U.S. patent application number 11/741266 was filed with the patent office on 2008-10-30 for multi-colored decorative laminate.
This patent application is currently assigned to Panolam Industries International, Inc.. Invention is credited to Robert A. Dumond.
Application Number | 20080268228 11/741266 |
Document ID | / |
Family ID | 39887348 |
Filed Date | 2008-10-30 |
United States Patent
Application |
20080268228 |
Kind Code |
A1 |
Dumond; Robert A. |
October 30, 2008 |
MULTI-COLORED DECORATIVE LAMINATE
Abstract
A decorative laminate, and method for making the same, includes
a core layer, a print layer, an overlay layer, and a luminescent
layer. The print layer includes patterns printed thereon using
conventional ink. In some embodiments, the overlay layer is
impregnated with a resin that includes photoluminescent material of
a single color which, when exposed to UV light, causes the single
color to be visible throughout. The luminescent layer includes
patterns of photoluminescent materials of different colors. In the
embodiments where the overlay layer includes a resin with a
photoluminescent material, the different colored patterns of the
luminescent layer are simultaneously visible with the single color
of the overlay layer when exposed to UV light.
Inventors: |
Dumond; Robert A.;
(Lewiston, ME) |
Correspondence
Address: |
O''Shea Getz P.C.
1500 MAIN ST. SUITE 912
SPRINGFIELD
MA
01115
US
|
Assignee: |
Panolam Industries International,
Inc.
Shelton
CT
|
Family ID: |
39887348 |
Appl. No.: |
11/741266 |
Filed: |
April 27, 2007 |
Current U.S.
Class: |
428/322.2 ;
156/307.4 |
Current CPC
Class: |
B32B 27/08 20130101;
Y10T 428/249998 20150401; B32B 37/14 20130101 |
Class at
Publication: |
428/322.2 ;
156/307.4 |
International
Class: |
B32B 7/00 20060101
B32B007/00; C09J 5/00 20060101 C09J005/00 |
Claims
1. A decorative laminate, comprising: a core layer impregnated with
a resin; a print layer with at least one pattern that is visible
under normal light; a first overlay layer impregnated with a resin
that includes a first photoluminescent material visible under
ultraviolet light; a luminescent layer with at least one pattern
that includes at least one second photoluminescent material that is
visible under ultraviolet light; and a second overlay layer.
2. The decorative laminate of claim 1, where the at least one
pattern of the luminescent layer overlays the at least one pattern
of the print layer.
3. The decorative laminate of claim 1, wherein the first
photoluminescent material luminesces at a first color, and wherein
the at least one second photoluminescent material luminesces at a
second color that is different than the first color.
4. The decorative laminate of claim 3, where an entirety of the
first overlay layer luminesces at the first color under ultraviolet
light.
5. The decorative laminate of claim 4, wherein at least a portion
of the first overlay layer is obstructed from view by the at least
one pattern of the luminescent layer under ultraviolet light.
6. The decorative laminate of claim 1, where the first
photoluminescent material is from a group consisting of a
phosphorescent material and a fluorescent material.
7. The decorative laminate of claim 1, where the second
photoluminescent material is from a group consisting of a
phosphorescent material and a fluorescent material.
8. The decorative laminate of claim 1, wherein the at least one
pattern within the luminescent layer comprises a plurality of
colors.
9. The decorative laminate of claim 8, wherein the luminescent
layer comprises a plurality of patterns, and the plurality of
patterns include a plurality of photoluminescent materials that
luminesce at different colors under ultraviolet light.
10. The decorative laminate of claim 9, wherein the plurality of
patterns with the luminescent layer overlay a plurality of patterns
with the print layer that are visible under normal light.
11. The decorative laminate of claim 9, where the first
photoluminescent material in the first overlay layer luminesces at
a first color that is different from the colors produced by the
patterns within the luminescent layer luminescing under ultraviolet
light.
12. A decorative laminate, comprising: a substrate; a print layer
with at least one pattern that is visible under normal light; a
first overlay layer impregnated with a resin that includes a first
photoluminescent material that is visible under ultraviolet light;
a luminescent layer with at least one pattern that includes at
least one second photoluminescent material that is visible under
ultraviolet light; and a second overlay layer.
13. The decorative laminate of claim 12, where the at least one
pattern of the luminescent layer overlays the at least one pattern
of the print layer.
