CHAPTER | laminate plastic laminate substrate Plasti@ Laminates Booey Relist 7.:1t-aiay Brenan (cag eaaees ioe 4 yt eee ee eae A faminate is made from several different layers of material that are firmly united together. The tops of tables, cabinets, desks, and chests are often covered with an xxtremely hard plastic laminate, Fig. 18-1, You may know this material by one ot its trade names. Paneiyte!™, Formical™, and Witsonart™ are examples, Fig, 184—Plastic laminate was used in the onstruction ofthis kitehen counter WUE 262 Chapter 18. Plastic Laminates,acts wood yteoue What's in a Name—n 1913, Daniel J, O'Conor, a Westinghouse chemical engineer, invented plastic laminate. He developed it to be used as an electrical insulator. Westinghouse was not very interested in his invention, so he and another engineer started their own com- pany to manufacture plastic laminates. One of their first orders was from an aiectric motor company for commuta- | tor V-rings, Until then, the Verings were always made of mica, another kind of insulator. Because plastic laminate was | a substitute for the mica, the new com: | pany was named “Formica.” Even though other companies make plastic laminates, | for many years the general public called | all plastic laminates Formica. Plastic laminate is made primarily from lay- ers of kraft paper. This paper is impregnated (filled) with resin. A rayon surface paper is covered with another kind of resin. These lay- ers are placed under high heat and pressure to produce a Yie-inch sheet of material that is very hard. It wears well and is scratch resis tant. Coffee, ink, iodine, crayon wax, and most other substances have no effect on this surface Soap and water can be used to clean it. LAMINATE MATERIALS On some furniture, plastic laminates that give the appearance of wood grain are used. However, a wide selection of laminates is available, You can choose among solid various textures, and a wide variety terns. If you will need to use a nun sheets, keep in mind that there will | Joints where the pieces meet. Dull finist patterns with straight lines hide joints than glossy finishes and solid colors. You can buy sheets of plastic laminate up to 5 feet by 12 feet. Large sheets wi enable you to cover large areas withow joints. Plan how you will lay out your la so that you can cover the most area w fewest joints and with the least waste. WORKING WITH PLASTIC LAMINATE Plastic laminates are usually applied to strate (underlayment) of plywood, p board, or medium-density fiberboard ig, 18-2. (Gee pp. 58-59.) When t laminate, begin by cutting the substrat sheet stock. Fig, 18-2 sartiheboard, vpes of substrate, Top £0 bottom: MOF and plywood, Chapcer 18 Plastic Laminates§uilding Up the Substrate Install build-up pieces on the substrate. To do this, turn the piece(s) upside down. Cut and install stretcher strips of %4-inch stock 4 inches wide around the edges. Place short crosspieces across the ends and at intervals of about 2 feet along the length. Also place them acrass any substrate joints and around any cutouts. Use glue and 14-inch self-tapping screws to install the strips. Fig. 18.3 Molding will need to be installed on the facing edge of your project. If the laminate will extend over any part of it, the molding should be installed now, before the laminate is applied. Fig. (S-+. Later in this chapter you will see how the edge is finished. Fig, 18-3--auild-up pieces are glued to the under: ide of the substrate before scrows are installed. WME 264 choprer 18 Plastic Laminates ting Laminate Plastic laminates are hard but very brittle. They must be well supported before being cut. Since a sheet is only ‘4s inch thick, it cracks easily. Any of the standard woodworking cut ting tools can be used to cut plastic laminate. However, most woodworkers prefer carbide- tipped tools. These are very hard and remain sharp longer than ordinary tools. A router with carbide-tipped bits works well for cutting plas- tic laminate. See Chapter 28. > Using Tools + Always wear eye protection when work- ing in the shop. + Use all tools property + Always take special care with tools that are sharp. suasrRare — auiLo.uP strip —fe ‘ a | soLoING ANINATE \ 3 Fig, 18.4 (A) if laminate will extend aver the mold. ing, install che molding first. (3) One example ut ow laminate may de applied over moiding.SCIENCE como Warpage in Plastic Laminates Like ordinary wood, plastic laminates are subject to changes in humidity. They | contract when humidity decreases and expand when it increases. The amount of change is different in one dimension than it is in the other. This change is known as dimensional movement. In most plas- tic laminates, the width of the laminate changes twice as much as the length, There are several ways to minimize the effect of humidity on plastic laminates: + Use backer sheets to help protect the substrate from changes in humidity. Use a substrate that has dimen- sional movement similar to that of the laminate, Allow the laminate, substrate, and adhe- sive to acclimate for at least 48 hours in the same conditions (heat and humid- ity) under which they will be used. Use the same laminate on both sides of a panel Use the same adhesive and application techniques on both sides of a panel. Use a router with a top-bearing bit to cut the laminate to rough length and width. The piece should be at least % inch longer and wider than the substrate. Position the sheet on several %-inch strips to provide clearance for the router bit. Clamp a straightedge across the laminate and use it as a guide when cutting, s-5, After making the first cut, go over it again to smooth and even out the cut Using a Router to Cut Laminate + Always wear eye protection. Sharp + fly from laminate when it is being « + Keep your hands and clothing « from the rotating cutters at all time + After turning off the power, wait the machine comes to a complete before setting it on its side. For further safety information about « ating a router, see Chapter 28. Fig, 18-5—Using 9 router 19 cut laminate, Chapter 13. Plastic LaminatesEdges that