Fiberglass curtains and high gloss and / or flame retardant and / or non-combustible laminates containing such curtains

Abstract

A nonwoven fiberglass veil and laminates made therefrom are described, the nonwoven fiberglass veil comprising: a plurality of glass fibers; a resin component; a flame retardant component; and a particulate component comprising inorganic particles having a refractive index higher than that of the flame retardant component and an average particle size of about 0.1 to about 0.5 μm; wherein the flame retardant component and the particulate component are present in a combined amount of about 50% to about 90% by weight, based on the total weight of the veil, and wherein the flame retardant component and the particulate component are present in a weight ratio of about 95:5 to about 50:50.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 053,016, filed on July 17, 2020, the entire contents of which are incorporated herein by reference. Background Art

[0003] Composite materials are known. Various composite materials are used in laminated, multi-layer building materials due to their combination of strength, weight, and mechanical properties. For example, fiberglass mats or veils have been used in materials laminated using various resins to create building panels.

[0004] Often, for certain uses, it may be important to provide such composite panels with safety features, including, for example, fire resistance. Thus, for example, fire retardant materials may be incorporated into the fiberglass mat and veil.

[0005] Often, it may be desirable to provide such panels with a decorative aspect on the surface. However, fiberglass panels are often rough in terms of topography. Variations in fiber content and arrangement can show up on the exposed surface of the mat and can be magnified in the resulting laminate. Including a decorative overlay on such surfaces can further enhance the visualization of such surface roughness.

[0006] Additionally, such surface roughness and irregularities prevent the printing of decorative images on such surfaces with acceptable image quality and high gloss. Summary of the Invention

[0007] Generally speaking, the present invention relates to fiberglass masks, and in particular to fiberglass masks that provide laminates with improved surface smoothness, regularity, and gloss properties. More specifically, various aspects and embodiments of the present invention relate to fiberglass masks comprising glass fibers, a resin component, a flame retardant component, and an additional particulate component. Various embodiments disclosed herein may include a nonwoven fiberglass mask coated or saturated with a slurry comprising a flame retardant particle component and a low surface area to volume ratio particle component (i.e., a light scattering component having a refractive index higher than that of the flame retardant component) dispersed in an aqueous resin binder system. The resin binder may be the same as or different from the resin binder used to form the fiberglass mask to be treated with the disclosed slurry. Various embodiments may also include coloring additives (e.g., pigments, dyes, etc.). Various embodiments disclosed herein may include a nonwoven fiberglass mask formed, for example, in a wet-laid process, wherein the resin binder system used to form the mask comprises a flame retardant particle component and a low surface area to volume ratio particle component dispersed in a resin binder.

[0008] Various embodiments of the present invention include multilayer laminates wherein at least one layer is a fiberglass veil according to the disclosure herein. Embodiments of the present invention may include laminates comprised of several layers of fiberglass veils according to the disclosure herein. Various embodiments may include laminates having additional decorative layers or overlays. Laminates according to the present invention may include an exterior decorative layer that is a fiberglass veil according to the disclosure herein. Thus, various embodiments of the present invention may be used in conjunction with, or may be saturated with, a decorative surface layer. In various embodiments of the present invention, the fiberglass veil may be used as a substrate for printing decorative designs. Various embodiments of the present invention may be used to produce high gloss products, as well as products that meet various national flame retardant standards, ranging from flame retardant to non-flammable. Various embodiments of the present invention may be used as a white barrier to provide opacity to light-colored, low basis weight decorative layers. Various embodiments of the present invention may provide antimicrobial properties. Various embodiments of the present invention may be used in interior and exterior grade applications and may be used in conjunction with other core materials to achieve the desired final properties.

[0009] One embodiment of the present invention includes a nonwoven fiberglass mask comprising: a plurality of glass fibers; a resin component; a flame retardant component; and a particulate component comprising inorganic particles having a refractive index higher than that of the flame retardant component and an average particle size of about 0.1 to about 0.5 μm; wherein the flame retardant component and the particulate component are present in a combined amount of about 50% to about 90% by weight, based on the total weight of the mask, and wherein the flame retardant component and the particulate component are present in a weight ratio of about 95:5 to about 50:50.