14. The decorative laminate of claim 12, wherein the first
photoluminescent material luminesces at a first color, and wherein
the at least one second photoluminescent material luminesces at a
second color that is different than the first color.
15. The decorative laminate of claim 14, where an entirety of the
first overlay layer luminesces at the first color under ultraviolet
light.
16. The decorative laminate of claim 15, wherein at least a portion
of the first overlay layer is obstructed from view by the at least
one pattern of the luminescent layer under ultraviolet light.
17. The decorative laminate of claim 12, wherein the at least one
pattern within the luminescent layer comprises a plurality of
colors.
18. The decorative laminate of claim 12, where the substrate
comprises a material from the group consisting of a particle board
and a fiber board.
21. A method of forming a heat and pressure consolidated decorative
laminate, comprising the steps of: providing a stack of layers,
including one or more core layer sheets, each at least partially
impregnated with a resin, a print layer with at least one pattern
printed thereon that is visible under normal light, a first overlay
layer impregnated with a resin that includes a photoluminescent
material that is visible under ultraviolet light, and a luminescent
layer with at least one pattern of a photoluminescent material that
is visible under ultraviolet light; and subjecting the stack to a
sufficiently high temperature and pressure for a period of time
that the resins cure and bond the layers into the decorative
laminate.
22. A method of forming a heat and pressure consolidated decorative
laminate, comprising the steps of: providing a stack including a
substrate and a plurality of layers, including a print layer with
at least one pattern printed thereon that is visible under normal
light, a first overlay layer impregnated with a resin that includes
a photoluminescent material that is visible under ultraviolet
light, and a luminescent layer with at least one pattern of a
photoluminescent material that is visible under ultraviolet light;
and subjecting the stack to a sufficiently high temperature and
pressure for a period of time that the resins cure and bond the
layers and substrate into the decorative laminate.
23. A decorative laminate, comprising: a core layer having at least
one resin impregnated cellulosic sheet; a decorative layer with a
plurality of patterns printed thereon with a plurality of different
photoluminescent material, where each photoluminescent material
luminesces at a different color when exposed to ultraviolet light;
and an overlay layer.
24. The decorative laminate of claim 23, where the decorative layer
includes at least one printed pattern visible under normal
light.
25. A decorative laminate, comprising: a substrate; a decorative
layer with a plurality of patterns printed thereon with a plurality
of different photoluminescent material, where each photoluminescent
material luminesces at a different color when exposed to
ultraviolet light; and an overlay layer.
26. A decorative laminate, comprising: a core layer having at least
one resin impregnated cellulosic sheet; a print layer with at least
one pattern visible under normal light, a first photoluminescent
material spread over substantially all of the print layer so that
substantially all of the print layer luminesces at the first color
when exposed to ultraviolet light, and at least one pattern of a
second photoluminescent disposed on the print layer, which second
luminescent material luminesces at a second color when exposed to
ultraviolet light, wherein the first color is different from the
second color; and an overlay layer.
27. A decorative laminate, comprising: a core layer having at least
one resin impregnated cellulosic sheet; a print layer with at least
one pattern visible under normal light; and a first overlay layer
having a first photoluminescent material spread over substantially
all of the first overlay layer so that substantially all of the
first overlay layer luminesces at the first color when exposed to
ultraviolet light, and at least one pattern of a second
photoluminescent disposed on the first overlay layer, which second
luminescent material luminesces at a second color when exposed to
ultraviolet light, wherein the first color is different from the
second color.
28. The laminate of claim 27, further comprising a second overlay
layer.
Description
CROSS REFERENCE
[0001] The general subject matter of the present invention is
related to U.S. patent application Ser. No. 11/504,266 filed on
Aug. 15, 2006.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to decorative laminates.
More particularly, this invention relates to decorative laminates
incorporating a plurality of printed patterns of different colors
which are visibly luminescent simultaneously upon exposure to
ultraviolet light, and to methods of producing the same.
[0004] 2. Background Information
[0005] Decorative laminates typically include a core layer and a
decorative layer. The core layer in general is a supporting layer
onto which the decorative layer is bonded. In typical high heat and
pressure laminates, the core layer comprises a plurality of
cellulosic sheets made from a kraft paper impregnated with a
laminating resin. Such laminating resins may include, for example,
phenolic, melamine, amino, epoxy, polyester, silicone, and diallyl
phthalate. A preferred laminating resin for the core layer is a
phenolic resin made from the reaction of phenols with
formaldehyde.
