Process for the manufacture of a decorative laminate

Abstract

A process for the manufacture of a decorative board, which board, on its upper surface includes a decorative layer and a wear layer of cellulose and thermosetting amino resin. A decorative layer and wear layer is applied as a surface layer on a base layer and bonded thereto by pressing under elevated temperature and pressure in a laminate press. The wear layer, the decor layer and the base layer are arranged to form a stack of layers. The stack of layers are fed into a laminate press and pressed therein under heat and pressure where at least the upper surface becomes heated. The decorative board is acquired from the laminate press whereupon a forced cooling of the decorative board is initiated in order to bring the surface temperature of the decorative board down.

1 . A process for the manufacture of a decorative board, which board, on its upper surface includes a decorative layer and a wear layer, said decorative layer and wear layer comprise cellulose and thermosetting amino resin wherein a decorative layer and wear layer is applied as a surface layer on a base layer and bonded thereto by pressing under elevated temperature and pressure in a laminate press wherein: 
 a) the wear layer, the decor layer and the base layer are arranged to form a stack of layers whereupon,    b) the stack of layers are fed into a laminate press and pressed therein under increased pressure and increased temperature so that the different layers are bonded to form a unit, through which process, at least the upper surface becomes heated, whereupon,    c) the decorative board is acquired from the laminate press whereupon a forced cooling of the decorative board is initiated in order to bring the surface temperature of the decorative board down.    
     
     
         2 . A process according to  claim 1 , wherein the base layer is constituted of a particle board with a thickness in the range 3-30 mm.  
     
     
         3 . A process according to  claim 1 , wherein the base layer is constituted of a medium density fibre board with a thickness in the range 3-30 mm.  
     
     
         4 . A process according to  claim 1 , wherein the base layer is constituted of a high density fibre board with a thickness in the range 3-30 mm.  
     
     
         5 . A process according to  claim 2 , wherein the base layer is preconditioned to a predetermined temperature prior to the lamination process.  
     
     
         6 . A process according to  claim 1 , wherein the cooling is achieved by means of convection cooling by blowing an air stream over the surface of the decorative board.  
     
     
         7 . A process according to  claim 6 , wherein the air in the air stream is conditioned to a specific moisture content range.  
     
     
         8 . A process according to  claim 6 , wherein the air in the air stream has a specific temperature range.  
     
     
         9 . A process according to  claim 6 , wherein the cooling is a two stage process, the first stage being a forced narrow high pressure air stream blown over the surface of the decorative board as soon as possible after the lamination procedure followed by stage two, being a slower cooling process where the air is conditioned to a specific temperature range and moisture content.  
     
     
         10 . A process according to  claim 1 , wherein the pressure in the laminate press is in the range 5-90 Bar, while the temperature is in the range 140-260° C.  
     
     
         11 . The process according to  claim 3 , wherein the base layer is preconditioned to a predetermined temperature prior to the lamination process.  
     
     
         12 . The process according to  claim 4 , wherein the base layer is preconditioned to a predetermined temperature prior to the lamination process.  
     
     
         13 . The process according to  claim 1 , wherein the pressure in the laminate press is in the range 15-70 Bar, while the temperature is in the range 160-200° C.  
     
     
         14 . The process according to  claim 1 , wherein the pressure in the laminate press is in the range of 15-70 Bar.  
     
     
         15 . The process according to  claim 1 , wherein the temperature is in the range of 160-200° C.