Method of processing laminated decorative sheet for imparting permanent shape thereto

Claim 1

A method of processing a laminated decorative sheet composed of two layers comprising a surface layer and a support layer for imparting a permanent shape thereto, which comprises the steps of: a. preparing a support layer by impregnating a first base paper with a synthetic rubber latex and/or a synthetic resin emulsion selected from the group consisting of styrene-butadiene copolymer, acrylonitrilebutadiene copolymer, methyl methacrylate-butadiene copolymer, polyvinyl acetate, polyvinyl chloride, polyacrylate and mixtures thereof; or by incorporating said synthetic rubber latex and/or said synthetic resin emulsion into a pulp slurry for the base paper by wet end addition, wherein said support layer contains the synthetic rubber and/or synthetic resin emulsion in an amount of at least 22.72 percent by weight; b. preparing a surface layer by impregnating a second base paper with a thermosetting resin selected from the group consisting of diallyl phthalate resin, benzoguanamine resin, unsaturated polyester resin and mixtures thereof; or by coating said thermosetting resin on the support layer obtained in a) above, the thickness of said surface layer being such that the laminate is flexible and capable of being embossed at pressures as low as 10 kg/cm 2 ; c. laminating said surface layer and said support layer at a temperature of from 100° to 200°C under a pressure of from about 4 to about 15 kg/cm 2 to cure the thermosetting resin in said surface layer and thereby obtain a laminated decorative sheet; and d. embossing the laminated decorative sheet using a plane sheet embossing press under the following conditions: temperature within the range of 100°C to 200°C and pressure within the range of 10 kg/cm 2 to 13 kg/cm 2 ; or embossing the laminated decorative sheet using a roll embosser under the following conditions: temperature within the range of 100°C to 200°C, and pressure within the range of 10 kg/cm to 30 kg/cm.

Claim 2

A method of processing a laminated decorative sheet composed of two layers comprising a surface layer and a support layer for imparting a permanent shape thereto, which comprises the steps of: a. preparing a support layer by impregnating a first base paper with a synthetic rubber latex and/or a synthetic resin emulsion selected from the group consisting of styrene-butadiene copolymer, acrylonitrilebutadiene copolymer, methyl methacrylate-butadiene copolymer, polyvinyl acetate, polyvinyl chloride, polyacrylate and mixtures thereof; or by incorporating said synthetic rubber latex and/or said synthetic resin emulsion into a pulp slurry for the base paper by wet end addition, wherein said support layer contains the synthetic rubber and/or synthetic resin emulsion in an amount of at least 22.72 percent by weight; b. preparing a surface layer by impregnating a second base paper with a thermosetting resin selected from the group consisting of diallyl phthalate resin, benzoguanamine resin, unsaturated polyester resin and mixtures thereof; or by coating said thermosetting resin on the support layer obtained in a) above, the thickness of said surface layer being such that the laminate is flexible and capable of being embossed at pressures as low as 10 kg/cm 2 ; c. laminating said surface layer and said support layer at a temperature of from 100° to 200°C under a pressure of from about 4 to about 15 kg/cm 2 to cure the thermosetting resin in said surface layer and thereby obtain a laminated decorative sheet; and d. embossing the laminated decorative sheet using a plane sheet embossing press under the following conditions: temperature within the range of 100°C to 200°C and pressure within the range of 10 kg/cm 2 to 13 kg/cm 2 ; or embossing the laminated decorative sheet using a roll embosser under the following conditions: temperature within the range of 100°C to 200°C, and pressure within the range of 10 kg/cm to 30 kg/cm.