The Evolution of Sustainable, Cost-Effective Decorative Surface. Materials

Transcription

1 C o n t i n u i n g E d u c a t i o n u n i t The Evolution of Sustainable, Cost-Effective Decorative Surface Today s market demands require the balancing of many competing priorities. Specifically, when 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. Materials PART 1: A Revolutionary Evolution No introduction to decorative surface materials would be complete without paying homage to the technological history of plastic laminates and the stage that has been set for future advances. The Machine Age [roughly ] During the Machine Age scientists around the world were working to develop synthetic plastics. They came to understand that plastic is an amorphous solid consisting of long-chain molecules known as polymers, which do not break apart when flexed and are usually made from artificial resins. Plastics were defined as thermosets and thermoplastics, and both would be used to engineer decorative surface materials. In the early 1900 s the first plastic laminate material was made by impregnating kraft paper (similar to brown bag paper) with phenolic resin and compressing it under high temperatures and pressure in a process called thermosetting that irreversibly cured the resin. The resulting material was resistant to heat, water, chemicals and electrical current. Originally it was used as an insulator for industrial products, but designers soon recognized the material s uniform character and durability and started using it for other applications such as radio exteriors. The Machine Age also saw the emergence of high-speed printing presses and large-scale production machinery. In the 1920 s, décor papers (printed with solid colors, woodgrains, natural and abstract designs) were added on top of kraft paper before thermosetting to give the finished plastic laminate product different visual effects. While phenolic resins are known for their hardness, durability and resistance to moisture, they are dark in color. So in the 1930 s a resin called melamine, which produces a clear surface, was developed. In contemporary manufacturing of plastic laminate (commonly referred to as high-pressure laminate or HPL), the top two layers, typically a transparent wear layer and décor paper design, are impregnated with melamine resin, and the bottom kraft layers use phenolic resins. During this same period industrial chemists were also Melamine-Treated Wear Layer Decorative Layer Phenolic-Treated Kraft Paper (number of sheets varies by product type) developing thermoplastic plastics. These turn into a liquid when heated, and solidify when sufficiently cooled. They include polyethylene polymers such as vinyl (PVC), which is flame, water and corrosion resistant characteristics that made it an excellent insulating material for the wires on U.S. military ships. Despite vinyl s practical beginnings, one of its most remarkable characteristics has proven to be its versatility, making it the second largest-selling plastic in the world today. For the production of thermoplastic decorative surface materials, a thin sheet

2 of PVC film is membrane vacuum pressed or profile wrapped to a substrate. PVC films can be solid color or carry printed designs such as wood grains and abstracts. The Atomic Age [roughly ] From their inception, decorative surface materials derived from plastics offered designers excellent performance. As the visual design offerings improved so did the markets for these materials. By the 1950 s, HPL plastic laminate was a popular decorative surface material for everything from cruise ships and soda fountains to high-end kitchens and furniture. Vinyl products, with their characteristic low-cost versatility, were specified for tabletops, seating upholstery and wall coverings, as well as carpets, textiles, plastic wrap and pipes. The early part of this period reflects the end of wartime and the promise of a brighter future built on mankind s ingenuity and collective work. This philosophy, combined with the ever-evolving palette of available building materials and decorative surfaces, gave architects and designers more room to dream. One result of this was Googie architecture. Though the space age motifs and giant tiki s of Googie faded away by the mid-1960 s, the movement itself stretched the imagination of design professionals and consumers alike. Around the same time that Googie lost its luster, advances in printing technology brought a new standard of consistency and realism to décor printing. Rotogravure printing is the historical printing process of choice for fine art and photography reproduction due to its remarkable color density light to dark gradient. It is also the industry standard for décor printing. One of the advantages of using decorative surface materials is the infinite design possibilities of décor printing, which can be done on paper of varying thickness (typically with water-based pigments) or on plastic films (typically with solvent-based inks). The photorealistic quality of gravure printing allows designers to replicate natural designs with great fidelity. At the same time, the process makes it possible to create décor papers and films with patterns and dimensionality that do not exist in nature. Rotogravure printing involves engraving the design image onto an image carrier, which in the case of rotary printing is a cylinder. The development of electro-mechanical cylinder engraving in 1968 greatly increased the fidelity of the engraved designs. During the gravure process, the engraved cylinder is partially submerged into an ink fountain, which then fills the recessed cells with ink. The rotational motion of the cylinder draws the ink out of the fountain, and a doctor blade scrapes the excess color from the non-printing areas of the cylinder before it makes contact with the paper, which is generally fed through the press from large rolls rather than sheets. The paper (or plastic film) is sandwiched between the gravure cylinder and an impression roller, which applies the force that transfers the ink to the paper. This method ensures maximum saturation of ink. Each color in a design requires its own printing unit (engraved cylinder). The paper goes through a dryer to make sure it is completely dry between color units. In addition to its aesthetic appeal, the performance of laminated surfaces was getting more attention during this period. HPL countertops offered consumers a viable option to solid wood (which was said to crack, warp and hold bacteria) and stone (which was said to be heavy, costly and porous). Kitchens decked out in HPL and vinyl furniture, cabinets and counter tops were the height of fashion. Often these materials were intended to look like what they were, which is to say plastic. While this was initially considered futuristic and cutting edge, it soon would appear dated. photos, clockwise, starting from top: PVC films can be 3-dimensionally laminated. In this example, a large component at the outfeed of a membrane press. Engraved cylinders in a rotogravure printing press High pressure laminate (HPL) is a reliable option for use in countertops and work surfaces. Designs from the 1950 s are making a comeback and are still sold by many HPL producers.