[0010] In various preferred embodiments of the present invention, the flame retardant component comprises at least one member selected from the group consisting of aluminum trihydrate, zinc oxide, magnesium hydroxide, calcium carbonate, magnesite and hydromagnesite, barium sulfate, antimony oxide, magnesium silicate, clay, and borate. In various preferred embodiments of the present invention, the flame retardant component comprises aluminum trihydrate. In various preferred embodiments of the present invention, the particulate component comprises titanium dioxide. In various preferred embodiments of the present invention, the resin component comprises a thermosetting resin. In various embodiments of the present invention, the fiberglass veil comprises a preformed fiberglass veil that is subsequently coated with or saturated with a slurry comprising a flame retardant component and a particulate component in a resin system, wherein the resin used to form the initial fiberglass veil and the resin used to form the flame retardant / particulate slurry comprise the same resin. In various embodiments, the fiberglass veil is formed using a resin binder system comprising the flame retardant and particulate components in the amounts described herein.

[0011] Another embodiment of the present invention includes a nonwoven fiberglass mask comprising: a plurality of glass fibers; a thermosetting resin component; aluminum trihydrate; and titanium dioxide, the titanium dioxide comprising rutile titanium dioxide having a low surface area to volume ratio and an average particle size of about 0.1 to about 0.5 μm; wherein the aluminum trihydrate and the titanium dioxide are present in a combined amount of about 60% to about 80% by weight, based on the total weight of the mask, and wherein the flame retardant component and the particulate component are present in a ratio of about 75:25 to about 55:45 by weight.

[0012] Another embodiment of the present invention includes a multilayer decorative laminate comprising at least one layer that is a nonwoven fiberglass curtain, the nonwoven fiberglass curtain comprising: a plurality of glass fibers; a resin component; a flame retardant component; and a particulate component comprising inorganic particles having a low surface area to volume ratio and an average particle size of about 0.1 to about 0.5 μm; wherein the flame retardant component and the particulate component are present in a combined amount of about 50% to about 90% by weight, based on the total weight of the curtain, and wherein the flame retardant component and the particulate component are present in a weight ratio of about 95:5 to about 50:50. Various additional embodiments include multilayer decorative laminates wherein at least one layer that is a nonwoven fiberglass curtain is a decorative element. Various additional embodiments include multilayer decorative laminates wherein a nonwoven fiberglass cover curtain for a decorative element provides an exterior viewing surface of the laminate, the exterior viewing surface having a 60° gloss value of from about 80 to about 120, a distinctness of image of from about 35 to about 99, a haze value of less than about 20, and a peak specular reflectance of from about 30 to about 110.

[0013] Other aspects, features, and advantages will be apparent from the following disclosure, including the detailed description, the preferred embodiments, and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The foregoing summary and the following detailed description of preferred embodiments of the present invention will be better understood when read in conjunction with the accompanying drawings. For the purpose of illustrating the present invention, there are shown in the accompanying drawings presently preferred embodiments. However, it should be understood that the invention is not limited to the precise arrangements and means shown.

[0015] In the attached figure:

[0016] Figure 1 is a graphical representation of the gloss characteristics of samples according to embodiments of the present invention;

[0017] Figure 2 is a graphical representation of the pore space characteristics of a sample according to an embodiment of the present invention;

[0018] Figures 3a to 3eare images of cross-sectional scanning electron micrographs of various samples according to embodiments of the present invention; and

[0019] Figures 4a to 4e yes Figures 3a to 3e Images of surface-view scanning electron micrographs of various samples imaged in Figure 2. DETAILED DESCRIPTION

[0020] As used herein, the singular terms "a," "an," and "the" are synonymous with and used interchangeably with "one or more," and "at least one," unless language and / or context clearly indicate otherwise. Thus, for example, reference herein or in the appended claims to "a layer" or "the layer" may refer to a single layer or to more than one layer. Furthermore, unless otherwise specifically noted, all numerical values ​​should be understood as being modified by the word "about."

[0021] For simplicity and clarity of illustration, the elements in the figures are not necessarily drawn to scale, and the same reference numerals in different figures refer to the same elements. For clarity of the drawings, elements are illustrated as having generally straight edges and precise angle corners. However, those skilled in the art will understand that edges need not be straight lines and corners need not be precise angles.

