Decorative laminates are laminated products primarily used as furniture surface materials or wall paneling. It can be manufactured as either high- or low-pressure laminate, with the two processes not much different from each other except for the pressure applied in the pressing process. Also, laminate can be produced either in batches or in a continuous process; the latter is called continuous pressure laminate (CPL). [1]
According to McGraw-Hill Dictionary of Architecture & Construction, high-pressure laminates consists of laminates "molded and cured at pressures not lower than 1,000 psi (70 kg/cm2) and more commonly in the range of 1,200 to 2,000 psi (80 to 140 kg/cm2)." [2]
HPL is made of resin impregnated cellulose layers, which are consolidated under heat and high pressure. The various layers are described below:
Trade names include Formica, Arborite, Greenlam, Wilsonart, GW-HPL, Micarta and Trespa.
After the Kraft papers are impregnated with the resins, the three layers of paper/resin are placed into a press which simultaneously applies heat (120 °C) and pressure (>70 bars). The pressing operation allows the thermoset resins to flow into the paper, then subsequently cure into a consolidated sheet with a density greater than 1.35 g/cm3 (84 lb/cu ft). During the press cycle, the decorative surface can also be cured while in contact with a textured surface to create one of many different surface finishes.
HPL consists of more than 60 to 70% Kraft paper, with the remaining 30 to 40% a combination of phenol-formaldehyde resin for the core layers mostly, and melamine-formaldehyde resin for the surface layer. Both resins belong to a class of thermosetting resins which crosslink during the press cycle creating irreversible chemical bonds that produce a nonreactive, stable material with characteristics different and superior to those of the component parts.
HPL can be produced using both continuous and discontinuous (batch) manufacturing processes. HPLs are supplied in sheet form, or compact form, in a variety of sizes, thicknesses and surface finishes.
Low-pressure laminate is defined as "a plastic laminate molded and cured at pressures in general of 400 pounds per square inch (27 atm; 2.8 MPa)". [3]
There are various industrial standards specifically applied for high-pressure decorative laminates:
The European Standard EN438 is one of the standards that most decorative laminates manufacturers selling to worldwide market adhere to. The specific code is EN438, entitled: Decorative high-pressure laminates (HPL) sheets based on thermosetting resins, specifications. It replaced all other national European standards.
The specific part of EN438 which applies to high-pressure laminates is Part 3. The full title to this standard is: High-pressure decorative laminates (HPL) Sheets based on thermosetting resins (Usually called laminates) Part 3: Classification and specifications for laminates less than 2 mm thick intended for bonding to supporting substrates. In total there are 9 parts to the EN438. [4]
Decorative laminates are grouped into the following types according to EN 438:
Product specifications applicable to HPL include the nine parts of EN 438 and the two parts of ISO 4586 as shown below:
Antibacterial properties are important for decorative laminates because these laminates are used as kitchen tops and counter tops, cabinets and table tops that may be in constant contact with food materials and younger children. Antibacterial properties are there to ensure that bacterial growth is minimal.
One of the standards for Anti-Bacterial is the ISO 22196:2007, [5] which is based on the Japanese Industrial Standards (JIS), code Z2801. This is one of the standards most often referred to in the industry with regards to tests on microbial activities (specifically bacteria) and in the JIS Z2801, two bacteria species are used as a standard, namely E. Coli and Staphylococcus aureus. However, some companies may have the initiative to test more than just these two bacteria and may also replace Staphylococcus aureus with MRSA, the methicillin-resistant version of the same bacteria.
Again, different countries may choose to specify different types of microbes for testing especially if they identified some bacteria groups which are more intimidating in their countries due to specific reasons.
A common anti-fungi standard is the ASTM G21-09. Not all manufacturers will take the initiatives for product R&D for anti-Fungi attributes. Manufacturers like Maica Laminates send their products for laboratory tests for certification following the ASTM G21-09 standard, [6] while Formica (South America) partners with Microban Protection, [7] which is a company manufacturing additives, including the anti-bacterial additives.
There are many different standards with regards to fire-resistant and flame-retardant properties of high-pressure decorative laminates. While different countries may have different standards for the building industry to adhere to, most countries may agree on some of the more common standards being used in the industry. Very often, just like other standards applicable to the industry, the tests may be European Standards with their equivalent in the US Standards.
For example, many Commonwealth countries may be comfortable with the British Standards 476 especially Parts 6 and 7, while there will still be US Standard equivalence in the ASTM.
