Fiber-Reinforced Impact Resistant Laminated Panel

• US 20130177750A1
• Filed: 01/11/2013
• Published: 07/11/2013
• Est. Priority Date: 01/11/2012
• Status: Abandoned Application

• Current Assignee: Panolam Industries International Incorporated (Genstar Capital LLC)
• Original Assignee: Panolam Industries International Incorporated (Genstar Capital LLC)
• Inventors: Canary, Stephen
• Application Number:
  US13/739,757
• Publication Number:
  US 20130177750A1
• Time in Patent Office: Days
• US Class Current: 428/212
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles
• CPC Class Codes: B32B 2479/00 Furniture
• CPC Class Codes: B32B 29/005 next to another layer of paper or cardboard layer
• CPC Class Codes: B32B 29/02 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 7/02 Physical, chemical or physicochemical properties
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/31971 Of carbohydrate
• CPC Class Codes: Y10T 442/30 Woven fabric [i.e., woven strand or strip material]

Abstract

An impact resistant laminated panel and a method for making the same is provided. The panel includes in stacked order: a first side overlay layer, a decorative layer, a first side fiber-reinforced layer, a core layer, a second side fiber-reinforced layer, and a base layer. The decorative layer has at least one appearance sheet and at least one flattening sheet. The flattening sheet is disposed between the appearance sheet and the first side fiber-reinforced layer. The decorative layer has a sufficient mass to prevent the formation of surface flatness and/or appearance variations in the outer surface of the first side overlay layer, which variations are attributable to the first side fiber-reinforced sheet.

Claims

1. An impact resistant laminated panel consolidated at elevated temperature and pressure, which laminated panel comprises in stacked order:

a first side overlay layer, having an outer surface;

a decorative layer;

a first side fiber-reinforced layer, having a textured outer surface that is contiguous with the decorative layer, which fiber-reinforced layer includes at least one fiber-reinforced sheet, which is substantially devoid of cellulose;

wherein the decorative layer has at least one appearance sheet and at least one flattening sheet, which flattening sheet is disposed between the appearance sheet and the first side fiber-reinforced layer, and which decorative layer has a sufficient mass to prevent the formation of surface flatness variations in the outer surface of the first side overlay layer, which flatness variations are attributable to the first side fiber-reinforced sheet and are perceivable by one or both of unaided human eye or touch;

a core layer comprising a plurality of cellulosic sheets;

a second side fiber-reinforced layer; and

a base layer.

2. The laminated panel of claim 1, wherein the first side fiber-reinforced layer includes one or more sheets of woven fiberglass having a basis weight in the range of 170-210 g/m².

3. The laminated panel of claim 2, wherein the first side fiber-reinforced layer includes one or more sheets of woven fiberglass having a basis weight of about 190 g/m².

4. The laminated panel of claim 2, wherein each sheet of woven fiberglass has a phenolic resin content of about 40% of a dry treated basis weight of the sheet.

5. The laminated panel of claim 2, wherein the cellulosic sheets of the core layer comprise kraft paper having a basis weight in the range of 240-260 g/m².

6. A method of producing an impact resistant laminated panel, the method comprising the steps of:

stacking in a superimposed order a first side overlay layer, having an outer surface, a decorative layer, a first side fiber-reinforced layer, having a textured outer surface that is contiguous with the decorative layer, which first-side fiber-reinforced layer includes at least one fiber-reinforced sheet, which is substantially devoid of cellulose, and wherein the decorative layer has at least one appearance sheet and at least one flattening sheet, which flattening sheet is disposed between the appearance sheet and the first side fiber-reinforced layer, and which decorative layer has a sufficient mass to prevent the formation of one or both of surface flatness variations and surface appearance variations in the outer surface of the first side overlay layer, which variations are attributable to the first side fiber-reinforced sheet and are perceivable by one or both of unaided human eye or touch, a core layer comprising a plurality of cellulosic sheets, a second side fiber-reinforced layer, and a base layer; and

simultaneously curing, under heat and pressure, the first side overlay layer, the decorative layer, the first side fiber-reinforced layer, the core layer, the second side fiber-reinforced layer, and the base layer to produce the laminated panel.

7. The method of claim 6, wherein the first side fiber-reinforced layer includes one or more sheets of woven fiberglass having a basis weight in the range of 170-210 g/m².

8. The method of claim 7, wherein the first side fiber-reinforced layer includes one or more sheets of woven fiberglass having a basis weight of about 190 g/m².

9. The method of claim 7, wherein each sheet of woven fiberglass has a phenolic resin content of about 40% of a dry treated basis weight of the sheet.

10. The method of claim 7, wherein the cellulosic sheets of the core layer comprise kraft paper having a basis weight in the range of 240-260 g/m².