Abrasion-resistant laminate
First Claim
Patent Images
1. A decorative sheet for use in the preparation of decorative laminates of high abrasion resistance, comprising:
- a decorative paper sheet substrate, and an ultra-thin abrasion resistant porous coating over said decorative substrate, said ultra-thin abrasion resistant coating comprising a mixture of (1) an abrasion resistant hard mineral of particle size 20-50 microns in high concentration sufficient to provide an abrasion resistant layer without interfering with visibility and (2) binder material for said mineral compatible with a thermosetting laminating resin selected from the group consisting of melamine-formaldehyde resin and polyester resin, and being impregnable with said laminating resin, said binder material being present in an amount sufficient to bind and stabilize said abrasion resistant mineral to the surface of said paper sheet.
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Abstract
An abrasion-resistant laminate is prepared by providing an ultra thin coating of mineral particles and micro crystalline cellulose on the surface of conventional printed paper, followed by impregnating the paper with a conventional laminating resin, and then using the print paper so obtained in a laminating process without the necessity of using an overlay sheet.
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Citations
15 Claims
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1. A decorative sheet for use in the preparation of decorative laminates of high abrasion resistance, comprising:
- a decorative paper sheet substrate, and an ultra-thin abrasion resistant porous coating over said decorative substrate, said ultra-thin abrasion resistant coating comprising a mixture of (1) an abrasion resistant hard mineral of particle size 20-50 microns in high concentration sufficient to provide an abrasion resistant layer without interfering with visibility and (2) binder material for said mineral compatible with a thermosetting laminating resin selected from the group consisting of melamine-formaldehyde resin and polyester resin, and being impregnable with said laminating resin, said binder material being present in an amount sufficient to bind and stabilize said abrasion resistant mineral to the surface of said paper sheet.
- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method of producing a decorative sheet for use in the manufacture of decorative laminates, comprising:
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providing a substrate sheet having a decorative appearance and formed of a porous material; coating said decorative sheet with an ultrathin wet layer of a mixture of (1) an abrasion resistant hard mineral of particle size 20-50 microns in quantities sufficient to provide an abrasion resistant layer without interfering with visibility, and (2) binder material for said mineral, which binder material has the properties of being capable of withstanding heat and pressure, and being compatible with a thermosettable resin, said binder being present in an amount sufficient to bind said abrasion resistant mineral to the surface of said decorative sheet, and the binder-mineral layer in the dry state being permeable to said thermosettable resin; drying said coated binder coated material mixture at a temperature sufficient to enhance the bonding of said abrasion resistant mineral by said binder material to said decorative sheet, to provide a porous, ultra-thin, dry layer of said binder-mineral mixture thereon. - View Dependent Claims (14)
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15. Process for the production of a decorative paper sheet having an enhanced abrasion-resistant surface, using abrasion-resistant, finely particled, mineral material and binder, the improvement wherein a wet, thin layer of a mixture of the abrasion-resistant, finely particled mineral and a binder material thereof, which in a dry state is permeable to thermosetting paper impregnating resin, is compatible therewith and is stable under impregnating and laminating conditions, is coated on the paper sheet and the sheet is dried.
Specification