Leather laminated decorative panel
View Patent ↗A heat and pressure consolidated laminate, and method for producing the same, is provided that includes in superimposed relationship a decorative layer consisting essentially of a leather material, an underlay layer, a substrate, and an optional backer layer. The substrate has a first surface and a second surface opposite one another. The underlay layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed between the decorative layer and the first layer of the substrate. The backer layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed contiguous with the second surface of the substrate.
1. A method for the production of a heat and pressure consolidated leather laminate comprising the steps of:
setting the temperature of a thermosetting press to a predetermined temperature;
stacking in a superimposed relationship a backing layer, a substrate, an underlay layer, a decorative layer comprised essentially of leather, and a textured release sheet;
inserting the stacked, superimposed layers into the thermosetting press;
increasing the pressure of the thermosetting press to a predetermined pressure;
maintaining the stacked layers in the heated, pressurized thermosetting press for a period of time sufficient to form a laminate;
removing the laminate from the thermosetting press; and
removing the textured release sheet from the laminate;
wherein the textured release sheet imparts an embossed texture on the decorative layer.
2. The method of claim 1 , wherein said predetermined temperature ranges from about 110° C. to about 250° C.
3. The method of claim 1 , wherein said predetermined pressure ranges from about 250 PSI to about 450 PSI.
4. The method of claim 1 , wherein said period of time sufficient to form a laminate ranges from about 20 seconds to about 150 seconds.
5. A method for the production of a heat and pressure consolidated leather laminate comprising the steps of:
setting the temperature of the continuous thermosetting press to a predetermined temperature;
setting the pressure of the press to a predetermined pressure;
stacking in a superimposed relationship a backing layer, a substrate, an underlay layer, a decorative layer comprised essentially of leather, and a textured release sheet upstream from a continuous thermosetting press;
feeding the stacked, superimposed layers into the continuous thermosetting press;
maintaining the stacked layers in the heated, pressurized continuous thermosetting press for a period of time sufficient to form a laminate;
removing the laminate from the thermosetting press; and
removing the textured release sheet from the laminate;
wherein the textured release sheet imparts an embossed texture on the decorative layer.
6. The method of claim 5 , further comprising the step of transporting the laminate to handling equipment located downstream from the continuous thermosetting press.
7. The method of claim 5 , wherein said predetermined temperature ranges from about 110° C. to about 250° C.
8. The method of claim 5 , wherein said predetermined pressure ranges from about 250 PSI to about 450 PSI.
9. The method of claim 5 , wherein said period of time sufficient to form a laminate ranges from about 20 seconds to about 150 seconds.
10. A method for the production of a heat and pressure consolidated leather laminate comprising the steps of:
setting the temperature of the continuous thermosetting press to a predetermined temperature, said predetermined temperature ranging from about 110° C. to about 250° C.;
setting the pressure of the press to a predetermined pressure, said predetermined pressure ranging from about 250 PSI to about 450 PSI;
stacking in a superimposed relationship a backing layer, a substrate, an underlay layer, a decorative layer comprised essentially of leather, and a textured release sheet upstream from a continuous thermosetting press;
feeding the stacked, superimposed layers into the continuous thermosetting press;
selecting a line speed of the continuous thermosetting press that allows the stacked, superimposed layers to remain in the heated, pressurized press for a period of time sufficient to form a laminate from said layers;
removing the laminate from the thermosetting press; and
removing the textured release sheet from the laminate;
wherein the textured release sheet imparts an embossed texture on the decorative layer.