS

• 3 – Impregnated sheets are then laid with the

desire number of plies and submitted to a hot

pressing

• 4 - The range of pressures used in the production

of HPL varies from 5.5 to 10.3 MPa, with the

layers consolidated at temperatures of 120-150ᵒC

4

Overlay paper (melamine

resin)

Décor paper (melamine

resin)Kraft paper (phenolic

resin)

3

3

High Pressure Laminates (HPL) – Industrial Process

COST Action FP1006 at Aristotle University of Thessaloniki, Thessaloniki, Greece, April 7 - 9, 2015

High Pressure Laminates (HPL) – Application

Laboratory ExteriorHospitalFurniture Kitchen

Demand for decorative laminates in the US is forecast to rise 4.1%/year to 11.9 billion square feet in 2018, a continuation

of the improvements between 2011 and 2013 after declines from 2007 to 2010

Source: http://www.woodworkingnetwork.com

COST Action FP1006 at Aristotle University of Thessaloniki, Thessaloniki, Greece, April 7 - 9, 2015

It is intended to use polyurethane resins during the impregnation process, in order to confer

postformability to the decorative laminate

High Pressure Laminates (HPL) – Main Goal

COST Action FP1006 at Aristotle University of Thessaloniki, Thessaloniki, Greece, April 7 - 9, 2015

Experimental

Experimental – Wetting behaviour

Name Resin Type of polyol Ion type on the backbone Contact Angle

A Polyurethane Polyether Anionic 73.49 ± 2.50

B Polyurethane Polyester Anionic 104.55 ± 3.9

C Polyurethane Polycarbonate Anionic 99.32 ± 10.29

D Polyurethane Polyester Cationic 22.51 ± 1.31

Name Resin

E Melamine 28.23 ± 0.49

COST Action FP1006 at Aristotle University of Thessaloniki, Thessaloniki, Greece, April 7 - 9, 2015

Decorative paper

Resin

θ > 90 ᵒ θ < 90 ᵒ θ = 0 ᵒ

θ = 0 ᵒ Complete wetting

θ > 90 ᵒ The liquid doesn’t “wet “the solid

θ < 90 ᵒ The liquid “wets” the solid

Experimental – Impregnation Process

NEW IMPREGNATION PROCESS

1 First Bath - POLYUREHTANE RESIN

In order to confer the flexible properties

2 Coating- MELAMINE RESIN

In order to confer the other properties

STANDARD IMPREGNATION PROCESS

1 First Bath - MELAMINE RESIN

2 Coating – MELAMINE RESIN

COST Action FP1006 at Aristotle University of Thessaloniki, Thessaloniki, Greece, April 7 - 9, 2015

Experimental – Impregnation Process

NEW IMPREGNATION PROCESS

STANDARD IMPREGNATION PROCESS

COST Action FP1006 at Aristotle University of Thessaloniki, Thessaloniki, Greece, April 7 - 9, 2015

Experimental – Impregnation Process

COST Action FP1006 at Aristotle University of Thessaloniki, Thessaloniki, Greece, April 7 - 9, 2015

Internal Test

NEW IMPREGNATION PROCESS STANDARD IMPREGNATION PROCESS

Experimental – Determination of properties

Resistance against water vapour

New impregnation process Standard impregnation process

2 2

COST Action FP1006 at Aristotle University of Thessaloniki, Thessaloniki, Greece, April 7 - 9, 2015

Resistance to stain

Staining Agent New impregnation process Standard impregnation process

Acetone (Contact time: 16h)

Coffee (Contact time: 16h)

Sodium Hydroxide (Contact time: 10 min)

3

5

3

5

5

2

Resistance to dry heat

New impregnation process Standard impregnation process

3 3

Rating 5: No visible change

Rating 4: Slight change of gloss and/or colour, only visible at certain viewing angles

Rating3: Moderate change of gloss and/or colour

Rating 2: Marked change of gloss and/or colour

Rating 1: Blistering and/or delamination

Conclusions

Conclusion

• The polyol and the ion type on the backbone influence the wettability of the polyurehtane resins in the

decorative paper.

• The cationic resins show a wetting behaviour similar to the melamine resin, being used as impregnation resin.

• The use of polyurethane resin in the first bath, and melamine resin in the second results in a flexible paper.

• This new paper shows an similar behaviour to the standard paper in resistance against water vapour, resistance

and resistance to dry heat. For resistance to stain, the polyurethane is better for the base however, the result is

worst for the solvent.

COST Action FP1006 at Aristotle University of Thessaloniki, Thessaloniki, Greece, April 7 - 9, 2015

Acknowledgement

• The authors wish to thank to Euroresinas – Industrias Químicas SA and Sonae Indústria de Revestimentos for

providing the raw materials needed for this work and the use of facilities.

• This work is co-funded by FEDER (Fundo Europeu de Desenvolvimento Regional) / QREN nº23006 (2Glam project)

under the framework of COMPETE-Programa Operacional Factor de Competitividade (POFC).

COST Action FP1006 at Aristotle University of Thessaloniki, Thessaloniki, Greece, April 7 - 9, 2015

Visit us!

Thank you for your attention!

eq05006@fe.up.pt