Connect public, paid and private patent data with Google Patents Public Datasets

Leather laminated decorative panel

Download PDF

Info

Publication number
US20040151936A1
US20040151936A1 US10762104 US76210404A US2004151936A1 US 20040151936 A1 US20040151936 A1 US 20040151936A1 US 10762104 US10762104 US 10762104 US 76210404 A US76210404 A US 76210404A US 2004151936 A1 US2004151936 A1 US 2004151936A1
Authority
US
Grant status
Application
Patent type
Prior art keywords
layer
decorative
leather
substrate
press
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10762104
Inventor
Sylvie Gauthier
George Tsangarides
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
DEUTSCHE BANK TRUST Co AMERICAS
Original Assignee
Panolam Industries
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date

Links

Images

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00Layered products comprising a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04Layered products comprising a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/06Layered products comprising a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • B32B38/06Embossing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00Layered products comprising a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/02Layered products comprising a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00Layered products comprising a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/02Layered products comprising a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch
    • B32B9/025Layered products comprising a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch comprising leather
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00Processes for producing special ornamental bodies
    • B44C5/04Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0469Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
    • B44C5/0492Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper containing wooden elements
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44FSPECIAL DESIGNS OR PICTURES
    • B44F9/00Designs imitating natural patterns
    • B44F9/12Designs imitating natural patterns of leather
    • CCHEMISTRY; METALLURGY
    • C14SKINS; HIDES; PELTS; LEATHER
    • C14BMECHANICAL TREATMENT OR PROCESSING OF SKINS, HIDES OR LEATHER IN GENERAL; PELT-SHEARING MACHINES; INTESTINE-SPLITTING MACHINES
    • C14B7/00Special leathers and their manufacture
    • C14B7/02Composite leathers
    • CCHEMISTRY; METALLURGY
    • C14SKINS; HIDES; PELTS; LEATHER
    • C14BMECHANICAL TREATMENT OR PROCESSING OF SKINS, HIDES OR LEATHER IN GENERAL; PELT-SHEARING MACHINES; INTESTINE-SPLITTING MACHINES
    • C14B7/00Special leathers and their manufacture
    • C14B7/02Composite leathers
    • C14B7/04Composite leathers by cementing or pressing together leather pieces, strips or layers, Reinforcing or stiffening leather by means of reinforcing layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • B32B2038/0052Other operations not otherwise provided for
    • B32B2038/0076Curing, vulcanising, cross-linking
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02Temperature
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/04Time
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/12Pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00Animal or vegetable based
    • B32B2317/08Natural leather
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00Animal or vegetable based
    • B32B2317/12Paper, e.g. cardboard
    • B32B2317/125Paper, e.g. cardboard impregnated with thermosetting resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00Walls, panels
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10Methods of surface bonding and/or assembly therefor
    • Y10T156/1002Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1039Surface deformation only of sandwich or lamina [e.g., embossed panels]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/13Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1348Cellular material derived from plant or animal source [e.g., wood, cotton, wool, leather, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/4935Impregnated naturally solid product [e.g., leather, stone, etc.]

Abstract

A heat and pressure consolidated laminate, and method for producing the same, is provided that includes in superimposed relationship a decorative layer consisting essentially of a leather material, an underlay layer, a substrate, and an optional backer layer. The substrate has a first surface and a second surface opposite one another. The underlay layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed between the decorative layer and the first layer of the substrate. The backer layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed contiguous with the second surface of the substrate.

