Leather laminated decorative panel

Abstract

A heat and pressure consolidated laminate, and method for producing the same, is provided that includes in superimposed relationship a decorative layer consisting essentially of a leather material, an underlay layer, a substrate, and an optional backer layer. The substrate has a first surface and a second surface opposite one another. The underlay layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed between the decorative layer and the first layer of the substrate. The backer layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed contiguous with the second surface of the substrate.

Description

[0001] This application claims the benefit of and priority from U.S. Provisional Patent Application Serial No. 60 / 441,889, filed 22 Jan. 2003, which is hereby incorporated by reference in its entirety.[0002] The present invention relates to thermally fused decorative laminates in general and, more particularly, to thermally fused decorative panels having a leather or leather-like material as a decorative layer. In addition, the present invention relates to a method for manufacturing the same.BACKGROUND INFORMATION[0003] Thermally fused decorative panels are often used in the construction of cabinetry, furniture, and other building products. There is considerable consumer demand for thermally fused decorative panels in a wide variety of colors, patterns, and textures. Natural leather is another popular material used in the construction of furniture and other applications. Leather is generally perceived as a quality material used in high-end applications. Unfortunately, leather and ot...

AI Technical Summary

Benefits of technology

[0004] According to an embodiment of the present invention, a heat and pressure consolidated laminate ("thermally fused decorative panel") is provided that comprises in superimposed relationship a decorative layer consisting essentially of a leather material, an underlay layer, a substrate, and an optional backer layer. The substrate has a first surface and a second surface opposite one another. The underlay layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed between the decorative layer and the first layer of the substrate. The backer layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed contiguous with the second surface of the substrate.

[0004] According to an embodiment of the present invention, a heat and pressure consolidated laminate ("thermally fused decorative panel") is provided that comprises in superimposed relationship a decorative layer consisting essentially of a leather material, an underlay layer, a substrate, and an optional backer layer. The substrate has a first surface and a second surface opposite one another. The underlay layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed between the decorative layer and the first layer of the substrate. The backer layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed contiguous with the second surface of the substrate.

[0004] According to an embodiment of the present invention, a heat and pressure consolidated laminate ("thermally fused decorative panel") is provided that comprises in superimposed relationship a decorative layer consisting essentially of a leather material, an underlay layer, a substrate, and an optional backer layer. The substrate has a first surface and a second surface opposite one another. The underlay layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed between the decorative layer and the first layer of the substrate. The backer layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed contiguous with the second surface of the substrate.

[0004] According to an embodiment of the present invention, a heat and pressure consolidated laminate ("thermally fused decorative panel") is provided that comprises in superimposed relationship a decorative layer consisting essentially of a leather material, an underlay layer, a substrate, and an optional backer layer. The substrate has a first surface and a second surface opposite one another. The underlay layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed between the decorative layer and the first layer of the substrate. The backer layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed contiguous with the second surface of the substrate.

[0004] According to an embodiment of the present invention, a heat and pressure consolidated laminate ("thermally fused decorative panel") is provided that comprises in superimposed relationship a decorative layer consisting essentially of a leather material, an underlay layer, a substrate, and an optional backer layer. The substrate has a first surface and a second surface opposite one another. The underlay layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed between the decorative layer and the first layer of the substrate. The backer layer includes one or more cellulosic sheets impregnated with a thermosetting resin, and is disposed contiguous with the second surface of the substrate.

Problems solved by technology

Unfortunately, leather and other natural skins can be difficult to work with because of size limitations, shrinkage, natural imperfections, etc.

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