# US 7,745,012 B2 · Leather decorative laminate

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- Number: US 7,745,012 B2
- Document ID: US7745012B2
- Status: Granted
- Kind: B2
- Application number: 10/762,103
- Filed: 2004-01-20
- Published: 2004-08-05
- Granted: 2010-06-29
- Earliest claimed: 2003-01-22
- Assignees: Panolam Industries International, Inc.
- Inventors: Sylvie Gauthier; George Tsangarides
- Web page: https://patentgrep.com/patent/US7745012B2

## CPC

- B32B 9/025: {comprising leather}
- B32B 7/06: permitting easy separation
- B32B 9/045: {of synthetic resin}
- B32B 9/06: of paper or cardboard
- B32B 27/28: comprising synthetic resins not wholly covered by any one of the sub-groups {B32B27/30 - B32B27/42}
- B32B 37/00: Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B 37/10: characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- B32B 38/06: Embossing
- C14B 1/56: Ornamenting, producing designs, embossing (pressing or rolling in general C14B1/30; producing design on furs C14B15/12)
- C14B 7/02: Composite leathers (with one or more laminae of plastics material B32B)
- C14C 13/00: Manufacture of special kinds or leather, e.g. vellum (chamois tanning C14C3/14)
- B32B 2037/268: {Release layers}
- B32B 2038/0076: {Curing, vulcanising, cross-linking}
- B32B 2260/028: Paper layer
- B32B 2260/046: Synthetic resin
- B32B 2309/02: Temperature
- B32B 2309/022: Temperature vs pressure profiles
- B32B 2309/04: Time
- B32B 2309/12: Pressure
- B32B 2309/14: Velocity, e.g. feed speeds
- B32B 2317/08: Natural leather
- B32B 2317/125: impregnated with thermosetting resin
- B32B 2451/00: Decorative or ornamental articles
- Y10T 428/31993: Of paper
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C14B: MECHANICAL TREATMENT OR PROCESSING OF SKINS, HIDES OR LEATHER IN GENERAL; PELT-SHEARING MACHINES; INTESTINE-SPLITTING MACHINES (making leather substitutes B29, D06N; making articles from leather B68F; mechanical cleaning of hides or the like D06G; artificial leather D06N)
- C14C: CHEMICAL TREATMENT OF HIDES, SKINS OR LEATHER, e.g. TANNING, IMPREGNATING, FINISHING; APPARATUS THEREFOR; COMPOSITIONS FOR TANNING (bleaching of leather or furs D06L; dyeing of leather or furs D06P)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A heat and pressure consolidated laminate, and a method for manufacturing the same, is provided that includes in superimposed relationship a core layer containing a plurality of cellulosic sheets impregnated with a thermosetting resin, and a decorative layer consisting essentially of a leather material.

## Claims

### Claim 1

A heat and pressure consolidated laminate, comprising in superimposed relationship:
a core layer containing at least one cellulosic sheet impregnated with a thermosetting resin;
a first decorative layer consisting essentially of leather; and
a bond formed from the thermosetting resin, which bond consolidates the layers together within the laminate.

### Claim 2 (depends on 1)

The laminate of claim 1 wherein said thermosetting resin is a phenol-formaldehyde resin.

### Claim 3 (depends on 1)

The laminate of claim 1, wherein said first decorative layer is bonded leather having a sheet thickness ranging from about 0.2 mm to about 4.0 mm.

### Claim 4 (depends on 1)

The laminate of claim 1, further comprising an overlay layer disposed on a side of said decorative layer opposite said core layer.

### Claim 5 (depends on 1)

The laminate of claim 1, further comprising a second decorative layer, disposed on the side of the core layer opposite the first decorative layer, said second decorative layer consisting essentially of leather.

### Claim 6 (depends on 1)

The laminate of claim 1, further comprising a backer layer of at least one cellulosic sheet impregnated with a thermosetting resin, said backer layer being disposed on the side of the core layer opposite the decorative layer.

