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GB1603556A - Manufacture of flexible sheet materials - Google Patents

Manufacture of flexible sheet materials Download PDF

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Publication number
GB1603556A
GB1603556A GB15353/78A GB1535378A GB1603556A GB 1603556 A GB1603556 A GB 1603556A GB 15353/78 A GB15353/78 A GB 15353/78A GB 1535378 A GB1535378 A GB 1535378A GB 1603556 A GB1603556 A GB 1603556A
Authority
GB
United Kingdom
Prior art keywords
resin
flexible sheet
laminate
bonding agent
sheet material
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
GB15353/78A
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
British Industrial Plastics Ltd
Original Assignee
British Industrial Plastics Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by British Industrial Plastics Ltd filed Critical British Industrial Plastics Ltd
Priority to GB15353/78A priority Critical patent/GB1603556A/en
Publication of GB1603556A publication Critical patent/GB1603556A/en
Expired legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/04Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/10Next to a fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00Coating on the layer surface
    • B32B2255/02Coating on the layer surface on fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00Coating on the layer surface
    • B32B2255/26Polymeric coating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2451/00Decorative or ornamental articles

Landscapes

  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Laminated Bodies (AREA)

Description

(54) IMPROVEMENTS IN OR RELATING TO THE MANUFACTURE OF FLEXIBLE SHEET MATERIALS (71) We, BRITISH INDUSTRIAL PLASTICS LIMITED, a Company organised under the laws of Great Britain, of 20 St. Mary's Parsonage, Manchester M3 2NL (formerly of 77 Fountain Street, Manchester M2 2EA), do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:- This invention concerns improvements in or relating to the manufacture of flexible sheet materials.
According to the present invention, a method of manufacturing a flexible sheet material comprises: (1) providing a bonded flexible sheet material comprising at least one organic fibrous material and a resin bonding agent, said bonding agent comprising a methylolmelamine resin of general formula I
wherein R1, R2, R3, R4, R5 and R6 are each a hydrogen atom or -CH2OR group, wherein R is a hydrogen atom or methyl, ethyl or propyl group, there being from 0 to 2 moles of hydrogen atoms and from 4 to 6 moles of -CH2OR groups per mole of melamine nucleus, at least 1.5 moles of the R groups being other than hydrogen atoms, or a uron resin of general formula II
wherein R' is H, -CH2OH, or -CH2OR" where R" is an alkyl group of from I to 4 carbon atoms; said resin bonding agent impregnating at least one surface of the bonded flexible sheet material; (2) decorating the surface of the laminate containing said resin, after drying of the resin, by a transfer printing technique.
The bonded flexible sheet material may be a laminate which is adhered together by the resinous bonding agent e.g. a laminate of a paper sheet and a textile fibre product, such as textured wallpaper, or a laminate of a textile fibre product and a foam. In such cases the textile fibre product may be a textile yarn, strand or woven or non-woven textile fabric. Alternatively the flexible sheet material may be a non-woven web of fibrous material bound together by the resinous bonding agent e.g. needle-punched non-woven flooring: felted sheet material.
In this specification the expression "organic fibrous material" means a material constituted by any natural or synthetic organic fibre such as natural cellulosic fibres, polyester fibres, or rayon fibres.
A laminate of textile and paper preferably is produced by passing the textile fibre product through a bath containing an aqueous solution of the resin, contacting the resinated fibre product with a face of the paper sheet, and drying and curing the resin in the fibre so that the fibre product and paper sheet become bonded together. The bath may contain in addition to the resin an acrylic or other thermoplastic polymer latex, such as styrenesbutadiene resin, butadiene acrylonitrile resin, or polyvinyl acetate.
As an alternative, or in addition, to treating the fibre product with the resin (or resin and latex), the paper sheet may be coated or impregnated with the resin (or resin and latex).
It should be noted, however, that this can have a deleterious effect on the properties, e.g. tear strength, of the paper. As an alternative to using a resin or resin/latex bath, a spraying or roller coating technique may be used.
