Continuous process for manufacturing thermoset decorative panels

Abstract

A continuous process for manufacturing decorative panels includes the steps of forming a first continuous fiber reinforced resin layer, laying a continuous decorated sheet on the first fiber reinforced resin layer, forming a second continuous fiber reinforced resin layer on the continuous decorated sheet, eliminating a substratum of the decorated sheet so that the first and second fiber reinforced resin layers can join one another to form a continuous consolidated strip of fiber reinforced resin with an image suspended therein, curing the continuous consolidated strip, and cutting a panel from the continuous consolidated strip. The first fiber reinforced resin layer is preferably at least partially cured in a first curing step before the second fiber reinforced resin layer is formed. It is also preferred to laminate the first fiber reinforced resin layer and decorated sheet in a first laminating step producing a first laminate and laminating the second fiber reinforced resin layer and the first laminate in a second laminating step before final curing.

What is claimed:  
     
         1 . A decorative panel comprising a decorated sheet disposed between first and second fiber reinforced resin layers, said decorated sheet including an image transferred onto at least one of said fiber reinforced resin layers by a substratum that has been eliminated, said first and second fiber reinforced resin layers joining each other to form a consolidated structure without distinct layers.  
     
     
         2 . The decorative panel of  claim 1  wherein the substratum is disintegrated and said fiber reinforced resin layers join each other through the disintegrated substratum.  
     
     
         3 . The decorative panel of  claim 1  further comprising at least one veil disposed on an outer surface of at least one of said fiber reinforced resin layers.  
     
     
         4 . The decorative panel of  claim 1  wherein said fiber reinforced resin layers include a resin chosen from the group consisting of transparent and translucent UV-curable resins.