[0006] The decorative layer is typically formed from one or more
sheets of cellulose pigmented paper containing a printed image,
pattern, grain design or a solid color, which oftentimes has been
impregnated with a transparent resin. Such resins may include, for
example, melamine, amino, epoxy, polyester, silicone, and diallyl
phthalate. A preferred resin for the decorative layer papers is
melamine-formaldehyde which, when cured, is colorless, resistant to
light and heat, and resistant to a variety of solvents and stains.
The decorative layer may also be "dry"--that is, lacking any
impregnating resin. The printed image is something that can be seen
in normal light; i.e., when the decorative layer is subjected to
visible light (the portion of the electromagnetic spectrum that is
visible to the human eye; e.g., about 400-700 nm) the printed image
can be seen by the human eye.
[0007] When the decorative layer includes a printed pattern and is
used in certain applications (e.g., bowling lanes), it is commonly
covered with an overlay layer, which is typically a high-quality
alpha cellulose paper impregnated with a melamine-formaldehyde
resin. The overlay layer helps to protect the decorative layer from
external abuse such as impact from objects, abrasive wear and tear,
harsh chemicals, burns, spills and the like. The
melamine-formaldehyde resin primarily accounts for these protective
properties of the laminate. The alpha-cellulose paper: 1) acts as a
translucent carrier for the water-thin resin; 2) imparts strength
to the melamine-formaldehyde resin; 3) maintains a uniform resin
thickness in the overlay layer by acting as a shim; and 4) controls
resin flow.
[0008] The core layer, the decorative layer and, when utilized, the
overlay layer, are typically stacked in a superimposed
relationship, between steel press plates and subjected to elevated
pressure and temperature for a time sufficient to cure the
laminating resins impregnating the respective layers. The elevated
temperature and pressure cause the impregnated resins to flow,
which consolidates the stack into an integral mass that is the
laminate. These laminates can be used in numerous applications,
including bowling lanes, floors, counter tops, table tops,
furniture, store fixtures, and the like. Examples of conventional
high pressure decorative laminates are disclosed in U.S. Pat. Nos.
3,418,189; 4,311,748; 4,473,613; and 4,741,968.
[0009] It is also known to provide a decorative laminate with an
image or pattern printed on one or more of the sheets comprising
the laminate using a photoluminescent material. When exposed to
ultraviolet light, the image or pattern visibly luminesces. See for
example, U.S. Pat. Nos. 6,596,416 and 6,395,408, which are hereby
incorporated by reference. Disclosed therein is a single image or
pattern of a single color. When such a decorative laminate is used,
for example, in bowling lane applications, the single color image
or pattern limits the applications for which the laminate can be
used. Further it is known to utilize aluminum oxide within the
overlay layer to contribute to its wear-resistant qualities.
However, the aluminum oxide tends to cause undesirable scuffing and
wear to the bowling ball and to the soles of the shoes worn by the
bowler. What is needed is a decorative laminate for use in, for
example, bowling lanes, where a plurality of printed images or
patterns, made from photoluminescent materials of different colors,
are visibly luminescent simultaneously when exposed to ultraviolet
light, against a backdrop of a single color that is also visibly
luminescent simultaneously when exposed to ultraviolet light,
thereby providing a relatively greater amount of visual information
to the bowler to add to the safety and enjoyment of the bowling
experience. What is also needed is an overlay layer less apt to
scuff and wear items in contact with the laminate; e.g., bowling
balls, bowling shoes, etc.
