Leather decorative laminate

Abstract

A method of manufacturing a heat and pressure consolidated laminate is provided that includes in superimposed relationship a core layer containing a plurality of cellulosic sheets impregnated with a thermosetting resin, and a decorative layer consisting essentially of a leather material.

1 - 7 . (canceled)  
   
   
       8 . A method for the production of a heat and pressure consolidated leather laminate comprising the steps of: 
 stacking in a superimposed relationship a core layer comprised of at least one cellulosic sheet impregnated with a thermosetting resin, a decorative layer consisting essentially of a leather material and a release sheet between plates of a thermosetting press;    increasing the pressure of the thermosetting press to a predetermined pressure;    increasing the temperature of the thermosetting press to a predetermined temperature;    maintaining the stacked layers in the heated, pressurized thermosetting press for a predetermined period of time sufficient to consolidate the stacked layers into a decorative laminate;    decreasing the temperature of the press while maintaining the elevated pressure for a predetermined period of time sufficient to cool the laminate;    removing the laminate from the thermosetting press; and    removing the release sheet from the laminate.    
   
   
       9 . The method of  claim 8 , wherein said predetermined temperature ranges from about 120° C. to about 250° C.  
   
   
       10 . The method of  claim 8 , wherein said predetermined pressure ranges from about 400 PSI to about 1600 PSI.  
   
   
       11 . The method of  claim 8 , wherein said period of time sufficient to consolidate the stacked layers into a laminate ranges from about 2 minutes to about 20 minutes.  
   
   
       12 . The method of  claim 8 , wherein said period of time sufficient to cool the laminate ranges from about 7 minutes to about 15 minutes.  
   
   
       13 . The method of  claim 8 , wherein said release sheet is textured to impart an embossed texture on the decorative layer.  
   
   
       14 . A method for the production of a heat and pressure consolidated leather laminate comprising the steps of: 
 stacking in a superimposed relationship a core layer comprised of at least one cellulosic sheet impregnated with a thermosetting resin, a decorative layer consisting essentially of a leather material and a release sheet between plates of a thermosetting press;    increasing the pressure of the thermosetting press to a predetermined pressure, said predetermined pressure ranging from about 400 PSI to about 1600 PSI;    increasing the temperature of the thermosetting press to a predetermined temperature, said predetermined temperature ranging from about 120° C. to about 250° C.;    maintaining the stacked layers in the heated, pressurized thermosetting press for a predetermined period of time sufficient to laminate the stacked layers, said period of time sufficient to laminate the stacked layers ranging from about 2 minutes to about 20 minutes;    decreasing the temperature of the press while maintaining the elevated pressure for a predetermined period of time sufficient to cool the laminate, said period of time sufficient to cool the laminate ranging from about 7 minutes to about 15 minutes;    decreasing the pressure of the thermosetting press; and    removing the laminate from the thermosetting press and removing the release sheet from the laminate.    
   
   
       15 . The method of  claim 14 , wherein said release sheet is textured to impart an embossed texture on the decorative layer.  
   
   
       16 . A method for the production of a heat and pressure consolidated leather laminate comprising the steps of: 
 setting the temperature of said continuous thermosetting press to a predetermined temperature;    setting the pressure of said continuous thermosetting press to a predetermined pressure;    feeding in a superimposed relationship a core layer comprised of at least one cellulosic sheet impregnated with a thermosetting resin, a decorative layer consisting essentially of a leather material and a release sheet into a continuous thermosetting press, said core layer, decorative layer and release sheet being fed into the continuous thermosetting press from a location upstream from said press;    selecting a line speed of the continuous thermosetting press that allows the superimposed layers to remain in the heated, pressurized press for a period of time sufficient to form a laminate from said layers; and    removing the release sheet from the laminate as it exits the press.    
   
   
       17 . The method of  claim 16  further comprising the step of transporting the leather laminate to handling equipment located downstream from said continuous thermosetting press for further processing.  
   
   
       18 . The method of  claim 16 , wherein said predetermined temperature ranges from about 120° C. to about 250° C.  
   
   
       19 . The method of  claim 16 , wherein said predetermined pressure ranges from about 400 PSI to about 1600 PSI.  
   
   
       20 . The method of  claim 16 , wherein said core layer, decorative layer consisting essentially of a leather material, and release sheet are fed into the continuous thermosetting press from continuous webs located upstream from said continuous thermosetting press.  
   
   
       21 . The method of  claim 16 , wherein said line speed is about 5 feet per minute.