Leather decorative laminate

Abstract

A method of manufacturing a heat and pressure consolidated laminate is provided that includes in superimposed relationship a core layer containing a plurality of cellulosic sheets impregnated with a thermosetting resin, and a decorative layer consisting essentially of a leather material.

Description

[0001] This application claims the benefit of and priority from U.S. Provisional Patent Application Ser. No. 60 / 441,888, filed 22 Jan. 2003, which is hereby incorporated by reference in its entirety.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to decorative laminates in general and, more particularly laminates having a leather or leather-like material as a decorative layer. In addition, the present invention relates to a method for manufacturing the same. [0004] 2. Background Information [0005] Decorative laminates are often used in the construction of cabinetry, furniture, countertops, and other building products. There is considerable consumer demand for decorative laminates 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, ...

AI Technical Summary

Benefits of technology

[0008] Historically, leather clad panels used in furniture often required the furniture maker to stretch the leather skin to fit the panel. In some applications it was necessary to attach the edges of the skin to the panel's underside prior to attaching the panel to a substrate. In other instances, it was necessary to apply an adhesive to the leather and / or the substrate. Sufficient shrinkage in some instances would-cause the skin to pull away from the underside of the panel, become detached from the substrate, or tear. An advantage of the present laminate is that it provides a leather-surfaced product that can be easily incorporated into furniture and cabinetry. Because the leather decorative layer is an integral part of the decorative laminate, there is no need to fit and / or adhere the skin to the panel or substrate. The present leather decorative laminate attaches to a substrate in the same manner high-pressure laminates are attached to a substrate. If necessary, the present leather decorative laminate can also be trimmed like high-pressure laminates. In short, the present leather decorative laminate provides a product that can reduce or eliminate many of the problems associated with using leather in cabinetry, furniture, and the like.

[0009] Another advantage of the present leather decorative laminate is that it is not dimensionally limited by the size of a natural leather skin. Some natural leathers are either limited by the size of the skin or require undesirable seams. The leather utilized in the present leather decorative laminate enables the present laminate to be manufactured in commercial size sheets without seams.

[0010] Another advantage of the present leather decorative laminate is that it can be made in a wide variety of colors and textures. As a result, it can be used in a variety of applications.

[0011] Another advantage of the present leather decorative laminate is that the present invention is a ready-to-use end product having a desirable leather surface.

[0012] Another advantage of the present leather decorative laminate is that it retains the smell of natural leather. Some leather or leather-like products used in furniture and cabinetry applications look like leather, but very few retain the desirable smell of leather. The fact that the present laminate retains the natural leather smells provides it with a definite commercial feature.

Problems solved by technology

Sufficient shrinkage in some instances would-cause the skin to pull away from the underside of the panel, become detached from the substrate, or tear.

Some natural leathers are either limited by the size of the skin or require undesirable seams.

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