Today’s market demands require the balancing of many competing priorities. Specifically, in dealing with the interior furnishings of both residential and commercial projects, there are many factors to consider when selecting the most appropriate decorative panel, including price-point, durability, cutting edge design and overall sustainability. The selection of surface materials is one key to making all of this happen. This continuing education course will guide you through the evolution of decorative surface materials to help you navigate and select the best engineered overlay for any commercial and residential application.

PART 2: Material Innovation

ABOUT SUBSTRATES:

Laminated decorative surfaces are usually laid up on a wood-based composite substrate. These base materials are generally medium density fiberboard (MDF) and particleboard which carry the decorative surface. An ideal substrate must be consistent, uniform in strength and free of defects. Wood composite materials are the substrate of choice for decorative surfaces because they can be engineered for specific performance characteristics and physical properties including – e.g., strength, flexibility, moisture resistance, fire resistance and low or no emission of volatile organic compounds (VOC’s). In addition to these qualities, composite panels are generally constructed in large part from recycled waste materials, making them especially “green.” Thoughtful combination of decorative surface materials and composite panel substrates is also an effective means of obtaining points for environmental building certification programs such as the U.S. Green Building Council’s Leadership in Energy and Environmental Design (LEED) certification and the National Association of Home Builders (NAHB) Green Home Building Guidelines.

HIGH PRESSURE LAMINATES [HPL]

HPL is the direct descendent of the original plastic laminate. It is considered to be one of the most durable decorative surface materials and is available with special performance properties including chemical, fire and wear resistance. Special grades of HPL can be postformed around curved edges by application of heat and restraint.

HPL is produced by saturating multiple layers of kraft paper with phenolic resin. A layer of printed décor paper is placed on top of the kraft paper before pressing. The resulting sandwich is fused together under heat and pressure (more than 1,000 PSI). Because phenolic and melamine resins are thermoset plastics, the curing process transforms the resin into plastic by a cross linking process that converts the paper sheets into a single, rigid laminated sheet. Thermosetting creates strong, irreversible bonds that contribute to HPL’s durability.

HPL is laminated to a panel utilizing a variety of adhesives. Particleboard or MDF are the preferred substrate because they provide a stable, durable, consistent and economical foundation.

Due to its durability, HPL is a common choice for horizontal surfaces including flooring, countertops and desktops. It also performs well in horizontal and vertical applications for high traffic settings such as hospitality, office furniture, healthcare, retail casework, commercial interiors and educational facilities.

CONTINUOUS PRESSED LAMINATE

A relatively new development in HPL technology is Double Belt Press (DBP) for the production of Continuous Pressed Laminate (CPL). CPL is decorative paper impregnated with resins and fused under heat and high pressure with resin-impregnated backer(s). Laminate properties are similar to standard HPL and typical thickness range is .4 mm to 1mm. CPL is available in desired sheet lengths or continuous rolls.

Flexible CPL is decorative paper impregnated with flexible thermosetting resins and fused under heat and high pressure with resin-impregnated backer(s). This engineered CPL offers a unique range of formable decorative laminates suitable for profile wrapping and edgebanding applications. Common thickness range is .2 mm through .4 mm. Surface properties are similar to vertical grade HPL and are used significantly to complement HPL and TFM laminates.

THERMALLY FUSED MELAMINE [TFM]

TFM is also referred to as thermally fused laminate. TFM is made from a resin-impregnated sheet of décor paper fused directly to a substrate (no kraft paper). Using heat and pressure, the saturated TFM sheet is laminated directly onto a substrate, primarily particleboard and MDF. Particleboard and MDF are ideal substrates for TFM, because they are consistent, uniform in strength and free of defects.

TFM can be manufactured with enhanced surface characteristics. Surface textures are created with steel press plates which emboss the decorative overlay to heighten the realism of wood grain, stone and abstract designs. Steel press plates can also be used to create or control the gloss level of the surface.

TFM has similar performance characteristics as HPL, with excellent scratch resistance. It is widely used in laminate flooring, office furniture, closet system components, store fixtures and cabinets. It is also appropriate in healthcare, hospitality, commercial and retail settings. TFM panels typically require a decorative edge treatment and can be specified with or without edge, and with single or opposite-side face treatments.

Due to the performance, design flexibility and cost advantages, TFM offers an excellent option for designers and specifiers.

DECORATIVE PAPERS/FOILS

These printed or solid decorative paper overlays are laminated directly to a wood substrate to achieve a desired visual effect. The products are differentiated by treatments (resin impregnation, printing and top coating) and basis weight of the paper prior to any treatment. Both treatment and basis weight (generally described in terms of g/m2) directly affect the opacity and performance of the end product, which allows for a wide range of specialized applications.