[0022] Certain terminology is used in the following description for convenience only and is not intended to be limiting. The words "right," "left," "lower," and "upper" designate directions in the drawings to which reference is made. The words "inwardly" and "outwardly" refer to directions toward and away from, respectively, the geometric center of the subject being described and designated parts thereof. The terminology includes the words specifically mentioned above, derivatives thereof, and words of similar import.

[0023] Various embodiments of the present invention are directed to fiber veils comprising a flame retardant component and a particulate component. In various embodiments, such fiber veils may comprise glass fiber veils. In other words, in various embodiments, inorganic fiber veils oriented in a random or ordered manner are dispersed in a binder. Suitable inorganic fibers include glass, but may be made from a variety of other materials known in the art. In various preferred embodiments according to the present invention, glass fibers are used, and the veil comprises a glass fiber veil. Fiber veils, and preferably glass fiber veils, may be manufactured by any suitable technique using, for example, fibers and binders, including wet-laid techniques, the techniques and materials of which are described in U.S. Patent Nos. 4,129,674, 4,112,174, 4,681,802, 4,810,576, 5,484,653, 6,187,697, and 8,084,378, the entire disclosures of each of which are incorporated herein by reference. For example, generally, a slurry of glass fibers can be produced by adding chopped glass fibers to an aqueous binder resin (optionally containing a flame retardant component and a particulate component according to the present invention) in a pulper to disperse the fibers in the resin, and feeding this slurry onto a moving inclined screen to form a line to dewater and form a wet nonwoven fiber web.

[0024] According to various embodiments disclosed herein, glass fibers suitable for use in fiberglass veils can have various fiber diameters and lengths, depending on the strength and other properties desired for the veil as is well known. Glass fibers suitable for use in the present invention can be formed from any type of glass. In various preferred embodiments according to the present invention, E-glass fibers can be used. Glass fibers suitable for use in various embodiments of the present invention can have a diameter of about 3 micrometers (μm) to about 25 micrometers. In various preferred embodiments, the diameter of the glass fibers is in the range of 8 to 20 micrometers, and more preferably in the range of 8 to 12 micrometers, and more preferably about 10 micrometers. Glass fibers suitable for use in various embodiments of the present invention can have any length, depending on the desired mechanical properties. In various preferred embodiments, fiber lengths of about 8 mm to about 20 mm can be used. The glass fibers used can all be of approximately the same length, but fibers of different lengths and diameters can also be used to achieve different properties in a known manner.

[0025] In various embodiments of the present invention, suitable resins comprise thermosetting resins. Generally, any suitable thermosetting resin may be used, including but not limited to acrylic resins, vinyl resins (e.g., polyvinyl acetate and polyvinyl alcohol), polyesters, polyurethanes, phenolics, aminoplasts, hexadecene phthalates, epoxides, polyamides, cyanates, and polycyanurates, or copolymers, terpolymers, or combinations thereof. In various preferred embodiments of the present invention, suitable resins may include phenolic resins and / or epoxy resins. In various preferred embodiments of the present invention, the resin comprises a melamine resin or a phenolic resin. Generally, resins with lower calorific values ​​are preferred.

[0026] In various embodiments according to the present invention, a fiber mask can be formed according to any of the above-described processes, such as a wet-laid technique, and subsequently treated with a slurry containing a resin, a flame retardant component, and a particulate component. Alternatively, the fiber mask can be initially formed by such techniques, wherein the slurry used in the wet-laid technique contains a flame retardant component and a particulate component. In various embodiments, a fiberglass mask can be formed and subsequently treated with a slurry containing a resin, a flame retardant component, and a particulate component. For example, in various embodiments, commercially available fiberglass masks, such as those available under the trade names Johns Manville 7610, Ahlstrom GFT-25G10-60, and Ahlstrom GFT-255M18-80, can be treated with a slurry containing a resin, a flame retardant component, and a particulate component. Fiberglass masks formed to have minimal surface irregularities are preferred. Fiberglass veils prepared using wet-laid or dry-laid processes known in the art can typically have a basis weight of about 20 gsm to about 110 gsm, and preferably about 30 gsm to about 90 gsm, before being treated with a slurry containing a flame retardant component and a particulate component, wherein the fibers are randomly oriented and bound together with a binder resin and various other optional components, and can be treated with the slurry to form fiberglass veils according to various embodiments of the present invention. In various preferred embodiments of the present invention where the starting fiberglass veil is treated with a slurry to form the treated veil, the starting fiberglass veil can have a basis weight of about 50 gsm to about 70 gsm.

