Abstract: A resin impregnated and resin coated has a decorative portion coated at least 1 mil thick with a vinyl ester terminated bisphenol A epoxy resin matrix, containing hollow plastic microspheres through its thickness.

Abstract: A laminate assembly, containing press plates having smooth polished sides and laminate stack-up sets, for producing high gloss laminates, is molded using a vapor impermeable barrier layer positioned between stack-ups in the stack-up set next to the exterior press plates, so that during the fast heatup of that stack-up set during molding, vapor travel toward the interior of the assembly is controlled, preventing vapor buildup, and low gloss areas on certain laminates.

Abstract: A method of impregnating a flexible, porous cellulosic sheet material involves passing the sheet through a low viscosity resin and across the resonant vibrating surface and through a cavitated zone in close proximity to at least one completely immersed ultrasonic wave generator, operating at a frequency and radiated power level effective to provide a combination vibratory pressure on the resin and cavitation effect causing degassing and heating of the resin, followed by passing the impregnated sheet through a drying means.

Abstract: A static-dissipating laminate is made, containing at least a bottom core layer and a top decorative layer, both layers being impregnated with a resin, where at least the decorative layer has contacting, long carbon fibers uniformly distributed through it in an amount effective to provide an antistatic effect to the laminate, so that static charges accumulating on the top of the decorative layer are dissipated.

Abstract: A static-dissipating laminate is made, containing at least a bottom core layer and a top decorative layer, both layers containing fibrous material which is impregnated with a resin, where at least the decorative layer has a metal salt distributed through it in an amount effective to provide an antistatic effect to the laminate, so that static charges accumulating on the top of the decorative layer are dissipated.

Abstract: An ultra thin laminate is made by: (1) assembling a laminate stack-up consisting of: one paper sheet having a top decorative surface and a bottom surface coated with a resinous film, about 0.25 mil to about 5 mil thick, effective to opacify the paper and provide a barrier to resin flow, and one abrasion resistant protective overlay sheet disposed in contact with the decorative surface of the paper sheet; (2) heat and pressure consolidating the stack-up to form a unitary decorative laminate having a thickness of between about 5 mil and about 15 mil, and having a resinous film on one side that is glue adherable.

Abstract: A heat and pressure consolidated embossing assembly, for use in making decorative laminates, consists of an embossing sheet, having a thickness of between about 0.025 inch to 0.250 inch, disposed between two fibrous exterior layers impregnated with a resinous material, where the thickness ratio of each fibrous exterior layer:embossing sheet is from about 1:2.5 to 1:12.

Abstract: A patterned, decorative laminate is made by: (1) preparing a core layer, comprising a plurality of fibrous sheets impregnated with a resinous material, (2) placing on top of the core, at least one unfilled kraft paper barrier sheet, impregnated with at least 30 weight percent of an aminotriazine-aldehyde, urea-aldehyde, thiourea-aldehyde or unsaturated polyester resin, (3) placing on top of the impregnated barrier sheet, an unfilled protective sheet, impregnated with an aminotriazine-aldehyde, urea-aldehyde, thiourea-aldehyde or unsaturated polyester resin; the protective sheet having a design printed on the bottom surface facing the barrier sheet, the design covered with colored pigmented material, and (4) heat and pressure consolidating the sheets into a unitary, bonded laminate.

Abstract: An embossing assembly, for use in making high pressure decorative laminates, contains at least one metal sheet 0.0003-0.05 inch thick, having a patterned embossing side and a support side, the support side having indentations therein which form the pattern on the embossing side, and an accompanying fibrous support having a thickness of from about 0.5-7 times the deepness of the indentations per metal sheet, disposed next to the support side of the metal sheet.