Nevamar Corporation, Llp

International Paper Company

Exxon Research and Engineering Company

Other

Joseph A Lex

Robin D O'Dell

Israel S Ungar

Herbert I Scher

Alice M Simon

Jayesh Shah

William C Decker, Iii

A decorative laminate surface layer composition is prepared by selectively applying dissimilar thermoset or thermoplastic polymers to a decorative laminate facing sheet to achieve a brillant visual or pearlescent appearance.

Process for producing aesthetic surface layer composition and aesthetic

A decorative laminate surface layer composition is prepared by selectively applying dissimilar thermoset or thermoplastic polymers to a decorative laminate facing sheet to achieve a brillant visual or pearlescent appearance. The surface of the decorative laminate sheet consists essentially of resin particulates which melted and flowed in the forming method to form a surface layer.

Forming a laminate sheet by pressing resin particulates on a decorative

Decorative laminate surface layer

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

Coated transfer sheet and laminate produced therefrom

A low-pressure board having reduced show-through and reduced resin migration is obtained by interposing a coating between the decor sheet and the substrate, e.g. fiberboard, chipboard or particle board, which is preferably microcrystalline cellulose or a mixture of microcrystalline cellulose with CMC at a dry-coating weight of 2-16 pounds per ream, preferably 4 pounds per ream.

Low pressure board

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 decorative laminate surface layer composition is prepared by selectively applying dissimilar thermoset or thermoplastic polymers that are compatible with a laminate resin system to a decorative laminate facing sheet.

Aesthetic surface layer

A wear and gouge resistant decorative laminate is made by consolidating, under heat and pressure, a suitable backing over which lays a decor layer covered by an overlay sheet, the overlay sheet being provided on its upper surface with an ultra-thin abrasion resistant layer consistent with the disclosure of Scher et al. U.S. Pat. No. 4,255,480 and optionally O'Dell et al. U.S. Pat. No. 4,499,137.

Abrasion resistant laminate

A glossy laminate is made using highly polished caul plates, the laminate having superior sliding can wear resistance, and without damaging the plates. This result is effected by use of the technology of Scher et al. U.S. Pat. No. 4,255,480; O'Dell et al. U.S. Pat. No. 4,491,137 and 4,567,087; and/or Ungar et al. U.S. Pat. No. 4,713,138, except that the particles size of the grit is maintained at less than 9 micrometers. In this way a glossy laminate is obtained which retains its glossy appearance under normal wear conditions, and without rapid destruction of the expensive polished caul plates.

Wear-resistant glossy laminates

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 laminate having registered color and embossing is produced by effecting a simultaneous embossing and laminating using a three-dimensional press plate acting against an overlay sheet containing high flow melamine resin and pigment beneath which lies a melamine resin impregnated print sheet and below that an underlay sheet containing high flow melamine resin and pigment of another color. During the pressing operation the resin and pigment in the overlay flow laterally from the high pressure areas to the low pressure areas with the result that the underlying print sheet is visible through the overlay sheet in the high pressure areas while the pigment in the overlay sheet in the low pressure areas masks the print sheet. In areas of even lower pressure the color from the underlay sheet strikes through to the surface to provide a third color.

Growing community of inventors

Pasadena, MD, United States of America

Joseph A Lex