[0027] The slurry containing the flame retardant component and the particulate component can be applied to the fiberglass veil in any known manner, including, for example, immersion in a slurry bath or roller coating. In various embodiments, the fiberglass veil can be provided as a continuous web from a roll of material and passed through a slurry having the resin, flame retardant component, and particulate component in a resin bath, followed by removal of excess slurry by an appropriate metering method, followed by at least partial drying in, for example, a hot air oven. Alternatively, for example, the slurry containing the resin, flame retardant component, and particulate component can be applied to the fiberglass veil using a roller coater and then smoothed and metered to the appropriate basis weight using a wound metering rod (also known as a Mayer rod or rod). The coated veil can then be dried in a hot air oven to remove volatile components. The fiberglass veil can be treated with the slurry one or more times, preferably one or two coatings.

[0028] In various embodiments of the present invention, the flame retardant component comprises mineral flame retardant particles. Various flame retardant components can be suitable for use in various embodiments of the present invention, as long as the flame retardant component does not react with the resin system and is incompressible. Therefore, mineral flame retardant particles are suitable for use in various embodiments of the present invention. In various preferred embodiments of the present invention, the flame retardant component comprises a component selected from the following: aluminum trihydrate (ATH), zinc oxide, calcium carbonate, barium sulfate, magnesium hydroxide and clay. In various preferred embodiments, the flame retardant component comprises aluminum trihydrate. For example, in various preferred embodiments according to the present invention, the flame retardant component includes aluminum trihydrate purchased from CustomGrinders in Chatsworth, Georgia as Polyfill 301. In various embodiments of the present invention, the average particle size of the flame retardant component may be from about 5 microns to about 20 microns. In various preferred embodiments according to the present invention, the average particle size of the flame retardant component may be from about 9 microns to about 11 microns. In various preferred embodiments according to the present invention, the pH value of the flame retardant component may be from about 9 to about 10.

[0029] Fiberglass veils according to various embodiments of the present invention contain a particulate component. Particulate components suitable for use in various embodiments of the present invention generally have a shape or crystal structure with a low surface area to volume ratio. Particulate components suitable for use in various embodiments of the present invention generally should have a refractive index higher than that of the flame retardant component being used. Particulate components suitable for use in various embodiments of the present invention preferably have an average particle size of about 0.1 μm to about 0.5 μm. As mentioned above, particulate components suitable for use in various embodiments of the present invention generally have a shape with a low surface area to volume ratio. In other words, the particles of the various particulate components have a shape that has the lowest or near-lowest possible surface area for a given volume. Typically, these include spherical, ellipsoidal, oval, and round particles. Cuboid and minimally elongated cubic shapes are also possible, as long as the shape has a low aspect ratio, such as less than about 10:1, more preferably less than about 5:1, and even more preferably less than about 2.5:1.

[0030] The particulate component suitable for use in various embodiments of the present invention should generally have a refractive index higher than the refractive index of the flame retardant component used. The particulate component suitable for use in various embodiments of the present invention may include titanium dioxide, zinc oxide, barium sulfate, zinc sulfide or similar equivalents, which include inorganic particles having a refractive index higher than the refractive index of the flame retardant component used. For example, the refractive index of ATH is about 1.57. In various preferred embodiments of the present invention, the particulate component may comprise titanium dioxide. Preferably, the titanium dioxide is rutile titanium dioxide. In various preferred embodiments, the particulate component comprises rutile titanium dioxide, said rutile titanium dioxide having a TiO2 content greater than 99%, more preferably greater than 99.9%, and even more preferably greater than 99.99%. In various embodiments, the average particle size of the titanium dioxide particles is from about 0.1 μm to about 0.5 μm.

