Self-adhesive laminate and method of making it

Abstract

A decorative laminate includes a laminate substrate coated with an adhesive layer. The adhesive layer is a layer of a physically setting, solvent-free adhesive material including an acrylic polymer. The adhesive layer is self-adhesive at room temperature. The adhesive-coated laminate substrate has a peeling-off force of at least 0.2 N/mm 2 , after application on a carrier. A method for the production of the adhesive-coated laminate substrate, its use as a coating material, and a composite of the adhesive-coated laminate substrate and a carrier material are also provided.

1 . An adhesive-coated laminate substrate, comprising: 
 a laminate substrate; and    an adhesive layer coating a surface of the substrate;    the adhesive layer comprising a physically setting, solvent-free adhesive material which includes an acrylic polymer, wherein the adhesive layer is self-adhesive at room temperature.    
     
     
         2 . The adhesive-coated laminate substrate according to  claim 1 , wherein the laminate substrate has a peeling-off force of at least about 0.2 N/mm 2  after application on a carrier substrate at room temperature.  
     
     
         3 . The adhesive-coated laminate substrate according to  claim 1 , wherein the laminate has a peeling-off force of about 0.5 to about 1.5 N/mm 2  after application on a carrier substrate.  
     
     
         4 . The adhesive-coated laminate substrate according to  claim 1 , wherein a peeling of the laminate from a carrier does not appear up to a temperature load of at least about 80° C. over at least about 2 hours.  
     
     
         5 . The adhesive-coated laminate substrate according to  claim 1 , wherein the adhesive layer has an add-on level of about 10 to about 300 g/m 2 .  
     
     
         6 . The adhesive-coated laminate substrate according to  claim 1 , wherein the adhesive layer has an add-on level of about 75 to about 100 g/m 2 .  
     
     
         7 . The adhesive-coated laminate substrate according to  claim 1 , wherein the adhesive layer further comprises at least one of an additional thermoplastic elastomer, a block copolymer, a hydrocarbon resin, and a plasticizer.  
     
     
         8 . The adhesive-coated laminate substrate according to  claim 1 , wherein the acrylic polymer comprises a terpolymer of vinyl acetate-ethylene and acrylic.  
     
     
         9 . The adhesive-coated laminate substrate according to  claim 1 , wherein the laminate substrate comprises a high-pressure laminate (HPL) or a continuously produced laminate (CPL).  
     
     
         10 . The adhesive-coated laminate substrate according to  claim 1 , further comprising a release layer, wherein the adhesive layer is disposed between the laminate substrate and the release layer.  
     
     
         11 . The adhesive-coated laminate substrate according to  claim 10 , wherein the release layer comprises a siliconized release paper or film.  
     
     
         12 . The adhesive-coated laminate substrate according to  claim 1 , further comprising a non-pressure sensitive adhesive layer.  
     
     
         13 . The adhesive-coated laminate substrate according to  claim 12 , wherein the non-pressure sensitive adhesive layer is disposed between the laminate substrate and the self-adhesive layer.  
     
     
         14 . The adhesive-coated laminate substrate according to  claim 13 , wherein the non-pressure sensitive adhesive layer comprises a second adhesive material having a glass transition temperature of about 20° C. or greater.  
     
     
         15 . The adhesive-coated laminate substrate according to  claim 14 , wherein the non-pressure sensitive adhesive layer has an add-on level of about 10 to about 30 g/m 2 .  
     
     
         16 . The adhesive-coated laminate substrate according to  claim 1 , wherein the adhesive layer is applied to the substrate by a roller coater.  
     
     
         17 . A composite material, comprising an adhesive-coated laminate substrate according to  claim 1  applied to a carrier.  
     
     
         18 . The composite material according to  claim 17 , wherein the carrier is selected from the group consisting of an uncoated particle board, an uncoated wood material, a metal, a ceramic, a glass, a coated wood material, a coated particle board, and combinations thereof.  
     
