International Paper Company

International Paper

Jayesh Shah

Robin D O'Dell

Alice M Simon

Joseph A Lex

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.

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Glen Burnie, MD, United States of America

Jayesh Shah