Method for forming an abrasion resistant laminate

Abstract

Abrasion resistant laminates which are aesthetically pleasing, water-resistant/water-repellant, and flexible are formed by laminating a wear-resistant durable multi-layer top assembly to a base layer formed from an inexpensive, water resistant, polymeric substrate. The durable multi-layer wear-resistant top layer assembly comprises a wear resistant upper layer, a decorative layer, and a core layer. The polymeric base layer comprises a water resistant substrate which is positioned beneath the top layer assembly and is laminated thereto with a water resistant adhesive. This abrasion resistant laminate could be applicable in a variety of situations wherever a decorative and/or abrasion resistant product could be used and would be particularly useful in the floor covering industry.

I claim:  
     
         1 . An abrasion resistant laminate comprising: 
 (a) a durable wear-resistant top layer assembly comprising the following layers: 
 a wear resistant upper layer;  
 a decorative layer; and  
 a core layer;  
   (b) a polymeric substrate for forming a base layer for said abrasion resistant laminate, said base layer being positioned beneath said top layer assembly; and    (c) a water resistant adhesive layer positioned between said top layer assembly and said base layer for adhering said assembly to said base layer to form said abrasion resistant laminate.    
     
     
         2 . An abrasion resistant laminate as recited in  claim 1  wherein said durable wear-resistant top layer assembly comprises a high pressure laminate which is formed by curing and laminating the layers of the top layer assembly under heat and high pressure prior to laminating the top layer assembly to the base layer to form said abrasion resistant laminate.  
     
     
         3 . An abrasion resistant laminate as recited in  claim 1  wherein said durable wear-resistant top layer assembly comprises a low pressure laminate which is formed by curing and laminating the layers of the top layer assembly under heat and low pressure prior to laminating the top layer assembly to the base layer to form said abrasion resistant laminate.  
     
     
         4 . An abrasion resistant laminate as recited in  claim 1  wherein said abrasion resistant laminate is a low pressure laminate which is formed by laying up the top layer assembly, the adhesive layer, and the base layer into a stack and curing and laminating the stack in a single step by the application of heat and pressure to form said abrasion resistant laminate.  
     
     
         5 . An abrasion resistant laminate as recited in  claim 1  wherein said wear resistant upper layer comprises an overlay layer comprising a sheet formed from a resin impregnated paper sheet having abrasion resistant particles coated thereon or dispersed throughout said paper sheet.  
     
     
         6 . An abrasion resistant laminate as recited in  claim 1  wherein said wear resistant upper layer comprises a coating of abrasive material applied directly to a decorative layer or dispersed throughout said decorative layer.  
     
     
         7 . An abrasion resistant laminate as recited in  claim 1  wherein said decorative layer is impregnated with a thermosetting resin in an amount equal to approximately 0-40% based upon the weight of the paper.  
     
     
         8 . An abrasion resistant laminate as recited in  claim 1  wherein said decorative layer is impregnated with a thermosetting resin in an amount equal to approximately 0-30% based upon the weight of the paper.  
     
     
         9 . An abrasion resistant laminate as recited in  claim 1  wherein said core layer comprises at least two sheets of resin impregnated paper.  
     
     
         10 . An abrasion resistant laminate as recited in  claim 1  wherein said core layer comprises at least one layer of a woven or nonwoven sheet formed from a material selected from the group consisting of fiberglass, polypropylene, polyester, nylon, and carbon fiber.  
     
     
         11 . An abrasion resistant laminate as recited in  claim 10  wherein said layer of a woven or nonwoven sheet is placed between the resin impregnated sheets recited in  claim 9 .  
     
     
         12 . An abrasion resistant laminate as recited in  claim 10  wherein said core layer includes a fiberglass layer having a basis weight of 25-60 g/m 2 .  
     
     
         13 . An abrasion resistant laminate as recited in  claim 1  wherein said polymeric substrate comprises a flexible waterproof material selected from the group consisting of vinyls, urethanes, polyolefins, polyesters, synthetic rubber, and natural rubber.  
     
     
         14 . An abrasion resistant laminate as recited in  claim 1  wherein said polymeric substrate comprises recycled polymeric material.  
     
     
         15 . An abrasion resistant laminate as recited in  claim 1  wherein said adhesive layer comprises an adhesive which is compatible with the core layer and the base layer.  
     
     
         16 . An abrasion resistant laminate as recited in  claim 1  wherein said adhesive layer comprises a film adhesive or a coating of adhesive.  
     
     
         17 . An abrasion resistant laminate as recited in  claim 1  wherein a balance sheet is laminated to a bottom surface of said base layer.  
     