Description

  • [0001]
    This application claims the benefit of and priority from U.S. Provisional Patent Application Serial No. 60/441,889, filed 22 Jan. 2003, which is hereby incorporated by reference in its entirety.
  • FIELD OF THE INVENTION
  • [0002]
    The present invention relates to thermally fused decorative laminates in general and, more particularly, to thermally fused decorative panels having a leather or leather-like material as a decorative layer. In addition, the present invention relates to a method for manufacturing the same.
  • BACKGROUND INFORMATION
  • [0003]
    Thermally fused decorative panels are often used in the construction of cabinetry, furniture, and other building products. There is considerable consumer demand for thermally fused decorative panels in a wide variety of colors, patterns, and textures. Natural leather is another popular material used in the construction of furniture and other applications. Leather is generally perceived as a quality material used in high-end applications. Unfortunately, leather and other natural skins can be difficult to work with because of size limitations, shrinkage, natural imperfections, etc. It would be useful, therefore, to provide a product that facilitates the incorporation of leather into applications including furniture, cabinetry, and the like.
  • DISCLOSURE OF THE INVENTION
  • [0004]
    According to an embodiment of the present invention, a heat and pressure consolidated laminate (“thermally fused decorative panel”) is provided that comprises in superimposed relationship a decorative layer consisting essentially of a leather material, an underlay layer, a substrate, and an optional backer layer. The substrate has a first surface and a second surface opposite one another. The underlay layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed between the decorative layer and the first layer of the substrate. The backer layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed contiguous with the second surface of the substrate.
  • [0005]
    The decorative layer includes a leather material. The “leather” referred to herein is an animal hide and is not limited to any particular type of animal. Preferably, the leather material is bonded leather. The term “bonded leather” as used herein refers to a leather product that comprises leather shavings made from scrap and/or recycled leather. The shavings are processed into a sheet product using bonding agents. Bonded leather is commercially available and will not, therefore, be further described herein. A leather sheet thickness in the range of about 0.2 mm to about 4.0 mm is acceptable for most applications. A sheet thickness of about 0.2 mm to about 0.8 mm has particular utility. Although leather with an embossed finished surface can be used, it is preferable to use leather that initially has a smooth surface. Textures and other design features can be imparted to the laminate during the manufacturing process as will be explained in greater detail below.
  • [0006]
    In some embodiments, the present leather laminated decorative panel further includes an overlay disposed on the side of the decorative leather sheet opposite the substrate.
  • [0007]
    In some embodiments of the present invention, the leather laminated decorative panel includes a second decorative leather layer in place of the backer layer.
  • [0008]
    These and other objects, features, and advantages of the present invention will become apparent in light of the drawings and detailed description of the present invention provided below.
  • DESCRIPTION OF THE DRAWINGS
  • [0009]
    [0009]FIG. 1 is a diagram illustrating the superimposed constituent layers of the present leather laminated decorative panel.
  • [0010]
    [0010]FIG. 2 is the present leather laminated decorative panel shown in FIG. 1, now including an overlay layer.
  • [0011]
    [0011]FIG. 3 is a diagram illustrating the superimposed constituent layers of the present leather laminated decorative panel, including a second decorative layer in place of the backing layer.
  • DETAILED DESCRIPTION OF THE INVENTION
  • [0012]
    Now referring to FIGS. 1-3, the present invention leather laminated decorative panel is generally represented by reference numeral 10. The leather laminated decorative panel 10 includes a decorative layer 12, an underlay 16, a substrate 14, and an optional backer layer 18.
  • [0013]
    The decorative layer 12 includes a leather material as described above. A leather sheet thickness in the range of about 0.2 mm to about 4.0 mm is acceptable for most applications. A sheet thickness of about 0.2 mm to 0.8 mm has particular utility.
  • [0014]
    The underlay layer 16 is of known construction, consisting of paper, woven fabrics, mats, felts, or the like. The preferred underlay layer 16 consists of one or more cellulosic sheets impregnated with a laminating resin. Any of the conventional laminating resins commonly used for an underlay layer 16, such as a phenolic, melamine, amino, epoxy, and polyester resin, to name a few, may be used to impregnate the underlay 16. The preferred laminating resin for the underlay sheets is a beta-staged melamine formaldehyde resin. Resins of this type can be purchased commercially or prepared according to conventional procedures.
  • [0015]
    In an alternative embodiment, the underlay layer 16 may be eliminated by utilizing a thermally activated backer attached to the surface of the decorative leather layer facing the substrate 14. Leather material utilizing a thermally activated backer is commercially available.
  • [0016]
    The substrate 14 includes a first surface 20 and a second surface 22, opposite one another. The material comprising the substrate 14 can be varied to suit the application. Acceptable substrate materials include particle board, fiber board, plywood, or the like having surfaces to which the underlay resin and backing sheet resin can bond. The surfaces 20,22 preferably are smooth. A preferred substrate material for many applications is medium density fiberboard (“MDF”).
