Process for the manufacturing of decorative laminate

Abstract

A process for the manufacturing of a decorative laminate, which laminate comprises an upper decorative and abrasion resistant thermosetting laminate layer and a carrying core. The upper side of the core is provided with the abrasion resistant thermosetting laminate with a dampening foil of an elastomer arranged between the upper side of the core and the abrasion resistant thermosetting laminate, which elastomer and which thermosetting laminate are joined with each other and with the core by means of pressing.

1 . A process for the manufacturing of a decorative laminate, which laminate comprises an upper decorative and abrasion resistant thermosetting laminate layer and a carrying core, wherein the carrying core is constituted by particle board or fibre board, the upper side of the core is provided with the abrasion resistant thermosetting laminate with a dampening foil of an elastomer arranged between the upper side of the core and the abrasion resistant thermosetting laminate which elastomer and which thermosetting laminate are joined with each other and with the core by means of pressing.  
   
   
       2 . A process according to  claim 1 , wherein the thermosetting laminate is constituted by one or more decor papers impregnated with melamine-formaldehyde resin and one or more overlay sheets impregnated with melamine formaldehyde resin arranged on top of the decor papers and optionally one or more conventional resin impregnated underlay papers, arranged under the decor paper or decor paper which papers are laminated together under increased pressure and increased temperature.  
   
   
       3 - 4 . (canceled)  
   
   
       5 . A process according to  claim 2 , wherein at least one of the sheets impregnated with thermosetting resin is provided with hard particles.  
   
   
       6 . A process according to  claim 2  wherein the thermosetting laminate has a thickness in the range 0.3 mm-1.2 mm.  
   
   
       7 . A process according to  claim 2 , wherein the thermosetting laminate has a density in the range 1250-1500 kg/m 3 .  
   
   
       8 . A process according to  claim 1 , wherein the dampening foil is constituted of a thermoplastic elastomer.  
   
   
       9 . A process according to  claim 8 , wherein the dampening foil has elasticity compression coefficient in the range 0.5-2.7 MPa.  
   
   
       10 . A process according to  claim 8 , wherein the dampening foil has a thickness in the range 0.1-0.7 mm.  
   
   
       11 . A process according to  claim 8 , wherein the dampening foil has a density in the range 150-400 kg/m 3 .  
   
   
       12 . A process according to  claim 1 , wherein the dampening foil and the thermosetting laminate is joined with the carrying core by means of glue and pressure.  
   
   
       13 . A process according to  claim 1 , wherein the dampening foil and the thermosetting laminate is joined with the carrying core by means of melt-glue, heat and pressure.  
   
   
       14 . A process according to  claim 2 , wherein the thermosetting laminate is constituted one or more conventional resin impregnated underlay papers, arranged under the decor paper or decor papers.  
   
   
       15 . A process according to  claim 5 , wherein the hard particles are selected from the group consisting of silicon oxide, aluminium oxide and silicon carbide.  
   
   
       16 . A process according to  claim 5 , wherein the hard particles have an average size of between about 5-60 μm.  
   
   
       17 . A process according to  claim 5 , wherein the hard particles have an average size of between about 1 and 100 μm.  
   
   
       18 . A process according to  claim 2 , wherein the thermosetting laminate has a thickness in the range 0.3 mm-0.9 mm.  
   
   
       19 . A process according to  claim 8 , wherein the dampening foil has elasticity compression coefficient in the range 0.8-2.0 MPa.  
   
   
       20 . A process according to  claim 8 , wherein the dampening foil has a thickness in the range 0.1-0.5 mm.  
   
   
       21 . A process according to  claim 8 , wherein the dampening foil has a density in the range 180-330 kg/m 3 .  
   
   
       22 . A process according to  claim 2 , wherein the one or more underlay papers comprise a phenol-formaldehyde resin.