     
         18 . An abrasion resistant laminate as recited in  claim 17  wherein said balance sheet comprises resin treated paper, polyvinyl chloride treated glass fiber, nonwoven fabric, soft polyvinyl chloride, or virgin polyvinyl chloride.  
     
     
         19 . An abrasion resistant laminate as recited in  claim 18  wherein said balance sheet comprises a virgin polyvinyl chloride sheet.  
     
     
         20 . An abrasion resistant laminate as recited in  claim 1  wherein said abrasion resistant laminate is a floor covering.  
     
     
         21 . An abrasion resistant laminate comprising: 
 (a) a durable wear-resistant top layer assembly comprising the following layers: 
 a wear resistant upper layer;  
 a decorative layer; and  
 a core layer;  
   (b) a base layer positioned beneath said top layer assembly, said base layer comprising a polymeric substrate formed from recycled polymeric material;    (c) a water resistant adhesive layer positioned between said top layer assembly and said base layer for adhering said assembly to said base layer; and    (d) a balance layer adhered to a bottom surface of said base layer.    
     
     
         22 . An abrasion resistant laminate as recited in  claim 21  wherein said balance sheet comprises resin treated paper, polyvinyl chloride treated glass fiber, nonwoven fabric, soft polyvinyl chloride, or virgin polyvinyl chloride.  
     
     
         23 . An abrasion resistant laminate as recited in  claim 21  wherein said recycled polymeric material comprises a recycled polyvinyl chloride material and said balance layer comprises a virgin polyvinyl chloride layer.  
     
     
         24 . An abrasion resistant laminate as recited in  claim 21  wherein said core layer comprises at least two sheets of resin impregnated paper.  
     
     
         25 . An abrasion resistant laminate as recited in  claim 21  wherein said core layer comprises at least one layer of a woven or nonwoven sheet formed from a material selected from the group consisting of fiberglass, polypropylene, polyester, nylon, and carbon fiber.  
     
     
         26 . An abrasion resistant laminate as recited in  claim 25  wherein said layer of a woven or nonwoven sheet is placed between the resin impregnated sheets recited in  claim 24 .  
     
     
         27 . An abrasion resistant laminate as recited in  claim 25  wherein said core layer includes a fiberglass layer having a basis weight of 25-60 g/m 2 .  
     
     
         28 . A method for forming an abrasion resistant laminate comprising: 
 (a) providing a durable wear-resistant top layer laminate comprising the following layers: 
 a wear resistant upper layer;  
 a decorative layer; and  
 a core layer;  
   (b) curing said top layer laminate under heat and pressure to form a top layer laminate;    (c) providing a polymeric substrate base layer and positioning said base layer beneath said top layer laminate;    (d) providing a water resistant adhesive layer for placement between said top layer laminate and said base layer; and    (e) adhering said base layer to said top layer laminate to form said abrasion resistant laminate.    
     
     
         29 . A method for forming an abrasion resistant laminate as recited in  claim 28  wherein said top layer laminate is formed by applying heat and high pressure to form a high pressure laminate.  
     
     
         30 . A method for forming an abrasion resistant laminate as recited in  claim 28  wherein said top layer laminate is formed by applying heat and low pressure to form a low pressure laminate.  
     
     
         31 . A method for forming an abrasion resistant laminate as recited in  claim 28  wherein said wear resistant upper layer comprises an overlay layer comprising a sheet formed from a resin impregnated paper sheet having abrasion resistant particles coated thereon or dispersed throughout said paper sheet.  
     
     
         32 . A method for forming an abrasion resistant laminate as recited in  claim 28  wherein said wear resistant upper layer comprises a coating of abrasive material applied directly to said decorative layer or dispersed throughout said decorative layer.  
     
     
         33 . A method for forming an abrasion resistant laminate as recited in  claim 28  wherein said decorative layer is impregnated with a thermosetting resin in an amount equal to approximately 0-40% based upon the weight of the paper.  
     
     
         34 . A method for forming an abrasion resistant laminate as recited in  claim 28  wherein said decorative layer is impregnated with a thermosetting resin in an amount equal to approximately 0-30% based upon the weight of the paper.  
     
     
         35 . A method for forming an abrasion resistant laminate as recited in  claim 28  wherein said core layer comprises at least two sheets of resin impregnated paper.  
     
     
         36 . A method for forming an abrasion resistant laminate as recited in  claim 28  wherein said core layer includes at least one layer of a woven or nonwoven sheet formed from a material selected from the group consisting of fiberglass, polypropylene, polyester, nylon, and carbon fiber.  
     
