IP Library › Patent Application 10845068
Patent Application
App. No. 10/845,068

Compound formable decorative laminate

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Quick Facts
Patent No.
US None
App. No.
10/845,068
Abstract

A compound formable decorative laminate includes a decorative layer composed of a bilaterally stretchable polyolefin decorative sheet and a resin impregnated core layer composed of a bilaterally stretchable kraft paper. The laminate is formed by providing a decorative sheet composed of a polyolefin that is bilaterally stretchable, providing a kraft paper that is bilaterally stretchable,—impregnating the kraft paper with a resin, layering the decorative sheet and the kraft paper, and—consolidating the layered decorative sheet and kraft paper under heat and pressure to form a sheet of decorative laminate.

Claims (57)

1 . A compound formable decorative laminate, comprising:

a decorative layer composed of a bilaterally stretchable polyolefin decorative sheet; and

a resin impregnated core layer composed of a bilaterally stretchable paper.

2 . The decorative laminate according to claim 1 , wherein the core layer is impregnated with a phenolic resin.

3 . The decorative laminate according to claim 1 , wherein the paper of the core layer is x-creped so as to impart stretchability thereto.

4 . The decorative laminate according to claim 1 , wherein the decorative sheet is capable of being stretched at least approximately 20%.

5 . The decorative laminate according to claim 1 , wherein the paper of the core layer is capable of being stretched at least approximately 20%.

6 . The decorative laminate according to claim 1 , further including an overlay positioned upon the decorative layer such that the decorative layer is positioned between the core layer and the overlay.

7 . The decorative laminate according to claim 6 , wherein the overlay is a nonwoven material.

8 . The decorative laminate according to claim 7 , wherein the overlay is composed of polyester fibers.

9 . The decorative laminate according to claim 7 , wherein the overlay is composed of a blend of polyester and rayon fibers.

10 . A laminate lay-up, comprising:

a resin impregnated decorative layer composed of a bilaterally stretchable polyolefin decorative sheet; and

a resin impregnated core layer composed of a bilaterally stretchable paper.

11 . The laminate lay-up according to claim 10 , wherein the core layer is impregnated with a phenolic resin.

12 . The laminate lay-up according to claim 10 , wherein the paper of the core layer is x-creped so as to impart stretchability thereto.

13 . The laminate lay-up according to claim 10 , wherein the decorative sheet is capable of being stretched at least approximately 20%.

14 . The laminate lay-up according to claim 10 , wherein the paper of the core layer is capable of being stretched at least approximately 20%.

15 . The laminate lay-up according to claim 10 , wherein the core layer includes multiple sheets of bilaterally stretchable kraft paper.

16 . The decorative laminate according to claim 10 , further including an overlay positioned upon the decorative layer such that the decorative layer is positioned between the core layer and the overlay.

17 . The decorative laminate according to claim 16 , wherein the overlay is a nonwoven material.

18 . A method of fabricating a compound formable decorative laminate, comprising:

providing a decorative sheet that is bilaterally stretchable, the decorative sheet being composed of a polyolefin;

providing a paper that is bilaterally stretchable;

impregnating the paper with a resin;

layering the decorative sheet and the paper, and

consolidating the layered decorative sheet and paper under heat and pressure to form a sheet of decorative laminate.

19 . The method according to claim 18 , wherein the step of impregnating the paper includes impregnating the paper with a phenolic resin.

20 . The method according to claim 18 , wherein the step of providing the paper includes x-creping so as to impart stretchability thereto.

21 . The method according to claim 18 , wherein the decorative sheet is capable of being stretched at least approximately 20%.

22 . The method according to claim 18 , wherein the paper is capable of being stretched at least approximately 20%.

23 . The method according to claim 18 , further including the step and positioning an overlay upon the decorative layer such that the decorative layer is positioned between the core layer and the overlay.

24 . The method according to claim 23 , wherein the overlay is nonwoven material.

25 . A compound formable decorative laminate panel, comprising:

a decorative layer composed of a bilaterally stretchable polyolefin decorative sheet;

a compound formable substrate; and

a resin impregnated core layer positioned between the decorative layer and the substrate.

26 . The decorative laminate panel according to claim 25 , wherein the compound formable substrate is medium density fiberboard.

27 . The decorative laminate panel according to claim 26 , wherein the medium density fiber board is approximately 0.3175 cm thick.

28 . The decorative laminate panel according to claim 26 , wherein the core layer is composed of a bilaterally stretchable kraft paper.

29 . The decorative laminate panel according to claim 28 , wherein the kraft paper is x-creped so as to impart stretchability thereto.

30 . The decorative laminate panel according to claim 25 , further including an overlay positioned upon the decorative layer such that the decorative layer is positioned between the core layer and the overlay.

31 . The decorative laminate panel according to claim 30 , wherein the overlay is a nonwoven material.

32 . A decorative laminate panel, comprising:

a compound formable decorative laminate including a bilaterally stretchable polyolefin decorative sheet and a resin impregnated core layer composed of a bilaterally stretchable kraft paper, and

a substrate to which the decorative laminate is bound.

33 . The decorative laminate panel according to claim 32 , wherein the core layer is impregnated with a phenolic resin.

34 . The decorative laminate panel according to claim 32 , wherein the kraft paper is x-creped so as to impart stretchability thereto.

35 . The decorative laminate panel according to claim 32 , wherein the decorative sheet is capable of being stretched at least approximately 20%.

36 . The decorative laminate panel according to claim 32 , wherein the kraft paper is capable of being stretched at least approximately 20%.

37 . The decorative laminate panel according to claim 32 , further including an overlay positioned upon the decorative layer such that the decorative layer is positioned between the core layer and the overlay.

38 . The decorative laminate panel according to claim 37 , wherein the overlay is a nonwoven material.

39 . A compound formable decorative laminate, comprising:

a polyolefin decorative layer; and

a resin impregnated core layer.

40 . The decorative laminate according to claim 39 , wherein the core layer is composed of resin impregnated kraft paper.

41 . The decorative laminate according to claim 40 , wherein the core layer is impregnated with a phenolic resin.

Assignments (1)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 22, 2007
From: INGRIM, MICHAEL E.
To: PREMARK RWP HOLDINGS, INC.
Reel/Frame 019088/0416 →