  • [0017]
    The backer layer 18 is of known construction, consisting of paper, woven fabrics, mats, felts, or the like. The preferred backer layer 18 consists of one or more cellulosic sheets impregnated with a laminating resin such as a melamine formaldehyde type resin. Backing sheets of this type can be purchased commercially or prepared according to conventional procedures.
  • [0018]
    Referring to FIG. 2, in some embodiments the present leather laminated decorative panel 10 further includes an overlay 24 disposed on the side of the leather decorative layer 12 opposite the underlay layer 16 and substrate 14. The overlay 24 may, for example, consist of a high-quality alpha cellulose paper impregnated with a melamine formaldehyde resin. The alpha-cellulose paper acts as a translucent carrier for the resin, imparts strength to the resin, facilitates maintaining a uniform resin thickness and provides additional abrasion resistance to the leather decorative layer 12.
  • [0019]
    Referring to FIG. 3, in an alternative embodiment the present leather laminated decorative panel 10 includes the above-described decorative layer 12, underlay layer 16, and substrate 14. In place of the backer layer 18, however, this embodiment includes a second decorative layer 26 and second underlay layer 28 disposed adjacent the second surface 22 of the substrate 14. The leather decorative layer 26 and underlay 28 are the same as those described above.
  • [0020]
    A first process for manufacturing the present leather laminated decorative panel 10 involves stacking the backing layer 18, substrate 14, underlay layer 16, and the leather decorative layer 12 and the release sheet on a lay-up station in a superimposed relationship (also referred to as a “build-up”). The physical properties of the release sheet are chosen to ensure the release sheet does not bond with the decorative leather layer or otherwise negatively affect the laminate materials and is typically textured to impart an embossed texture to the decorative layer 12.
  • [0021]
    The press is typically maintained at a predetermined processing temperature. The build-up is inserted into the heated press. The press is closed and is brought to the laminating pressure. The pressure and temperature are maintained for a “pressing cycle” that usually lasts in the range of about 20 seconds to about 150 seconds. The press is subsequently opened and the build-up, which is now a leather laminated decorative panel 10, is removed. The pressing cycle parameters provided reflect the amount of time, temperature and pressure typically necessary to achieve thermofusion of the various layers forming the decorative panel. The actual parameters may vary for different applications and process equipment.
  • [0022]
    A second process for manufacturing the leather laminated decorative panel 10 involves providing the backer layer 18, the substrate 14, the underlay layer 16, and the leather decorative layer 12 in the aforesaid superimposed relationship upstream of a continuous press. The press is set up to create the temperature and pressure environment required to bond the layers into the finished decorative panel 10. The line speed of the continuous press is chosen to create a dwell time within the press for the decorative panel 10 that is adequate to ensure proper thermofusion. A release sheet is disposed on the top side of the decorative layer 12 of the build-up prior to entering the press. As stated above, the release sheet, which is contiguous with the leather decorative layer 12, is typically textured to impart an embossed texture to the laminate. The release sheet is typically drawn off after the panel exits the press, and rolled for further handling. The leather laminated decorative panel 10 continues onto downstream handling equipment; e.g., equipment that cuts the continuous decorative panel product into sheets, and handling equipment for the sheets. The continuous press is advantageous because it decreases the processing time of the decorative panels.
  • [0023]
    In both manufacturing processes, the elevated temperature and pressure environment causes the impregnated resins within the sheets to flow, which consolidates the constituents into the integral leather laminated decorative panel 10. The present leather laminated decorative panel 10 is typically processed at a temperature in the range from about 110° C. to about 250° C., and at a pressure within the range of about 250 psi to about 450 psi. As stated above, the “pressing cycle” usually lasts in the range of about 20 seconds to about 150 seconds.
  • [0024]
    The following example is illustrative of the present leather laminated decorative panel and does not constitute any limitation with regard to the subject matter of the invention:
  • EXAMPLE I
  • [0025]
    A leather laminated decorative panel 10 is manufactured using a non-continuous press. A build-up consisting of a backing layer 18, a substrate 14, an underlay 16, a leather decorative layer 12, and a textured release sheet is made in a superimposed relationship on the lay-up station. The build-up is inserted into the heated press and subjected to a temperature of about 130° C. and a pressure of about 350 psi for a pressing cycle of about 50-60 seconds. After the pressing cycle is completed, the press is opened, the build-up, which is now a leather laminated decorative panel 10, is removed and the release sheet is drawn off.
  • [0026]
    It will be obvious to those skilled in the art that various changes may be made without departing from the scope of the present invention and that the invention is not to be considered limited to what is described and exemplified in the specification.

