Multiple layer decorated paper, laminate prepared therefrom and process

Abstract

A decorated multiple layer paper suitable for use as a top surface in resin impregnated abrasion resistance decorated laminates, and the laminates prepared therefrom, said multiple layer having a base layer and a top layer, the top layer comprising abrasion resisting mineral particles having a hardness of 7 or more on the Moh scale and a particle size ranging from 10 to 75 microns, and with a printed pattern over the exposed surface of the top layer. The multiple layer paper is made by depositing a base layer on a paper machine forming wire, and while the base layer is in a wet state and still supported on the forming wire, depositing the top layer thereover. Abrasion resistant decorative laminates are prepared from said decorated multiple layer paper by saturating said paper with a resin, suitably a thermosetting resin followed by uniting with a core and curing of said resin.

What is claimed is: 
     
       1. An abrasion resistant laminate comprising a core and a resin impregnated cured decorated surface paper, said surface paper, prior to resin impregnation comprising (a) a paper base layer;   (b) a top layer integral with said base layer and comprising from about 2 to 100 percent by weight of abrasion resisting mineral particles having a hardness of from 7 to 10 on the Moh scale and an average particle size ranging from 10 to 75 microns, and   (c) printing applied on the exposed outer surface of said top layer.   
     
     
       2. The abrasion resistant laminate of claim 1 wherein said resin is a thermosetting resin. 
     
     
       3. The abrasion resistant laminate of claim 1 wherein said top layer includes fibers. 
     
     
       4. The abrasion resistant laminate of claim .[.2.]. .Iadd.3 .Iaddend.wherein said top layer comprises from 10% to 50% of said mineral particles and from 90% to 50% of said fibers. 
     
     
       5. The abrasion resistant laminate of claim 1 wherein said mineral particles are alumina. 
     
     
       6. The abrasion rsistant laminate of claim 1 wherein said mineral particles are silica. 
     
     
       7. The abrasion resistant laminate of claim 1 wherein said mineral particles are silicon carbide. 
     
     
       8. The abrasion resistant laminate of claim 1 wherein said mineral particles are a mixture of tungsten carbide and borron carbide. 
     
     
       9. The abrasion resistant laminates of claim 1 wherein said top layer has a basis weight ranging from 1 to 20 lbs. per ream of 3000 sq. ft. 
     
     
       10. The abrasion resistant laminate of claim 1 wherein said base layer comprises fibers. 
     
     
       11. The abrasion resistant laminate of claim 9 wherein said base layer has a basis weight ranging from 10 to 100 lbs. per ream of 3000 sq. ft. 
     
     
       12. The abrasion resistant laminate of claim 1 wherein said base layer comprises fibers and opacifying pigments, and has a basis weight ranging from 30 to 100 lbs. per ream of 3000 sq. ft. and said top layer comprises from 10% to 50% alumina having a particle size distribution of 96% in the size range of 20 to 60 microns and 90% to 50% of bleached hardwood fibers, said top layer having a basis weight ranging from 4 to 14 lbs. per ream of 3000 sq. ft. .Iadd.13. An abrasion resistant laminate comprising a core and a resin impregnated printed decor paper, said printed decor paper comprising: (a) a base paper layer of fibers and opacifying pigments; and   (b) integral with said base paper layer a printed layer comprising a mixture of abrasion resisting mineral particles having a hardness of 7 to 10 on the Moh scale and print receptive fibers, the fibers and abrasion resisting mineral particles being present in said printed layer in an amount and size to impart printability to the printed surface of the printed layer and to provide such abrasion resistance to said decor paper that upon lamination, without the presence of overlay paper, the resulting laminate has a wear rate of under 0.08 gm/100 cycles and a minimum of 400 cycles in the NEMA Method LD1-2.01 abrasion test, the printing on said printed layer being on the surface opposite the surface integral with said base layer. .Iaddend. .Iadd.14. The abrasion resistant laminate of claim 13 wherein said base paper layer has a dry basis weight ranging from 30 to 100 lbs. per ream of 3000 sq. ft. and said printed layer has a dry basis weight ranging from 4 to 14 lbs. per ream of 3000 sq. ft. .Iaddend. .Iadd.15. The abrasion resistant laminate of claim 13 wherein said printed layer includes a small amount of adhesive. .Iaddend. .Iadd.16. The abrasion resistant laminate of claim 15 wherein said adhesive is starch. .Iaddend. .Iadd.17. The abrasion resistant laminate of claim 13 wherein said decor paper includes a thin fiber layer over said printable layer. .Iaddend. .Iadd.18. An abrasion resistant laminate comprising a core and a resin impregnated printed decor paper, said printed decor paper comprising:   (a) a base paper layer;   (b) integral with said base paper layer a printed layer comprising a mixture of abrasion resisting mineral particles having a hardness of 7 to 10 on the Moh scale and print receptive fibers, the fibers and abrasion resisting mineral particles being present in said printed layer in an amount and size to impart printability to the printed layer and to provide such abrasion resistance to said decor paper that upon lamination, without the presence of overlay paper, the resulting laminate has a wear rate of under 0.08 gm/100 cycles and a minimum of 400 cycles in the NEMA Method LD1-2.01 abrasion test; and   (c) the printing on said printed layer being on the surface opposite the   
     
     
        surface integral with said base paper layer. .Iaddend. .Iadd. 19.  The abrasion resistant laminate of claim 18 wherein said base paper layer has a dry basis weight ranging from 30 to 100 lbs. per ream of 3000 sq. ft. and said printed layer has a dry basis weight ranging from 4 to 14 lbs. per ream of 3000 sq. ft. .Iaddend..Iadd. 20. An abrasion resistant laminate comprising a core and a resin impregnated printed decor paper, said printed decor paper comprising: (a) a base paper layer of fibers and opacifying pigments; and   (b) integral with said base paper layer a printed layer comprising a mixture of abrasion resisting alumina particles, print receptive fibers and starch, the fibers and abrasion resisting alumina particles being present in said printed layer in an amount and size to impart printability to the printable surface of the printed layer and to provide such abrasion resistance to said decor paper that upon lamination, without the presence of overlay paper, the resulting laminate has a wear rate of under 0.08 gm/100 cycles and a minimum of 400 cycles in the NEMA Method LD1-2.01 abrasion test, the printing on said printed layer being on the surface opposite the surface integral with said base paper layer. .Iaddend. .Iadd.21. The abrasion resistant laminate of claim 20 wherein said base paper layer has a dry basis weight ranging from 30 to 100 lbs. per ream of 3000 sq. ft. and said printed layer has a dry basis weight ranging from 4 to 14 lbs. per ream of 3000 sq. ft. .Iaddend..Iadd. 22. The abrasion resistant laminate of claim 20 wherein said decor paper includes a thin fiber layer over said printed layer. .Iaddend.