3 The Information Age [roughly 1985 until early 2000 s] This early part of this time frame might be characterized as the pre-pubescence of laminated decorative surface materials. It was a time of great growth and opportunity, as well as some awkwardness and misunderstanding. New techniques were developed to expand the usage of decorative surface materials. Some of them improved the performance of plastic laminates, such as the 20-fold increase of durability that evolved with the introduction of laminate flooring products. A classic example is vertical surfaces. HPL is an extremely high performance product. It is perfect for usage in horizontal work surface and high-traffic areas. Value-engineered new products were designed and introduced to meet the needs of similar applications with lower manufacturing costs. A good example of this is thermally fused melamine (TFM), which is essentially the top layers of HPL (décor paper impregnated with melamine resins), thermally fused to particleboard or MDF forming a stand-alone decorative panel. As these derivative products emerged they were not always specified based on the value of their performance, but often purely on cost. This had a negative effect on the perception of laminated decorative surfaces and the term laminate took on the connotation of a low quality imitation product, an unfortunate misconception. In a sense, engineered products were victims of their own genius, particularly considering how quickly technology advanced in the information age. But all was not lost, and savvy professionals knew that to maximize the use of any material it was important to understand its strengths and limitations. This explains the resurgence of design interest in the potential of laminated decorative surface materials. In addition to specialized performance, decorative surfaces were undergoing a paradigm shift in visual realism during this period. Computers and digital scanning technology now allow décor designers to replicate any material with unprecedented fidelity and dimensionality. Imaging software has made it possible to bring any design that can be imagined into being. Laser engraving of rotogravure cylinders enables sharper contrast and more subtle tonal gradients than was previously possible. It has also expedited the process of décor development and sampling. New digital ink-jet printing technologies are driving décor development to move beyond commodity designs and into experimental boutique fashions and customized surfaces such as logos and murals. Advanced surface treatments and overlay technologies also play important roles in the development of decorative surface materials, enhancing both the visual and tactile qualities of the products. One technique uses engineered press plates to create embossed texture in register with the décor paper design. This can include ticking that matches wood grain, or variations in gloss levels to enhance geometric or stone designs. Another method for adding interest to decorative surfaces is the addition of a transparent overlay called an inclusion that is embedded with fibers or particles. Inclusions of metal filings, organic materials (such as banana fibers and coffee beans) and textiles are all used to add an extra layer of interest on top of solid or printed décor papers. photos, clockwise, starting from top: Digital printing technology makes the production of low volume custom laminates possible. Some laminate materials are made with natural fibers or other inclusions in the base paper. Thermally Fused Melamine (TFM) is used extensively in the production of kitchen cabinets. Laminate Flooring is a testament to high pressure laminate s performance characteristics.