Claims (20)

What is claimed is:
1. A heat and pressure consolidated laminate, comprising in superimposed relationship:
a decorative layer consisting essentially of a leather material;
a substrate, having a first surface and a second surface opposite one another;
an underlay layer, containing one or more cellulosic sheets impregnated with a thermosetting resin, the underlay layer disposed between the decorative layer and the first surface of the substrate; and
a backer layer containing one or more cellulosic sheets impregnated with a thermosetting resin, the backer layer disposed adjacent the second surface of the substrate.
2. The laminate of claim 1 wherein said decorative layer is bonded leather having a sheet thickness ranging from about 0.2 mm to about 4.0 mm.
3. The laminate of claim 1 wherein said thermosetting resin is a melamine formaldehyde resin.
4. The laminate of claim 1, wherein said substrate is either plywood, particleboard or medium density fiberboard.
5. The laminate of claim 1, further comprising an overlay layer disposed on a side of said decorative layer opposite the underlay layer and substrate.
6. A heat and pressure consolidated laminate, comprising in superimposed relationship:
a first decorative layer consisting essentially of a leather material;
a substrate, having a first surface and a second surface opposite one another;
a first underlay layer, containing one or more cellulosic sheets impregnated with a thermosetting resin, the first underlay layer disposed between the first decorative layer and the first surface of the substrate; and
a second decorative layer consisting essentially of a leather material; and
a second underlay layer, containing one or more cellulosic sheets impregnated with a thermosetting resin, said second underlay layer disposed between the second decorative layer and the second surface of the substrate.
7. The laminate of claim 6 wherein said first and second decorative layers are bonded leather, said first and second decorative layers each having a sheet thickness ranging from about 0.2 mm to about 4.0 mm.
8. The laminate of claim 6 wherein said thermosetting resin is a melamine formaldehyde resin.
9. The laminate of claim 6, wherein said substrate is either plywood, particleboard or medium density fiberboard.
10. A method for the production of a heat and pressure consolidated leather laminate comprising the steps of:
setting the temperature of a thermosetting press to a predetermined temperature;
stacking in a superimposed relationship a backing layer, a substrate, an underlay layer, a decorative layer comprised essentially of leather, and a release sheet;
inserting the stacked, superimposed layers into the thermosetting press;
increasing the pressure of the thermosetting press to a predetermined pressure;
maintaining the stacked layers in the heated, pressurized thermosetting press for a period of time sufficient to form a laminate;
removing the laminate from the thermosetting press; and
removing the release sheet from the laminate.
11. The method of claim 10, wherein said predetermined temperature ranges from about 110° C. to about 250° C.
12. The method of claim 10, wherein said predetermined pressure ranges from about 250 PSI to about 450 PSI.
13. The method of claim 10, wherein said period of time sufficient to form a laminate ranges from about 20 seconds to about 150 seconds.
14. The method of claim 10, wherein said release sheet is textured to impart an embossed texture on the decorative layer.
15. A method for the production of a heat and pressure consolidated leather laminate comprising the steps of:
setting the temperature of the continuous thermosetting press to a predetermined temperature;
setting the pressure of the press to a predetermined pressure;
stacking in a superimposed relationship a backing layer, a substrate, an underlay layer, a decorative layer comprised essentially of leather, and a release sheet upstream from a continuous thermosetting press;
feeding the stacked, superimposed layers into the continuous thermosetting press;
maintaining the stacked layers in the heated, pressurized continuous thermosetting press for a period of time sufficient to form a laminate;
removing the laminate from the thermosetting press; and
removing the release sheet from the laminate.
16. The method of claim 16, further comprising the step of transporting the laminate to handling equipment located downstream from the continuous thermosetting press.
17. The method of claim 16, wherein said predetermined temperature ranges from about 110° C. to about 250° C.
18. The method of claim 16, wherein said predetermined pressure ranges from about 250 PSI to about 450 PSI.
19. The method of claim 16, wherein said period of time sufficient to form a laminate ranges from about 20 seconds to about 150 seconds.
20. A method for the production of a heat and pressure consolidated leather laminate comprising the steps of:
setting the temperature of the continuous thermosetting press to a predetermined temperature, said predetermined temperature ranging from about 110° C. to about 250° C.;
setting the pressure of the press to a predetermined pressure, said predetermined pressure ranging from about 250 PSI to about 450 PSI;
stacking in a superimposed relationship a backing layer, a substrate, an underlay layer, a decorative layer comprised essentially of leather, and a release sheet upstream from a continuous thermosetting press;
feeding the stacked, superimposed layers into the continuous thermosetting press;
selecting a line speed of the continuous thermosetting press that allows the stacked, superimposed layers to remain in the heated, pressurized press for a period of time sufficient to form a laminate from said layers;
removing the laminate from the thermosetting press; and
removing the release sheet from the laminate.
US10762104 2003-01-22 2004-01-20 Leather laminated decorative panel Abandoned US20040151936A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US44188903 true 2003-01-22 2003-01-22
US10762104 US20040151936A1 (en) 2003-01-22 2004-01-20 Leather laminated decorative panel

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10762104 US20040151936A1 (en) 2003-01-22 2004-01-20 Leather laminated decorative panel
US12962333 US8262827B2 (en) 2003-01-22 2010-12-07 Leather laminated decorative panel

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US12962333 Division US8262827B2 (en) 2003-01-22 2010-12-07 Leather laminated decorative panel

Publications (1)

Publication Number Publication Date
US20040151936A1 true true US20040151936A1 (en) 2004-08-05

Family

ID=32771988

Family Applications (2)

Application Number Title Priority Date Filing Date
US10762104 Abandoned US20040151936A1 (en) 2003-01-22 2004-01-20 Leather laminated decorative panel
US12962333 Expired - Fee Related US8262827B2 (en) 2003-01-22 2010-12-07 Leather laminated decorative panel

Family Applications After (1)

Application Number Title Priority Date Filing Date
US12962333 Expired - Fee Related US8262827B2 (en) 2003-01-22 2010-12-07 Leather laminated decorative panel

Country Status (6)

Country Link
US (2) US20040151936A1 (en)
JP (1) JP4150817B2 (en)
CN (1) CN1741901B (en)
CA (1) CA2512903C (en)
EP (1) EP1594993B1 (en)
WO (1) WO2004065637A3 (en)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040151852A1 (en) * 2003-01-22 2004-08-05 Panolam Industries International, Inc. Flexible leather laminate
US20060213137A1 (en) * 2005-03-22 2006-09-28 Kemlite Company, Inc. Thermofused reinforced decorative composite material with thermoplastic stiffener core
US20070287004A1 (en) * 2006-05-25 2007-12-13 Gottzmann Andreas M Laminate and Method of Manufacture
US20090087643A1 (en) * 2007-10-02 2009-04-02 Gottzmann Andreas M Laminate Surface Layer Without an Overlay and Method of Manufacture
US20100186337A1 (en) * 2009-01-29 2010-07-29 Barretto Peter M Prefinished bonded leather paneling system
WO2010083598A1 (en) * 2009-01-21 2010-07-29 Peter Barretto Composite bonded leather material
US20140250564A1 (en) * 2013-03-11 2014-09-11 The North Face Apparel Corp. Waterproof Taped Glove and Mitten with Laminated Leather
EP2808463A1 (en) * 2013-05-30 2014-12-03 Flooring Technologies Ltd. Composite wood panel with leather particles or printed layer of leather particles and process for their preparation

