PANELS WITH A DECORATIVE FACING AND A PROCESS FOR PREPARING THE PANELS

摘要

1433464 Decorative laminates FORMICA INTERNATIONAL Ltd 21 Feb 1975 [5 March 1974] 9792/74 Heading B5N A decorative faced panel comprising a supporting substrate, a decorative sheet and a wear surface layer, said supporting substrate being a ligno-cellulosic material, a metal sheet or an inorganic board material, said decorative sheet being a decorative fibrous sheet impregnated with a first noble thermoset resin and said wear surface layer being a coating, on that surface of the decorative sheet remote from the supporting substrate, comprising a second noble thermoset resin and finely divided barium sulphate, said first and second resins being the same or different resins is made by coating a decorative face of a decorative fibrous web impregnated with a varnish comprising a first noble thermosettable resin and finely divided barium sulphate, drying the coated web, cutting a sheet of desired size from the web, assembling said sheet in superposed relationship upon the substrate with the coated decorative face remote from the substrate and consolidating the assembly by the application of heat and pressure. The decorative fibrous sheet may be any suitable plain-coloured or printed decorative fibrous sheet, e.g. paper, woven cotton or a sheet composed wholly or partially of synthetic fibrous material. The noble resin may be a melamine - formaldehyde, urea - formaldehyde, melamine - urea - formaldehyde or crosslinked polyester resin. The coating composition may comprise a small amount of an abrasion resistant substance, e.g. silica or alumina, a penetration control additive, e.g. carboxymethyl cellulose or sodium alginate may also be included therein. Specified substrates are wood, chipboard, blockboard, hardboard, plywood, steel, plasterboard, cement-board and asbestos board. An adhesive layer, e.g. a curable synthetic resin composition in the form of a film, a coating or as an impregnant in a fibrous sheet may be provided between the decorative sheet and the substrate prior to consolidation. Panels having two decorative surfaces may be provided by positioning a decorative sheet on each surface of the substrate. The decorative face(s) of the panels may be provided with a texture, design or pattern in relief or in intaglio by using, in co-operation with the decorative surface, a press plate or die having an appropriately contoured working-face. Consolidation is preferably effected in an hydraulic press.