Compound formable decorative laminate door panel
A decorative laminate door panel includes a compound formable decorative laminate including a resin impregnated decorative layer composed of a bilaterally stretchable decorative sheet and a resin impregnated core layer composed of a bilaterally stretchable kraft paper. The door panel also includes a substrate to which the decorative laminate is bound.
1 . A decorative laminate door panel, comprising:
a compound formable decorative laminate including a resin impregnated decorative layer composed of a bilaterally stretchable 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.
2 . The decorative laminate door panel according to claim 1 , wherein the decorative layer is impregnated with a melamine resin.
3 . The decorative laminate door panel according to claim 1 , wherein the core layer is impregnated with a phenolic resin.
4 . The decorative laminate door panel according to claim 1 , wherein the decorative sheet is x creped so as to impart stretchability thereto.
5 . The decorative laminate door panel according to claim 1 , wherein the kraft paper is x creped so as to impart stretchability thereto.
6 . The decorative laminate door panel according to claim 1 , wherein the decorative sheet is capable of being stretched at least approximately 20%.
7 . The decorative laminate door panel according to claim 1 , wherein the kraft paper is capable of being stretched at least approximately 20%.
8 . The decorative laminate door panel according to claim 1 , wherein the substrate is medium density fiberboard.
9 . The decorative laminate door panel according to claim 8 , wherein the substrate is compound formable.
10 . The decorative laminate door panel according to claim 1 , wherein substrate is compound formable.
11 . A method of fabricating a compound formable decorative laminate door panel, comprising:
preparing a decorative sheet such that it is bilaterally stretchable;
preparing a kraft paper such that it is bilaterally stretchable;
impregnating the preprocessed kraft paper with a resin;
layering the decorative sheet and the kraft paper upon a compound formable substrate; and
bonding the layered decorative sheet, kraft paper and substrate to form a panel.
12 . The method according to claim 11 , further including the step of impregnating the decorative sheet with a melamine resin.
13 . The method according to claim 11 , wherein the step of impregnating the kraft paper includes impregnating the kraft paper with a phenolic resin.
14 . The method according to claim 11 , wherein the step of preparing the decorative sheet includes x creping so as to impart stretchability thereto.
15 . The method according to claim 11 , wherein the step of preparing the kraft paper includes x creping so as to impart stretchability thereto.
16 . The method according to claim 11 , wherein the prepared decorative sheet is capable of being stretched at least approximately 20%.
17 . The method according to claim 11 , wherein the prepared kraft paper is capable of being stretched at least approximately 20%.
18 . The method according to claim 11 , wherein the substrate is medium density fiberboard.
19 . The method according to claim 11 , further including the step of consolidating the decorative sheet and the kraft paper prior to the step of layering.
20 . The method according to claim 19 , wherein the step of bonding includes pressing the decorative sheet, kraft paper and substrate under heat and pressure to form a panel.
21 . The method according to claim 20 , wherein the step of layering includes positioning a tie layer between the kraft paper and the substrate.
22 . The method according to claim 20 , wherein the step of bonding includes simultaneously pressing and forming the decorative sheet, kraft paper and substrate.
23 . The method according to claim 11 , wherein the step of layering includes positioning a tie layer between the kraft paper and the substrate.
24 . A method of fabricating a compound formable decorative laminate door panel, comprising:
layering a decorative sheet and a kraft paper upon a compound formable substrate; and
simultaneously consolidating and forming the layered decorative sheet, kraft paper and substrate under heat and pressure to form a panel.