     
         37 . A method for forming an abrasion resistant laminate as recited in  claim 36  wherein said layer of a woven or nonwoven sheet is placed between the resin impregnated sheets recited in  claim 35 .  
     
     
         38 . A method for forming an abrasion resistant laminate as recited in  claim 36  wherein said core layer includes a fiberglass layer having a basis weight of 25-60 g/m 2 .  
     
     
         39 . A method for forming an abrasion resistant laminate as recited in  claim 28  wherein said substrate comprises a flexible waterproof material selected from the group consisting of vinyls, urethanes, polyolefins, polyesters, synthetic rubber and natural rubber.  
     
     
         40 . A method for forming an abrasion resistant laminate as recited in  claim 28  wherein said substrate comprises recycled polymeric material.  
     
     
         41 . A method for forming an abrasion resistant laminate as recited in  claim 28  wherein said adhesive layer comprises an adhesive which is compatible with the core layer and the base layer.  
     
     
         42 . A method for forming an abrasion resistant laminate as recited in  claim 28  wherein said adhesive layer comprises a film adhesive or a coating of adhesive.  
     
     
         43 . A method for forming an abrasion resistant laminate as recited in  claim 28  wherein a balance sheet is laminated to a bottom surface of said base layer.  
     
     
         44 . A method for forming an abrasion resistant laminate as recited in  claim 43  wherein said balance sheet comprises resin treated paper, polyvinyl chloride treated glass fiber, nonwoven fabric, soft polyvinyl chloride, or virgin polyvinyl chloride.  
     
     
         45 . A method for forming an abrasion resistant laminate as recited in  claim 44  wherein said balance sheet comprises a virgin polyvinyl chloride sheet.  
     
     
         46 . A method for forming an abrasion resistant laminate as recited in  claim 28  wherein said abrasion resistant laminate is a floor covering.  
     
     
         47 . A method for forming an abrasion resistant laminate comprising: 
 (a) providing a durable wear-resistant top layer laminate comprising the following layers: 
 a wear resistant upper layer;  
 a decorative layer; and  
 a core layer;  
   (b) curing said top layer laminate under heat and pressure to form a top layer laminate;    (c) providing a polymeric substrate base layer comprised of a recycled polymeric material and positioning said base layer beneath said top layer laminate;    (d) providing a water resistant adhesive layer for placement between said top layer laminate and said base layer;    (e) adhering said base layer to said top layer laminate with said water resistant adhesive layer;    (f) providing a balance layer; and    (g) adhering said balance layer to a bottom surface of said base layer.    
     
     
         48 . A method for forming an abrasion resistant laminate as recited in  claim 47  wherein said recycled polymeric material comprises recycled polyvinyl chloride and said balance layer comprises virgin polyvinyl chloride.  
     
     
         49 . A method for forming an abrasion resistant laminate as recited in  claim 47  wherein said core layer comprises at least two sheets of resin impregnated paper.  
     
     
         50 . A method for forming an abrasion resistant laminate as recited in  claim 47  wherein said core layer comprises at least one layer of a woven or nonwoven sheet formed from a material selected from the group consisting of fiberglass, polypropylene, polyester, nylon, and carbon fiber.  
     
     
         51 . A method for forming an abrasion resistant laminate as recited in  claim 50  wherein said layer of a woven or nonwoven sheet is placed between the resin impregnated sheets recited in  claim 49 .  
     
     
         52 . A method for forming an abrasion resistant laminate as recited in  claim 50  wherein said core layer includes a fiberglass layer having a basis weight of 25-60 g/m 2 .  
     
     
         53 . A method for forming an abrasion resistant laminate comprising: 
 (a) providing a durable wear-resistant top layer assembly comprising the following layers: 
 a wear resistant upper layer;  
 a decorative layer; and  
 a core layer;  
   (b) providing a polymeric substrate base layer and positioning said base layer beneath said wear-resistant top layer assembly;    (c) providing a water resistant adhesive layer and placing said adhesive layer between said top surface assembly and said base layer;    (d) applying heat and pressure to cure and laminate said layers in said top surface assembly and to laminate the assembly to said base layer to form said abrasion resistant laminate.    
     
     
         54 . A method for forming an abrasion resistant laminate as recited in  claim 53  wherein said wear resistant upper layer comprises an overlay layer comprising a sheet formed from a resin impregnated paper sheet having abrasion resistant particles coated thereon or dispersed throughout said paper sheet.  
     
