Process for the manufacturing of an improved core for decorative laminates and a decorative laminate obtained by the process

Abstract

A process for the manufacturing of a board, used as a core, forming a carrying structure for decorative laminates. Particles are achieved by grinding cured, and possibly foamed, rigid, polyurethane, polyisocyanurate and/or phenolic resin so that it passes through a 2 mm screen, preferably a 1 mm screen. The particles are allowed to absorb a selected amount of water in the range 1-7% by weight, 85 parts per weight of particles is mixed with 2-15 parts per weight of a bonding agent, the bonding agent selected from the group consisting of, a) a mixture of polyols, such as polyester or polyether, crude methylene diphenyl diisocvanate, or, b) a formaldehyde based resin such as phenol-formaldehyde resin, ureaformaldehyde resin, melamine-urea-formaldehyde resin, melamine-urea phenol-formaldehyde resin or phenol-resorcinol-formaldehyde resin, or c) polyvinyl acetate resin, and that, the mixture is applied in a press, possibly with at least one intermediate carrier web, whereby a slightly porous and preconditioned core with a selected water content in the range 0.8 - 6.5 % is achieved. The invention also relates to a decorative laminate achieved through the process.

1 - 63 . Cancelled  
     
     
         64 . A process for the manufacturing of a laminate comprising: 
 providing a printed foil, wherein the foil comprises one selected from the group consisting of: 
 α-cellulose impregnated with a polymeric lacquer or resin; and  
 a polymer;  
   coating the printed foil with one or more wear layers, wherein the wear layer comprises one more layers of acrylic or maleamid lacquer.    
     
     
         65 . The process of  claim 64 , further comprising passing the printed foil and at least one of a core and a support web through a belt press prior to coating with the one or more wear layers.  
     
     
         66 . The process of  claim 64 , wherein the support web comprises melamine-formaldehyde resin impregnated α-cellulose paper.  
     
     
         67 . The process of  claim 64 , wherein the printed foil comprises one or more polymers selected from the group consisting of polyvinyl chloride, polyester, polypropylene, polyethylene, polyurethane and acrylic.  
     
     
         68 . The process of  claim 64 , wherein the lacquer is curable by UV or electron beams.  
     
     
         69 . A process for the manufacturing of a laminate comprising: 
 providing a core;    applying a translucent or semi-translucent layer on the core,    adding a printed decor to the translucent or semi-translucent layer, wherein the printed decor is semi-translucent or opaque; and    applying a wear layer to the printed decor.    
     
     
         70 . The process of  claim 69 , wherein the printed decor covers only a segment of the translucent or semi-translucent layer, such that the printed decor does not cover all of the translucent or semi-translucent layer.  
     
     
         71 . The process of  claim 69 , wherein the core comprises particles and a resin, wherein the particles have a color different than the color of the resin.  
     
     
         72 . The process of  claim 69 , wherein the printed decor comprises a polymer, selected from the group consisting of polyvinyl chloride acrylic, polyester, polypropylene, polyethylene, and polyurethane.  
     
     
         73 . The process of  claim 69 , wherein the translucent or semi-translucent layer comprises α-cellulose impregnated with a polymeric lacquer or resin.  
     
     
         74 . The process of  claim 69 , wherein the translucent or semi-translucent layer comprises at least one wear layer, the at least one wear layer comprises at least one selected from the group consisting of abrasion resistance providing first particles and scratch resistance providing second particles.  
     
     
         75 . The process of  claim 69 , wherein the translucent or semi-translucent layer comprises a polymer selected from the group consisting of polyvinyl chloride, polyester, polypropylene, polyethylene, polyurethane and acrylic.  
     
     
         76 . A process for the manufacturing of a laminate comprising: 
 providing a core and    printing a decor directly on the core; and    providing at least one wear layer on the printed core.    
     
     
         77 . The process of  claim 76 , wherein the printing is applied by transfer printing.  
     
     
         78 . The process of  claim 76 , further comprising sanding or coating the core prior to the printing step.  
     
     
         79 . The process of  claim 76 , wherein at least one of the at least one wear layer comprises a lacquer.  
     
     
         80 . The process of  claim 76 , wherein the lacquer is selected from the group consisting of acrylic and maleamide, and the lacquer is optionally curable with an electron or UV beam.  
     
     
         81 . The process of  claim 76 , further comprising providing at least one of the at least one wear layer with particles to provide scratch and/or abrasion resistance.  
     
     
         82 . The laminate formed by the process of  claim 76 .  
     
     
         83 . The laminate formed by the process of  claim 64 .  
     
     
         84 . The laminate formed by the process of  claim 69 .  
     
     
         85 . A laminate comprising: 
 a wear layer, an acrylic or maleamid lacquer; and    a printed foil, comprising one selected from the group consisting of printed paper and α-cellulose impregnated with lacquer or resin.    
     
     
         86 . A laminate comprising: 
 a core;    a semi-transparent or translucent web on top of the core;    a printed decor layer atop the web; and    at least one wear layer on the printed decor, wherein the at least one wear layer comprises α-cellulose impregnated lacquer or resin.    
     
     
         87 . The laminate of  claim 86 , wherein the printed decor layer covers only part of the web.  
     
     
         88 . The laminate of  claim 86 , wherein the core comprises particles having a color, and particles being bound with a binding agent with binding agent differs from the color of the particles.  
     
     
         89 . The laminate of  claim 88 , wherein the binding agent is pigmented.  
     
     
         90 . A laminate comprising: 
 a core having an upper surface, and a decor printed directly on the upper surface of the core, and    a least one wear layer atop the core, wherein the at least one wear layer comprises a lacquered surface containing α-cellulose.    
     
     
         91 . A process for the manufacturing of a laminate comprising: 
 providing a core;    applying a decor on the core;    adding a wear layer to the decor, wherein the wear layer comprises a lacquer.    
     
     
         92 . A laminate comprising: 
 a core, having an upper surface;    a decor on the upper surface of the core; and    a lacquered wear layer on the decor.