Abrasion resistant laminate

Abstract

An abrasion-resistant laminate is prepared by providing an ultra thin coating of mineral particles and micro crystalline cellulose on the surface of conventional printed paper, followed by impregnating the paper with a conventional laminating resin, and then using the print paper so obtained in a laminating process without the necessity of using an overlay sheet.

What is claimed is: 
     
       1. An abrasion resistant decorative laminate meeting NEMA abrasion resistance standards and also capable of withstanding 175-200 cycles of initial wear in the same test comprising: a backing layer and laminated thereto a thermoset laminating resin impregnated decorative facing sheet, said decorative facing sheet having a print design thereon and an ultra-thin abrasion resistant coating over said print design, said ultra-thin abrasion resistant coating having a thickness of up to about 0.3 mils comprising a mixture of (1) an abrasion resistant hard mineral particle size 20-50 microns in high concentration sufficient to provide for abrasion resistance without interfering with visibility and (2) stabilizing binder material for said mineral, said thermoset resin being impregnated throughout said print sheet and said coating, said binder material not interfering with visibility, and with said ultra-thin abrasion resistant coating forming the uppermost layer of said laminate.   
     
     
       2. A decorative laminate in accordance with claim 1 wherein said thermoset resin is melamineformaldehyde resin. 
     
     
       3. A laminate in accordance with claim 2 wherein said binder comprises predominantly microcrystalline cellulose. 
     
     
       4. A laminate in accordance with claim 3 wherein said abrasion resistant mineral particles constitute alumina, silica or mixtures thereof. 
     
     
       5. A laminate in accordance with claim 2 wherein said abrasion resistant mineral is alumina, and wherein said alumina is chemically bound to said melamine resin with a silane. 
     
     
       6. A laminate in accordance with claim 1 wherein said ultra-thin abrasion resistant coating is directly over said print design and has a thickness of 0.02-0.2 mils. 
     
     
       7. A decorative, high-pressure laminate in accordance with claim 1 wherein said backing comprises a plurality of phenolic impregnated paper sheets and said facing sheet comprises a paper sheet impregnated with melamine resin, said abrasion resistant particles comprising alumina particles, said binder material comprising microcrystalline cellulose, said abrasion resistant coating comprising about 5-10 parts by weight of said microcrystalline cellulose for about 20-120 parts by weight of said alumina, the thickness of said coating being about 0.02-0.2 mils. 
     
     
       8. A laminate in accordance with claim 7 wherein said alumina is bonded to said melamine resin with a silane. 
     
     
       9. A laminate in accordance with claim 1, wherein said ultra-thin abrasion resistant coating has a thickness no greater than 0.3 mils. 
     
     
       10. A laminate in accordance with claim 1 wherein the quantity by weight of said binder material in said abrasion resistant coating is no greater than the quantity by weight of said mineral therein, and said binder material constitutes a mixture. .Iadd. 
     
     
       11.  An abrasion resistant decoration laminate having superior NEMA abrasion resistance, superior initial wear resistance in the same test, and superior wear resistance in the Sliding Can Test comprising: a backing layer and laminated thereto a thermoset laminating resin impregnated decorative facing sheet, said decorative facing sheet having an ultra-thin abrasion resistant coating thereover, said ultra-thin abrasion resistant coating having a thickness of up to about 0.3 mils comprising a mixture of (1) an abrasion resistant hard mineral of fine particle size sufficiently great such that said decretive laminate meets NEMA abrasion resistance standards and withstands 175-200 cycles of initial wear in the same test, in high concentration sufficient to provide for abrasion resistance without interfering with visibility, and (2) stabilizing binder material for said mineral, said thermoset resin being impregnated throughout said decorative sheet and said coating, said binder material not interfering with visibility, and with said ultra-thin abrasion resistant coating forming the uppermost layer of said laminate. .Iaddend. .Iadd.12. A laminate in accordance with claim 11 wherein said ultra-thin abrasion resistant coating has a thickness of 0.02-0.2 mils. .Iaddend. .Iadd.13. A laminate in accordance with claim 11 wherein the quantity by weight of said binder material in said abrasion resistant coating is no greater than the quantity by weight of said mineral therein, and said binder material constitutes a mixture. .Iaddend. .Iadd.14. A laminate in accordance with claim 11 wherein said ultra-thin abrasion resistant coating has a thickness no greater than 0.3 mils, and said abrasion resistant hard mineral particles have a size of 20-50 microns.   
     
     
        .Iaddend. .Iadd.15.  A decorative, high-pressure laminate in accordance with claim 11 wherein said backing comprises a plurality of phenolic impregnated paper sheets and said facing sheet comprises a paper sheet impregnated with melamine resin, said abrasion resistant particles comprising alumina particles of 20-50 microns, said binder material comprising microcrystalline cellulose, the thickness of said coating being about 0.02-0.2 mils. .Iaddend. .Iadd.16. A laminate in accordance with claim 15 wherein said alumina is bonded to said melamine resin with a silane. .Iaddend. .Iadd.17. A decorative laminate in accordance with claim 11 wherein said thermoset resin is melamineformaldehyde resin, and the minimum particle size of said abrasion resistant hard material is about 20 microns. .Iaddend. .Iadd.18. A laminate in accordance with claim 17 wherein said abrasion resistant mineral is alumina, and wherein said alumina is chemically bound to said melamine resin with a silane. .Iaddend. .Iadd.19. A laminate in accordance with claim 17 wherein said binder comprises predominantly microcrystalline cellulose, and the minimum particle size of said abrasion resistant hard mineral is about 20 microns. .Iaddend. .Iadd.20. A laminate in accordance with claim 19 wherein said abrasion resistant mineral particles constitute alumina, silica or mixtures thereof. .Iaddend.