[0031] Fiberglass masks according to various embodiments of the present invention include (a) glass fibers, (b) a resin component, (c) a flame retardant component, and (d) a particulate component. In various embodiments of the present invention, the fiberglass mask may contain glass fibers in an amount of about 5% to about 15% by weight of the combined components (a) to (d) of the mask. In various preferred embodiments of the present invention, the fiberglass mask may contain glass fibers in an amount of about 5% to about 8% by weight of the combined components (a) to (d) of the mask. In various embodiments of the present invention, the mask may contain the resin component in an amount of about 5% to about 30% by weight of the combined components (a) to (d) of the mask. The aforementioned disclosed amounts of resin may be composed of the resin used to prepare the untreated starting fiberglass mask and subsequent resin introduced by treating the slurry to provide the flame retardant component and the particulate component. Alternatively, this amount of resin may be the result of forming the fiberglass mask in a wet-laid or other process, wherein the flame retardant component and the particulate component are provided during the initial mask formation process. In various embodiments of the present invention, the mask may contain a flame retardant component in an amount of about 25% to about 80% by weight of the combined components (a) to (d) of the mask. In various embodiments of the present invention, the mask may contain a particulate component in an amount of about 4% to about 50% by weight of the combined components (a) to (d) of the mask.

[0032] In various embodiments of the present invention, the flame retardant component and the particulate component may be present in a weight ratio of about 95:5 to about 50:50. That is, in various embodiments of the present invention, aluminum trihydrate, for example, and titanium dioxide, for example, may be present in a fiberglass curtain according to various embodiments disclosed herein in a weight ratio of ATH:TiO2 of about 95:5 to about 50:50. In various preferred embodiments, the flame retardant component and the particulate component may be present in a weight ratio of about 90:10 to about 55:45, about 85:15 to about 55:45, about 80:20 to about 55:45, about 80:20 to about 60:40, about 75:25 to about 60:40, about 80:20 to about 65:35, or about 75:25 to about 65:35. In various preferred embodiments, the flame retardant component and the particulate component are present in a weight ratio of about 80:20, about 70:30, or about 60:40. In certain preferred embodiments, the flame retardant component and the particulate component are present in a weight ratio of 80:20, or 70:30, or 60:40, with each value of each ratio varying within a range of ±5%, more preferably ±2%, and even more preferably ±1%. In various preferred embodiments, each of the aforementioned weight ratios can be specifically applied to each disclosed flame retardant component and each disclosed particulate component with respect to each other.

[0033] The treated slurry according to various embodiments of the present invention may additionally have one or more optional additives added thereto, such as surfactants, defoamers, rheology modifiers, anti-blocking agents, odorants, insect repellents, antimicrobials, dyes, pigments, and similar additives known in the art for inclusion in fiberglass curtain or mat treatments.

[0034] According to various embodiments of the present invention, the treatment slurry used to apply the flame retardant component and the particulate component to the preformed fiberglass veil can have a solids content of about 57 to about 76%, and preferably about 65 to about 75%. According to various embodiments of the present invention, the treatment slurry used to apply the flame retardant component and the particulate component to the preformed fiberglass veil is prepared as an aqueous mixture of the selected resin or resin system, the flame retardant component, the particulate component, and any optional ingredients as mentioned above. The treatment slurry used according to various embodiments of the present invention is mixed to achieve a uniform slurry and avoid coagulation and dilatation rheology. The slurry viscosity should generally be >400 cP (Brookfield 50 rpm spindle 03, 25°C) to achieve the appropriate slurry coating weight and avoid sedimentation.

[0035] Fiberglass curtains according to various embodiments of the present invention can be used as one or more layers in a multi-layer decorative laminate product. In various embodiments according to the present invention, a laminate can include multiple layers of fiberglass curtains according to the present invention. In various embodiments according to the present invention, a laminate can include multiple layers of fiberglass curtains that do not contain both a flame retardant component and a particulate component, with at least one upper layer disposed thereon, the upper layer comprising a fiberglass curtain according to an embodiment of the present invention. In various embodiments according to the present invention, a laminate can include multiple fiberglass curtain layers according to any of the foregoing embodiments and further include one or more cover layers, which can include decorative layers and protective cover layers as known in the art. In additional embodiments, fiberglass curtains according to various embodiments of the present invention can be used as one or more layers in a multi-layer ballistic-resistant laminate product or acoustic panel product. Various embodiments in which a ballistic-resistant panel includes a fiberglass curtain according to an embodiment of the present invention can further include an epoxy resin or a viscoelastic material, and optionally one or more ballistic-resistant cloth materials, such as aramid fibers (e.g., Kevlar).

