Decorative laminate assembly and method of producing same

Abstract

A decorative laminate assembly having a decorative laminate top layer assembly. This top layer assembly includes, in descending superimposed relationship, a decorative layer and a core layer that includes PETG, or other polymeric material. Preferably, the top layer assembly also includes a wear resistant overlay layer on top of the decorative layer, and the core layer's PETG is in a sheet form. The top layer assembly may be directly bonded to a water resistant substrate. The decorative laminate assembly of the present invention can be used for a variety of purposes, including flooring applications. When the present invention is used for flooring applications, it is preferred that the overlay layer has enhanced wear resistant qualities and that the water resistant substrate comprise PVC or cement fiberboard.

1 . A method for producing a decorative laminate comprising: 
 (a) assembling, in order in the following superimposed relationship, a wear resistant layer, a decorative layer, and a core layer, said core layer comprising PETG; and    (b) subjecting said assembly to heat and pressure, thereby laminating said assembly.    
   
   
       2 . The method of  claim 1 , wherein said wear resistant layer is an overlay layer, said overlay layer including abrasive particles.  
   
   
       3 . The method of  claim 1 , wherein said PETG is 0.020 inches thick.  
   
   
       4 . The method of  claim 1 , wherein said pressure is between 1000 and 1200 psig.  
   
   
       5 . The method of  claim 4 , wherein said temperature is between 125° C. and 127° C.  
   
   
       6 . The method of  claim 5 , wherein said heat and pressure is maintained for 25-30 minutes.  
   
   
       7 . The method of  claim 1 , further comprising bonding said overlay layer, decorative layer, and core layer to a water resistant substrate after said subjecting to heat and pressure laminating step.  
   
   
       8 . The method of  claim 7 , wherein said water resistant substrate comprises PVC.  
   
   
       9 . The method of  claim 7 , wherein said water resistant substrate comprises fiber reinforced cement board.  
   
   
       10 . The method of  claim 7 , wherein said PETG comprises at least one sheet of PETG.  
   
   
       11 . A method for producing a decorative laminate comprising: 
 (a) assembling a wear resistant layer, a decorative layer comprising a thermosetting resin impregnated cellulosic material, a core layer below said decorative layer, said core layer comprising polyethylene terephthalate glycol, and a substrate; and    (b) subjecting said assembly to heat and pressure, thereby laminating said assembly.    
   
   
       12 . The method of  claim 11 , wherein said wear resistant layer is an overlay layer, said overlay layer including abrasive particles.  
   
   
       13 . The method of  claim 11 , wherein said polyethylene terephthalate glycol is 0.020 inches thick.  
   
   
       14 . The method of  claim 11 , wherein said pressure is about 400 to about 600 psig.  
   
   
       15 . The method of  claim 14 , wherein said temperature is about 125° C. to about 127° C.  
   
   
       16 . The method of  claim 14 , wherein said heat and pressure is maintained for about 25 to about 30 minutes.  
   
   
       17 . The method of  claim 11 , wherein said substrate comprises PVC.  
   
   
       18 . The method of  claim 11 , wherein said substrate comprises fiber reinforced cement board.  
   
   
       19 . The method of  claim 11 , wherein said polyethylene terephthalate glycol comprises at least one sheet of polyethylene terephthalate glycol.