Wear-resistant decorative laminates and methods of producing sam

Details Wear-resistant decorative laminates and methods of producing sam Wear-resistant decorative laminates and methods of producing sam

1994-07-06

1996-09-24

Beck, Shrive

Coating processes

Solid particles or fibers applied

427202, 427417, 427439, B05D 118, B05D 136

Patent

active

055589065

ABSTRACT:
Process for the production of decorative laminates having improved scratch, mar, scrape and abrasion resistance comprising the initial step of preparing a mixture of a melamine-formaldehyde resin and an abrasion resistant material, wherein the mixture includes abrasion resistant alumina particles having a particle size of about 25 microns and abrasion resistant alumina particles having a particle size of about 3 microns at a ratio of about 2 to 1; about 0.25 percent silane; about 0.075 percent xanthan gum; and about 0.3 percent to about 1.2 percent polyvinyl alcohol or about 0.1 percent polyethylene glycol distearate having a molecular weight of about 6000, wherein all percentages are measured by weight of the total wet weight of the resin solution of the mixture. The process further includes the steps of simultaneously coating and impregnating a decorative paper sheet with the mixture such that a portion of the amount of melamine-formaldehyde resin required for saturation of the decorative sheet is impregnated therein; dipping the impregnated decorative sheet into an identically formulated mixture or a neat resin bath such that the remaining amount of resin required for saturation is impregnated therein; metering the total amount of melamine-formaldehyde resin impregnated into the decorative sheet; and then drying and consolidating the impregnated decorative sheet. The coating and impregnating step can be performed using either a sparge pipe applicator or a gravure pad coating cylinder.

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