Method of making an ultra thin glue adherable decorative laminate
AssigneeWestinghouse Electric Corp.
InventorsHarold O. McCaskey, Jr., Daniel L. Cannady, Jr.
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Abstract
An ultra thin laminate is made by: (1) assembling a laminate stack-up consisting of: one paper sheet having a top decorative surface and a bottom surface coated with a resinous film, about 0.25 mil to about 5 mil thick, effective to opacify the paper and provide a barrier to resin flow, and one abrasion resistant protective overlay sheet disposed in contact with the decorative surface of the paper sheet; (2) heat and pressure consolidating the stack-up to form a unitary decorative laminate having a thickness of between about 5 mil and about 15 mil, and having a resinous film on one side that is glue adherable.
Claims7
A method of making an ultra thin, glue adherable, high pressure decorative thermoset veneer laminate, comprising the steps of:
- (A) assembling a laminate stack-up consisting of:
- (1) one thermosetting resin impregnated paper sheet having a top decorative surface, and a bottom surface coated with an alginate resinous film, about 0.25 mil to about 5 mil thick, to an alginate content of from between about 2 weight percent and about 40 weight percent of the coated paper sheet, said film being effective to opacify the paper sheet and provide a barrier to resin flow, and
- (2) one thermosetting resin impregnated abrasion resistant, protective overlay sheet disposed in contact with the decorative surface of the paper sheet,
- (B) placing the stack-up in a press and molding the stack-up at temperatures of between about 100.degree. C. and about 200.degree. C. and pressures of between about 500 psi. and about 2,000 psi., and
- (C) cooling and releasing the press and removing the stack-up;
- wherein the stack-up is heat and pressure consolidated to form a unitary decorative laminate, the laminate having a thickness of between about 5 mil and about 15 mil and a resinous film on one side that is glue adherable without sanding.
Dependencies are inferred from the claim text.