     
         55 . A method for forming an abrasion resistant laminate as recited in  claim 53  wherein said wear resistant upper layer comprises a coating of abrasive material applied directly to said decorative layer or dispersed throughout said decorative layer.  
     
     
         56 . A method for forming an abrasion resistant laminate as recited in  claim 53  wherein said decorative layer is impregnated with thermosetting resin in an amount equal to approximately 0-40% based upon the weight of the paper.  
     
     
         57 . A method for forming an abrasion resistant laminate as recited in  claim 53  wherein said decorative layer is impregnated with thermosetting resin in an amount equal to approximately 0-30% based upon the weight of the paper.  
     
     
         58 . A method for forming an abrasion resistant laminate as recited in  claim 53  wherein said core layer comprises at least two sheets of resin impregnated paper.  
     
     
         59 . A method for forming an abrasion resistant laminate as recited in  claim 53  wherein said core layer comprises at least one layer of a woven or nonwoven sheet formed from a material selected from the group consisting of fiberglass, polypropylene, polyester, nylon, and carbon fiber.  
     
     
         60 . A method for forming an abrasion resistant laminate as recited in  claim 59  wherein said layer of a woven or nonwoven sheet is placed between the resin impregnated sheets recited in  claim 58 .  
     
     
         61 . A method for forming an abrasion resistant laminate as recited in  claim 59  wherein said core layer includes a fiberglass layer having a basis weight of 25-60 g/m 2 .  
     
     
         62 . A method for forming an abrasion resistant laminate as recited in  claim 53  wherein said substrate comprises a flexible waterproof material selected from the group consisting of vinyls, urethanes, polyolefins, polyesters, synthetic rubber, and natural rubber.  
     
     
         63 . A method for forming an abrasion resistant laminate as recited in  claim 53  wherein said substrate comprises recycled polymeric material.  
     
     
         64 . A method for forming an abrasion resistant laminate as recited in  claim 53  wherein said adhesive layer comprises an adhesive which is compatible with the core layer and the base layer.  
     
     
         65 . A method for forming an abrasion resistant laminate as recited in  claim 53  wherein said adhesive layer comprises a film adhesive or a coating of adhesive.  
     
     
         66 . A method for forming an abrasion resistant laminate as recited in  claim 53  wherein a balance sheet is laminated to a bottom surface of said base layer.  
     
     
         67 . A method for forming an abrasion resistant laminate as recited in  claim 66  wherein said balance sheet comprises resin treated paper, polyvinyl chloride treated glass fiber, nonwoven fabric, soft polyvinyl chloride, or virgin polyvinyl chloride.  
     
     
         68 . A method for forming an abrasion resistant laminate as recited in  claim 67  wherein said balance sheet comprises a virgin polyvinyl chloride sheet.  
     
     
         69 . A method for forming an abrasion resistant laminate as recited in  claim 53  wherein said abrasion resistant laminate is a floor covering.  
     
     
         70 . A method for forming an abrasion resistant laminate comprising: 
 (a) providing a durable wear-resistant top layer assembly comprising the following layers: 
 a wear resistant upper layer;  
 a decorative layer; and  
 a core layer;  
   (b) providing a polymeric substrate base layer comprised of a recycled polymeric material and positioning said base layer beneath said top layer laminate;    (c) providing a water resistant adhesive layer and placing said adhesive layer between said top surface assembly and said base layer;    (d) providing a balance layer and placing said balance layer beneath said base layer    (e) applying heat and pressure to cure and laminate said layers in said top surface assembly and to laminate the assembly, base layer, and balance layer together to form said abrasion resistant laminate.    
     
     
         71 . A method for forming an abrasion resistant laminate as recited in  claim 70  wherein said recycled polymeric material comprises recycled polyvinyl chloride and said base layer comprises virgin polyvinyl chloride.  
     
     
         72 . A method for forming an abrasion resistant laminate as recited in  claim 70  wherein said core layer comprises at least two sheets of resin impregnated paper.  
     
     
         73 . A method for forming an abrasion resistant laminate as recited in  claim 70  wherein said core layer comprises at least one layer of a woven or nonwoven sheet formed from a material selected from the group consisting of fiberglass, polypropylene, polyester, nylon, and carbon fiber.  
     
     
         74 . A method for forming an abrasion resistant laminate as recited in  claim 73  wherein said layer of a woven or nonwoven sheet is placed between the resin impregnated sheets recited in  claim 72 .  
     
     
         75 . A method for forming an abrasion resistant laminate as recited in  claim 73  wherein said core layer includes a fiberglass layer having a basis weight of 25-60 g/m 2 .