The list of tests applicable to decorative laminates will never be exhaustive. As the technology improves, there will be many more tests to ensure the safety of the products upon use by the end consumer, for example perhaps the tests on transfer of surface substance to food materials if prepared on the decorative laminates as a kitchen surface. The core tests will then also branch out based on the specific requirements and standards adopted by different countries.
Two of the internationally acknowledged "Green" certificates for decorative laminates are MAS Certified Green and GREENGUARD. The MAS Certified Green and GREENGUARD marks are to certify that the products have low chemical emissions. Chemicals tested include VOCs, formaldehyde and other harmful particles. The tests are based on single occupancy room with outdoor ventilation following the ANSI/ASHRAE Standard 62.1-2007, Ventilation for Acceptable Indoor Air Quality. [8] [9] GREENGUARD especially, has two main consideration, GREENGUARD and GREENGUARD GOLD. The GREENGUARD n GOLD was previously known as the GREENGUARD Children and Schools Certified, signifying its relevance of very low allowable chemical emissions levels to ensure the safety of young children and school environment.
There are also many other "Green" certifications, some which are requirements by the authorities before the product can be used as building materials. These include the Singapore Green Label which is recognised by the Global Ecolabelling Network (GEN) and all its member countries. [10]
Decorative high-pressure laminates are usually used for furniture tops especially on flat surfaces, including cabinets and tables. Decorative compact laminates are sometimes constructed as toilet cubicle systems, laboratory tables and kitchen tops. Some new usage models include wall panels with conceptual designs and custom prints. [11]
The popularity of large format printing using inkjet printers has produced a cheaper alternative to decorative laminates, minus the quality. For most uninformed consumers, the large format printing are similar to laminates, and seem to offer more variety of designs and applications. For example, large format prints can be printed on wall stickers, and then installed on walls. Unlike decorative laminates, there is no special adhesive to be used, and the price may sometimes seem much cheaper comparatively.
However, there are health considerations for large format prints because of the solvent inks used, especially with their relatively high concentrations of VOCs. [12] These health considerations may be alleviated with newer wide format technology that uses Eco-Solvent or Latex inks.
Bakelite, formally polyoxybenzylmethyleneglycolanhydride, is a thermosetting phenol formaldehyde resin, formed from a condensation reaction of phenol with formaldehyde. The first plastic made from synthetic components, it was developed by Leo Baekeland in Yonkers, New York, in 1907, and patented on December 7, 1909.
Plywood is a composite material manufactured from thin layers, or "plies", of wood veneer that are glued together with adjacent layers, having both glued with each other at right angle or at 90 degrees angle. It is an engineered wood from the family of manufactured boards, which include plywood, medium-density fibreboard (MDF), oriented strand board (OSB), and particle board.
Corrugated fiberboard, corrugated cardboard, or corrugated is a type of packaging material consisting of a fluted corrugated sheet and one or two flat linerboards. It is made on "flute lamination machines" or "corrugators" and is used for making corrugated boxes. The corrugated medium sheet and the linerboard(s) are made of kraft containerboard, a paperboard material usually over 0.25 millimetres (0.01 in) thick.
Fiberglass or fibreglass is a common type of fiber-reinforced plastic using glass fiber. The fibers may be randomly arranged, flattened into a sheet called a chopped strand mat, or woven into glass cloth. The plastic matrix may be a thermoset polymer matrix—most often based on thermosetting polymers such as epoxy, polyester resin, or vinyl ester resin—or a thermoplastic.
Engineered wood, also called mass timber, composite wood, human-made wood, or manufactured board, includes a range of derivative wood products which are manufactured by binding or fixing the strands, particles, fibres, or veneers or boards of wood, together with adhesives, or other methods of fixation to form composite material. The panels vary in size but can range upwards of 64 by 8 feet and in the case of cross-laminated timber (CLT) can be of any thickness from a few inches to 16 inches (410 mm) or more. These products are engineered to precise design specifications, which are tested to meet national or international standards and provide uniformity and predictability in their structural performance. Engineered wood products are used in a variety of applications, from home construction to commercial buildings to industrial products. The products can be used for joists and beams that replace steel in many building projects. The term mass timber describes a group of building materials that can replace concrete assemblies.
In materials science, a thermosetting polymer, often called a thermoset, is a polymer that is obtained by irreversibly hardening ("curing") a soft solid or viscous liquid prepolymer (resin). Curing is induced by heat or suitable radiation and may be promoted by high pressure or mixing with a catalyst. Heat is not necessarily applied externally, and is often generated by the reaction of the resin with a curing agent. Curing results in chemical reactions that create extensive cross-linking between polymer chains to produce an infusible and insoluble polymer network.
