Laminated panel

Abstract

A method for the production of a laminate is provided, comprising the steps of: 1) providing a stack of layers including a decorative layer, a core layer, and optionally an overlayer; 2) impregnating one or both of the decorative layer and overlayer with a resin formulation that includes nanoclay particles disposed within a thermoset resin, wherein the concentration of the nanoclay particles within the thermoset resin is great enough to form a physical barrier within the resin and low enough to avoid a hazy appearance; and 3) subjecting the stack of layers to sufficient heat and pressure to cause the layers to bond to one another. According to an aspect of the present invention, a laminate is provided producible by the above-described method.

1 . A method for the production of a laminate, comprising the steps of:
 providing a decorative layer and a core layer, said decorative layer including at least one paper sheet;   impregnating the decorative layer with a resin formulation that includes electrostatically charged synthetic particles disposed within a thermoset resin, wherein the charged synthetic layered particles attract to one another upon application of the resin formulation and are in sufficient concentration to form a barrier within the resin; and   subjecting a stack of the decorative layer and core layer to sufficient heat and pressure to cause the layers to bond to one another.   
     
     
         2 . The method of  claim 1 , wherein the barrier within the resin is operable to provide resistance to chemical degradation. 
     
     
         3 . The method of  claim 1 , wherein the synthetic layered silicate particles are in the range of about 0.005% to 2.00% of the weight of the resin formulation. 
     
     
         4 . The method of  claim 1 , comprising the further step of providing a backer layer and wherein the core layer is disposed between the decorative layer and the backer layer within the stack. 
     
     
         5 . The method of  claim 1 , further comprising the step of providing an overcoat layer disposed on a side of the decorative layer opposite the core layer, which overcoat layer includes the resin formulation. 
     
     
         6 . The method of  claim 1 , further comprising the step of drying the decorative sheet to a volatile content in the range of about 5.0% to 15.0%, prior to subjecting the stack to heat and pressure. 
     
     
         7 . A method for the production of a laminate, comprising the steps of:
 providing a decorative layer having at least one paper sheet, a first side and a second side;   providing a core layer comprising one or more materials selected from the group consisting of plywood, medium density fiberboard, high density fiberboard, particleboard, plastic and nylon;   impregnating the decorative layer with a resin formulation that includes electrostatically charged synthetic particles disposed within a thermoset resin, wherein the charged synthetic layered particles attract to one another upon application of the resin formulation and are in sufficient concentration to form a barrier within the resin; and   stacking the core layer and the decorative layer such that the core layer is disposed in contact with the second side of the decorative layer;   subjecting the stack of layers to heat in the range of about 180° C. to 210° C. and pressure in the range of about 300 psi to 400 psi for a sufficient amount of time to cause the layers to bond to one another.   
     
     
         8 . A method for the production of a laminate, comprising the steps of:
 providing a decorative layer having at least one paper sheet, a first side and a second side;   providing a core layer comprising one or more materials selected from the group consisting of plywood, medium density fiberboard, high density fiberboard, particleboard, plastic and nylon;   applying an overcoat layer to the first side of the decorative layer, which overcoat layer includes a resin formulation having electrostatically charged synthetic particles disposed within a thermoset resin, wherein the charged synthetic layered particles attract to one another upon application of the resin formulation to the decorative layer, and which particles are in sufficient concentration within the overcoat layer to form a barrier within the resin; and   stacking the core layer and the decorative layer such that the core layer is disposed in contact with the second side of the decorative layer;   subjecting the stack of layers to sufficient heat and pressure to cause the layers to bond to one another.