SUMMARY OF THE INVENTION
[0010] According to a preferred embodiment of the present
invention, a decorative laminate comprises a core layer, a print
layer, a high-wear overlay layer, a luminescent layer, and a clear
overlay layer. The core layer includes one or more resin
impregnated paper sheets. The print layer includes a dry paper
sheet with a plurality of patterns printed thereon using
conventional ink visible under normal light. The high-wear overlay
layer includes a single sheet of resin impregnated paper. The resin
includes a photoluminescent material of a single color that, when
exposed to ultraviolet light, causes the single color to be visible
throughout this overlay layer. The luminescent layer includes a dry
paper sheet having a plurality of patterns printed thereon using
different color photoluminescent materials, which are each also of
a different color than the single color of the high-wear overlay
layer. The patterns of different colors are simultaneously visible
with each other and with the single color of the high-wear overlay
layer when exposed to ultraviolet light such that the different
colors in the luminescent layer block from view the single color of
the high-wear overlay layer in the areas of the patterns in the
overlay layer. The blocking occurs because the photoluminescent
material patterns within the luminescent layer absorb the
ultraviolet light and prevent the ultraviolet light from reaching
the photoluminescent material of the high-wear overlay layer. In
the absence of ultraviolet light, the photoluminescent material of
the overlay layer will not luminesce; hence, it is "blocked". The
clear overlay layer includes one or more resin impregnated paper
sheets. All of the layers may be stacked together and laminated
under heat and pressure to form the decorative laminate.
[0011] In some embodiments, an additional print layer may be
disposed on an opposite side of the core layer, followed by an
additional high-wear overlay layer next to the additional print
layer, followed by an additional clear overlay layer. These
additional layers allow for a more balanced construction of the
overall decorative laminate, thereby helping to resist warping and
allowing the laminate to remain flat over time.
[0012] In an alternative embodiment of the present invention, a
decorative laminate comprises a core layer, a decorative layer, a
high-wear overlay layer, and a clear overlay layer. The core layer
includes one or more resin impregnated paper sheets. The decorative
layer includes a dry paper sheet with a plurality of patterns
printed thereon with photoluminescent material of different colors,
where the resulting patterns of different colors are simultaneously
visible when exposed to ultraviolet light. The high-wear overlay
layer includes a single sheet of resin impregnated paper. The clear
overlay layer includes one or more resin impregnated paper sheets.
The layers may be stacked together and laminated under heat and
pressure to form the decorative laminate.
[0013] As indicated above, an additional decorative layer may be
disposed on an opposite side of the core layer, followed by an
additional high-wear overlay layer next to the additional
decorative layer, followed by an additional clear overlay layer.
These additional layers allow for a more balanced construction of
the decorative laminate, thereby helping to resist warping and
allowing the laminate to remain flat over time.
[0014] In some embodiments, the core layer may be replaced by a
substrate and the remaining layers laminated in a low pressure
process or thermofused to the substrate.
[0015] These and other features and advantages of the present
invention will become apparent in light of the drawings and
detailed description of the present invention provided below.
DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a cross-sectional view (not to scale) of the
stacked layers of a decorative laminate according to a first
embodiment of the present invention;
[0017] FIG. 2 is a top view of the decorative laminate of FIG. 1
illustrating the various patterns formed in the laminate which is
used, for example, in a bowling lane application; and
[0018] FIG. 3 is a cross-sectional view (not to scale) of the
stacked layers of a decorative laminate according to a second
embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The invention relates to decorative laminates which
incorporate a photoluminescent material. The term
"photoluminescent" as used herein denotes a material which is
either visibly phosphorescent (i.e., where there is a continued
luminescence after termination of the exciting ultraviolet
radiation), or visibly fluorescent (i.e., where the luminescence
ceases as soon as the exciting ultraviolet radiation is
removed).
[0020] Referring to FIG. 1, in a first embodiment of the invention
the decorative laminate 10 comprises a core layer 20, a print layer
30, a high-wear overlay layer 40, a luminescent layer 50, and a
clear overlay layer 60. The core layer 20 comprises one or more
cellulosic sheets (e.g., kraft paper) impregnated with a laminating
resin. Acceptable laminating resins for the core layer 20 include
phenolic, melamine, amino, epoxy, polyester, silicone, and diallyl
phthalate resins. A phenolic resin made from the reaction of
phenols with formaldehyde is a more specific example of an
acceptable laminating resin.
[0021] The print layer 30 is disposed next to the core layer 20.
The print layer 30 typically includes at least one single
cellulosic sheet (e.g., alpha cellulose paper) that is "dry" in
that no resins are impregnated in this layer. A plurality of
patterns is printed on the dry paper sheet with conventional ink
visible under normal light and not under ultraviolet light. The
patterns may be printed using conventional methods, such as screen
printing, gravure printing, digital printing or the like. For
bowling lane applications (FIG. 2), the patterns may comprise one
or more foul lines 62, a straight line row of dots 64, and a
staggered row of darts 66. The dots and darts assist the bowler in
guiding the ball down the lane while also providing the bowler with
safety information. Also, the print layer 30 may have a wood grain
design.