[0036] Any lamination method can be used to prepare the laminated board according to various embodiments of the present invention, including, for example, high pressure lamination (HPL), continuous pressure lamination (CPL), hot melt melamine (TFM) method and other known methods. Suitable temperature, pressure and holding time conditions can be varied according to parameters known in the art. Various pressing plates and equipment known in the art can be used. In various embodiments according to the present invention, the laminated board produced using high pressure lamination may be preferred.

[0037] The fiberglass curtain according to various embodiments of the present invention can provide a non-combustible and flame-retardant material for the laminate. As used herein, "non-combustible" refers to a flame retardant rating of A2 or higher (according to EN ISO 1716 and EN 13823). As used herein, "flame retardant" refers to a flame retardant rating of B or higher (according to EN 13823 and EN 11925-2).

[0038] Thus, for example, depending on the desired basis weight of the resulting treated fiberglass veil, and the starting basis weight of the glass fibers prior to treatment with the slurry containing the flame retardant component and the particulate component, A2-grade and flame-retardant treated veils can be obtained using the resulting component contents as shown in Tables 1 and 2 below (Table 1 is expressed in weight percent, and Table 2 is expressed in gsm). The amounts shown in Tables 1 and 2 are non-limiting and are merely examples of suitable formulations. In the following tables, the basis weight in the leftmost column refers to the final basis weight of the treated fiberglass veil. "Binder + Resin" refers to the combined amount of binder from the preformed veil and resin from the treatment slurry.

[0039] Table 1.

[0040]

[0041] Table 2.

[0042]

[0043] The present invention will now be described in more detail with reference to the following non-limiting examples.

[0044] Example

[0045] Examples 1a to 1f :

[0046] A GFT-25G10-60 fiberglass mask having a basis weight of 60 gsm, obtained from Ahlstrom, was treated with melamine resin using six different slurries containing varying amounts of aluminum trihydrate (Polyfill 301 from Chatsworth Custom Grinders) and rutile titanium dioxide.

[0047] The slurry was applied to each mask using a double-pass reverse roller coating with a Mayer rod.Four fiberglass masks according to each of the six different slurry formulations were stacked and high pressure laminated at a temperature of about 130°C and a pressure of 1300 psi for about half an hour.

[0048] The resulting laminates were evaluated for 60° gloss, distinctness of image ("DOI"), peak specular reflectance, and haze using a Rhopoint IQ (goniophotometer) as shown in Table 3 (by weight percent) and Table 4 (gsm) below. The results of these analyses are given in Table 3. Figure 2 The surface gloss values ​​are measured on the decorative melamine layer of the pressed laminate.

[0049] Table 3.

[0050]

[0051] Table 4.

[0052]

[0053] from Figure 1 As can be seen, including the particulate component (in this case, rutile titanium dioxide) in increased amounts relative to the combined total amount of the flame retardant component and the particulate component provides significantly increased and improved DOI, improved peak specular reflectance, and better haze characteristics, while maintaining very high 60° gloss values.

[0054] like Figure 2 As shown in Figure 1, pore space is reduced by the inclusion of TiO2. Using samples prepared in Examples 1a to 1e and imaging techniques (see Examples 3 and 4 below), pore space was determined. The pore space values ​​for 0% TiO2 in the samples corresponding to Examples 1a to 1e were approximated using the values ​​from Example 2 below. The actual pore space in the 0% TiO2 sample using higher basis weight materials was even higher, at 22%. As TiO2 inclusion increases, displacing flame retardant particles, pore space decreases, reaching an approximate plateau of nearly 50%.

[0055] Example 2 :

[0056] GFT-255M18-80 fiberglass drapes with a basis weight of 80 gsm, obtained from Ahlstrom, were treated at both 0 and 34% TiO2 (% ATH replaced with TiO2), otherwise in the same format as described in Examples 1a to 1f. In terms of cross-sectional void space after pressing, we see a reduction from 22% to 13% with the addition of TiO2. This translates into an improvement in DOI from 55 to 91. Laminates prepared using 80 gsm fiberglass and 0% and 34% titanium dioxide were also compared to competitive products. The inclusion of titanium dioxide resulted in superior DOI, haze, and peak reflectivity (Rspec) compared to the fiberglass product without titanium dioxide, as well as both the CGS laminate product and the MDF lacquer product. The results are summarized in Table 5 below.

