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US 4,435,234 AGranted
Method of producing high pressure decorative laminates containing an air-laid web
AssigneeFormica Corporation
InventorJames E. B. Hunt
Life of this patent
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Abstract
The invention relates to high pressure decorative laminates containing an air-laid web as a substrate and to a method of preparing such a decorative laminate from an assembly comprising said substrate and a thermosetting resin impregnated decor sheet.
Claims3
A method of producing a heat and pressure consolidated, high pressure decorative laminate which comprises,
- (1) defibrating cellulosic fibers to produce fibers of an average length of about 0.5 to 2.5 mm in the presence of air to thereby form an air-fiber stream,
- (2) incorporating into said air-fiber stream from about 20%-35% of particles of a thermosetting resin to thereby form an air-fiber-resin stream,
- (3) depositing the fibers and resin from said air-fiber-resin stream, under conditions of 40-80% relative humidity, onto a foraminous belt at a thickness ranging from about 5-100 mm to form a layer of uniform composition and basis weight,
- (4) pre-consolidating the deposited fibers and resin to a thickness of from about 0.5-10.0 mm,
- (5) forming a laminate assembly comprising, in superimposed relationship,
- (A) a monostichous layer of said preconsolidated fibers and resin and
- (B) a thermosetting resin impregnated decorative sheet, and
- (6) heat and pressure consolidating said laminate assembly.
5 more elements
Dependencies are inferred from the claim text.