• Light basis weight papers (LBWP) range in weight between 23 to 60 g/m2
• Decorative foil paper basis weight ranges between 40-160 g/m2

LBWP is usually divided into two categories: standard (lower resin content) and industrial (higher resin content). As the resin content increases, so does the processing and production performance (i.e., improved cutting and machinability).

Decorative papers and foils are available with or without resin. Adding resin to the paper increases internal bond strength improves machinability and offers a good printing surface. Papers can be unimpregnated (no resin added), pre-impregnated (resin added) or post-impregnated (resin added after paper production).

Foils and papers are fully cured at the time of manufacturing. Decorative papers require a glue system to adhere to the substrate. The glue system can be hot melt (pre-applied or in line), PVA, urea-based or acrylic, and each system may affect the paper’s performance. With their smooth surfaces, MDF and particleboard are the ideal substrate and common choice for lamination of decorative papers. It is not necessary to laminate both sides of the substrate to achieve a balanced panel.

Decorative papers can be finished and top coated with resin to improve performance, including scratch, wear, stain and moisture resistance.

Decorative papers are a mainstay for highlevels of value engineering. They are widely used in cabinets, store fixtures, drawer interiors, closets, shelving systems, RTA and home office furniture. Some foils can be profile wrapped around contoured surfaces, such as raised-panel drawer fronts, providing a 3-D effect that matches fl at surfaces.

FILM OVERLAYS:

Known as rigid thermoformable foils (RTF), 3 dimensional laminate (3DL) and 2 dimensional laminate (2DL), are thermoplastic film overlays. They provide end users the freedom to design components with contoured surface profiles and seamless edges without needing edge treatments. Designers can also use film overlays to customize shapes and incorporate punch-outs, logos and concave/convex surfaces. These films are available in solid colors or printed designs.

The films used in 3DL and 2DL are thermoplastic, meaning they soften when heated to take on the shape of their substrate and return to a firm state when sufficiently cooled.

3DLs are primarily made of polyvinyl chloride (PVC) and polyester (PET) films. They can be seamlessly membrane pressed or vacuum formed around contoured components, including edges. 3DL can also be used in 2DL applications such as profile wrapping and fl at lamination. 3D laminates are available in typical thicknesses from 0.008" to 0.040" and customized gloss ranges. In addition, they are able to be embossed with specific emboss patterns to improve realistic aesthetics.

3D laminates are resistant to chipping, cracking or breaking making them a popular choice for retail store fixtures. In addition, their application seals the core panel substrate from bacteria and moisture, which make them an increasingly popular choice in healthcare settings for over bed tray tables, furniture and cabinetry. Thanks to their ability to wrap around custom shapes, edges and contoured surfaces, designers often specify 3DL materials for POP displays, commercial hospitality components, office furniture and door/drawer fronts for cabinetry.

2DLs are generally made from vinyl, polypropylene (PP) or oriented polypropylene (OPP). They are designed to be fl at laminated or profile wrapped.

2DLs are available in a variety of thicknesses ranging from 0.001" to 0.007", and can be solid colored, reverse printed or top printed with an overlay based on end use requirements.

2D laminates provide excellent water and chemical resistance, and varying degrees of scratch and stain resistance. Common uses for 2D Laminates include walls and ceilings of recreational vehicles, vertical surfaces for retail store fixtures, cabinets, commercial flooring, and residential components. s&p

RESOURCES

The Composite Panel Association (CPA) is the trade association for the North American composite panel decorative surfacing industry. CPA sponsors an annual Surface & Panel Buyers Guide which is dedicated to providing the most comprehensive information on North American composite panel and decorative surfacing products.

Manufacturers and processors of surface materials should reference the Voluntary Compendium of Standards for Decorative Overlays which was re-published in July 2009 by the Composite Panel Association (www.pbmdf.com). The voluntary standards cover decorative overlays made from cellulosic or polymeric materials. The compendium outlines the attributes of each type of overlay, provides the user with information and industry-accepted test methods to determine the performance and physical characteristics of the different overlays, and allows identification of the appropriate product for a particular application. The decorative overlays covered in the compendium are decorative foils, three-dimensional lamination overlays, light basis weight papers, oriented polypropylene films (OPP), thermally fused papers, and vinyl films.

The use of this compendium does not preclude anyone from manufacturing, marketing, purchasing or using products not conforming to the standards.

Separately, HPL is covered under NEMA’s High-Pressure Decorative Laminate standard. The standard covers HPDL sheets that consist of paper, fabrics or other core materials that have been laminated at pressures of more than 5.0 MPa (725 psi) using thermosetting condensation resins as binders. NEMA is the trade association for the electrical manufacturing industry.

For more information visit the Composite Panel Association, www.decorativesurfaces.org and www.pbmdf.com.