Formica Laminate is a laminated composite material invented at the Westinghouse Electric Corporation in the United States in 1912. Originally used to replace mica in electrical applications, it has since been manufactured for multiple applications. It has been produced by Formica Group manufacturing sites across the globe since. Formica Group are best known for the company's classic product: a heat-resistant, wipe-clean laminate of paper with melamine resin.
Lamination is the technique/process of manufacturing a material in multiple layers, so that the composite material achieves improved strength, stability, sound insulation, appearance, or other properties from the use of the differing materials, such as plastic. A laminate is a layered object or material assembled using heat, pressure, welding, or adhesives. Various coating machines, machine presses and calendering equipment are used.
FR-4 is a NEMA grade designation for glass-reinforced epoxy laminate material. FR-4 is a composite material composed of woven fiberglass cloth with an epoxy resin binder that is flame resistant (self-extinguishing).
Particle board, also known as particleboard, chipboard, and low-density fiberboard, is an engineered wood product manufactured from wood chips and a synthetic resin or other suitable binder, which is pressed and extruded. Particle board is often confused with oriented strand board, a different type of fiberboard that uses machined wood flakes and offers more strength.
FR-2 is a NEMA designation for synthetic resin bonded paper, a composite material made of paper impregnated with a plasticized phenol formaldehyde resin, used in the manufacture of printed circuit boards. Its main properties are similar to NEMA grade XXXP (MIL-P-3115) material, and can be substituted for the latter in many applications.
Arborite is the leading Canadian manufacturer of high-pressure decorative plastic laminates (HPL). Best known as a counter top surfacing material, this laminate is a durable decorative veneer applied to cabinetry, furniture, and other horizontal and vertical surfaces. The original Arborite material was developed in 1942 by the Howard Smith Paper Company as an innovative way to utilize waste by-products of the Canadian papermaking industry, and to this day any laminate used for the same purpose is commonly referred to in Canada by the trade name Arborite.
Micarta is a brand name for composites of linen, canvas, paper, fiberglass, carbon fiber, or other fabric in a thermosetting plastic. It was originally used in electrical and decorative applications. Micarta was developed by George Westinghouse at least as early as 1910 using phenolic resins invented by Leo Baekeland. These resins were used to impregnate paper and cotton fabric which were cured under pressure and high temperature to produce laminates. In later years this manufacturing method included the use of fiberglass fabric, and other resin types were also used. Today Micarta high-pressure industrial laminates are produced with a wide variety of resins and fibers. The term has been used generically for most resin impregnated fiber compounds. Common uses of modern high-pressure laminates include electrical insulators, printed circuit board substrates, and knife handles.
A countertop, also counter top, counter, benchtop, worktop or kitchen bench, bunker is a raised, firm, flat, and horizontal surface. They are built for work in kitchens or other food preparation areas, bathrooms or lavatories, and workrooms in general. The surface is frequently installed upon and supported by cabinets, positioned at an ergonomic height for the user and the particular task for which it is designed. A countertop may be constructed of various materials with different attributes of functionality, durability and aesthetics, and may have built-in appliances, or accessory items relative to the intended application.
Melamine resin or melamine formaldehyde is a resin with melamine rings terminated with multiple hydroxyl groups derived from formaldehyde. This thermosetting plastic material is made from melamine and formaldehyde. In its butylated form, it is dissolved in n-butanol and xylene. It is then used to cross-link with alkyd, epoxy, acrylic, and polyester resins, used in surface coatings. There are many types, varying from very slow to very fast curing.
FRP is a modern composite material of construction for chemical plant, pulp and paper mill, and food and pharmaceutical equipment like tanks and vessels. Chemical equipment that range in size from less than a metre to 20 metres are fabricated using FRP as material of construction.
Maica Laminates Sdn Bhd is the first high-pressure laminate (HPL) manufacturer in Malaysia. It is one of the earliest local-foreign joint venture manufacturing companies in Penang.
The International Committee of the Decorative Laminates Industryaisbl (ICDLI) is an association with its head office in Brussels.The ICDLI is the international representation of the European HPL manufacturers and their suppliers.
Trespa is the brand name of a type of high-pressure laminate (HPL) plate manufactured by Trespa International BV, based in Weert, the Netherlands. Their panels are used for exterior cladding, decorative facades and interior surfaces. It is composed of woodbased fibres or Kraft paper with phenolic resin applied.
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