Nevamar Corporation, Llp

International Paper Company

International Paper

Other

Robin D O'Dell

Joseph A Lex

Israel S Ungar

Alice M Simon

Herbert I Scher

Jayesh Shah

Christine C Wyche

Leonard R Elbon

Eric A Franzoi

Nelson L O'Neill

William C Decker, Iii

Witold Kostrzewski

Sheridan Neimark

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 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 solid thermoplastic filler-filled surfacing material having a deep semi-translucent appearance, in the form of a thin, rigid sheet contains 19-25% polymethyl methacrylate, 19-25% styrene acrylonitrile copolymer, 5-20% styrene maleic anhydride copolymer, and 30-60% finely divided filler of barium sulfate, kaolin, basic aluminum oxalate and/or wollastonite.

Solid thermoplastic surfacing material

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

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

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 static dissipative laminate consistently having an internal resistance less than 2.times.10.sup.6 and a resistance to ground measurement of about 5.times.10.sup.6 and a surface resistance in the static dissipative range even at a very low humidities is produced by the use of an ionic salt and an humectant in the overlay and further by the use of a special top core sheet containing 0.6-1.0% by weight of carbon fibers.

Static dissipative laminate containing an interior special core layer

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 decorative static dissipative high pressure laminate having a plurality of consolidated thermosetting resin impregnated layers including a core and a decor surface layer to provide a surface resistance no greater than 2.times.10.sup.9. The core comprises at least one thermosetting resin impregnated paper core sheet and at least one special thermosetting resin impregnated core sheet of predominately paper fibers and a small quantity of stainless steel fibers irregularly distributed among the paper fibers.

Growing community of inventors

Pasadena, MD, United States of America

Robin D O'Dell