Granted Patent B2

US 12,485,653 · App. 18/155,891 · Granted Dec 2, 2025

Inventor: Benjamin Clement (Waregem, BE)

Assignee: Unilin, BV

B32B21/06B05D7/534B32B21/10B32B38/08B32B38/164B44C5/0469B32B2250/02B32B2260/028B32B2260/046B32B2451/00B41J2/01

Abstract

Claims (49)

1 . A method for manufacturing a laminate assembly, the method comprising:

providing a decorative paper including a printed pattern;

impregnating the decorative paper with a first thermosetting resin;

laminating the resin provided decorative paper on a substrate; and

impregnating the decorative paper with a second thermosetting resin before laminating;

wherein the first thermosetting resin,

is provided in a dry weight amount of at least 3.5 g/sqm on the decorative paper, and/or

is provided in a dry weight amount of less than 50 g/sqm on the decorative paper;

wherein the first and the second thermosetting resins are different from each other;

wherein the first thermosetting resin is a (methacrylate resin;

wherein the second thermosetting resin is a melamine formaldehyde based resin.

2 . The method according to claim 1 , wherein the first thermosetting resin satisfies less than 50% of the absorption capacity of the decorative paper; and/or

wherein the first thermosetting resin satisfies at least 5% of the absorption capacity of the decorative paper.

3 . The method according to claim 1 , wherein the second thermosetting resin is provided to satisfy up to 100% or more of the absorption capacity of the decorative paper.

4 . The method according to claim 1 , wherein the second thermosetting resin is provided in a dry weight amount of at least 20 g/sqm on the decorative paper; and/or

wherein the second thermosetting resin is provided in a dry weight amount of less than 120 g/sqm on the decorative paper.

5 . The method according to claim 1 , wherein the first thermosetting resin has a lower solid content than the second thermosetting resin.

6 . The method according to claim 1 , wherein the first thermosetting resin has a solid content below 45%; and/or

wherein the second thermosetting resin has a solid content between 45 and 62%; and/or

wherein the first thermosetting resin shows a viscosity below 20s measured with a Din cup 4.

7 . The method according to claim 1 , further comprising partially drying the decorative paper between impregnating with the first thermosetting resin and impregnating with the second thermosetting resin.

8 . The method according to claim 1 , wherein the decorative paper comprises a base paper having a base paper weight higher than 20 grams per square meter.

9 . The method according to claim 1 , wherein the printed pattern is formed using inkjet color pigments; and

wherein the printed pattern comprises an average dry quantity of pigment below 9 g/sqm.

10 . A method for manufacturing a laminate assembly, the method comprising:

providing a decorative paper including a printed pattern;

impregnating the decorative paper with a first thermosetting resin;

laminating the resin provided decorative paper on a substrate;

impregnating the decorative paper with a second thermosetting resin before laminating;

wherein the first thermosetting resin,

has a solid content below 45%, and/or

has a viscosity below 20s measured with a Din cup 4;

wherein the first and the second thermosetting resins are different from each other;

wherein the first thermosetting resin is a (meth)acrylate resin;

wherein the second thermosetting resin is a melamine-formaldehyde based resin.

11 . A method for manufacturing a decorative paper for decorative panels, the method comprising:

providing a printable paper;

printing a decorative pattern on a surface of the printable paper; and

impregnating the printed paper with a first thermosetting resin;

impregnating the printed paper with a second thermosetting resin;

wherein the first thermosetting resin,

is provided in a dry weight amount of at least 3.5 g/sqm on the decorative paper, and/or

is provided in a dry weight amount of less than 50 g/sqm on the decorative paper;

wherein the first and the second thermosetting resins are different from each other;

wherein the first thermosetting resin is a (methacrylate resin;

wherein the second thermosetting resin is a melamine-formaldehyde based resin.

12 . The method according to claim 11 , wherein the first thermosetting resin is provided to satisfy less than the 50% of the absorption capacity of the decorative paper.

13 . The method according to claim 11 , wherein the first thermosetting resin satisfies at least the 5% of the absorption capacity of the decorative paper.

14 . The method according to claim 11 , further comprising partially drying the decorative paper after impregnating the decorative paper with the first thermosetting resin.

Assignments (2)

Priority Claims (1)

Continuity (1)

References Cited (20)