Citations (32)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1672537A (en) * 1922-04-12 1928-06-05 Raybestos Co Floor covering
US2622991A (en) * 1948-07-30 1952-12-23 Sturm Robert Heinrich Process for printing on thermoplastics
US3391056A (en) * 1964-05-27 1968-07-02 Hercules Inc Resin-coated fibrous sheet material and members prepared therefrom
US3398042A (en) * 1962-01-05 1968-08-20 Bayer Ag Leather laminates
US3475267A (en) * 1965-03-04 1969-10-28 Monsanto Co Laminates bonded with an ethylene/crotonic acid copolymer salt
US3661672A (en) * 1970-07-17 1972-05-09 Exxon Research Engineering Co Method of forming high pressure decorative laminates having registered color and embossing
US3698978A (en) * 1969-04-22 1972-10-17 Exxon Research Engineering Co Registered embossed high pressure laminates
US3700537A (en) * 1970-12-01 1972-10-24 Enjay Fibers And Laminates Co High pressure laminates with deeply embossed surface
US3869310A (en) * 1969-04-02 1975-03-04 Kuraray Co Flexible sheet materials
US3914479A (en) * 1971-07-02 1975-10-21 Ajinomoto Kk Process for manufacturing leather-like materials
US3929545A (en) * 1972-07-03 1975-12-30 Dart Ind Inc Pressure laminating method
US4132821A (en) * 1977-09-22 1979-01-02 Scott Chatham Company Textile fabric with leather-like appearance
US4154882A (en) * 1974-12-02 1979-05-15 Nevamar Corporation High pressure decorative laminate having registered color and embossing
US4255480A (en) * 1978-02-22 1981-03-10 Nevamar Corporation Abrasion-resistant laminate
US4297408A (en) * 1978-12-29 1981-10-27 Imperial Chemical Industries Limited Laminates of cloth and filled crystalline polypropylene and a method for making them
US4311748A (en) * 1979-06-06 1982-01-19 Formica Corporation No-overlay decorative laminates
US4473613A (en) * 1983-03-15 1984-09-25 Formica Corp. Decorative laminate
US4864790A (en) * 1988-05-26 1989-09-12 Andre Liardet Leather floor
US4880689A (en) * 1985-10-18 1989-11-14 Formica Corporation Damage resistant decorative laminate
US5344692A (en) * 1987-06-24 1994-09-06 Helmuth Schmoock Leather-containing laminate
US5484646A (en) * 1994-10-05 1996-01-16 Mann Industries, Inc. Artificial leather composite material and method for producing same
US5534327A (en) * 1990-05-11 1996-07-09 Idemitsu Petrochemical Co., Ltd. Powdered leather and method of producing the same
US5811122A (en) * 1995-05-26 1998-09-22 Kansas State University Research Foundation Hide/polymer and leather/polymer composite materials formed by in situ polymerization of polymer precursors impregnated into hide and leather
US6099938A (en) * 1998-04-03 2000-08-08 Advanced Laminationtechnoloties Ltd. Leather piece lamination to low melt film adhesive
US6324809B1 (en) * 1997-11-25 2001-12-04 Premark Rwp Holdings, Inc. Article with interlocking edges and covering product prepared therefrom
US6395408B1 (en) * 1996-06-28 2002-05-28 Pioneer Plastics Corporation Decorative laminate incorporating photoluminescent material
US6423167B1 (en) * 1998-06-05 2002-07-23 Premark Rwp Holdings Method for controlling laminate gloss
US6440538B1 (en) * 2000-04-03 2002-08-27 Lg Chem Ltd. Abrasion resistant laminate
US6558799B2 (en) * 2000-04-27 2003-05-06 Dai Nippon Printing Co., Ltd. Decorative material
US6623851B1 (en) * 2000-07-27 2003-09-23 Daniel Benjamin Kaplan Composite for fine and graphic art applications and method for making composite
US6632507B2 (en) * 1998-06-05 2003-10-14 Premark Rwp Holdings, Inc. Holographically enhanced decorative laminate
US7179538B2 (en) * 2003-01-22 2007-02-20 Panolam Industries International, Inc. Flexible leather laminate