4 The Connected Age [early 2000 s to present] According to web technologist Anna Zelenka, the defining characteristic of the information age is the creation and management of information to produce knowledge goods. The subtle shift into the connected age is the use of web-based communication tools to create and manage relationships across knowledge goods, hardware and people. This seemingly subtle shift in technology is manifested in one of the most important developments in decorative surface material manufacturing: cross product matching programs. After a quick and revolutionary history over the past 100 years, we re now seeing decorative designs available across a broad range of surface materials and manufacturers thanks to these matching programs. This allows designers to value-engineer end products based on the specific performance demands of each component, ensuring the highest quality in design, value and durability. For example, matched materials can be used to construct a desk that incorporates printed papers in drawer and cabinet interiors, TFM or printed paper for the vertical exterior panels, HPL on the high-wear horizontal work surface and 3DL for contoured drawer fronts. Despite each of these materials unique performance characteristics, they share the same visual. Matching programs make it easier for design professionals to maximize performance and cost without sacrificing design integrity. The next age is hard to predict, but it starts with a better understanding of the basic materials in use today. 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. photos, clockwise, starting from top: Particleboard (PB) andmedium Density Fiberboard (MDF) are versatile composites. Both can be specified as fire or moisture resistant products. HPL flooring and example of an HPL postformed component. HPL is a favorite product for use in horizontal work surfaces and office furniture. HPL, TFM and 3DL are often matched and used together in kitchen cabinets.

5 photos, clockwise, starting from top: HPL in commercial interiors and office furniture (both shots) Decorative foils used in kitchens TFM and PVC films in store kiosks Closet systems often employ TFM. 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. 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/m 2 ) directly affect the opacity and performance of the end product, which allows for a wide range of specialized applications. 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

6 Light basis weight papers (LBWP) range in weight between 23 to 60 g/m 2 Decorative foil paper basis weight ranges between g/m 2 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 flat 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 flat 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 flat 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 photos, clockwise, starting from top: Low basis weight papers and decorative foils are often the surface materials of choice in ready-to assemble (RTA) furniture. These store fixtures are made from a combination of 2dl and 3dl pvc film overlays. Decorative foils, rather than HPL were used in this wall unit to reduce the overall weight of the product. 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 R E S O U R C E S 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 ( 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, DecorativeSurfaces.org and

7 C o n t i n u i n g E d u c a t i o n u n i t Circle the letter of the correct answer for each question below. This course is registered with the AIA/CES. To receive one learning unit (LU) as approved by AIA, answer at least 80% of the following questions correctly. A certificate of completion will be sent to you after submitting the quiz. There is no fee to take this course. Take this quiz online at Mail, fax or completed quiz to: Allyson O Sullivan Composite Panel Association Deerfield Avenue, Suite 306 Leesburg, VA , extension 251 Fax: aosullivan@cpamail.org Contact Information: Name Company Name Address City/State/Zip Phone AIA # o I would like to receive future CEU courses. sponsored by: Composite Panel Association & Decorative Surfaces Council 1. What attributes make MDF and particleboard ideal substrates for decorative surfaces? a. Consistency b. Uniform strength c. Free of defects d. Cost effectiveness e. All of the Above 2. What overlay is produced by saturating multiple layers of kraft paper in conjunction with a decorative sheet? a. Thermally Fused Melamine b. High Pressure Laminates c. Decorative Papers d. Film Overlays 3. What makes Thermally Fused Melamine unique as a decorative surface? a. 3D laminated b. Ability to be flat laminated c. Profile wrapped d. Forms a stand-alone decorative panel 4. What is the primary difference between Decorative Papers and Foils? a. Paper color b. Curing c. Production techniques d. Basis weight paper and resin 5. Which overlay is made using a Double Belt Press? a. Decorative Papers b. Decorative Foils c. Continuous Pressed Laminates d. Thermally Fused Melamine 6. What decorative surface can be flat laminated or membrane pressed around contoured components? a. 3D Laminates b. Thermally Fused Melamine c. Decorative Foils d. High Pressure Laminates 7. Decorative Papers and Foils can be finished and top coated to enhance what performance characteristics? a. Scratch resistance b. Stain resistance c. Wear resistance d. All of the Above 8. Which overlay is made from polypropylene or oriented polypropylene (OPP), and has excellent water and chemical resistance? a. 2D Laminates b. Decorative Papers c. Thermally Fused Melamine d. Decorative Foils 9. What offers designers the flexibility to value-engineer consistency in their overall product design while maximizing performance? a. Matching programs b. Paper saturation c. Ink-jet Printing d. Thermoplastics