[0022] The high-wear overlay layer 40 is disposed next to the print
layer 30. The high-wear overlay layer 40 includes at least one
sheet of resin impregnated paper. Melamine resin is an acceptable
resin for impregnating the overlay layer 40. An acceptable basis
weight for the overlay layer paper is about 28 lbs. The basis
weights given for the overlay layer 40 and other layers below
represent acceptable basis weights that may vary depending upon the
laminate application at hand. Aluminum oxide may be added to the
paper to increase the wear resistance of the high-wear overlay
layer 40. The impregnating resin includes a photoluminescent
material of a single color that, when exposed to ultraviolet light,
causes the single color to be visible throughout this overlay layer
40. As described in more detail hereinafter, the single color
essentially comprises a backdrop against which patterns (e.g., foul
lines 62, dots 64, darts 66) of different colors can be seen under
ultraviolet light. An acceptable photoluminescent material for the
single color is Leucophor BCR.TM., available from Clariant Corp. of
Charlotte, N.C. Leucophor BCR.TM. is a stilbene fluorescent
material supplied as a liquid having about 49% solids and which
generates a blue color upon luminescence.
[0023] The luminescent layer 50 is disposed next to the high-wear
overlay layer 40. The luminescent layer 50 may include a dry paper
sheet having a basis weight of about 13.5 lbs. The paper sheet of
the luminescent layer 50 includes at least one pattern of
luminescent material. Some embodiments include a plurality of
patterns of different photoluminescent materials to create
different color patterns. Patterns are typically printed onto the
luminescent layer, although other application methods may be used
alternatively. For bowling lane applications, the colors of the
decorative luminescent layer 50 are preferably different than the
single photoluminescent color (e.g., blue) of the high-wear overlay
layer 40. The color patterns may be printed in the luminescent
layer 50 using any known printing method, such as screen printing,
gravure printing, digital printing or the like. The luminescent
patterns may include different colors depending upon the
application for the decorative laminate 10. For bowling lane
applications, the patterns may comprise the same patterns (FIG. 2)
as those printed on the print layer 30; that is, one or more foul
lines 62, a straight line row of dots 64, and a staggered row of
darts 66. Typically, as mentioned above, patterns such as foul
lines 62, dots 64 and darts 66 are printed on the print layer 30
using conventional inks that are visible only under normal light
and not under ultraviolet light. The bowling lane beyond the
traditional foul lines 62 typically is oiled, making it relatively
slippery and thus possible for a bowler to slip and fall if the
bowler travels beyond the foul lines.
[0024] In accordance with this embodiment of the invention, a
second set of foul lines 62, dots 64 and darts 66 is printed on the
luminescent layer 50 using the different colored photoluminescent
materials. Preferably, these photoluminescent patterns are printed
on the luminescent layer 50 such that they outline (i.e., are
disposed over) the foul lines 62, dots 64 and darts 66 printed on
the print layer 30. In particular, each of the patterns in the
luminescent layer 50 may be sized slightly larger (e.g., one-eighth
of an inch larger) than the corresponding patterns in the print
layer 30. FIG. 2 illustrates this larger "outlining" feature of the
foul lines 62, dots 64 and darts 66 in a somewhat exaggerated
manner. Additional design graphics such as, for example, a logo 68,
swirled lines 70 (e.g., a "boomerang pattern") and the like, which
are visible only under ultraviolet light, may also be printed on
the luminescent layer 50 using the photoluminescent materials to
enhance the bowling experience. As illustrated in FIG. 2, the
swirled lines 70 occupy only a portion of the luminescent layer 50.
However, this is purely exemplary; the swirled lines 70 may, if
desired, occupy the entire luminescent layer 50. The
photoluminescent patterns in the luminescent layer 50 are
preferably of different colors to assist in providing safety
information to the bowler and to enhance the bowling experience,
and are generally invisible under normal light. The resulting
patterns of different colors are simultaneously visible with each
other and with the single color of the high-wear overlay layer 40
for the most part only when exposed to ultraviolet light. In
particular, under ultraviolet light, the different colors in the
luminescent layer 50 block out from view the single color of the
high-wear overlay layer 40 in the areas of the patterns 62, 64, 66
in the luminescent layer 50. Thus, in an exemplary embodiment, the
patterns 62-70 may be visibly defined under ultraviolet light as
comprising various colors (e.g., yellow, red, green)--all against a
backdrop of a blue color for the remainder of the bowling lane.
