Abstract: An abrasion resistant laminate includes a substrate and a durable wear-resistant top layer assembly laminated over a top side of the substrate. The layer assembly includes a wear-resistant upper layer and an underlying decorative layer which together include a first paper sheet impregnated with a first resin. The top layer assembly further includes a core layer underlying the decorative layer. The core layer includes second and third paper sheets impregnated with a second resin. A fourth paper sheet is interposed between the second and third paper sheets in the core layer. The fourth paper sheet is impregnated with the first resin, whereby the fourth paper sheet functions as a balance sheet to equalize expansion and contraction of the layers under the influence of environmental factors.

Abstract: A static dissipative laminate consistently having an internal resistance less than 2.times.10.sup.6 and a resistance to ground measurement of about 5.times.10.sup.6 and a surface resistance in the static dissipative range even at a very low humidities is produced by the use of an ionic salt and an humectant in the overlay and further by the use of a special top core sheet containing 0.6-1.0% by weight of carbon fibers.

Abstract: A method and apparatus for continuous casting of polymerizable thermosetting materials comprises mixing the materials with controlled amounts of two or more catalyst groups and passing said mixture through two or more series of heating stages. The initially gelled mixture which has not yet undergone excessive shrinkage is mechanically isolated from the ungelled mixture.

Abstract: A decorative static dissipative high pressure laminate having a plurality of consolidated thermosetting resin impregnated layers including a core and a decor surface layer to provide a surface resistance no greater than 2.times.10.sup.9. The core comprises at least one thermosetting resin impregnated paper core sheet and at least one special thermosetting resin impregnated core sheet of predominately paper fibers and a small quantity of stainless steel fibers irregularly distributed among the paper fibers.

Abstract: A method and apparatus for continuous casting of polymerizable materials that shrink during polymerization includes rapidly heating a moving matrix substantially uniformly throughout its cross section by radio frequency energy to initiate polymerization and maintaining the matrix thereafter in substantial thermal isolation such that substantially adiabatic polymerization occurs.

Abstract: A wear and gouge resistant decorative laminate is made by consolidating, under heat and pressure, a suitable backing over which lays a decor layer covered by an overlay sheet, the overlay sheet being provided on its upper surface with an ultra-thin abrasion resistant layer consistent with the disclosure of Scher et al. U.S. Pat. No. 4,255,480 and optionally O'Dell et al. U.S. Pat. No. 4,499,137.

Abstract: A wear and gouge resistant decorative laminate is made by consolidating, under heat and pressure, a suitable backing over which lays a decor layer covered by an overlay sheet, the overlay sheet being provided on its upper surface with an ultra-thin abrasion resistant layer consistent with the disclosure of Scher et al. U.S. Pat. No. 4,255,480 and optionally O'Dell et al. U.S. Pat. No. 4,499,137.

Abstract: A glossy laminate is made using highly polished caul plates, the laminate having superior sliding can wear resistance, and without damaging the plates. This result is effected by use of the technology of Scher et al. U.S. Pat. No. 4,255,480; O'Dell et al. U.S. Pat. No. 4,491,137 and 4,567,087; and/or Ungar et al. U.S. Pat. No. 4,713,138, except that the particles size of the grit is maintained at less than 9 micrometers. In this way a glossy laminate is obtained which retains its glossy appearance under normal wear conditions, and without rapid destruction of the expensive polished caul plates.

Abstract: A static dissipative laminate having a resistivity on the order of 10.sup.6 to 10.sup.9 ohms/square and a surface resistance in the static dissipative range even at very low humidities is produced by adding to the melamine resin for the decor sheet a small amount of ionic salt and a small amount of an aliphatic tertiary amine or glycerin which is believed to function as a humectant. The core sheets are formed of carbon filled paper impregnated with a phenolic resin containing a small amount of ionic salt.

Abstract: The scuff-resistance and rub-resistance of decorative laminate made using the special paper of Lane et al U.S. Pat. No. 3,798,111 is substantially improved by incorporating in or very near the surface of the decor paper finely divided polyethylene wax having a particle size of 1-30 microns.

Abstract: A decorative, high pressure, conductive laminate for flooring material is formed of a plurality of phenolic impregnated carbon-containing core sheets, a melamine resin impregnated decor sheet containing about 3-5% carbon fibers having a length greater than 1/16 inch and preferably 1/8 inch or more, and a melamine resin impregnated abrasion resistant overlay. The overlay melamine resin also contains an ionic salt and a tertiary aliphatic amine, both also preferably being in the decor melamine as well. The laminate has a volume resistance of 2.5.times.10.sup.4 to about 10.sup.6 ohms. To make the product more dimensionally stable, carbon containing core sheets are interleaved with non-carbon-containing kraft sheets, the phenolic resin of which also contains ionic salt.