Preferably the textile fibre product will contain from 2 to 200/0/ by weight cured resin solids, and preferably from 15 to 50% by weight of the thermoplast polymer.
The resinous bonding agent is dried, and preferably substantially fully cured, before transfer printing is effected. Curing may be effected by any of the means usually used to cure the particular resin used, for example by passing the laminate over a heated roller or through a radiant heat zone, optionally with application of pressure. Partial curing, to a stage where most or all of the volatiles (particularly the noxious ones) have been evolved, may be effected prior to transfer printing, final cure taking place during the printing.
We have found that the resin specified in this invention is particularly useful in sensitizing organic fibres to transfer printing techniques using conventional transfer printing papers carrying sublimable dyestuffs. In any particular instance the particular dyestuff utilized will depend upon the nature of the materials used in the flexible sheet material and will be selected to give optimum clarity of transfer and colour fastness. In general the dyestuff should be one which is capable of forming a chemical link with the sensitizing resin.
Most commercial transfer printing papers may be used: these normally comprise a paper carrier having on one face a design formed by printing sublimable dyestuffs, the design being transferred by contacting that face with a face of the article to be decorated, and heating the system to a temperature of from about 180"C to about 220"C.
The methylolmelamine and uron based resins used in this invention may be used in an aqueous or an organic solvent system, preferably an aqueous system, and will normally require to be catalysed by addition of a catalyst. Suitable catalysts are (NH4)2HPO4; (NH4)H2PO4; zinc nitrate; ammonium sulphate, nitrate, chloride or thiocyanate; phosphoric, hydrochloric or nitric acid; and organic salts. When the resin is being used with a latex, catalysts of high electrolyte content are to be avoided e.g. magnesium chloride, since such catalysts are liable to destabilise the latex.
The invention will now be described in its application to the production of a textured wallpaper.
A number of hessian yarns are led from a spool system through a bath containing in parts by weight: Primal B15 acrylic latex (Rohm & Haas) (50XÓ by weight solids) 100 parts Beetle* Lit5 155 hexamethylolmelamine resin (92% by weight solids) 10 parts Monoammonium dihydrogen phosphate (catalyst) 0.2 parts Water 50 parts *Beetle is a Registered Trade Mark of British Industrial Plastics Limited. Primal is also a Registered Trade Mark.
On emergence from the bath, 100 parts of hessian are impregnated with 100 parts of the bath solution. The impregnated hessian is then led through a heated roller system where it is adhered to the top face of a paper sheet by drying the bath solution and curing the resin. After curing, the resultant laminate is contacted with a transfer print paper and printing is effected at 2100C for 25 seconds on a heated roller system. The transfer print carrier sheet is removed, and the printed, textured wallpaper is wound for subsequent trimming and cutting as is the normal practice in wallpaper manufacture.
The transfer print paper used in this case is a standard transfer printing paper using an acetate disperse dyestuff commercially available from Jas. Broadley Limited, design number 226.
- Obviously. modifications may be made in the process and apparatus described above. For example, the lamination and curing stages may be effected by one manufacturer and the transfer printing by another, and any of the modifications indicated above may be made. The printed textured paper may be made to suit applications other than wall papering.
WHAT WE CLAIM IS: 1. A method of manufacturing a flexible sheet material which comprises: (1) providing a bonded flexible sheet material comprising at least one organic fibrous material and a resinous bonding agent, said bonding agent comprising a methylolmelamine resin of general formula I
wherein R1 R2, R3, R4, R5 and R6 are each a hydrogen atom or -CH2OR group, wherein R is a hydrogen atom or methyl, ethyl or propyl group, there being from 0 to 2 moles of hydrogen atoms and from 4 to 6 moles of -CH2OR groups per mole of melamine nucleus, at least 1.5 moles of the R groups being other than hydrogen atoms, or a uron resin of general formula II
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (11)

