Process for the manufacturing of an improved core for decorative laminates and a decorative laminate obtained by the process

Abstract

A process for the manufacturing of a board, used as a core, forming a carrying structure for decorative laminates. Particles are achieved by grinding cured, and possibly foamed, rigid, polyurethane, polyisocyanurate and/or phenolic resin so that it passes through a 2 mm screen, preferably a 1 mm screen. The particles are allowed to absorb a selected amount of water in the range 1-7% by weight, 85 parts per weight of particles is mixed with 2-15 parts per weight of a bonding agent, the bonding agent selected from the group consisting of, a) a mixture of polyols, such as polyester or polyether, crude methylene diphenyl diisocyanate, or, b) a formaldehyde based resin such as phenol-formaldehyde resin, ureaformaldehyde resin, melamine-urea-formaldehyde resin, melamine-urea phenol-formaldehyde resin or phenol-resorcinol-formaldehyde resin, or c) polyvinyl acetate resin, and that, the mixture is applied in a press, possibly with at least one intermediate carrier web, whereby a slightly porous and preconditioned core with a selected water content in the range 0.8-6.5% by weight is achieved. The invention also relates to a decorative laminate achieved through the process.

Dependencies are inferred from the claim text.