Abstract: A decorative laminate lay-up used in the manufacture of decorative laminates includes a decorative laminate sheet assembly composed of resin impregnated paper layers and a textured release sheet positioned on a top surface of the decorative laminate sheet assembly. The textured release sheet provides a textured surface to decorative laminates resulting from processing of the decorative laminate sheet assembly, wherein the textured release sheet includes a textured surface exhibiting superhydrophobicity, self-cleaning and low surface energy.

Abstract: A press plate for producing decorative laminate from resin impregnated paper, with alumina particles on its pressing surface, is coated with diborides selected from the group consisting of hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, or zirconium diboride or mixtures thereof for making the press plate resistant to scratching. The preferred diborides are titanium and zirconium. The most preferred diboride is titanium. The color, gloss and surface appearance of laminate pressed with a titanium diboride coated press plate is substantially the same as laminate pressed with the press plate before coating.

Abstract: Decorative paper with a wear resistant decorative layer is made by limiting the flow of melamine resin through the decorative paper. A partially cured melamine resin impregnated overlay is placed over non-impregnated decorative paper and cured at temperatures of about 230-310° F. (110-155° C.) and pressures of greater than about 300 psi (20 bar) and preferably about 750-1500 psi (51-102 bar) for causing melamine resin to flow from the overlay into the decorative paper and for substantially fully curing the melamine resin. Flow of the melamine resin is limited to about 10-20 and preferably about 12-17 percent by weight of the impregnated overlay. Flow of melamine resin in impregnated decorative paper is limited to about 1-3 and preferably about 1-2 percent by weight of the impregnated decorative paper.

Abstract: A press plate for producing decorative laminate from resin impregnated paper, with alumina particles on its pressing surface, is coated with diborides selected from the group consisting of hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, or zirconium diboride or mixtures thereof for making the press plate resistant to scratching using a process wherein the press plate and the sputtering head are moved relative to one another to provide a scanning speed sufficient to give a thermal gradient in the press plate of 50° F. or less, to provide reduced built-in stress and more delocalized heat distribution throughout the press plate.

Abstract: A press plate for producing decorative laminate from resin impregnated paper, with alumina particles on its pressing surface, is coated with diborides selected from the group consisting of hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, or zirconium diboride or mixtures thereof for making the press plate resistant to scratching. The preferred diborides are titanium and zirconium. The most preferred diboride is titanium. The color, gloss and surface appearance of laminate pressed with a titanium diboride coated press plate is substantially the same as laminate pressed with the press plate before coating.

Abstract: A press plate for producing decorative laminate from resin impregnated paper, with alumina particles on its pressing surface, is coated with diborides selected from the group consisting of hafnium diboride, molybdenum diboride, tantalum diboride, titanium diboride, tungsten diboride, vanadium diboride, or zirconium diboride or mixtures thereof for making the press plate resistant to scratching. The preferred diborides are titanium and zirconium. The most preferred diboride is titanium. The color, gloss and surface appearance of laminate pressed with a titanium diboride coated press plate is substantially the same as laminate pressed with the press plate before coating.