Family Cites Families (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2361296A (en) * 1941-06-06 1944-10-24 William D Kennedy Treating leathers and the like
US2946713A (en) * 1955-10-06 1960-07-26 Gen Motors Corp Process for embossing decorative articles
US3674619A (en) * 1969-10-13 1972-07-04 Exxon Research Engineering Co Embossing separator
DE3834993A1 (en) 1988-10-14 1990-04-19 Held Kurt Method and apparatus for the continuous production of laminates
DE4216691A1 (en) * 1992-05-20 1993-11-25 Dieffenbacher Gmbh Maschf Equipment for surfacing e.g. chipboard with e.g. impregnated papers etc. - takes papers from vertically moved stacks above and below board, and holds them by suction bars inside rollers which press them against boards
DE4447171A1 (en) 1994-12-30 1996-07-04 Schmidt Troschke Ursula Composite body
DE19815115C2 (en) * 1998-04-03 2002-02-14 Eldra Kunststofftechnik Gmbh Leather-clad interior member and the method for bonding a leather layer comprising a substrate
EP0962315A3 (en) * 1998-06-05 2001-01-17 Premark RWP Holdings, Inc. Textured release sheet and method of making textured decorative laminates therewith
WO2000013897A1 (en) 1998-09-09 2000-03-16 Thermopal Dekorplatten Gmbh & Co. Kg Laminate, method for the production and use thereof
DE19920915A1 (en) * 1999-05-07 2000-11-09 Thermopal Dekorplatten Gmbh & Compound plate of wood material is particularly flatly pressed and at least on one side by single press process and additional heating effect decorative surface is applied comprising not previously pressed together single layers
WO2001003927A1 (en) * 1999-07-07 2001-01-18 Magna Eybl Ges.M B H Multi-layer decorative structure for a vehicle trim element and such a vehicle trim element
CA2308247A1 (en) * 1999-07-29 2001-01-29 Robert R. Krebs System and method for producing a laminate employing a plastic film
JP2001047544A (en) 1999-08-04 2001-02-20 Sumitomo Bayer Urethane Co Ltd Manufacture of car interior material of sandwich structure
DE10017486A1 (en) 2000-04-07 2001-10-11 Basf Ag Multi-layer composite of leather and thermoplastics

Patent Citations (32)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1672537A (en) * 1922-04-12 1928-06-05 Raybestos Co Floor covering
US2622991A (en) * 1948-07-30 1952-12-23 Sturm Robert Heinrich Process for printing on thermoplastics
US3398042A (en) * 1962-01-05 1968-08-20 Bayer Ag Leather laminates
US3391056A (en) * 1964-05-27 1968-07-02 Hercules Inc Resin-coated fibrous sheet material and members prepared therefrom
US3475267A (en) * 1965-03-04 1969-10-28 Monsanto Co Laminates bonded with an ethylene/crotonic acid copolymer salt
US3869310A (en) * 1969-04-02 1975-03-04 Kuraray Co Flexible sheet materials
US3698978A (en) * 1969-04-22 1972-10-17 Exxon Research Engineering Co Registered embossed high pressure laminates
US3661672A (en) * 1970-07-17 1972-05-09 Exxon Research Engineering Co Method of forming high pressure decorative laminates having registered color and embossing
US3700537A (en) * 1970-12-01 1972-10-24 Enjay Fibers And Laminates Co High pressure laminates with deeply embossed surface
US3914479A (en) * 1971-07-02 1975-10-21 Ajinomoto Kk Process for manufacturing leather-like materials
US3929545A (en) * 1972-07-03 1975-12-30 Dart Ind Inc Pressure laminating method
US4154882A (en) * 1974-12-02 1979-05-15 Nevamar Corporation High pressure decorative laminate having registered color and embossing
US4132821A (en) * 1977-09-22 1979-01-02 Scott Chatham Company Textile fabric with leather-like appearance
US4255480A (en) * 1978-02-22 1981-03-10 Nevamar Corporation Abrasion-resistant laminate
US4297408A (en) * 1978-12-29 1981-10-27 Imperial Chemical Industries Limited Laminates of cloth and filled crystalline polypropylene and a method for making them
US4311748A (en) * 1979-06-06 1982-01-19 Formica Corporation No-overlay decorative laminates
US4473613A (en) * 1983-03-15 1984-09-25 Formica Corp. Decorative laminate
US4880689A (en) * 1985-10-18 1989-11-14 Formica Corporation Damage resistant decorative laminate
US5344692A (en) * 1987-06-24 1994-09-06 Helmuth Schmoock Leather-containing laminate
US4864790A (en) * 1988-05-26 1989-09-12 Andre Liardet Leather floor
US5534327A (en) * 1990-05-11 1996-07-09 Idemitsu Petrochemical Co., Ltd. Powdered leather and method of producing the same
US5484646A (en) * 1994-10-05 1996-01-16 Mann Industries, Inc. Artificial leather composite material and method for producing same
US5811122A (en) * 1995-05-26 1998-09-22 Kansas State University Research Foundation Hide/polymer and leather/polymer composite materials formed by in situ polymerization of polymer precursors impregnated into hide and leather
US6395408B1 (en) * 1996-06-28 2002-05-28 Pioneer Plastics Corporation Decorative laminate incorporating photoluminescent material
US6324809B1 (en) * 1997-11-25 2001-12-04 Premark Rwp Holdings, Inc. Article with interlocking edges and covering product prepared therefrom
US6099938A (en) * 1998-04-03 2000-08-08 Advanced Laminationtechnoloties Ltd. Leather piece lamination to low melt film adhesive
US6423167B1 (en) * 1998-06-05 2002-07-23 Premark Rwp Holdings Method for controlling laminate gloss
US6632507B2 (en) * 1998-06-05 2003-10-14 Premark Rwp Holdings, Inc. Holographically enhanced decorative laminate
US6440538B1 (en) * 2000-04-03 2002-08-27 Lg Chem Ltd. Abrasion resistant laminate
US6558799B2 (en) * 2000-04-27 2003-05-06 Dai Nippon Printing Co., Ltd. Decorative material
US6623851B1 (en) * 2000-07-27 2003-09-23 Daniel Benjamin Kaplan Composite for fine and graphic art applications and method for making composite
US7179538B2 (en) * 2003-01-22 2007-02-20 Panolam Industries International, Inc. Flexible leather laminate

