Method of making a self-adhesive laminate

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.

We claim: 
     
         1 . A method of making a high pressure decorative laminate, comprising the steps of:
 providing a hardened high pressure decorative laminate substrate formed of a homogeneously closed material having a density not less than about 1.35 grams per cubic centimeter;   positioning an adhesive layer adjacent to the hardened high pressure decorative laminate substrate, the adhesive layer including a physically setting, solvent-free terpolymer of vinyl acetate-ethylene and acrylic; and   positioning a release layer adjacent to the adhesive layer.   
     
     
         2 . The method of  claim 1 , wherein the step of providing the hardened high pressure decorative laminate substrate comprises:
 impregnating fibrous strips with a curable resin to form impregnated fibrous strips; and   pressing the impregnated strips in the presence of heat, causing the curable resin to flow and subsequently harden.   
     
     
         3 . The method of  claim 2 , wherein the pressing step is performed at a temperature of about 120° C. to about 150° C. and a pressure of at least about 7 mPa. 
     
     
         4 . The method of  claim 3 , further comprising the step of applying a decorative layer to the fibrous steps. 
     
     
         5 . The method of  claim 2 , wherein the curable resin comprises a melamine resin. 
     
     
         6 . The method of  claim 2 , wherein the pressing step is performed at a temperature of about 140° C. to about 200° C. 
     
     
         7 . The method of  claim 1 , wherein the hardened high pressure decorative laminate substrate has a thickness of about 0.3 mm to about 15 mm. 
     
     
         8 . The method of  claim 1 , wherein the adhesive layer is free of water and organic liquids. 
     
     
         9 . A method of making a high pressure decorative laminate, comprising the steps of:
 impregnating fibrous strips with a curable resin to form impregnated fibrous strips;   pressing the impregnated fibrous strips in the presence of heat to form a hardened high pressure decorative laminate substrate;   positioning a self-adhesive layer adjacent to the hardened high pressure decorative laminate substrate, the self-adhesive layer being free of water and organic liquids; and   positioning a release layer adjacent to the self-adhesive layer.   
     
     
         10 . The method of  claim 9 , wherein the hardened high pressure decorative laminate substrate has a density of not less than about 1.35 grams per cubic centimeter. 
     
     
         11 . The method of  claim 9 , wherein the self-adhesive layer comprises a solvent-free terpolymer of vinyl acetate-ethylene and acrylic. 
     
     
         12 . The method of  claim 9 , wherein the self-adhesive layer comprises an elastomer, a plasticizer, and a hydrocarbon resin. 
     
     
         13 . The method of  claim 12 , wherein the elastomer constitutes about 10% to about 70% by weight of the self-adhesive layer. 
     
     
         14 . The method of  claim 13 , wherein the elastomer comprises a solvent-free terpolymer of vinyl acetate-ethylene and acrylic. 
     
     
         15 . The method of  claim 12 , wherein the plasticizer comprises a low molecular weight polyisobutylene having a molecular weight of about 800 to about 5000 grams/mol. 
     
     
         16 . The method of  claim 9 , further comprising the steps of:
 applying the self-adhesive layer to the release layer to form an adhesive-coated release layer; and   overlaying the adhesive-coated release layer on the hardened high pressure decorative laminate substrate with the self-adhesive layer facing the hardened high pressure decorative laminate substrate.   
     
     
         17 . A method of  claim 16 , further comprising the steps of applying about 3-70 N/cm 2  pressure to the adhesive-coated release layer to press the self-adhesive layer onto the high pressure decorative laminate substrate. 
     
     
         18 . The method of  claim 17 , further comprising the step of heating at least one of the self-adhesive layer and the high pressure decorative laminate substrate. 
     
     
         19 . A method of making a high pressure decorative laminate, comprising the steps of:
 impregnating fibrous strips with a curable resin to form impregnated fibrous strips;   pressing the impregnated fibrous strips in the presence of heat to form a hardened high-pressure decorative laminate substrate;   positioning a non-pressure sensitive adhesive layer adjacent to the laminate substrate;   positioning a self-adhesive layer adjacent to the non-pressure sensitive adhesive layer, the self-adhesive layer being free of water and organic liquids; and   positioning a release layer adjacent to the self-adhesive layer.   
     
     
         20 . The method of  claim 19 , wherein the self-adhesive layer comprises a physically setting, solvent-free terpolymer of vinyl acetate-ethylene and acrylic. 
     
     
         21 . The method of  claim 19 , wherein the impregnated fibrous strips are pressed under a pressure of at least about 5 mPa.