Decorative Multi-Layer Surfacing Materials Having Embedded Conductive Materials, Solid Surfaces Made Therewith, Methods for Making Such Surfacing Materials and Uses Therefor

Abstract

Decorative, multi-layer surfacing materials, surfaces made therewith, methods of making such and wireless power transmission using the same, which surfacing materials comprise: a first resin-impregnated paper layer and a second resin-impregnated paper layer, and a first conductive material having a first terminus and a second terminus and capable of carrying an electric current from the first terminus to the second terminus; wherein the first conductive material is disposed on a first surface of the first resin-impregnated paper layer; wherein the first resin-impregnated paper layer and the second resin-impregnated paper layer are disposed in a stacked and compressed such that the first conductive material is encapsulated between the first resin-impregnated paper layer and the second resin-impregnated paper layer; and wherein at least one of the first resin-impregnated paper layer, the second resin-impregnated paper layer or an optional additional resin-impregnated paper layer is a decorative layer,

What is claimed is: 
     
         1 . A decorative, multi-layer surfacing material comprising: a first resin-impregnated paper layer and a second resin-impregnated paper layer, and a first conductive material having a first terminus and a second terminus and capable of carrying an electric current from the first terminus to the second terminus; wherein the first conductive material is disposed on a first surface of the first resin-impregnated paper layer; wherein the first resin-impregnated paper layer and the second resin-impregnated paper layer are disposed in a stacked and compressed relationship such that the first conductive material is encapsulated between the first resin-impregnated paper layer and the second resin-impregnated paper layer; and wherein at least one of the first resin-impregnated paper layer, the second resin-impregnated paper layer or an optional additional resin-impregnated paper layer is a decorative layer. 
     
     
         2 . The decorative, multi-layer surfacing material according to  claim 1 , further comprising at least one outer protective layer. 
     
     
         3 . The decorative, multi-layer surfacing material according to  claim 2 , wherein the at least one outer protective layer comprises a polymer selected from the group consisting of acrylics, polyesters, melamine resins, vinyl resins, and urethanes. 
     
     
         4 . The decorative, multi-layer surfacing material according to  claim 2 , wherein the at least one outer protective layer comprises a melamine resin. 
     
     
         5 . The decorative, multi-layer surfacing material according to  claim 1 , wherein the decorative layer comprises a visual attribute selected from the group consisting of colorings, patterns, indicia, pictures, embedded objects, and combinations thereof 
     
     
         6 . The decorative, multi-layer surfacing material according to  claim 1 , wherein the first conductive material disposed on the first surface of the first resin-impregnated paper layer is patterned. 
     
     
         7 . The decorative, multi-layer surfacing material according to  claim 6 , wherein the patterned first conductive material comprises a continuous meandering line selected from the group consisting of spirals, spirangles, sawtooth waves and combinations thereof 
     
     
         8 . The decorative, multi-layer surfacing material according to  claim 1 , further comprising an enhancement layer comprising a soft magnetic material dispersed in a thermoset resin, the enhancement layer disposed and cured between the first conductive material and one of the first and second resin impregnated layers. 
     
     
         9 . The decorative, multi-layer surfacing material according to  claim 1 , further comprising a third resin-impregnated paper layer and a second conductive material having a first terminus and a second terminus and capable of carrying an electric current from the first terminus to the second terminus, wherein the second conductive material is disposed on a second surface of the first resin-impregnated paper layer, wherein the second surface is on a side of the first resin-impregnated paper layer opposite of the first surface, and wherein the first resin-impregnated paper layer and the third resin-impregnated paper layer are disposed in a stacked and compressed and relationship such that the second conductive material is encapsulated between the first resin-impregnated paper layer and the third resin-impregnated paper layer. 
     
     
         10 . The decorative, multi-layer surfacing material according to  claim 9 , wherein the first conductive material and the second conductive material are conductively connected through the first resin-impregnated paper layer. 
     
     
         11 . The decorative, multi-layer surfacing material according to  claim 9 , further comprising an enhancement layer comprising a soft magnetic material dispersed in a thermoset resin, the enhancement layer disposed and cured between one of the first and second conductive materials and an adjacent resin impregnated layer. 
     
     
         12 . The decorative, multi-layer surfacing material according to  claim 10 , further comprising a third conductive material having a first terminus and a second terminus and capable of carrying an electric current, wherein the third conductive material is disposed on a first surface of the second resin-impregnated paper layer, wherein the third conductive material is in a facing relationship with the first conductive material, wherein the resin impregnating the first and second paper layers comprises a thermoset resin, and wherein an additional layer selected from the group consisting of an interposed resin-impregnated paper layer, an enhancement layer comprising a soft magnetic material dispersed in a thermoset resin, and combinations thereof, is disposed and cured between the first conductive material and the third conductive material. 
     
     
         13 . The decorative, multi-layer surfacing material according to  claim 12 , wherein the first conductive material and the third conductive material are conductively connected through the additional layer. 
     
     
         14 . The decorative, multi-layer surfacing material according to  claim 1 , further comprising a first conductive protrusion and a second conductive protrusion extending from the first terminus and second terminus of the first conductive material, respectively, to two positions along a periphery of the surfacing material and configured such that an external electrical current can be supplied to the conductive protrusion. 
     
     
         15 . The decorative, multi-layer surfacing material according to  claim 1 , further comprising a circuit component disposed on the first surface of the first resin-impregnated paper layer and in conductive contact with the first conductive material. 
     
     
         16 . The decorative, multi-layer surfacing material according to  claim 1 , wherein the material is a high pressure laminate. 
     
     
         17 . A solid surface comprising the decorative, multi-layer surfacing material according to  claim 1  disposed on a supporting substrate. 
     
     
         18 . A method comprising:
 (a) providing at least two sheets of resin-impregnated paper;   (b) disposing a patterned conductive material on a surface of one of the at least two sheets of resin-impregnated paper; and   (c) compressing the at least two sheets of resin-impregnated paper together with heat and pressure in a facing relationship wherein the conductive material is disposed between the at least two sheets of resin-impregnated paper.   
     
     
         19 . The method according to  claim 18 , wherein at least one of the at least two sheets of resin-impregnated paper or an additional sheet of resin-impregnated paper comprises a decorative layer. 
     
     
         20 . The method according to  claim 18 , wherein a second patterned conductive material is disposed on a second surface of the one of the at least two sheets of resin-impregnated paper and the first and second conductive material are conductively connected through the sheet. 
     
     
         21 . (canceled) 
     
     
         22 . (canceled)