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Home Heat Accumulators Composition-board-with-improved-polymeric-skin-and-method-of-preparing-same

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Details
Inventors: Degens, Alfredo;
Assignee:
Primary Examiner: McCamish; Marion E.
Assistant Examiner:
Attorney, Agent or Firm: Crowley; Richard P.

A flexible, integrally bonded sheet material suitable for use as a face surface covering on a composition board, which sheet material comprises: first and second fibrous sheet materials bonded together by a cured thermosetting resin, the first sheet and at least a portion of the second sheet impregnated with a cured thermosetting resin, the face surface of the first sheet material characterized by a cured thermosetting resin surface, and the back surface of the second sheet material consisting essentially of fibers and capable of absorbing into the fibrous surface of the second sheet material an adhesive material for bonding purposes.

DETAILED DESCRIPTION My invention relates to an improved, flexible, fully cured, resin-impregnated sheet material suitable for use as a surface on a composition board or other substrate, to an improved laminate, such as a composition board, prepared with my cured sheet material secured thereto, and to the method of preparing the cured resin sheet material and the improved laminate.
I have discovered a novel and unique flexible, cured, thin sheet material comprising at least first and second fibrous sheet materials bonded together, which integrally bonded sheet material is suitable for use as a surface covering, and to a process of preparing such integral sheet material.
In the process of preparing my sheet material, I provide a first, thin, fibrous sheet material impregnated with a curable thermosetting resin, such as a condensable resin like a heat-curable melamine-formaldehyde resin, impregnated into a thin cellulosic sheet material, such as alpha cellulose, which thin sheet material may be a printed, opaque or translucent sheet.
The process includes placing into contact with one surface of the first curable resin-impregnated sheet material a second flexible fibrous sheet material, such as, for example, a sheet material like kraft or alpha paper.
The second fibrous sheet material is adapted to serve as a carrier for the first sheet material for bonding the sheet to a substrate.
The surface of the second sheet is further capable of absorbing an adhesive material therein in one embodiment while being bonded to a substrate material and prior to bonding in another embodiment.
The process includes then subjecting the first and second sheet materials to a high pressure; typically a pressure of over about 20 kilos per centimeter square (k/cm.
sup.
2), and at a thermosetting resin-curing temperature and for a period of time in a press to cure the resin in the first sheet, and to bond the one surface of the second fibrous sheet material, contacting the first fibrous sheet material by the resin flow and subsequent cure, to the surface of the first fibrous sheet material



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