Process for producing aesthetic surface layer composition and aesthetic surface layer

A method for providing a decorative laminate sheet suitable for use as the surface layer of a decorative laminate, said decorative sheet having an ultra-thin surface coating consisting essentially of a surface coating laminating resin that melts and flows under heat and pressure and said decorative sheet being impregnated with an impregnating laminating resin, the method comprising:

• preparing a surface coating dispersion of at least one particulate surface coating resin that melts and flows under heat and pressure, said resin being suspended in a diluent with a suitable binding material that is compatible with said impregnating resin and capable of withstanding subsequent laminating conditions and said surface coating resin being dissimilar from said impregnating resin;
• coating an exterior surface of a decorative sheet with said dispersion, such that a surface coating layer of said surface coating resin is provided in an amount of from about one pound to about ten pounds per ream of the decorative sheet;
• drying said dispersion coating in a manner such that said surface coating resin is bound to the exterior surface of said decorative sheet;
• saturating the coated decorative sheet with an impregnating resin;
• and
• pressing said coated and impregnated decorative sheet to form a decorative laminate sheet having an ultra-thin surface coating consisting essentially of the surface coating resin.