Through color high pressure decorative laminate and method of making same
OwnerKevin Francis O'Brien, Frederic Auguste Taillaninventors
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Abstract
A decorative laminate is provided and includes a core having a plurality of stacked paper sheets which are impregnated therein a melamine-formaldehyde resin and an internal plasticizer for the melamine-formaldehyde resin, the plasticizer comprising an amino-functional monomer; a decorative sheet overlying the core, the decorative sheet having impregnated therein a melamine-formaldehyde resin and an internal plasticizer for the melamine-formaldehyde resin; and, optionally, an overlay sheet on the decorative sheet. A combustion accelerant is also included in the resin.
Claims28
A cellulosic paper sheet having impregnated therein from about 32% to about 43% by weight of resin solids, based on the total weight of said impregnated sheet, of a melamine-formaldehyde resin, wherein the molar ratio of formaldehyde-to-melamine is in the range of from about 1.20:1 to 1.60:1, from about 15% to about 32% by weight based on total resin solids weight of a plasticizer for said melamine-formaldehyde resin, said plasticizer comprising an amino-functional monomer selected from the group consisting of sulfonamides, guanidines, and substituted melamines, and from about 10% to about 24% by weight based on total resin solids weight of a combustion accelerant for said melamine-formaldehyde resin, said combustion accelerant comprising a hydroxy or polyhydroxy-functional monomer selected from the group consisting of alcohols and glycols.
A decorative laminate comprising (a) a core comprising a plurality of stacked paper sheets having impregnated therein from about 32% to about 43% by weight of resin solids, based on the total weight of said impregnated sheet, of a melamine-formaldehyde resin, wherein the molar ratio of formaldehyde-to melamine is in the range of from about 1.20:1 to 1.60:1, from about 15% to about 32% by weight based on total resin solids weight of a plasticizer for said melamine-formaldehyde resin, said plasticizer comprising an amino-functional monomer selected from the group consisting of sulfonamides, guanidines, and substituted melamines, and from about 10% to about 24% by weight based on total resin solids weight of a combustion accelerant for said melamine-formaldehyde resin, said combustion accelerant comprising a hydroxyl or polyhydroxyl-functional monomer selected from the group consisting of alcohols and glycols;
- and either (b) a decorative solid color sheet overlying said core, said decorative solid color sheet having impregnated therein from about 45% to about 53% by weight of resin solids, based on the total weight of said impregnated sheet, of a melamine-formaldehyde resin, wherein the molar ratio of melamine to formaldehyde is in the range of from about 1.25:1 to about 1.45:1, and from about 5% to about 12% by weight based on total resin solids weight of a plasticizer for said melamine-formaldehyde resin, said plasticizer comprising an amino-functional monomer selected from the group consisting of sulfonamides, guanidines, and substituted melamines;
- or (c) a decorative print sheet overlying said core, said decorative print sheet having impregnated therein from about 33% to about 39% by weight of resin solids, based on the total weight of said impregnated sheet, of a melamine-formaldehyde resin, wherein the molar ratio of melamine to formaldehyde is in the range of from about 1.25:1 to about 1.45:1, and from about 5% to about 12% by weight based on total resin solids weight of a plasticizer for said melamine-formaldehyde resin, said plasticizer comprising an amino-functional monomer selected from the group consisting of sulfonamides, guanidines, and substituted melamines.
Dependencies are inferred from the claim text.