# US 5,702,806 A · Decorative laminate surface layer > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 5,702,806 A - Document ID: US5702806A - Status: Granted - Kind: A - Application number: 08/599,705 - Filed: 1996-04-25 - Granted: 1997-12-30 - Earliest claimed: 1991-07-18 - Inventors: Robin D. O'Dell; Joseph Lex - Web page: https://patentgrep.com/patent/US5702806A ## CPC - E04F 13/0871: {having an ornamental or specially shaped visible surface (E04F13/0867 takes precedence)} - B44C 5/0476: {with abrasion resistant properties} - B44C 5/0492: {containing wooden elements} - B44F 1/14: Iridescent effects - Y10T 428/24893: including particulate material - Y10T 428/24901: including coloring matter - Y10T 428/24909: Free metal or mineral containing - Y10T 428/25: Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles - Y10T 428/252: Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.] - Y10T 428/256: Heavy metal or aluminum or compound thereof - Y10T 428/259: Silicic material - Y10T 428/31511: Of epoxy ether - Y10T 428/31551: Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.] - Y10T 428/31862: Melamine-aldehyde - Y10T 428/31935: Ester, halide or nitrile of addition polymer - E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B) - B44C: PRODUCING DECORATIVE EFFECTS (processes for applying liquids or other fluent materials to surfaces, in general B05D; shaping of plastics or substances in a plastic state B29C; printing processes to produce transfer pictures B41M3/12; thermographic duplication or marking methods B41M5/00); MOSAICS; TARSIA WORK (imitation of mosaic or tarsia work patterns B44F11/04); PAPERHANGING {(labels G09F; multi-step processes for making paper labels or tags B31D1/02)} - B44F: SPECIAL DESIGNS OR PICTURES - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A decorative laminate surface layer composition is prepared by selectively applying dissimilar thermoset or thermoplastic polymers to a decorative laminate facing sheet to achieve a brillant visual or pearlescent appearance. ## Claims ### Claim 1 A decorative laminate comprising: a core backing layer serving as a supporting layer; a decorative facing sheet having a first exterior surface laminated to said backing layer and an opposing exterior surface; and a coating including at least two dissimilar resins applied on the opposing exterior surface of said decorative facing sheet prior to laminating said facing sheet to said backing layer, one of said resins being a liquid impregnating resin and another of said resins being a particulate surface coating resin that melts and flows under heat and pressure during lamination to form a laminate surface having an ultra-thin surface layer consisting essentially of the surface coating resin and having one or more of the following properties, enhanced wearability, chemical, thermal, ultraviolet radiation resistance or abrasion resistance. ### Claim 2 (depends on 1) A decorative laminate in accordance with claim 1, wherein said surface coating resin is selected from the group consisting essentially of polyester, polyurethane, epoxy, polyvinyl chloride, acrylic, and mixtures of two or more of the foregoing. ### Claim 3 (depends on 1) A decorative laminate in accordance with claim 1, wherein the impregnating resin is a liquid melamine resin. ### Claim 4 (depends on 1) A decorative laminate in accordance with claim 1, wherein said coating further includes a mixture of an abrasion resistant hard mineral having a particle size of between about 1-200 microns in a concentration sufficient to provide abrasion resistance without interfering with visibility. ### Claim 5 (depends on 4) A decorative laminate in accordance with claim 4, wherein said abrasion resistant hard mineral is selected from the group consisting essentially of alumina, silica, zirconium oxide, cerium oxide, glass beads, diamond dust and mixtures of two or more of the foregoing. ### Claim 6 (depends on 4) A decorative laminate in accordance with claim 4, wherein said abrasion resistant mineral is alumina and wherein said alumina is chemically bound to said impregnating resin with silane. ### Claim 7 A decorative laminate comprising: a core backing layer; a decorative facing sheet having a first exterior surface laminated to said backing layer and having a pearlescent ink on a second exterior surface; and a coating including at least two dissimilar resins applied on the second exterior surface of said decorative facing sheet prior to laminating said facing sheet to said backing layer, one of said resins being a liquid impregnating resin and another of said resins being a particulate surface coating resin that melts and flows under heat and pressure during lamination, to form a laminate surface having an ultra-thin surface layer consisting essentially of the surface coating resin, said surface coating resin having a refractive index in the cured laminate dissimilar from the refractive index of the pearlescent ink on the facing sheet to form a laminate having a pearlescent appearance. ### Claim 8 (depends on 7) A decorative laminate in accordance with claim 7, wherein said surface coating resin is selected from the group consisting essentially of polyester, polyurethane, epoxy, polyvinyl chloride, acrylic, and mixtures of two or more of the foregoing. ### Claim 9 (depends on 7) A decorative laminate in accordance with claim 7, wherein the impregnating resin is a liquid melamine resin. ### Claim 10 (depends on 7) A decorative laminate in accordance with claim 7, wherein said coating further includes a mixture of an abrasion resistant hard mineral having a particle size of between about 1-200 microns in a concentration sufficient to provide abrasion resistance without interfering with visibility. ### Claim 11 (depends on 10) A decorative laminate in accordance with claim 10, wherein said abrasion resistant hard mineral is selected from the group consisting essentially of alumina, silica, zirconium oxide, cerium oxide, glass beads, diamond dust and mixtures of two or more of the foregoing. ### Claim 12 (depends on 10) A decorative laminate in accordance with claim 10, wherein said abrasion resistant mineral is alumina and wherein said alumina is chemically bound to said impregnating resin with a silane. ### Claim 13 A decorative laminate sheet for use in the preparation of decorative laminates, comprising: a decorative facing sheet, and a coating applied to said facing sheet, said coating including at least two dissimilar resins, one of said resins being a liquid impregnating resin and another of said resins being a particulate surface coating resin that melts and flows under heat and pressure applied to the decorative facing sheet to form a decorative laminate sheet having an ultra-thin surface layer consisting essentially of the surface coating resin and having one or more of the following properties, enhanced wearability, chemical, thermal, ultra-violet radiation resistance or abrasion resistance. ### Claim 14 (depends on 13) A decorative laminate sheet in accordance with claim 13, wherein said surface coating resin is selected from the group consisting essentially of polyester, polyurethane, epoxy, polyvinyl chloride, acrylic, and mixtures of two or more of the foregoing. ### Claim 15 (depends on 13) A decorative laminate sheet in accordance with claim 13, wherein said surface coating further includes a mixture of an abrasion resistant hard mineral having a particle size of between about 1-200 microns in a concentration sufficient to provide abrasion resistance without interfering with visibility. ### Claim 16 (depends on 15) A decorative laminate sheet in accordance with claim 15, wherein said abrasion resistant hard mineral is selected from the group consisting essentially of alumina, silica, zirconium oxide, cerium oxide, glass beads, diamond dust and mixtures of two or more of the foregoing. ### Claim 17 (depends on 15) A decorative laminate sheet in accordance with claim 15, wherein said abrasion resistant mineral is alumina and wherein said alumina is chemically bound to said impregnating resin with silane. ### Claim 18 (depends on 13) A decorative facing sheet in accordance with claim 13, wherein the impregnating resin is a liquid melamine resin. ### Claim 19 (depends on 13) A decorative laminate produced from the decorative laminate sheet of claim 13, wherein the decorative laminate sheet is laminated to a backing layer under heat and pressure.