[0057] Table 5.

[0058]

[0059] Examples 3 and 4 :

[0060] Scanning electron micrographs of the laminates prepared according to Examples 1a to 1e, including cross-sectional and surface views, are shown in FIG. Figures 3a to 3e (cross section) and Figures 4a to 4e (Surface view). As can be seen, the pore space decreases with the amount of titania replacing ATH.

[0061] It has also been discovered that various embodiments of the present invention can provide such a uniform, low-porosity substrate that shrinks paper with fewer porosity defects to amplify. Therefore, even under accelerated drying conditions where paper shrinks more than fiberglass, the laminated fiberglass surface with the decorative paper cover does not exhibit defects amplified by paper shrinkage. The addition of TiO2 further improves the appearance of the fiberglass core with the decorative paper surface, again as an improvement over 100% paper products.

[0062] Those skilled in the art will appreciate that changes can be made to the above-described embodiments without departing from the broad inventive concept thereof. It should therefore be understood that the present invention is not limited to the particular embodiments disclosed, but is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.

Claims

1. A multilayer decorative laminate comprising at least one layer of a nonwoven fiberglass curtain, wherein an exterior viewable surface of the laminate has a peak specular reflectance of 30 to 110, The non-woven fiberglass veil comprises: (a) a plurality of glass fibers; (b) a resin component; (c) a flame retardant component; and (d) a particle component. wherein the particle component (d) comprises rutile titanium dioxide having a refractive index higher than that of the flame retardant component (c) and an average particle size of 0.1 to 0.5 μm; in: The plurality of glass fibers (a) are present in an amount of 5% to 15% by weight of the combination (a) to (d), the resin component (b) is present in an amount of 5% to 30% by weight of the combination (a) to (d), the flame retardant component (c) is present in an amount of 25% to 80% by weight of the combination (a) to (d), and the particle component (d) is present in an amount of 4% to 50% by weight of the combination (a) to (d), wherein the flame retardant component (c) and the particulate component (d) are present in an amount of 65% to 75% by weight based on the total weight of the nonwoven fiberglass veil; wherein the exterior visible surface of the laminate has a 60° gloss value of 100 to 120, an image clarity of 60 to 99, a haze value of less than 15, and a difference between the peak specular reflectance and the 60° gloss value of less than 40.

2. The multilayer decorative laminate according to claim 1, wherein the flame retardant component (c) comprises one or more selected from the group consisting of aluminum trihydrate, zinc oxide, magnesium hydroxide, calcium carbonate, magnesite and hydromagnesite, barium sulfate, antimony oxide, magnesium silicate, clay, and borates.

3. The multilayer decorative laminate of claim 1, wherein the resin component (b) comprises a thermosetting resin. 4 . The multilayer decorative laminate of claim 1 , wherein the plurality of glass fibers (a) are randomly oriented and have an average fiber diameter of 8 μm to 20 μm and an average fiber length of 8 mm to 20 mm.

5. The multilayer decorative laminate of claim 1 , wherein the nonwoven fiberglass veil has a basis weight of 200 gsm to 1200 gsm.

6. The multilayer decorative laminate of claim 1 wherein the thermosetting resin is a melamine resin.

7. The multilayer decorative laminate of claim 1, wherein the flame retardant component (c) and the particulate component (d) are present in a weight ratio of 80:20 to 50:

50.

8. The multilayer decorative laminate of claim 1, wherein the flame retardant component (c) and the particulate component (d) are present in a weight ratio of 75:25 to 55:

45.

9. The multilayer decorative laminate of claim 1, wherein the flame retardant component (c) and the particulate component (d) are present in a weight ratio of 70:30 to 60:

40.

10. The multilayer decorative laminate of claim 1, wherein the at least one layer of the nonwoven fiberglass veil is a decorative element.

11. The multilayer decorative laminate of claim 1 , wherein the at least one layer of the nonwoven fiberglass veil is an outer surface layer.

12. The multilayer decorative laminate of claim 1, wherein the particle component (d) comprises one or more selected from the group consisting of titanium dioxide, zinc oxide, barium sulfate, and zinc sulfide.

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