Method for producing a deep embossed tile design postformable high pressure decorative laminate

Abstract

A method of producing a deep embossed tile design postformable high pressure decorative laminate by first preparing artwork having a first layer of fibrous sheets impregnated with a thermosetting resin, a second layer having a plurality of adjacent tiles comprising a plurality of fibrous sheets impregnated with a thermosetting resin, wherein the tiles were previously pressed and heated, and a third layer having a plurality of shims. The assembly is then pressed and heated against a rigid substrate whereby the second layer forms a substantially convex shape on the upper surface of each tile, thus imparting substantially concave impressions on the first layer. The first layer is subsequently removed from the second and third layers, and grooves are formed in the first layer, preferably by machining. The method also includes forming a negative image texturing plate from the artwork and then forming the embossed laminate from the texturing plate.

Dependencies are inferred from the claim text.