Abrasion-resistant laminate

A method of producing an abrasion resistant decorative laminate from at least one backing layer and a thermosetting resin impregnated decorative facing sheet, said laminate having enhanced abrasion resistance without an overlay layer, the method comprising:

• coating a decorative facing sheet with an ultra-thin wet layer of a mixture of (1) an abrasion resistant hard mineral of particle size 20-50 microns in quantity sufficient to provide an abrasion resistant layer without interfering with visibility and (2) binder material for said mineral which binder material has the properties of withstanding the subsequent laminating conditions, being compatible with said thermosetting resin, said binder being present in an amount sufficient to bind said abrasion resistant mineral to the surface of said decorative facing sheet, and the binder-mineral layer in the dry state being permeable to said thermosetting resin;
• drying said coated binder mineral mixture at a temperature sufficient to enhance the bonding of said abrasion resistant material by said binder material to said decorative facing sheet, to provide an ultra-thin dry porous layer of said binder-mineral mixture thereon;
• impregnating said coated facing sheet with said thermosetting resin;
• assembling said resin impregnated and coated facing sheet over said backing layer;
• and
• subjecting said assembly to heat and pressure sufficient to effect consolidation of said backing layer and said facing sheet to thereby provide said abrasion resistant decorative laminate.