     
         19 . A method for the production of the adhesive-coated laminate substrate of  claim 1 , comprising: 
 heating an adhesive material to a temperature of about 150° C. to about 190° C.;    applying the adhesive material to the laminate substrate; and    cooling the adhesive material to form the adhesive layer.    
     
     
         20 . The method according to  claim 19 , wherein the adhesive material is applied using a roller coater.  
     
     
         21 . A laminate, comprising: 
 a laminate substrate;    a non-pressure sensitive adhesive layer applied to the laminate substrate; and    a self-adhesive layer applied to the non-pressure sensitive adhesive layer, the self-adhesive layer including a physically setting, solvent-free adhesive material, wherein the self-adhesive layer is self-adhesive at room temperature.    
     
     
         22 . The laminate according to  claim 21 , additionally comprising a release layer disposed over the self-adhesive layer.  
     
     
         23 . The laminate according to  claim 21 , wherein the non-pressure sensitive adhesive layer comprises an adhesive material having a glass transition temperature of about 20° C. or greater.  
     
     
         24 . The laminate according to  claim 21 , wherein the non-pressure sensitive adhesive layer comprises an add-on level of about 10 to about 30 g/m 2 , and the self-adhesive layer comprises an add-on level of about 75 to about 100 g/m 2 .  
     
     
         25 . The laminate according to  claim 21 , wherein the self-adhesive layer comprises an adhesive material including an acrylic polymer.  
     
     
         26 . The laminate according to  claim 21 , wherein the self-adhesive layer comprises a terpolymer of vinyl acetate-ethylene and acrylic.  
     
     
         27 . The laminate according to  claim 26 , wherein the non-pressure sensitive layer comprises polyvinyl acetate.  
     
     
         28 . A method of coating a laminate substrate with an adhesive, comprising the steps of: 
 providing a release layer coated with a layer of physically setting, solvent-free adhesive comprising an acrylic polymer;    applying the adhesive to a surface of the laminate substrate by overlaying the adhesive-coated release layer on the laminate substrate; and    applying pressure to the release layer to press the adhesive onto the surface of the laminate substrate;    wherein the release layer is manually peelable to expose the adhesive on the laminate substrate.    
     
     
         29 . The method of  claim 28 , wherein the laminate substrate comprises a high pressure laminate of cellulose strips.  
     
     
         30 . The method of  claim 28 , wherein the adhesive is applied to the surface of the laminate substrate without first sanding the surface of the laminate substrate.  
     
     
         31 . The method of  claim 28 , further comprising the step of priming the surface of the laminate substrate to create a primed surface, wherein the adhesive is applied to the primed surface.  
     
     
         32 . The method of  claim 31 , further comprising the step of sanding the surface of the laminate substrate before priming it.  
     
     
         33 . The method of  claim 28 , wherein the pressure is applied by passing the adhesive-coated release layer and the laminate substrate between a pair of nip rolls.  
     
     
         34 . The method of  claim 28 , wherein the release layer comprises a silicone-coated paper.  
     
     
         35 . The method of  claim 28 , wherein the layer of physically setting, solvent-free adhesive is provided by applying an aqueous acrylic-based adhesive to the release layer and drying the adhesive on the release layer.  
     
     
         36 . The method of  claim 28 , wherein the layer of physically setting, solvent-free adhesive has a thickness of about 50-500 microns.  
     
     
         37 . The method of  claim 28 , wherein the layer of physically setting, solvent-free adhesive has a thickness of about 100-300 microns.  
     
     
         38 . The method of  claim 28 , further comprising the step of heating at least one of the adhesive and the laminate substrate before applying the pressure to the release layer.  
     
     
         39 . The method of  claim 31 , wherein the primed surface comprises an acrylic-based primer.  
     
     
         40 . The method of  claim 39 , wherein the primer has a dry thickness of about 10-50 microns.  
     
     
         41 . The method of  claim 38 , wherein the heating step comprises heating at least one of the adhesive and the laminate substrate to a temperature of about 30-120° C.