Nevamar Corporation, Llp

International Paper Company

International Paper

Alice M Simon

Robin D O'Dell

Joseph A Lex

Jayesh Shah

Israel S Ungar

Aminoplast and phenoplast particles are obtained by providing an aqueous solution of such a resin having a water tolerance level, adding a particulate core-forming material in solid form, e.g. mineral particles or cured resin particles, as well as a mixture of water and a stabilizing agent, the amount of water being sufficient to exceed the water tolerance level of the aminoplast or phenoplast, and thus forming an emulsion or suspension of the resin coated particles in water, and advancing cure of the resin to form partially or fully cured resin coatings having a thickness preferably about 5-75 .mu.m encapsulating the particulate core-forming material.

Aminoplast- and phenoplast- resin encapsulated particles

A suspension of finally divided hardened aminoplast or phenoplast resin, particularly melamine-formaldehyde resin, is prepared by mixing an aqueous solution of the resin or its precursors with a water-insoluble stabilizing agent, particularly microcrystalline cellulose; sufficient water is provided to exceed the water tolerance level of the resin and thus form a uniform emulsion or suspension of resin particles in water. Cure of the resin is then advanced such as by heating to form partially or fully cured resin particles of relatively uniform particle size.

Method of making cured resin particles

A highly glossy thick aesthetic laminate surface layer is achieved by using pre-cured particulates of the impregnating resin preferably along with an initial binder material and abrasion resistant mineral particles. The protective overcoating may be applied in a thick layer to give gouge resistance and a deep look in the glossy laminate. The overcoated decor sheet is pressed against a mirror plate in the laminate manufacturing process, and gives a gloss meter reading well over 100. Because the impregnating resin and the pre-cured particulates have the same index of refraction, the transparency of the coating and the resultant clarity of the underlying decor sheet are excellent.

Wear resistant glossy laminates

A thick aesthetic laminate surface layer is achieved by using pre-cured particulates of the impregnating resin along with an initial binder material and preferably also abrasion resistant mineral particles. The protective overcoating may be applied in a thick layer to give gouge resistance and a deep look. Because the impregnating resin and the pre-cured particulates have the same index of refraction, the transparency of the coating and the resultant clarity of the underlying decor sheet are excellent.

Abrasion-resistant, aesthetic surface layer laminate

A static dissipative laminate having a resistivity on the order of 10.sup.6 to 10.sup.9 ohms/square and a surface resistance in the static dissipative range even at very low humidities is produced by adding to the melamine resin for the decor sheet a small amount of ionic salt and a small amount of an aliphatic tertiary amine or glycerin which is believed to function as a humectant. The core sheets are formed of carbon filled paper impregnated with a phenolic resin containing a small amount of ionic salt.

Static dissipative laminate for work surfaces

A decorative, high pressure, conductive laminate for flooring material is formed of a plurality of phenolic impregnated carbon-containing core sheets, a melamine resin impregnated decor sheet containing about 3-5% carbon fibers having a length greater than 1/16 inch and preferably 1/8 inch or more, and a melamine resin impregnated abrasion resistant overlay. The overlay melamine resin also contains an ionic salt and a tertiary aliphatic amine, both also preferably being in the decor melamine as well. The laminate has a volume resistance of 2.5.times.10.sup.4 to about 10.sup.6 ohms. To make the product more dimensionally stable, carbon containing core sheets are interleaved with non-carbon-containing kraft sheets, the phenolic resin of which also contains ionic salt.

Growing community of inventors

Glen Burnie, MD, United States of America

Alice M Simon