Abstract: A method for the production of a laminate is provided, comprising the steps of: 1) providing a stack of layers including a decorative layer, a core layer, and optionally an overlayer; 2) impregnating one or both of the decorative layer and overlayer with a resin formulation that includes nanoclay particles disposed within a thermoset resin, wherein the concentration of the nanoclay particles within the thermoset resin is great enough to form a physical barrier within the resin and low enough to avoid a hazy appearance; and 3) subjecting the stack of layers to sufficient heat and pressure to cause the layers to bond to one another. According to an aspect of the present invention, a laminate is provided producible by the above-described method.

Abstract: A method for the production of a laminate is provided, comprising the steps of: 1) providing a stack of layers including a decorative layer, a core layer, and optionally an overlayer; 2) impregnating one or both of the decorative layer and overlayer with a resin formulation that includes nanoclay particles disposed within a thermoset resin, wherein the concentration of the nanoclay particles within the thermoset resin is great enough to form a physical barrier within the resin and low enough to avoid a hazy appearance; and 3) subjecting the stack of layers to sufficient heat and pressure to cause the layers to bond to one another. According to an aspect of the present invention, a laminate is provided producible by the above-described method.

Abstract: A method for the production of a laminate is provided, comprising the steps of: 1) providing a stack of layers including a decorative layer, a core layer, and optionally an overlayer; 2) impregnating one or both of the decorative layer and overlayer with a resin formulation that includes nanoclay particles disposed within a thermoset resin, wherein the concentration of the nanoclay particles within the thermoset resin is great enough to form a physical barrier within the resin and low enough to avoid a hazy appearance; and 3) subjecting the stack of layers to sufficient heat and pressure to cause the layers to bond to one another. According to an aspect of the present invention, a laminate is provided producible by the above-described method.

Abstract: A method for forming a saturating paper comprising the steps of selecting a sheet of paper, creating an embossed pattern of polygons on the sheet to increase the absorption capacity of the sheet, and causing a resin to contact the sheet such that the sheet absorbs at least a portion of the resin. The invention also includes a method for forming a decorative laminate including the steps of providing an overlay sheet, embossing the overlay sheet to increase the absorption capacity of the overlay sheet, and causing a resin to contact the overlay sheet such that the overlay sheet absorbs at least a portion of the resin. The method also includes the steps of locating the overlay sheet onto a decor sheet, and heating the overlay sheet and the decor sheet under pressure to bond the overlay sheet to the decor sheet.

Abstract: A decor sheet for use in a decorative laminate includes cellulosic fibers, a sulfur dye, and a water insoluble precipitate of a basic salt.

Abstract: A decor sheet for use in a decorative laminate includes cellulosic fibers, a sulfur dye, and a water insoluble precipitate of a basic salt.

Abstract: A laminated paperboard product and a process for making the product and shoe insoles made therefrom. The product is formed of a first layer with a mixture of a predominance of a polyolefin fibers (preferably polyethylene) that has been treated to make it hydrophilic and long fiber softwood pulp, and a second layer formed of a mixture of the polyolefin fiber (again preferably polyethylene) and a predominance long fiber softwood pulp.When made into shoe insoles, the product has a second ply formed of a third and a fourth layer. The third layer has a composition that is similar to the second layer in that the quantity of polyolefin is greater then the quantity of wood pulp and the fourth layer has a composition that is similar to the first layer in that the quantity of polyolefin is less then the quantity of wood pulp.