Other color schemes for the patterns and the backdrop are possible,
as should be apparent to one of ordinary skill in the art in light
of the teachings herein.
[0025] The photoluminescent materials within the patterns 62-70 may
be dispersed in a suitable vehicle which offers the flow
characteristics desired for the selected printing method. The
photoluminescent materials are provided in an amount which causes
the printed patterns 62-70 to visibly luminesce in the decorative
luminescent layer 50. Selection of a particular ultraviolet light
sensitive dye or pigment will typically depend upon the desired
color to be generated when the particular pattern luminesces in the
presence of ultraviolet light. In addition, the selected
photoluminescent dyes or pigments in general must be able to
withstand the heat and pressure to which the layers are exposed
during the lamination process. An acceptable photoluminescent
material is the aforementioned Leucophor BCR.TM., which generates a
blue color upon fluorescence. Other acceptable photoluminescent
materials include AIT4466 (yellow upon fluorescence) from Dayglo
Color Corp. of Cleveland, Ohio; Uvitex NFW Liquid, (blue upon
fluorescence) from CIBA Specialty Chemicals of Mobile, Ala.;
Fluorescent Brightener 0556 (blue upon fluorescence) from
Chromatech Inc. of Canton, Mich.; Phosphorescent Orange P500480
(orange upon phosphorescence) from USR Optonix, Inc. of Washington,
N.J.; Phosphorescent MBW Green, 2330 (green upon phosphorescence)
from USR Optonix, Inc.; Phosphorescent LBY Green 2330 (green upon
phosphorescence) from USR Optonix, Inc.; 2210 (green upon
fluorescence) from USR Optonix, Inc.; 3336 (yellow/orange upon
fluorescence) from USR Optonix, Inc.; YS-A-Red (red upon
fluorescence) from United Mineral and Chemical Corp. of Lyndhurst,
N.J.; GBF Orange (orange upon fluorescence) from United Mineral and
Chemical Corp.; and GBF Green (green upon fluorescence) from United
Mineral and Chemical Corp. Other photoluminescent materials may be
utilized, as should be apparent to one of ordinary skill in the art
in light of the teachings herein, such that a particular pattern
62-70 may be visibly luminescent (either by phosphorescence or
fluorescence) at a certain color when exposed to ultraviolet
light.
[0026] The photoluminescent pigment or dye may be combined with
conventional printing inks with which the selected photoluminescent
pigment or dye is compatible and can be readily dispersed. For
example, the photoluminescent pigment or dye may be combined with a
Clear Screen Print Extender.TM., commercially available from Gotham
Ink of Marlboro, Mass., or NAZDAR Clear 2700 AquaSafe Gloss Screen
Ink 2727 Overprint Clear, from NAZDAR of Shawnee, Kans. As will be
appreciated by those skilled in the art, the printing composition
may also include suitable amounts of other additives, such as
viscosity modifiers, heat stabilizers, wetting agents, binders or
the like. Generally, when the patterns 62-70 are printed onto the
paper sheet of the decorative luminescent layer 50 using a known
screen printing technique, each pattern or all patterns of one
color are printed separately, one at a time, in the overall
printing process.
[0027] Still referring to FIG. 1, the clear overlay layer 60 is
disposed next to the luminescent layer 50. The clear overlay layer
60 comprises one or more sheets of cellulosic paper impregnated
with a suitable transparent resin, such as melamine-formaldehyde.
High-quality alpha cellulose paper having a basis weight of about
22 lbs. is acceptable for the clear overlay layer 60. The clear
overlay layer 60 helps to protect the underlying luminescent layer
50, and is therefore desirable in applications such as bowling
lanes.
[0028] In forming the decorative laminate 10 of this embodiment of
the present invention, the core layer 20, the print layer 30, the
high-wear overlay layer 40, the luminescent layer 50 and the clear
overlay layer 60 are stacked in a superimposed relationship between
steel press plates or the like. An additional print layer 100 may
be disposed on the opposite surface of the core layer 20 (FIG. 1).