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040151852A1 (en) * 2003-01-22 2004-08-05 Panolam Industries International, Inc. Flexible leather laminate
US7179538B2 (en) * 2003-01-22 2007-02-20 Panolam Industries International, Inc. Flexible leather laminate
US20070095470A1 (en) * 2003-01-22 2007-05-03 Panolam Industries International, Inc. Method for producing a flexible leather laminate
US20070104924A1 (en) * 2003-01-22 2007-05-10 Panolam Industries International, Inc. Flexible leather laminate
US20060213137A1 (en) * 2005-03-22 2006-09-28 Kemlite Company, Inc. Thermofused reinforced decorative composite material with thermoplastic stiffener core
US20070287004A1 (en) * 2006-05-25 2007-12-13 Gottzmann Andreas M Laminate and Method of Manufacture
US20090087643A1 (en) * 2007-10-02 2009-04-02 Gottzmann Andreas M Laminate Surface Layer Without an Overlay and Method of Manufacture
WO2010083598A1 (en) * 2009-01-21 2010-07-29 Peter Barretto Composite bonded leather material
US20100186337A1 (en) * 2009-01-29 2010-07-29 Barretto Peter M Prefinished bonded leather paneling system
US20140250564A1 (en) * 2013-03-11 2014-09-11 The North Face Apparel Corp. Waterproof Taped Glove and Mitten with Laminated Leather
EP2808463A1 (en) * 2013-05-30 2014-12-03 Flooring Technologies Ltd. Composite wood panel with leather particles or printed layer of leather particles and process for their preparation
EP2808462A1 (en) * 2013-05-30 2014-12-03 Flooring Technologies Ltd. Composite wood panel with leather particles or printed layer of leather particles and process for their preparation

Also Published As

Publication number Publication date Type
WO2004065637A3 (en) 2004-11-11 application
CN1741901B (en) 2010-09-29 grant
JP2006516229A (en) 2006-06-29 application
EP1594993A4 (en) 2007-01-24 application
EP1594993A2 (en) 2005-11-16 application
CA2512903C (en) 2010-08-24 grant
US20110073245A1 (en) 2011-03-31 application
US8262827B2 (en) 2012-09-11 grant
CA2512903A1 (en) 2004-08-05 application
JP4150817B2 (en) 2008-09-17 grant
EP1594993B1 (en) 2011-08-10 grant
WO2004065637A2 (en) 2004-08-05 application
CN1741901A (en) 2006-03-01 application

Similar Documents

Publication Publication Date Title
US3371003A (en) Process for making self-edged laminated panel
US4865912A (en) Precious-wood-faced sheet for decoration, board having the same laminated thereupon, and process of manufacture
US6803110B2 (en) Decorative laminate assembly and method for producing same
US4154882A (en) High pressure decorative laminate having registered color and embossing
US6517935B1 (en) Process for the production of a floor strip
US4158713A (en) Composition board with improved polymeric skin and method of preparing same
US5925211A (en) Low pressure melamine/veneer panel and method of making the same
US20020168503A1 (en) Decorative and/or flame retardant laminates and/or polyolefin laminates and processes of manufacture thereof
US6423167B1 (en) Method for controlling laminate gloss
US20080263985A1 (en) Building slab, floor panels in particular, and method of manufacturing the same
US4374886A (en) Color registered decorative laminates
US4142007A (en) Embossed laminated board
US4689102A (en) Method for the production of abrasion-resistant decorative laminates
US3663353A (en) Plastic laminate structure consisting of a plastic film laminated to a substrate with a resin impregnated paper intermediate layer
US5286545A (en) Laminated wooden board product
US5919575A (en) Plastic laminated structural board and method for making same
US3441959A (en) Textured panel and process of producing same
US20050266221A1 (en) Fiber-reinforced decorative laminate
WO2010088769A1 (en) Sound attenuating laminate materials
US5938881A (en) Decorative molded product and process for the production thereof
RU2383441C1 (en) Method for manufacturing of decorative paper laminate
US3738900A (en) Textured film finished panels and doors
US20050136276A1 (en) Synthetic crossband
US20100239820A1 (en) Laminated decorative plate and method for the production thereof
EP0962315A2 (en) Textured release sheet and method of making textured decorative laminates therewith