Abstract: An improved process of making abrasion-resistant decorative laminate without overlay comprises simultaneously impregnating and coating a laminate decor sheet with a mixture of the liquid impregnating resin and an abrasion-resistant composition of microcrystalline cellulose and abrasion-resistant mineral particles such as alumina. The microcrystalline cellulose functions not only as a binder material in the product, but also serves to maintain the mineral particles in suspension in the liquid resin. The mixture is deposited onto the top surface of the decor sheet which absorbs the liquid resin leaving on the upper surface thereof an ultra-thin layer of the abrasion-resistant composition plus a small amount of resin. After drying, the decor sheet is ready for use in the manufacture of high and low pressure decorative laminates.

Abstract: The scuff resistance of high-pressure laminated plastic is improved by incorporating in or very near the surface thereof, finely divided polyethylene wax having a particle size of about 1-25 microns and a melting point of preferably 220.degree.-230.degree. F. The wax is incorporated as part of an abrasion-resistant coating mixture applied to the face of an unimpregnated decor paper sheet in an ultra-thin layer, which layer is dried at a temperature below the wax melting point and then impregnated with conventional melamine-formaldehyde resin. The impregnated sheet is placed onto a sheet of convention phenolic resin impregnated core sheets and consolidated in the conventional way under heat and pressure. During consolidation, the wax particles "bloom", or migrate to the surface. The finished laminate surface has greatly improved scuff resistance.

Abstract: The scuff resistance of a high-pressure laminate is improved by incorporating in or very near the surface thereof, finely divided polyethylene wax preferably having a particle size of about 1-25 microns and a melting point of 220.degree.-230.degree. F. The wax is incorporated as part of a coating mixture applied to the face of an unimpregnated decor paper sheet in an ultra-thin layer, which layer is dried at a temperature below the wax melting point and then impregnated with conventional melamine-formaldehyde resin. The impregnated sheet is placed onto a sheet of convention phenolic resin impregnated core sheets and consolidated in the conventional way under heat and pressure. During consolidation, the wax particles "bloom", or migrate to the surface. The finished laminate surface has greatly improved scuff resistance.

Abstract: Highly abrasion-resistant transfer coatings are provided on a wide variety of substrates, thermoplastic or thermosetting, by transfer coating from a mold surface or a flexible web, such as by use of a heat transfer tape, an ultra-thin coating consisting essentially of a non-resinous binder material such as microcrystalline cellulose together with mineral abrasive particles, preferably alumina or a mixture of silica and alumina which have been heated together at a temperature of at least 140.degree. F., the ultra-thin coating also preferably containing a silane and a small quantity of a sticking agent such as a thermoplastic or thermosetting resin.

Abstract: Highly abrasion-resistant transfer coatings are provided on a wide variety of substrates, thermoplastic or thermosetting, by transfer coating from a mold surface or a flexible web, such as by use of a heat transfer tape, an ultra-thin coating consisting essentially of a non-resinous binder material such as microcrystalline cellulose together with mineral abrasive particles, preferably alumina or a mixture of silica and alumina which have been heated together at a temperature of at least 140.degree. F., the ultra-thin coating also preferably containing a silane and a small quantity of a sticking agent such as a thermoplastic or thermosetting resin.

Abstract: The scuff resistance of a high-pressure laminate is improved by incorporating in or very near the surface thereof, finely divided polyethylene wax preferably having a particle size of about 1-25 microns and a melting point of 220.degree.-230.degree. F. The wax is incorporated as part of a coating mixture applied to the face of an unimpregnated decor paper sheet in an ultra-thin layer, which layer is dried at a temperature below the wax melting point and then impregnated with conventional melamine-formaldehyde resin. The impregnated sheet is placed onto a sheet of convention phenolic resin impregnated core sheets and consolidated in the conventional way under heat and pressure. During consolidation, the wax particles "bloom", or migrate to the surface. The finished laminate surface has greatly improved scuff resistance.

Abstract: An abrasion-resistant laminate is prepared by providing an ultra thin coating of mineral particles and micro crystalline cellulose on the surface of conventional printed paper, followed by impregnating the paper with a conventional laminating resin, and then using the print paper so obtained in a laminating process without the necessity of using an overlay sheet.

Abstract: A decorative high pressure laminate having registered color and embossing is produced by effecting simultaneous embossing and laminating using a three dimensional press plate acting against an overlay sheet containing high flow melamine resin and pigment, so that during the pressing operation the resin and pigment flows laterally from the high pressure areas to the low pressure areas with the result that the underlying print sheet is visible through the overlay sheet in the high pressure areas while the pigment in the overlay sheet in the low pressure areas mask the print sheet.

Abstract: An abrasion-resistant laminate is prepared by providing an ultra thin coating of mineral particles and micro crystalline cellulose on the surface of conventional printed paper, followed by impregnating the paper with a conventional laminating resin, and then using the print paper so obtained in a laminating process without the necessity of using an overlay sheet.