Next to the additional print layer 100 may be disposed an
additional high-wear overlay layer 110, followed by an additional
clear overlay layer 120. The construction of these additional
layers 100, 110, 120 may be similar to the corresponding layers 30,
40, 60 described hereinabove. The resulting decorative laminate 10
in this alternative is of a more balanced construction, thereby
helping to resist warping and allowing the overall decorative
laminate 10 to better remain flat over time. The stacked layers are
subjected to a sufficient pressure and temperature, and for a time
sufficiently long, to cure the laminating resins impregnating the
respective layers. The laminating temperature is at least about
230.degree. F., and is usually in the range of about 250.degree. F.
to about 300.degree. F. The pressure is generally increased to
between about 305 to 1500 psi. The elevated temperature and
pressure cause the resins within each of the impregnated sheets of
the layers to flow, which consolidates the stack into an integral
mass that comprises the decorative laminate 10.
[0029] When the laminate is subjected to ultraviolet light (e.g.,
in the range of between about 200 nm to 400 nm), the light
penetrates the clear overlay layer 60 and impinges upon the
luminescent layer 50 and the high-wear overlay layer 40. As a
result, the patterns 62-70 printed with photoluminescent materials
on the luminescent layer 50 and the high-wear overlay layer 40 emit
luminescent radiation such that the solid color in the high-wear
overlay layer 40 and the printed patterns 62-70 in the luminescent
layer 50 are visible. A reduced level of visible light impinging
upon the decorative laminate 10 will likely enhance the visibility
of the luminescent patterns.
[0030] In some embodiments, the print layer 30, the high-wear
overlay layer 40, the luminescent layer 50 and the clear overlay
layer 60 are prepared as discussed above, and are then incorporated
into a low pressure laminate in which a rigid substrate (e.g.,
particle board, fiber board, etc.) replaces the core layer 20. The
print layer 30 is stacked in a superimposed relationship with the
substrate. Selected ones of the layers are impregnated with a resin
in the same manner as for the high pressure laminate discussed
above, although a higher catalyst level may be employed. The layers
are placed in a hot press between steel press plates and subjected
to a relatively low pressure and temperature for a time
sufficiently long enough to cure the resins impregnating the
respective layers.
[0031] In a second embodiment of the present invention illustrated
in FIG. 3, a decorative laminate 200 comprises a core layer 210
that is similar in construction to the core layer 20 of the
decorative laminate 10 of FIG. 1. Disposed next to the core layer
210 is a decorative layer 220 that comprises one or more cellulosic
sheets (e.g., alpha cellulose paper) which may include a wood grain
design. A plurality of patterns similar to those illustrated in
FIG. 2 (e.g., foul lines 62, dots 64, darts 66) is printed onto the
cellulosic sheet(s) forming the decorative layer 220 using
conventional inks that are visible under normal light. The
photoluminescent patterns 62-70 are preferably of different colors
to assist in providing safety information to the bowler and to
enhance the bowling experience, and are generally invisible under
normal light.
[0032] Next to the decorative layer 220 is disposed a high-wear
overlay layer 230, which may be similar to the high-wear overlay
layer 40 of the decorative laminate 10 of FIG. 1, with the
exception that the high-wear overlay layer of this embodiment does
not contain any photoluminescent material. As such, the high-wear
overlay layer 230 of this embodiment does not luminesce at a single
color when exposed to ultraviolet light. Next to the high-wear
overlay layer 230 is disposed a clear overlay layer 240, which may
be similar to the clear overlay layer 60 of the decorative laminate
10 of FIG. 1. In this embodiment of the present invention, the
clear overlay layer 240 may be less wear-resistant than the
high-wear overlay layer 230 and is utilized to protect objects that
contact the laminate 200 (e.g., bowling balls and shoes) from
excessive wear due to the aluminum oxide or other wear resistant
particles. In some embodiments, an additional decorative layer 250,
high-wear overlay layer 260, and clear overlay layer 270 may be
disposed on the opposite side of the core layer 210, as shown in
FIG. 3. The stacked layers are subjected to a sufficient pressure
and temperature, and for a time sufficiently long, to cure the
laminating resins impregnating the respective layers. The
laminating temperature is at least about 230.degree. F., and is
usually in the range of about 250.degree. F. to about 300.degree.
F. The pressure is generally increased to between about 305 to 1500
psi.
