Multiple layer decorated paper, laminate prepared therefrom and process

Claim 2

An abrasion resistant laminate comprising a core and a resin impregnated cured decorated surface paper, said surface paper, prior to resin impregnation comprising (a) a paper base layer; (b) a top layer integral with said base layer and comprising from about 2 to 100 percent by weight of abrasion resisting mineral particles having a hardness of from 7 to 10 on the Moh scale and an average particle size ranging from 10 to 75 microns, and (c) printing applied on the exposed outer surface of said top layer.

Claim 3

The abrasion resistant laminate of claim 1 wherein said resin is a thermosetting resin.

Claim 4

The abrasion resistant laminate of claim 1 wherein said top layer includes fibers.

Claim 5

The abrasion resistant laminate of claim .[.2.]. .Iadd.3 .Iaddend.wherein said top layer comprises from 10% to 50% of said mineral particles and from 90% to 50% of said fibers.

Claim 6

The abrasion resistant laminate of claim 1 wherein said mineral particles are alumina.

Claim 7

The abrasion rsistant laminate of claim 1 wherein said mineral particles are silica.

Claim 8

The abrasion resistant laminate of claim 1 wherein said mineral particles are silicon carbide.

Claim 9

The abrasion resistant laminate of claim 1 wherein said mineral particles are a mixture of tungsten carbide and borron carbide.

Claim 10

The abrasion resistant laminates of claim 1 wherein said top layer has a basis weight ranging from 1 to 20 lbs. per ream of 3000 sq. ft.

Claim 11

The abrasion resistant laminate of claim 1 wherein said base layer comprises fibers.

Claim 12

The abrasion resistant laminate of claim 9 wherein said base layer has a basis weight ranging from 10 to 100 lbs. per ream of 3000 sq. ft.

Claim 13

The abrasion resistant laminate of claim 1 wherein said base layer comprises fibers and opacifying pigments, and has a basis weight ranging from 30 to 100 lbs. per ream of 3000 sq. ft. and said top layer comprises from 10% to 50% alumina having a particle size distribution of 96% in the size range of 20 to 60 microns and 90% to 50% of bleached hardwood fibers, said top layer having a basis weight ranging from 4 to 14 lbs. per ream of 3000 sq. ft. .Iadd.13. An abrasion resistant laminate comprising a core and a resin impregnated printed decor paper, said printed decor paper comprising: (a) a base paper layer of fibers and opacifying pigments; and (b) integral with said base paper layer a printed layer comprising a mixture of abrasion resisting mineral particles having a hardness of 7 to 10 on the Moh scale and print receptive fibers, the fibers and abrasion resisting mineral particles being present in said printed layer in an amount and size to impart printability to the printed surface of the printed layer and to provide such abrasion resistance to said decor paper that upon lamination, without the presence of overlay paper, the resulting laminate has a wear rate of under 0.08 gm/100 cycles and a minimum of 400 cycles in the NEMA Method LD1-2.01 abrasion test, the printing on said printed layer being on the surface opposite the surface integral with said base layer. .Iaddend. .Iadd.14. The abrasion resistant laminate of claim 13 wherein said base paper layer has a dry basis weight ranging from 30 to 100 lbs. per ream of 3000 sq. ft. and said printed layer has a dry basis weight ranging from 4 to 14 lbs. per ream of 3000 sq. ft. .Iaddend. .Iadd.15. The abrasion resistant laminate of claim 13 wherein said printed layer includes a small amount of adhesive. .Iaddend. .Iadd.16. The abrasion resistant laminate of claim 15 wherein said adhesive is starch. .Iaddend. .Iadd.17. The abrasion resistant laminate of claim 13 wherein said decor paper includes a thin fiber layer over said printable layer. .Iaddend. .Iadd.18. An abrasion resistant laminate comprising a core and a resin impregnated printed decor paper, said printed decor paper comprising: (a) a base paper layer; (b) integral with said base paper layer a printed layer comprising a mixture of abrasion resisting mineral particles having a hardness of 7 to 10 on the Moh scale and print receptive fibers, the fibers and abrasion resisting mineral particles being present in said printed layer in an amount and size to impart printability to the printed layer and to provide such abrasion resistance to said decor paper that upon lamination, without the presence of overlay paper, the resulting laminate has a wear rate of under 0.08 gm/100 cycles and a minimum of 400 cycles in the NEMA Method LD1-2.01 abrasion test; and (c) the printing on said printed layer being on the surface opposite the

Claim 14

surface integral with said base paper layer. .Iaddend. .Iadd. 19. The abrasion resistant laminate of claim 18 wherein said base paper layer has a dry basis weight ranging from 30 to 100 lbs. per ream of 3000 sq. ft. and said printed layer has a dry basis weight ranging from 4 to 14 lbs. per ream of 3000 sq. ft. .Iaddend..Iadd. 20. An abrasion resistant laminate comprising a core and a resin impregnated printed decor paper, said printed decor paper comprising: (a) a base paper layer of fibers and opacifying pigments; and (b) integral with said base paper layer a printed layer comprising a mixture of abrasion resisting alumina particles, print receptive fibers and starch, the fibers and abrasion resisting alumina particles being present in said printed layer in an amount and size to impart printability to the printable surface of the printed layer and to provide such abrasion resistance to said decor paper that upon lamination, without the presence of overlay paper, the resulting laminate has a wear rate of under 0.08 gm/100 cycles and a minimum of 400 cycles in the NEMA Method LD1-2.01 abrasion test, the printing on said printed layer being on the surface opposite the surface integral with said base paper layer. .Iaddend. .Iadd.21. The abrasion resistant laminate of claim 20 wherein said base paper layer has a dry basis weight ranging from 30 to 100 lbs. per ream of 3000 sq. ft. and said printed layer has a dry basis weight ranging from 4 to 14 lbs. per ream of 3000 sq. ft. .Iaddend..Iadd. 22. The abrasion resistant laminate of claim 20 wherein said decor paper includes a thin fiber layer over said printed layer. .Iaddend.