Reverse printed high-pressure laminates

Claim 1

A method of making a heat and pressure consolidated decorative laminate comprising the steps of: A. preparing a core layer comprising a plurality of fibrous sheets impregnated with a resinous material; and then B. placing on top of the core at least one unfilled kraft paper barrier sheet impregnated with at least 30 weight percent of a resin selected from the group consisting of aminotriazine-aldehyde resin, urea-aldehyde resin, thiourea-aldehyde resin, mixtures thereof, and unsaturated polyester resin; and then C. placing on top of the barrier sheet an unfilled, protective, fibrous overlay sheet selected from the group consisting of alpha cellulose and regenerated cellulose paper impregnated with a resin selected from the group consisting of aminotriazine-aldehyde resin, urea-aldehyde resin, thiourea-aldehyde resin, mixtures thereof, and unsaturated polyester resin; said protective sheet having a design printed on the surface facing the barrier sheet, said design having applied thereto a coating of pigmented material, said pigmented material, containing about 2 to 80 weight percent colored pigment dispersed in a carrier medium, and D. heat and pressure consolidating the sheets into a unitary, bonded laminate; wherein the barrier sheet is effective to prevent core resin bleed through to the overlay sheet, and the pigmented material applied to coat the protective sheet design is effective to mask the color of the barrier and core sheets.

Claim 2

A method of making a heat and pressure consolidated decorative laminate comprising the steps of: A. preparing a core layer comprising a plurality of fibrous sheets impregnated with a resinous material; and then B. placing on top of the core at least one unfilled kraft paper barrier sheet impregnated with at least 30 weight percent of a resin selected from the group consisting of aminotriazine-aldehyde resin, urea-aldehyde resin, thiourea-aldehyde resin, mixtures thereof, and unsaturated polyester resin; and then C. placing on top of the barrier sheet an unfilled, protective, fibrous overlay sheet selected from the group consisting of alpha cellulose and regenerated cellulose paper impregnated with a resin selected from the group consisting of aminotriazine-aldehyde resin, urea-aldehyde resin, thiourea-aldehyde resin, mixtures thereof, and unsaturated polyester resin; said protective sheet having a design printed on the surface facing the barrier sheet, said design having applied thereto a coating of pigmented material, said pigmented material, containing about 2 to 80 weight percent colored pigment dispersed in a carrier medium, and D. heat and pressure consolidating the sheets into a unitary, bonded laminate; wherein the barrier sheet is effective to prevent core resin bleed through to the overlay sheet, and the pigmented material applied to coat the protective sheet design is effective to mask the color of the barrier and core sheets.

Claim 10

A method of making a heat and pressure consolidated high pressure decorative laminate comprising the steps of: A. preparing a core layer comprising a plurality of kraft paper sheets impregnated with a phenolic resin; and then B. placing on top of the core at least one kraft paper barrier sheet, containing no filler particles and having a basis of weight of between about 30 lb. to about 125 lb. per 3000 sq. ft. of sheet, impregnated with about 30 to 75 weight percent of an aminotriazine-aldehyde resin; and then C. placing on top of the barrier sheet a protective, fibrous overlay sheet selected from the group consisting of alpha cellulose and regenerated cellulose paper, containing no filler particles and impregnated with an aminotriazine-aldehyde resin; said protective sheet having a design printed on the surface facing the barrier sheet, said design having applied thereto a coating of pigmented material in the range of about 0.05 gram/sq. ft. to about 1.20 gram/sq. ft. of overlay surface, said pigmented material containing about 2 to 80 weight percent pigment of a color contrasting with the printed design dispersed in a carrier medium, and D. heat and pressure consolidating the sheets into a unitary, bonded laminate; wherein the barrier sheet is effective to prevent phenolic resin bleed through to the overlay sheet, and the pigmented material applied to coat the protective sheet design is effective to mask the color of the barrier and core sheets.

Claim 11

A method of making a heat and pressure consolidated high pressure decorative laminate comprising the steps of: A. preparing a core layer comprising a plurality of kraft paper sheets impregnated with a phenolic resin; and then B. placing on top of the core at least one kraft paper barrier sheet, containing no filler particles and having a basis of weight of between about 30 lb. to about 125 lb. per 3000 sq. ft. of sheet, impregnated with about 30 to 75 weight percent of an aminotriazine-aldehyde resin; and then C. placing on top of the barrier sheet a protective, fibrous overlay sheet selected from the group consisting of alpha cellulose and regenerated cellulose paper, containing no filler particles and impregnated with an aminotriazine-aldehyde resin; said protective sheet having a design printed on the surface facing the barrier sheet, said design having applied thereto a coating of pigmented material in the range of about 0.05 gram/sq. ft. to about 1.20 gram/sq. ft. of overlay surface, said pigmented material containing about 2 to 80 weight percent pigment of a color contrasting with the printed design dispersed in a carrier medium, and D. heat and pressure consolidating the sheets into a unitary, bonded laminate; wherein the barrier sheet is effective to prevent phenolic resin bleed through to the overlay sheet, and the pigmented material applied to coat the protective sheet design is effective to mask the color of the barrier and core sheets.