Directly laminated plate

Abstract

The invention relates to a directly laminated plate or board that is produced by hot-pressing a core with absorbent, resin-impregnated layers, wherein at least one board surface has a decorative layer with a graphic representation of the surface of an imitated material, in addition to a resin-impregnated, transparent cover layer on said decorative layer, with a relief-like reproduction of the surface structure of the imitated material, where a resinous intermediate ply is provided between the decorative layer and the core.

1 . A method for producing a directly laminated plate or board by hot-pressing, comprising the steps of:
 arranging a resinous intermediate ply adhesive layer on a surface of a core of wood material core;   arranging a decorative paper layer on the intermediate ply adhesive layer, the decorative layer having a graphic representation of a surface of an imitated material;   arranging a resin-impregnated transparent cover layer bearing a relief-like reproduction of the graphic representation on the decorative layer so that the relief-like reproduction aligns with the graphic representation on the decorative layer, thereby yielding a structure comprising the following:
 a) the resin-impregnated transparent cover layer on top of the decorative paper layer; 
 b) the decorative paper layer on top of the resinous intermediate ply adhesive layer; 
 c) the intermediate ply adhesive layer on top of the wood material core material; and 
 d) the wood material core material; 
   hot-pressing the layers together in a single pressing step so that the layers are bonded together and the relief-like representation on the transparent cover layer corresponds to the graphic representation of the decorative layer;   wherein the intermediate ply adhesive layer allows for flexibility of the decorative paper layer so as to prevent crushing of the decorative paper layer by the core.   
     
     
         2 . The method of  claim 1  wherein the intermediate ply adhesive layer is arranged directly on the core material, the decorative layer is arranged directly on the intermediate ply adhesive layer, and the resin-impregnated, transparent cover layer is arranged directly on the decorative paper layer. 
     
     
         3 . The method of  claim 1  wherein the hot-pressing comprises pressing the decorative paper layer deeper into the intermediate ply adhesive layer at impressed points of the transparent cover layer than at points on either side of the impressed points. 
     
     
         4 . The method of  claim 2  wherein the hot-pressing comprises pressing the decorative paper layer deeper into the intermediate ply adhesive layer at impressed points of the transparent cover layer than at points on either side of the impressed points. 
     
     
         5 . The method of  claim 1  wherein the hot-pressing comprises pressing the decorative paper layer deeper into the intermediate ply adhesive layer at impressed points of the transparent cover layer than at points on either side of the impressed points, with no crushing of paper fibers in the decorative paper layer. 
     
     
         6 . The method of  claim 2  wherein the hot-pressing comprises pressing the decorative paper layer deeper into the intermediate ply adhesive layer at impressed points of the transparent cover layer than at points on either side of the impressed points, with no crushing of paper fibers in the decorative paper layer. 
     
     
         7 . The method of  claim 1  wherein the intermediate ply adhesive layer is a coating applied to the core material. 
     
     
         8 . The method of  claim 1  wherein the intermediate ply adhesive layer is an adhesive layer comprising a matrix embedded with impregnating resin and prefabricated prior to the hot pressing. 
     
     
         9 . The method of  claim 8  wherein the intermediate ply adhesive layer has a quantity of impregnating resin which is tailored to the absorbency of the core material. 
     
     
         10 . The method of  claim 8  wherein the matrix of the intermediate ply adhesive layer is paper. 
     
     
         11 . The method of  claim 1  wherein the decorative paper layer is not impregnated with resin and is dry prior to hot pressing. 
     
     
         12 . The method of  claim 1  wherein the decorative paper layer comprises a quantity of impregnating resin below the paper's saturation point for the resin prior to hot pressing. 
     
     
         13 . The method of  claim 12  wherein the decorative paper layer comprises a quantity of impregnating resin between 0% and 20% of the paper's saturation for the resin prior to hot pressing. 
     
     
         14 . The method of  claim 12  wherein the decorative paper layer comprises a quantity of impregnating resin between 20% and 40% of the paper's saturation for the resin prior to hot pressing. 
     
     
         15 . The method of  claim 12  wherein the decorative paper layer comprises a quantity of impregnating resin between 40% and 60% of the paper's saturation for the resin prior to hot pressing. 
     
     
         16 . The method of  claim 12  wherein the decorative paper layer comprises a quantity of impregnating resin between 80% and 100% of the paper's saturation for the resin prior to hot pressing. 
     
     
         17 . The method of  claim 1  wherein:
 the intermediate ply adhesive layer is arranged directly on the core material, the decorative layer is arranged directly on the intermediate ply adhesive layer, and the resin-impregnated, transparent cover layer is arranged directly on the decorative paper layer; 
 the hot-pressing comprises pressing the decorative paper layer deeper into the intermediate ply adhesive layer at impressed points of the transparent cover layer than at points on either side of the impressed points; 
 the intermediate ply adhesive layer is an adhesive layer comprising a paper matrix embedded with impregnating resin and prefabricated prior to the hot pressing; 
 the decorative paper layer is not impregnated with resin and is dry prior to hot pressing; and 
 the arranging the resinous intermediate ply adhesive layer on the surface of the core of wood material core.