High pressure decorative laminate having a top layer of energy cured acrylated urethane polymer
A decorative laminate lay-up includes a top layer of a radiation and thermally cured composition coated directly onto an untreated decorative paper layer, a paper layer impregnated with resin, and a core layer composed of one or more sheets of paper impregnated with resin.
1. A decorative laminate lay-up, comprising:
a top layer of a radiation and thermally cured composition coated directly onto an untreated decorative paper layer consisting essentially of alpha cellulose paper having a basis weight of approximately 50 grams per square meter to 200 grams per square meter;
a paper layer impregnated with resin; and
a core layer composed of one or more sheets of paper impregnated with resin.
2. The decorative laminate lay-up according to claim 1 , wherein the paper layer is a low basis weight paper impregnated with resin.
3. The decorative laminate lay-up according to claim 2 , wherein the low basis weight paper is impregnated with melamine-formaldehyde resin.
4. The decorative laminate lay-up according to claim 1 , wherein the core layer is composed of one or more color sheets of paper impregnated with melamine-formaldehyde resin.
5. The decorative laminate lay-up according to claim 1 , wherein the paper of the core layer is a Kraft paper that contains melamine-formaldehyde resin on one side and a phenolic resin on the other side.
6. The decorative laminate lay-up according to claim 1 , wherein the radiation and thermally cured composition is comprised of 60% to 90%, by weight, urethane acrylate, 8% to 38%, by weight, reactive diluent, a photo initiator, and 0.5%-5%, by weight, thermal initiator.
7. The decorative laminate lay-up according to claim 1 , wherein the radiation and thermally cured composition employs a fust curing mechanism resulting in creation of free radicals with UV light and a second curing mechanism involving polymerization with the application of thermal energy.
8. A decorative laminate, comprising:
a top layer of a radiation and thermally cured composition coated directly onto an untreated decorative paper layer consisting essentially of alpha cellulose paper having a basis weight of approximately 50 grams per square meter to 200 grams per square meter;
a paper layer impregnated with resin; and
a core layer composed of one or more sheets of paper impregnated with resin.
9. The decorative laminate according to claim 8 , wherein the paper layer is a low basis weight paper impregnated with resin.
10. The decorative laminate according to claim 9 , wherein the low basis weight paper is impregnated with melamine-formaldehyde resin.
11. The decorative laminate according to claim 8 , wherein the core layer is composed of one or more color sheets of paper impregnated with melamine-formaldehyde resin.
12. The decorative laminate according to claim 8 , wherein the paper of the core layer is a Kraft paper that contains melamine-formaldehyde resin on one side and a phenolic resin on the other side.
13. The decorative laminate according to claim 8 , wherein the radiation and thermally cured composition is comprised of 60% to 90%, by weight, urethane acrylate, 8% to 38%, by weight, reactive diluent, a photo initiator, and 0.5%-5%, by weight, thermal initiator.
14. The decorative laminate according to claim 8 , wherein the radiation and thermally cured composition employs a first curing mechanism resulting in creation of free radicals with UV light and a second curing mechanism involving polymerization with the application of thermal energy.
15. A decorative laminate manufactured in accordance with the method comprising:
providing a top layer of a radiation and thermally cured composition coated directly onto an untreated decorative paper layer consisting essentially of alpha cellulose paper having a basis weight of approximately 50 grams per square meter to 200 grams per square meter to define a coated decorative paper layer;
providing a paper layer impregnated with resin;
providing a core layer composed of one or more sheets of paper impregnated with resin;
stacking the top layer, the paper layer, and the core layer to form a laminate lay-up; and
consolidating the laminate lay-up under heat and pressure to form the decorative laminate.
16. The decorative laminate manufactured in accordance with the method according to claim 15 , wherein the paper layer is a low basis weight paper impregnated with resin.
17. The decorative laminate manufactured in accordance with the method according to claim 16 , wherein the low basis weight paper is impregnated with melamine-formaldehyde resin.
18. The decorative laminate manufactured in accordance with the method according to claim 15 , wherein the core layer is composed of one or more color sheets of paper impregnated with melamine-formaldehyde resin.
19. The decorative laminate manufactured in accordance with the method according to claim 15 , wherein the paper is a Kraft paper that contains melamine-formaldehyde resin on one side and a phenolic resin on the other side.
20. The decorative laminate manufactured in accordance with the method according to claim 15 , wherein the radiation and thermally cured composition is comprised of 60% to 90%, by weight, urethane acrylate, 8% to 38%, by weight, reactive diluent, a photo initiator, and 0.5%-5%, by weight, thermal initiator.
21. The decorative laminate manufactured in accordance with the method according to claim 15 , wherein the radiation and thermally cured composition employs a first curing mechanism resulting in creation of free radicals with UV light and a second curing mechanism involving polymerization with the application of thermal energy.