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 method for forming a glossy decorative laminate is disclosed. The method is achieved by stacking a decorative laminate sheet assembly having a top layer, casting a polypropylene release sheet wherein the polypropylene release sheet is processed with chill rollers treated in a manner which improves the gloss characteristics of the resulting decorative laminate, positioning the polypropylene release sheet on the top layer of the decorative laminate sheet assembly, applying heat and pressure to the decorative laminate sheet assembly and the polypropylene release sheet sufficient to bond the decorative laminate and releasably bond the polypropylene release sheet to the top layer of the decorative laminate sheet assembly, and removing the polypropylene release sheet from the top layer of the decorative laminate sheet assembly to reveal a decorative laminate exhibiting desirable gloss characteristics.

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: An apparatus is disclosed for transporting panel substrates with adhesive on both sides such that the panel substrates may be used in the manufacture of decorative panels. The apparatus includes a adhesive applicator which coats a panel substrate with adhesive. The apparatus also includes a first edge support member and a second edge support member located adjacent an outlet end of the adhesive applicator such that edges of the panel substrate are respectively supported by the first edge support member and the second edge support member without interfering with the adhesive being applied to the panel substrate. The apparatus further includes a support for selectively supporting the coated panel substrate and releasing the panel substrate while only contacting edges of the panel substrate so as not to substantially interfere with the adhesive applied to the panel substrate by the adhesive applicator. A method for manufacturing a panel is also disclosed.

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.