Process for the manufacturing of a thermosetting laminate

Abstract

A process for the manufacturing of a decorative laminate, having an upper decorative and abrasion resistant thermosetting laminate layer and a carrying core. The upper side of the core has the abrasion resistant thermosetting laminate while the lower side of the core has a balance layer. This balance layer prevents warping of the decorative laminate while at the same time providing acoustic dampening. The balance layer includes a layer of a polymer. The balance layer and the thermosetting laminate are joined with the core by pressing. The carrying core further is provided with a dampening foil of an elastomer arranged between the upper side of the core and the abrasion resistant thermosetting laminate. The elastomer and thermosetting laminate are joined with each other and with the core by pressing. The achieved laminate is then cut into panels and provided with edges intended for joining.

1 . A process for producing a decorative laminate, the process comprising:
 providing a balance layer;   providing a core layer over a portion of the balance layer;   providing a dampening foil over a portion of the core layer;   providing a surface layer over a portion of the dampening foil, wherein the surface layer comprises an abrasion resistant and decorative surface; and   pressing the balance layer, the core layer, the dampening foil, and the surface layer to form the decorate laminate.   
     
     
         2 . The process of  claim 1 , wherein the balance layer comprises a thermoplastic elastomer, rubber, a non-woven fiber arranged on a polyolefin foil, cellulose, polyethylene, or aluminum. 
     
     
         3 . The process of  claim 1 , wherein the balance layer comprises a density of approximately 500 kg/m 3  to 950 approximately kg/m 3 . 
     
     
         4 . The process of  claim 1 , wherein the balance layer comprises an elasticity compression coefficient in the range of approximately 0.5 to 2.7 MPa. 
     
     
         5 . The process of  claim 1 , wherein the balance layer comprises an expanded physically cross-linked polyolefin with closed cells. 
     
     
         6 . The process of  claim 2 , wherein the balance layer further comprises an electrically conductive material. 
     
     
         7 . The process of  claim 7 , wherein the electrically conductive material comprises carbon black, carbon fiber, or aluminum particulates. 
     
     
         8 . The process of  claim 1 , wherein the balance layer is approximately 0.1 mm to 5 mm thick. 
     
     
         9 . The process of  claim 1 , wherein the core layer comprises particle board, fiber board, oriented strand board, polyurethane, or fiber cement. 
     
     
         10 . The process of  claim 1 , wherein the surface layer is provided with particles comprising silicon oxide, aluminum oxide, and/or silicon carbide. 
     
     
         11 . The process of  claim 11 , wherein the particles comprise an average size of approximately 0.1 mm to 1.2 mm. 
     
     
         12 . The process of  claim 1 , wherein the dampening foil comprises a thermoplastic elastomer. 
     
     
         13 . The process of  claim 1 , wherein the dampening foil comprises an elasticity compression coefficient in the range of approximately 0.5 to 2.7 MPa. 
     
     
         14 . The process of  claim 1 , wherein the dampening foil is approximately 0.1 mm to 0.7 mm thick. 
     
     
         15 . The process of  claim 1 , wherein the dampening foil comprises an expanded physically cross-linked polyolefin with closed cells. 
     
     
         16 . The process of  claim 1 , wherein the dampening foil comprises a density of approximately 150 kg/m 3 to  400 kg/m 3 . 
     
     
         17 . The process of  claim 1 , wherein the dampening foil comprises an electrically conductive material. 
     
     
         18 . The process of  claim 17 , wherein the electrically conductive material comprises carbon black or carbon fiber. 
     
     
         19 . The process of  claim 1 , wherein the surface layer comprises a thermosetting laminate having a density in the range from approximately 1250 kg/m 3  to 1500 kg/m 3 . 
     
     
         20 . The process of  claim 1 , wherein the surface layer is approximately 0.1 mm to 1.2 mm thick.