**WARNING** start of CLMS field may overlap end of DESC **. Primal B15 acrylic latex (Rohm & Haas) (50XÓ by weight solids) 100 parts Beetle* Lit5 155 hexamethylolmelamine resin (92% by weight solids) 10 parts Monoammonium dihydrogen phosphate (catalyst) 0.2 parts Water 50 parts *Beetle is a Registered Trade Mark of British Industrial Plastics Limited. Primal is also a Registered Trade Mark. On emergence from the bath, 100 parts of hessian are impregnated with 100 parts of the bath solution. The impregnated hessian is then led through a heated roller system where it is adhered to the top face of a paper sheet by drying the bath solution and curing the resin. After curing, the resultant laminate is contacted with a transfer print paper and printing is effected at 2100C for 25 seconds on a heated roller system. The transfer print carrier sheet is removed, and the printed, textured wallpaper is wound for subsequent trimming and cutting as is the normal practice in wallpaper manufacture. The transfer print paper used in this case is a standard transfer printing paper using an acetate disperse dyestuff commercially available from Jas. Broadley Limited, design number 226. - Obviously. modifications may be made in the process and apparatus described above. For example, the lamination and curing stages may be effected by one manufacturer and the transfer printing by another, and any of the modifications indicated above may be made. The printed textured paper may be made to suit applications other than wall papering. WHAT WE CLAIM IS:
1. A method of manufacturing a flexible sheet material which comprises: (1) providing a bonded flexible sheet material comprising at least one organic fibrous material and a resinous bonding agent, said bonding agent comprising a methylolmelamine resin of general formula I
wherein R1 R2, R3, R4, R5 and R6 are each a hydrogen atom or -CH2OR group, wherein R is a hydrogen atom or methyl, ethyl or propyl group, there being from 0 to 2 moles of hydrogen atoms and from 4 to 6 moles of -CH2OR groups per mole of melamine nucleus, at least 1.5 moles of the R groups being other than hydrogen atoms, or a uron resin of general formula II
wherein R' is H, -CH2OH. or -CH2OR" where R" is an alkyl group of from 1 to 4 carbon atoms; said resin bonding agent impregnating at least one surface of the bonded flexible sheet material, (2) decorating the surface of the laminate containing said resin, after drying of the resin, by a transfer printing technique.
2. A method according to Claim 1 in which the bonded flexible sheet material which is provided is a laminate which is adhered together by the resinous bonding agent.
3. A method according to Claim 2 in which said laminate is a laminate of a paper sheet and a textile fibre product.
4. A method according to Claim 2 in which the laminate is a laminate of a textile fibre product and a foam.
5. A method according to Claim I in which the bonded flexible sheet material which is provided comprises a non-woven web of fibrous material bound together by the resinous bonding agent.
6. A method according to Claim 2 or 3 in which the bonded flexible sheet material is a laminate of textile and paper which is produced by passing textile fibre product through a bath containing an aqueous solution of the resin bonding agent, contacting the resinated fibre product with a face of a paper sheet and drying and curing the resin in the fibre product so that the fibre product and paper sheet become bonded together.
7. A method as claimed in Claim 6 except that said aqueous solution of the resin is applied to the textile fibre product by a spraying or roller-coating technique.
8. A method according to any one of claims 1 to 7 in which the resinous bonding agent is substantially fully cured before transfer printing is effected.
9. A method according to any one of claims 1 to 7 in which the resinous bonding agent is partially cured prior to transfer printing being effected, cure being completed during or after the transfer printing step.
10. A method of manufacturing a flexible sheet material substantially as described herein.
11. A flexible sheet material when made by the method of any preceding claim.
GB15353/78A 1978-04-19 1978-04-19 Manufacture of flexible sheet materials Expired GB1603556A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB15353/78A GB1603556A (en) 1978-04-19 1978-04-19 Manufacture of flexible sheet materials

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB15353/78A GB1603556A (en) 1978-04-19 1978-04-19 Manufacture of flexible sheet materials

Publications (1)

Publication Number Publication Date
GB1603556A true GB1603556A (en) 1981-11-25

Family

ID=10057652

Family Applications (1)

Application Number Title Priority Date Filing Date
GB15353/78A Expired GB1603556A (en) 1978-04-19 1978-04-19 Manufacture of flexible sheet materials

Country Status (1)

Country Link
GB (1) GB1603556A (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT394973B (en) * 1981-07-25 1992-08-10 Sony Corp PRINTED PAPER AND METHOD FOR PRODUCING AN IMAGE USING THIS

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT394973B (en) * 1981-07-25 1992-08-10 Sony Corp PRINTED PAPER AND METHOD FOR PRODUCING AN IMAGE USING THIS

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Legal Events

Date Code Title Description
PS Patent sealed [section 19, patents act 1949]
PCNP Patent ceased through non-payment of renewal fee