will butt against each other must match. Cut these at the same time. Overlap the ends about 1 inch. Place a cutting guide over these and clamp them all together. ix. 14-0. Make the cut using a router with a top-bearing bit. The cut edges of both pieces should match very closely. ntact Cement When adhering laminate to substrate, use con- tact cement, Contact cement is an adhesive that is coated on the two surfaces to be joined and then allowed to dry. Once it has dried, it will not adhere to any surface not coated with contact cement. When placed in contact with another coated surface, however, it bonds immediately and permanently. Applying Contact Cement Before applying contact cement, be sure the surfaces to be joined are clean and free of sawdust. Apply the cement to the underside of the laminate and the top of the substrate. A good-quality brush or roller could be used. ‘The cement may also be poured on the surface ‘oP Oe RING PATTERN aT FOLLOWS AGAINST CLEAR, CUTTING THROUGH SOTM SHEETS OF LAMINATE, \W One SHEET OF Lamar "OVER THE OTHER and spread with a trowel. Spread the cement evenly over each surface, Allow this first coat to dry to the point that kraft paper will not stick to it. Then apply a second coat, When contact cement is ready for bonding, the dry coats will have a glossy appearance. If any part appears dull, apply more cement. Let the second coat dry, again to the point at which kraft paper will not stick. When this point is reached, the parts are ready to be joined. Using Adhesives + Always wear a respirator with a charcoal filter to protect yout lungs from fumes ‘when using adhesives. + Be sure the filters in the respirator are new. * Work in a well-ventilated area, Ross sreton 266 Chapter 18. Plastic Laminates ~ yom tameRemember that contact cement adheres imme: diately when contact is made between the prepared surfaces. Because of this, you will need separators between the surfaces as you position the laminate over the substrate. Lay 4-inch or !s-inch dowels every 6 to 8 inches across the substrate. The dowels should be long enough to extend past the edges of the pieces to be joined. Lay the laminate on the dowels. Position it so that it extends past all edges of the substrate. IF the laminate has a pattern with straight lines, these should align with the edges or ends for good appearance. Begin the gluing process by removing the dowels. ! As each dowel is removed, press down on the laminate so that contact is made with the substrate. Work your way toward the ends, removing a dowel fir one side and then from the other, Smo laminate on the substrate to keep air | from forming. Fig. 1-5 Strengthening the Bond To make sure the cement achieves strength, you will need to apply pressuy the entire surface. It's best to use the rubber roller specifically designed f purpose. His, 13-9 268). Larger do not work well. Less pressure can be because it is spread over a larger area. If a small roller is not available, use let and a 3-inch square block with cha edges. Slide the block over the surfac ping it with the mallet. If glue is fore along the edges, use your fingers to rer while it is still in a rubbery state. 18-7—Winan inst eta ove the si sa Fara he tau 18:.8--Smoothin. 1s the formation af sir pockets. the laminate toward Chapter 18 Plastic Laminates‘rimming the Laminate ‘Trim the laminate to the same size as the substrate. Use a router with a lower-bearing flush-trim bit. ig, 1-10, Remember to follow all safety rules. ‘As you cut, the bit tends to become clogged with cement and dust. To prevent this, make a few cuts and stop. Allow the cutters to stop and spray both the cutters and the bearings with aerosol oil such as WD-40 or CRC. Repeat the process as you work. installing Molding and Making ‘inish Cuts To provide a finished appearance, molding is installed on the facing edges of objects topped with plastic laminates. If the molding was installed before the laminate, cut a decora- tive shape, ot profile, along the top edge. Fv. S11, Pre-shaped molding is installed after the laminate has been applied. Fig. 18:9—using a subber roller to apply pressure M268 Chaprer 18. Plastic Laminates Fig. 18-10—ihim che laminate to she ade of the substrate, SPLINE BISCUIT |OPTIONAL) j cur aa seo sMOLOING OPTIONAL) Fl Fig. 18-114 decorative profile ean be cut slong the fop edge of the molding. Note ssa tha optional ceural features,Review & Applications Chapter Summary Major points from this chapter that you i should remember include: ' + Plastic laminate is a very hard, brittle mate- rial used to top counters and furniture. + Plastic laminates are usually applied to a substrate, + A router with carbide-tipped bits is effective for cutting plastic laminate. * Contact cement is an excellent adhesive to use when adhering laminate to substrate. + To install laminate, begin in the middle. Remove the dowel separators one at a time, pressing the laminate against the substrate. + After adhering laminate to substrate, apply pressttre over the entire surface to achieve the strongest bond possible. | | | | | | | | Review Questions |. What materials make up plastic lami How are they joined? 2. Why are carbide-tipped tools effectis, cutting plastic laminates? ) What type of breathing protection de should you wear when working with tact cement? Why? + What are the adhesive tendencies of tact cement that has dried on a surfs 5, How can you tell when contact ceme ready for bonding? ©. Describe the procedure for installing nate on substrate. 7 What can be done to give the facing of a project topped with plastic lami: finished appearance? Solving Real-World Problems Davids remodeling the master bath in his 20-yearold rome. the off orange plastic laminate simpy has to go! David manages to pee, scrape, and sand the old lami- rate and ult from the surface ofthe vanity. Fllewing be itectons ofa friend, Davi prepares the surface for ‘ne new laminate, However, witen he purchases the new interial, ne finds that it must be spliced, How can fe be 14e a splice will ot be 190 noticeable? Chapter 18. Plastic Laminates