### Claim 7

A heat and pressure consolidated laminate, comprising in superimposed relationship:
a core layer containing at least one cellulosic sheet impregnated with a thermosetting phenol-formaldehyde resin, said cellulosic sheet having a resin content ranging from about 25 percent to about 35 percent;
a first decorative layer consisting essentially of a bonded leather having a sheet thickness ranging from about 0.2 mm to about 4.0 mm; and
an overlay layer disposed on a side of said first decorative layer opposite the core layer, said overlay layer being at least one sheet of alpha cellulose paper impregnated with a melamine formaldehyde resin.

### Claim 8 (depends on 7)

The laminate of claim 7, further comprising a second decorative layer disposed on the side of the core layer opposite the first decorative layer.

### Claim 9 (depends on 8)

The laminate of claim 8, where the second decorative layer consists essentially of a leather material.

### Claim 10 (depends on 7)

The laminate of claim 7, further comprising a backer layer disposed on the side of the core layer opposite the first decorative layer.

### Claim 11 (depends on 10)

The laminate of claim 10, where the backer layer comprises at least one cellulosic sheet impregnated with a thermosetting resin.

### Claim 12

A heat and pressure consolidated laminate, comprising in superimposed relationship:
a core layer containing at least one cellulosic sheet impregnated with a thermosetting phenol-formaldehyde resin, the cellulosic sheet having a resin content ranging from about 25 percent to about 35 percent;
a first decorative layer consisting essentially of leather, the first decorative layer having a sheet thickness ranging from about 0.2 mm to about 4.0 mm; and
a bond formed from the thermosetting resin, which bond consolidates the layers together within the laminate.

### Claim 13 (depends on 12)

The laminate of claim 12, further comprising an overlay layer disposed on a side of the first decorative layer opposite the core layer.

### Claim 14 (depends on 13)

The laminate of claim 13, where the overlay layer comprises at least one sheet of alpha cellulose paper impregnated with a melamine formaldehyde resin.

### Claim 15 (depends on 12)

The laminate of claim 12, further comprising a second decorative layer disposed on the side of the core layer opposite the first decorative layer.

### Claim 16 (depends on 15)

The laminate of claim 15, where the second decorative layer consists essentially of leather.

### Claim 17 (depends on 12)

The laminate of claim 12, further comprising a backer layer disposed on the side of the core layer opposite the first decorative layer.

### Claim 18 (depends on 17)

The laminate of claim 17, where the backer layer comprises at least one cellulosic sheet impregnated with a thermosetting resin.

### Claim 19

A heat and pressure consolidated laminate, comprising in superimposed relationship:
a core layer containing at least one cellulosic sheet impregnated with a thermosetting resin;
a first decorative layer consisting essentially of a leather animal hide; and
a bond formed from the thermosetting resin, which bond consolidates the layers together within the laminate.

### Claim 20 (depends on 19)

The laminate of claim 19, further comprising a second decorative layer, disposed on the side of the core layer opposite the first decorative layer, said second decorative layer consisting essentially of a leather animal hide.

### Claim 21 (depends on 19)

The laminate of claim 19, further comprising a backer layer of at least one cellulosic sheet impregnated with a thermosetting resin, said backer layer being disposed on the side of the core layer opposite the decorative layer.

### Claim 22

A heat and pressure consolidated laminate, comprising in superimposed relationship:
a core layer containing at least one cellulosic sheet impregnated with a thermosetting phenol-formaldehyde resin;
a first decorative layer consisting essentially of a bonded leather animal hide;
an overlay layer disposed on a side of said first decorative layer opposite the core layer; and
a bond formed from the thermosetting resin, which bond consolidates the layers together within the laminate.

### Claim 23 (depends on 22)

The laminate of claim 22, further comprising a second decorative layer disposed on the side of the core layer opposite the first decorative layer, and wherein the second decorative layer consists essentially of a leather animal hide.