# US 4,395,452 A · Abrasion resistant laminate > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 4,395,452 A - Document ID: US4395452A - Status: Granted - Kind: A - Application number: 06/298,548 - Filed: 1981-09-02 - Granted: 1983-07-26 - Earliest claimed: 1977-01-10 - Assignees: Nevamar Corporation - Inventors: Herbert I. Scher; Israel S. Ungar - Web page: https://patentgrep.com/patent/US4395452A ## CPC - B32B 38/08: Impregnating - B41M 7/0027: {using protective coatings or layers by lamination or by fusion of the coatings or layers} - D21H 27/28: treated to obtain specific resistance properties, e.g. against wear or weather (water-repelling agents D21H21/16) - B32B 2305/30: Fillers, e.g. particles, powders, beads, flakes, spheres, chips - B32B 2307/554: Wear resistance - B32B 2317/12: Paper, e.g. cardboard - Y10T 428/24413: Metal or metal compound - Y10T 428/24421: Silicon containing - Y10T 428/2443: Sand, clay, or crushed rock or slate - Y10T 428/24612: Composite web or sheet - Y10T 428/24901: including coloring matter - Y10T 428/257: Iron oxide or aluminum oxide - Y10T 428/259: Silicic material - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B41M: PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING, (correction of typographical errors B41J; processes for applying transfer pictures or the like B44C1/16; fluid media for correction of typographical errors by coating C09D10/00; printing textiles D06P) - D21H: PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract An abrasion-resistant laminate is prepared by providing an ultra thin coating of mineral particles and micro crystalline cellulose on the surface of conventional printed paper, followed by impregnating the paper with a conventional laminating resin, and then using the print paper so obtained in a laminating process without the necessity of using an overlay sheet. ## Claims ### Claim 1 A print sheet for use in the preparation of decorative laminates of high abrasion resistance, comprising: a paper sheet substrate having a print design thereon, and an ultra-thin abrasion resistant porous coating over said print design, said ultra-thin abrasion resistant coating comprising a mixture of (1) an abrasion resistant hard mineral of particle size 20-50 microns in high concentration sufficient to provide an abrasion resistant layer without interfering with visbility and (2) binder material for said mineral compatible with a thermosetting laminating resin selected from the group consisting of melamine-formaldehyde resin and polyester resin, and being impregnable with said laminating resin, said binder material being present in an amount sufficient to bind and stabilize said abrasion resistant mineral to the surface of said paper sheet. ### Claim 2 (depends on 1) A print sheet in accordance with claim 1 impregnated with a thermosetting laminating resin selected from the group consisting of polyester resin and melamine-formaldehyde resin. ### Claim 3 (depends on 1) A print sheet in accordance with claim 1 wherein said binder material comprises predominantly microcrystalline cellulose. ### Claim 4 (depends on 1) A print sheet in accordance with claim 1 wherein said abrasion resistant mineral is alumina, silica or mixtures thereof. ### Claim 5 (depends on 1) A print sheet in accordance with claim 1 impregnated with a thermosetting laminating resin. ### Claim 6 (depends on 1) A print sheet in accordance with claim 1 wherein said binder material comprises a mixture of microcrystalline cellulose and carboxymethylcellulose. ### Claim 7 (depends on 1) A print sheet in accordance with claim 1 wherein the quantity by weight of said binder material in said abrasion resistant coating is no greater than the quantity by weight of said mineral therein. ### Claim 8 (depends on 1) A print sheet in accordance with claim 1 impregnated with melamine resin, wherein said abrasion resistant mineral is alumina, silica or mixtures thereof, and said binder material comprises microcrystalline cellulose, said ultra-thin coating having a thickness of about 0.02-0.3 mils, said coating comprising at least 5 parts by weight of said microcrystalline cellulose for about 20-120 parts by weight of said mineral. ### Claim 9 (depends on 8) A print sheet in accordance with claim 8 wherein said coating further comprises 0.5 to 2.0% by weight of a silane based on the weight of said mineral. ### Claim 10 (depends on 1) A print sheet in accordance with claim 1, wherein said ultra-thin layer has a maximum calculated thickness of about 0.3 mils. ### Claim 11 (depends on 1) A print sheet in accordance with claim 1, wherein said ultra-thin layer has a maximum thickness after pressing of about 0.3 mils. ### Claim 12 A print sheet for use in the preparation of decorative laminates of high abrasion resistance, comprising: a paper sheet substrate having a print design thereon, and an ultra-thin abrasion resistant coating over said print design, said ultra-thin abrasion resistant coating having a calculated thickness on the order of 0.02-0.3 mils and comprising a mixture of (1) abrasion resistant hard mineral of small particle size and quantity sufficient to provide an abrasion resistant layer without interfering with visibility and (2) binder material for said mineral, said binder being present in an amount sufficient to bind and stabilize said abrasion resistant mineral to said paper sheet so as to provide abrasion resistance without the necessity of an overlay sheet, said coating being impregnable by a laminating resin selected from the group consisting of melamine-formaldehyde resin and polyester resin. ### Claim 13 A print sheet for use in the preparation of decorative laminates of high abrasion resistance in which a thermosetting laminating resin selected from the group consisting of melamine-formaldehyde resin and polyester resin is employed, and print sheet comprising a paper sheet substrate unimpregnated with laminating resin having a print design thereon, and an ultra-thin abrasion resistant coating having a calculated thickness on the order of 0.02-0.3 mils and comprising a mixture of (1) abrasion resistant hard mineral of small particle size and quantity sufficient to provide an abrasion resistant layer without interfering with visibility and (2) binder material for said mineral, said binder material being present in a lesser amount than said mineral but sufficient to bind and stabilize said abrasion resistant mineral over said paper sheet, said print sheet including said coating being impregnable with said laminating resin.