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US 4,468,264 AGranted
High pressure decorative laminates containing an air-laid web of fibers and filler and method of producing same
AssigneeFormica Corporation
InventorsTheodore R. Clarke, John F. Hosler
Life of this patent
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Abstract
The invention relates to high pressure decorative laminates containing an air-laid web of fibers, filler and resin as a core and to a method of preparing such a decorative laminate from an assembly comprising said substrate and a thermosetting resin impregnated decor sheet.
Claims5
A method of producing heat and pressure consolidated laminate which comprises,
- (1) defibrating cellulosic fibers to produce fibers having an average length of about 0.5 to 2.5 mm in the presence of air having a humidity of about 50-80% to thereby form an air-fiber stream,
- (2) incorporating into said air-fiber stream about 10-40% of particles of a thermosetting resin and from about 1% to about 20% of a pulverized, particulate filler having a particle size no larger than about 200 microns, to thereby form an air-fiber-filler-resin stream,
- (3) depositing the fibers, resin and filler from said air-fiber-filler-resin stream onto a foraminous belt,
- (4) pre-consolidating the deposited fibers, filler and resin to a thickness of from about 0.5-10 mm,
- (5) forming a laminate assembly comprising, in superimposed relationship,
- (A) a monostichous layer of said preconsolidated fibers, filler and resin and
- (B) a thermosetting resin impregnated cellulosic print sheet and
- (6) heat and pressure consolidating said laminate assembly.
5 more elements
Dependencies are inferred from the claim text.