[0033] In some embodiments, the decorative layer 220, the high-wear
overlay layer 230, and the clear overlay layer 240 are prepared as
discussed above, and are incorporated into a low pressure laminate
in which a rigid substrate (e.g., particle board, fiber board,
etc.) replaces the core layer 210. The decorative layer 220 is
stacked in a superimposed relationship with the substrate. As
indicated above, a higher catalyst level may be employed with a low
pressure laminate or thermofused laminate. The layers are placed in
a hot press between steel press plates and subjected to a
relatively low pressure and temperature for a time sufficiently
long enough to cure the laminating resins impregnating the
respective layers, as is conventional.
[0034] The following examples are illustrative of the present
invention and do not constitute any limitation with regard to the
subject matter of the invention.
EXAMPLE 1
[0035] Referring to FIG. 1, the stack of layers that ultimately
form a decorative laminate 10 includes a clear overlay layer 60, a
luminescent layer 50, a high-wear overlay layer 40, a print layer
30, and a core layer 20. The clear overlay layer 60 includes a
light basis weight melamine-formaldehyde impregnated overlay sheet.
The luminescent layer 50 includes at least one light basis weight
dry sheet with one or more different colored pigments screen
printed onto the sheet. The high-wear overlay layer 40 includes a
melamine-formaldehyde impregnated sheet that is also impregnated
with Leucophor BCR.TM., which is a photoluminescent material that
fluoresces blue in the presence of ultraviolet light. The core
layer 20 includes a plurality of phenolic impregnated kraft paper
sheets. The embodiment shown in FIG. 1 also includes a second print
layer 100 (e.g., the same as print layer 30), a second high-wear
overlay layer 110 (e.g., the same as overlay layer 40), and a
second clear overlay layer 120 (e.g., the same as clear overlay
layer 60).
[0036] The following colored pigments may be mixed in varying
percentages together with Clear Screen Print Extender.TM.,
available from Gotham Ink of Marlboro, Mass. The pigments, which
can be screen printed onto the decorative luminescent layer 50 to
form the various patterns 62-70 (FIG. 2), include the following:
Yellow AIT4466 pigment from Dayglo Color Corp. of Cleveland, Ohio;
Blue Uvitex NFW Liquid from CIBA Specialty Chemicals of Mobile,
Ala.; YS-A Red pigment from United Mineral and Chemical Corp. of
Lyndhurst, N.J.; GBF Orange pigment from United Mineral and
Chemical Corp.; and GBF Green pigment from United Mineral and
Chemical Corp. The eight layers 20-60, 100-120 are positioned
between steel press plates and subjected to about 1200 psi at a
maximum temperature of about 300.degree. F. for a total of about 20
minutes to form the decorative laminate 10.
EXAMPLE 2
[0037] Now referring to FIG. 3, the stack of layers that ultimately
form a laminate decorative panel 200 include an overlay layer 240,
a high-wear overlay layer 230, a decorative layer 220, and a core
layer 210. A light basis weight melamine-formaldehyde impregnated
sheet comprises the overlay layer 240. A sheet impregnated with
melamine-formaldehyde resin having abrasion resistant particles
comprises the high-wear overlay layer 230. A sheet with screen
printed images in various colors comprises the decorative layer
220. A plurality of phenolic impregnated kraft paper sheets
comprises the core layer 210. The embodiment shown in FIG. 3 also
includes a high-wear overlay layer 260 (e.g., the same as high-wear
overlay layer 230) and an overlay sheet 270 (e.g., the same as
overlay layer 240).
[0038] The following colored pigments may be mixed in varying
percentages together with Clear Screen Print Extender.TM.,
available from Gotham Ink of Marlboro, Mass. The pigments, which
can be screen printed onto the decorative layer 220 to form the
various patterns 62-70 (FIG. 2) include the following: Yellow
AIT4466 pigment from Dayglo Color Corp. of Cleveland, Ohio; Blue
Uvitex NFW Liquid from CIBA Specialty Chemicals of Mobile, Ala.;
YS-A Red pigment from United Mineral and Chemical Corp. of
Lyndhurst, N.J.; GBF Orange pigment from United Mineral and
Chemical Corp.; and GBF Green pigment from United Mineral and
Chemical Corp. The eight layers are positioned between steel press
plates and subjected to about 1200 psi at a maximum temperature of
about 300.degree. F. for a total of about 20 minutes to form the
laminate 200.
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