Abrasion-resistant, aesthetic surface layer laminate
AssigneeNevamar Corporation
InventorsRobin D. O'Dell, Joseph A. Lex, Alice M. Simon
Life of this patent
Estimating the term…
Abstract
A thick aesthetic laminate surface layer is achieved by using pre-cured particulates of the impregnating resin along with an initial binder material and preferably also abrasion resistant mineral particles. The protective overcoating may be applied in a thick layer to give gouge resistance and a deep look. Because the impregnating resin and the pre-cured particulates have the same index of refraction, the transparency of the coating and the resultant clarity of the underlying decor sheet are excellent.
Claims32
In a decorative laminate meeting NEMA abrasion resistance standards comprising a substrate having a decorative upper layer, and a protective overlayer on top of said decorative layer, the improvement wherein:
- said protective overlayer is transparent and consists essentially of a cured thermoset resin formed of pre-cured resin particles and optionally mineral particles of fine particle size having a Moh hardness of at least 7 in a thermoset resin matrix, the index of refraction of said pre-cured resin particles being substantially the same as the index of refraction of said thermoset matrix.
An abrasion resistant decorative laminate comprising a core and a single surface lamina positioned thereover, said surface lamina comprising a decor sheet impregnated with a thermoset laminating resin and coated with a protective overlayer consisting essentially of:
- (1) from about 5 to about 30 parts by weight of a particulate mineral selected from the group consisting of alumina, silica and mixtures thereof;
- (2) from about 1 to about 5 parts by weight of an initial binder material selected from the group consisting of microcrystalline cellulose, sodium alginate, carboxy methyl cellulose and mixtures thereof;
- (3) an amount of pre-cured resin particles at least equal to the amount of said particulate mineral up to 6X the amount of said mineral particulate;
- and
- (4) an amount sufficient of said thermoset laminating resin having an index of refraction substantially the same as the index of refraction of said pre-cured resin particles to form a permanent matrix for said particulate mineral and said pre-cured resin particles, said protective overlayer being clear and transparent.
In a decorative consolidated laminate consisting of a rigidity imparting core layer, a decorative paper sheet impregnated with a noble thermoset resin supported on the core layer, and a protective overlayer on the decorative sheet, the decorative sheet being clearly visible through the protective overlayer, the improvement wherein:
- the protective overlayer consists essentially of a thermoset noble resin matrix, particles of pre-cured resin having the same index of refraction as said noble thermoset resin and wherein substantially all of said pre-cured resin particles have a size less than 250 .mu.m, and optionally up to 100 parts by weight per 100 parts of pre-cured resin particles of a finely divided colorless abrasion-resistant mineral particulate material having a Moh hardness of at least 7 and a mean particle size not greater than 50 .mu.m, and when said finely divided abrasion resistant mineral particulate material is present, said protective overlayer also includes an amount sufficient of an initial binder material to retain the mineral particles and pre-cured resin particulates in place on the surface of said decorative paper sheet.
A decor sheet for use in the manufacture of a decorative laminate comprising a sheet of thermosettable resin impregnated paper having a protective overlayer thereon, said protective overlayer being substantially transparent and consisting essentially of pre-cured thermoset resin particles and optionally mineral particles of fine particle size having a Moh hardness of at least 7 in a thermosettable resin matrix, the index of refraction of said pre-cured resin particles being substantially the same as the index of refraction of said thermosettable resin, and optionally an initial binder material.
In a method of making a decorative laminate meeting NEMA abrasion resistant standards comprising assembling a substrate and a decorative upper layer into an assembly, said decorative upper layer being impregnated with a thermosettable resin and having a protective overlayer thereon, and subjecting said assembly to heat and pressure so as to cause flowing and at least partial curing of said thermosettable resin, the improvement wherein:
- said protective overlayer is transparent and consists essentially of a cured thermoset resin formed of pre-cured resin particles and optionally mineral particles of fine particle size having a Moh hardness of at least 7 in a thermosettable resin matrix compatible with the thermosettable resin impregnant of said decorative upper layer, the index of refraction of said pre-cured resin particles being substantially the same as the index of refraction of said thermosettable resin of said matrix in at least partially cured form, and optionally an initial binder material.
In a method of preparing a decor sheet for use in the manufacture of decorative laminates, comprising coating said decor sheet with a protective overlayer and impregnating said decor sheet with a thermosettable resin, the improvement wherein:
- said protective overlayer consists essentially of pre-cured thermoset resin particles and optionally mineral particles of fine particle size having a Moh hardness of at least 7, the index of refraction of said pre-cured resin particles being substantially the same as the index of refraction of said thermosettable resin matrix;
- and when said fine mineral particles are present also an initial binder material.
Dependencies are inferred from the claim text.