Leather laminated decorative panel

Abstract

A heat and pressure consolidated laminate, and method for producing the same, is provided that includes in superimposed relationship a decorative layer consisting essentially of a leather material, an underlay layer, a substrate, and an optional backer layer. The substrate has a first surface and a second surface opposite one another. The underlay layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed between the decorative layer and the first layer of the substrate. The backer layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed contiguous with the second surface of the substrate.

What is claimed is:  
     
         1 . A heat and pressure consolidated laminate, comprising in superimposed relationship: 
 a decorative layer consisting essentially of a leather material;    a substrate, having a first surface and a second surface opposite one another;    an underlay layer, containing one or more cellulosic sheets impregnated with a thermosetting resin, the underlay layer disposed between the decorative layer and the first surface of the substrate; and    a backer layer containing one or more cellulosic sheets impregnated with a thermosetting resin, the backer layer disposed adjacent the second surface of the substrate.    
     
     
         2 . The laminate of  claim 1  wherein said decorative layer is bonded leather having a sheet thickness ranging from about 0.2 mm to about 4.0 mm.  
     
     
         3 . The laminate of  claim 1  wherein said thermosetting resin is a melamine formaldehyde resin.  
     
     
         4 . The laminate of  claim 1 , wherein said substrate is either plywood, particleboard or medium density fiberboard.  
     
     
         5 . The laminate of  claim 1 , further comprising an overlay layer disposed on a side of said decorative layer opposite the underlay layer and substrate.  
     
     
         6 . A heat and pressure consolidated laminate, comprising in superimposed relationship: 
 a first decorative layer consisting essentially of a leather material;    a substrate, having a first surface and a second surface opposite one another;    a first underlay layer, containing one or more cellulosic sheets impregnated with a thermosetting resin, the first underlay layer disposed between the first decorative layer and the first surface of the substrate; and    a second decorative layer consisting essentially of a leather material; and    a second underlay layer, containing one or more cellulosic sheets impregnated with a thermosetting resin, said second underlay layer disposed between the second decorative layer and the second surface of the substrate.    
     
     
         7 . The laminate of  claim 6  wherein said first and second decorative layers are bonded leather, said first and second decorative layers each having a sheet thickness ranging from about 0.2 mm to about 4.0 mm.  
     
     
         8 . The laminate of  claim 6  wherein said thermosetting resin is a melamine formaldehyde resin.  
     
     
         9 . The laminate of  claim 6 , wherein said substrate is either plywood, particleboard or medium density fiberboard.  
     
     
         10 . A method for the production of a heat and pressure consolidated leather laminate comprising the steps of: 
 setting the temperature of a thermosetting press to a predetermined temperature;    stacking in a superimposed relationship a backing layer, a substrate, an underlay layer, a decorative layer comprised essentially of leather, and a release sheet;    inserting the stacked, superimposed layers into the thermosetting press;    increasing the pressure of the thermosetting press to a predetermined pressure;    maintaining the stacked layers in the heated, pressurized thermosetting press for a period of time sufficient to form a laminate;    removing the laminate from the thermosetting press; and    removing the release sheet from the laminate.    
     
     
         11 . The method of  claim 10 , wherein said predetermined temperature ranges from about 110° C. to about 250° C.  
     
     
         12 . The method of  claim 10 , wherein said predetermined pressure ranges from about 250 PSI to about 450 PSI.  
     
     
         13 . The method of  claim 10 , wherein said period of time sufficient to form a laminate ranges from about 20 seconds to about 150 seconds.  
     
     
         14 . The method of  claim 10 , wherein said release sheet is textured to impart an embossed texture on the decorative layer.  
     
     
         15 . A method for the production of a heat and pressure consolidated leather laminate comprising the steps of: 
 setting the temperature of the continuous thermosetting press to a predetermined temperature;    setting the pressure of the press to a predetermined pressure;    stacking in a superimposed relationship a backing layer, a substrate, an underlay layer, a decorative layer comprised essentially of leather, and a release sheet upstream from a continuous thermosetting press;    feeding the stacked, superimposed layers into the continuous thermosetting press;    maintaining the stacked layers in the heated, pressurized continuous thermosetting press for a period of time sufficient to form a laminate;    removing the laminate from the thermosetting press; and    removing the release sheet from the laminate.    
     
     
         16 . The method of  claim 16 , further comprising the step of transporting the laminate to handling equipment located downstream from the continuous thermosetting press.  
     
     
         17 . The method of  claim 16 , wherein said predetermined temperature ranges from about 110° C. to about 250° C.  
     
     
         18 . The method of  claim 16 , wherein said predetermined pressure ranges from about 250 PSI to about 450 PSI.  
     
     
         19 . The method of  claim 16 , wherein said period of time sufficient to form a laminate ranges from about 20 seconds to about 150 seconds.  
     
     
         20 . A method for the production of a heat and pressure consolidated leather laminate comprising the steps of: 
 setting the temperature of the continuous thermosetting press to a predetermined temperature, said predetermined temperature ranging from about 110° C. to about 250° C.;    setting the pressure of the press to a predetermined pressure, said predetermined pressure ranging from about 250 PSI to about 450 PSI;    stacking in a superimposed relationship a backing layer, a substrate, an underlay layer, a decorative layer comprised essentially of leather, and a release sheet upstream from a continuous thermosetting press;    feeding the stacked, superimposed layers into the continuous thermosetting press;    selecting a line speed of the continuous thermosetting press that allows the stacked, superimposed layers to remain in the heated, pressurized press for a period of time sufficient to form a laminate from said layers;    removing the laminate from the thermosetting press; and    removing the release sheet from the laminate.