Legal Events

Date Code Title Description
AS Assignment

Owner name: PANOLAM INDUSTRIES INTERNATIONAL, INC., CONNECTICU

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:GAUTHIER, SYLVIE;TSANGARIDES, GEORGE;REEL/FRAME:014924/0210

Effective date: 20040115

AS Assignment

Owner name: DEUTSCHE BANK TRUST COMPANY AMERICAS, NEW YORK

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:PANOLAM INDUSTRIES INTERNATIONAL, INC.;REEL/FRAME:015788/0885

Effective date: 20041201

Owner name: DEUTSCHE BANK TRUST COMPANY AMERICAS,NEW YORK

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:PANOLAM INDUSTRIES INTERNATIONAL, INC.;REEL/FRAME:015788/0885

Effective date: 20041201

AS Assignment

Owner name: DEUTSCHE BANK TRUST COMPANY AMERICAS, NEW YORK

Free format text: GRANT OF SECOND-LIEN SECURITY INTERES;ASSIGNOR:PANOLAM INDUSTRIES INTERNATIONAL, INC.;REEL/FRAME:015797/0308

Effective date: 20041201

Owner name: DEUTSCHE BANK TRUST COMPANY AMERICAS,NEW YORK

Free format text: GRANT OF SECOND-LIEN SECURITY INTERES;ASSIGNOR:PANOLAM INDUSTRIES INTERNATIONAL, INC.;REEL/FRAME:015797/0308

Effective date: 20041201

AS Assignment

Owner name: CREDIT SUISSE, CAYMAN ISLANDS BRANCH, AS ADMINISTR

Free format text: GRANT OF PATENT SECURITY INTEREST;ASSIGNOR:PANOLAM INDUSTRIES INTERNATIONAL, INC.;REEL/FRAME:016610/0814

Effective date: 20050930

AS Assignment

Owner name: PANOLAM INDUSTRIES INTERNATIONAL, INC. (F/K/A PANO

Free format text: RELEASE OF SECURED PARTY S PATENT SECURITY INTEREST IN PATENTS ORIGINALLY RECORDED ON REEL/FRAME;ASSIGNOR:DEUTSCHE BANK TRUST COMPANY AMERICAS;REEL/FRAME:016610/0926

Effective date: 20050930

Owner name: PANOLAM INDUSTRIES INTERNATIONAL, INC. (F/K/A PANO

Free format text: RELEASE OF SECURED PARTY S PATENT SECURITY INTEREST IN PATENTS ORIGINALLY RECORDED ON REEL/FRAME;ASSIGNOR:DEUTSCHE BANK TRUST COMPANY AMERICAS;REEL/FRAME:016610/0921

Effective date: 20050930

Owner name: PANOLAM INDUSTRIES INTERNATIONAL, INC. (F/K/A PANO

Free format text: RELEASE OF SECURED PARTY S PATENT SECURITY INTEREST IN PATENTS ORIGINALLY RECORDED ON REEL/FRAME: 015797/0308 (AND INCLUDED IN THIS PATENT RELEASE);ASSIGNOR:DEUTSCHE BANK TRUST COMPANY AMERICAS;REEL/FRAME:016610/0921

Effective date: 20050930

Owner name: PANOLAM INDUSTRIES INTERNATIONAL, INC. (F/K/A PANO

Free format text: RELEASE OF SECURED PARTY S PATENT SECURITY INTEREST IN PATENTS ORIGINALLY RECORDED ON REEL/FRAME: 015788/0885 (AND INCLUDED IN THIS PATENT RELEASE);ASSIGNOR:DEUTSCHE BANK TRUST COMPANY AMERICAS;REEL/FRAME:016610/0926

Effective date: 20050930

AS Assignment

Owner name: CREDIT SUISSE AG, CAYMAN ISLANDS BRANCH AS ADMINIS

Free format text: GRANT OF SECURITY INTEREST (FIRST LIEN);ASSIGNOR:PANOLAM INDUSTRIES INTERNATIONAL, INC.;REEL/FRAME:023699/0778

Effective date: 20091223

AS Assignment

Owner name: APOLLO LAMINATES AGENT, LLC, AS ADMINISTRATIVE AGE

Free format text: GRANT OF PATENT SECURITY INTEREST;ASSIGNOR:PANOLAM INDUSTRIES INTERNATIONAL, INC.;REEL/FRAME:023720/0039

Effective date: 20091223

AS Assignment

Owner name: PANOLAM INDUSTRIES INTERNATIONAL, INC., CONNECTICU

Free format text: RELEASE BY SECURED PARTY;ASSIGNOR:CREDIT SUISSE AG, CAYMAN ISLANDS BRANCH;REEL/FRAME:028845/0958

Effective date: 20120823