Abstract: A decorative laminate having improved scratch and abrasion resistance is provided. In one embodiment, the decorate laminate includes a substrate or core, a decorative sheet on the substrate, and an overlay sheet on the decorative sheet. The overlay sheet is coated on both major surfaces to provide scratch and abrasion resistance to the laminate. The coating on the interior facing surface contains mineral particles having a particle size of from between about 10-30 microns. The coating on the exterior facing surface contains a mixture of first mineral particles having a particle size of from between about 3-8 microns and second mineral particles having a particle size of less than about 1.0 micron. The first mineral particles are preferably alumina particles, and the second mineral particles are preferably sol gel process alumina particles.

Abstract: Plastic surfacing material of the FOUNTAINHEAD® type having a bold and aesthetically pleasing appearance is achieved by the use TFR pigments, the latter of which are manufactured by orienting reflective flake pigments in a plastic substrate and grinding the substrate to a particulate material.

Abstract: A solid surface product having a thickness of 3 cm or greater is provided which is substantially free from warping, has a homogeneous surface appearance, and is substantially free from entrapped air bubbles or voids. The solid surface material includes from about 25 to about 95 wt %, i.e. weight percent, of a polymer resin and from about 0 to about 70 wt % of a filler. A method for producing the solid surface material is also provided and includes forming a mixture of from about 25 to about 95 wt % of a polymer resin and from about 0 to about 70 wt % of a filler; casting the mixture into an open mold to a thickness of 3 cm or greater; applying a vacuum to the molded mixture to release entrapped gases therein; and curing the molded mixture to produce a thick solid surface material.

Abstract: A solid surface material which exhibits a pearlescent visual appearance and method of making it are provided. The solid surface material includes a polymer resin, optionally, a filler, and oriented anisotropic pigment particles dispersed substantially throughout the polymer resin to provide the pearlescent visual appearance. The solid surface material is made by forming a mixture of polymer resin, optional filler, and anisotropic pigment particles; dispersing the pigment particles substantially throughout the mixture; casting the mixture into an open mold; applying a vacuum to the molded mixture to release entrapped gases therein to cause the pigment particles to become oriented in the mixture; and curing the molded mixture to produce the solid surface material.

Abstract: A wood veneer surfaced laminate and method of making it are provided which produces a product having the appearance of a natural wood product, but with the toughness, moisture resistance, stain resistance, impact resistance, and abrasion resistance of melamine resin surfaced laminate products. The wood veneer surfaced laminate is made by providing a sheet of a natural or engineered wood veneer; impregnating the sheet with a first liquid curable resin such that said liquid resin substantially completely impregnates the sheet; coating a second liquid curable resin onto a surface of the sheet; laminating the sheet to a core while curing the resins to form a natural or engineered wood veneer surfaced laminate.