Textured laminate and method of manufacture

Claim 2

A heat and pressure consolidated, durable, heat-stable, embossed design master for use in producing embossed laminates consisting essentially of at least about 45%, by weight, on a resin-free basis, of at least five thermoset resin impregnated asbestos paper sheets of which at least about 85%, by weight, is bound asbestos fibers of No. 3 to No. 7 size, and, on at least one major surface thereof, not more than about 55%, by weight, on a resin-free basis, of at least one sheet of thermoset resin impregnated cellulosic extensible kraft paper which acts as a telegraphing preventative, the master being embossed on said sheeted major surface, said sheeted major surface forming an exterior surface of said master adapted to contact the surface of a laminate during the formation thereof to impart an embossment thereto.

Claim 3

A master according to claim 1 wherein both major surfaces of said consolidated asbestos sheets have at least one sheet of a thermosetting resin impregnated cellulosic extensible kraft paper thereon.

Claim 4

A master according to claim 2 wherein both said sheeted major surfaces are embossed.

Claim 5

A master according to claim 1 wherein said kraft paper has a bonded metallic layer thereon.

Claim 6

A process for producing a heat and pressure consolidated, durable, heat-stable, embossed design master for use in producing embossed laminates which comprises A. releasably impressing a sculptured design plate under heat and pressure into the kraft paper sheeted surface of an assemblage of at least about 45%, by weight, on a resin-free basis, of at least five thermosetting resin impregnated asbestos paper sheets of which at least about 85%, by weight, is bound asbestos fibers of No. 3 to No. 7 size, and not more than about 55%, by weight, on a resin-free basis, of at least one sheet of thermosetting resin impregnated cellulosic extensible kraft paper which acts as a telegraphing preventative to form an embossment on said sheeted surface of said master and recovering the resultant embossed master.

Claim 7

A process for producing a heat and pressure consolidated, durable, heat-stable, embossed design master for use in producing embossed laminates which comprises A. releasably impressing a sculptured design plate under heat and pressure into the kraft paper sheeted surface of an assemblage of at least about 45%, by weight, on a resin-free basis, of at least five thermosetting resin impregnated asbestos paper sheets of which at least about 85%, by weight, is bound asbestos fibers of No. 3 to No. 7 size, and not more than about 55%, by weight, on a resin-free basis, of at least one sheet of thermosetting resin impregnated cellulosic extensible kraft paper which acts as a telegraphing preventative to form an embossment on said sheeted surface of said master and recovering the resultant embossed master.

Claim 8

A process according to claim 5 including B. releasably impressing said embossed design master under heat and pressure into the kraft paper sheeted surface of a second assemblage identical to (A) to produce a reproduction master, and C. releasably impressing said reproduction master under heat and pressure into the kraft paper sheeted surface of a third assemblage identical to (A) to produce a copy master and recovering the resultant embossed copy master.

Claim 9

A process according to claim 5 wherein said assemblage comprises extensible kraft paper on both major surfaces of said assemblage of asbestos sheets.

Claim 10

A process according to claim 7 wherein both major surfaces of said assemblage of asbestos sheets are impressed.

Claim 11

A process according to claim 5 wherein a metal foil is bonded atop said extensible kraft paper sheet.

Claim 12

A process for producing a heat and pressure consolidated, embossed, decorative laminate which comprises A. releasably impressing a sculptured design plate under heat and pressure into the kraft paper sheeted surface of an assemblage of at least about 45%, by weight, on a resin-free basis, of at least five thermosetting resin impregnated asbestos paper sheets of which at least about 85%, by weight, is bound asbestos fibers of No. 3 to No. 7 size, and not more than about 55%, by weight, on a resin-free basis of at least one sheet of thermosetting resin impregnated cellulosic extensible kraft paper which acts as a telegraphing preventative to form an embossment on said sheeted surface of said master, B. releasably impressing said master under heat and pressure into the kraft paper sheeted surface of a second assemblage identical to (A) to produce a reproduction master, C. releasably impressing said reproduction master under heat and pressure into the kraft paper sheeted surface of a third assemblage identical to (A) to produce a copy master and D. releasably impressing said copy master under heat and pressure into a superimposed assemblage of thermosetting resin impregnated kraft sheets, a thermosetting resin impregnated decorative sheet and a thermosetting resin impregnated overlay sheet and recovering the resultant embossed decorative laminate.

Claim 13

A process for producing a heat and pressure consolidated, embossed, decorative laminate which comprises A. releasably impressing a sculptured design plate under heat and pressure into the kraft paper sheeted surface of an assemblage of at least about 45%, by weight, on a resin-free basis, of at least five thermosetting resin impregnated asbestos paper sheets of which at least about 85%, by weight, is bound asbestos fibers of No. 3 to No. 7 size, and not more than about 55%, by weight, on a resin-free basis of at least one sheet of thermosetting resin impregnated cellulosic extensible kraft paper which acts as a telegraphing preventative to form an embossment on said sheeted surface of said master, B. releasably impressing said master under heat and pressure into the kraft paper sheeted surface of a second assemblage identical to (A) to produce a reproduction master, C. releasably impressing said reproduction master under heat and pressure into the kraft paper sheeted surface of a third assemblage identical to (A) to produce a copy master and D. releasably impressing said copy master under heat and pressure into a superimposed assemblage of thermosetting resin impregnated kraft sheets, a thermosetting resin impregnated decorative sheet and a thermosetting resin impregnated overlay sheet and recovering the resultant embossed decorative laminate.