HK1033816B

HK1033816B - A process for the manufacturing of a decorative laminate, a decorative laminate obtained by the process and use thereof

Info

Publication number: HK1033816B
Application number: HK00107632.9A
Authority: HK
Inventors: 斯蒂芬‧佩尔松; 丹尼斯‧拉斯穆森; 托尔德‧安德松; 伯耶‧舍斯泰特
Original assignee: 表面装潢控股股份公司
Priority date: 1997-05-06
Filing date: 1998-05-04
Publication date: 2004-09-24

Description

Method for producing a decorative laminate, decorative laminate obtained by said method and use thereof

Technical Field

The present invention relates to a method for the manufacture of a thermosetting decorative laminate, mainly equiaxed, a thermosetting decorative laminate obtained by the method and its use.

Background

Products coated with thermosetting laminates are now common. They are used in most cases where high demands are made on the wear resistance but also resistance to different chemicals and moisture is required. Floors, floor skirtings, surfaces of articles, table tops, doors, panels are examples of such products. Thermoset laminates are most commonly constructed of a number of base sheets and a decorative sheet closest to the surface. The decorative panels may have a desired decoration or be textured. Thicker decking materials typically have a fiberboard or particle board core covered on both sides with a thermosetting laminate board. On at least one surface, the outermost sheet is typically a trim sheet.

One problem with such thicker laminates is that the core is softer than the surface layer made of paper impregnated with thermosetting resin. This results in a significant reduction in axial compression and impact resistance compared to laminates of the same thickness made from paper impregnated with thermosetting resin only.

Another problem with thicker laminates having a fiberboard or particleboard core is that they will typically absorb a large amount of moisture, which will cause the thicker laminate to expand and soften, which will cause the laminate to warp. The surface layer may even peel off partly or in extreme cases completely, since the core will expand more than the surface layer. Therefore, such laminates cannot be used without problems in humid areas such as humid rooms.

This problem can be solved to some extent by also impregnating the paper core with a thermosetting resin. Such laminates are commonly referred to as dense laminates. However, these dense laminates are expensive and laborious to manufacture because several tens of layers of paper must be impregnated, dried and stacked. The direction of the fibres in the paper also causes temperature and humidity differences in connection with expansion. The expansion in the cross direction of the fiber is two to three times higher than the expansion in the fiber direction. The longitudinal direction of the fibres coincides with the longitudinal direction of the paper. Although other materials may prove suitable, the use of cellulose as a base layer is limited.

Disclosure of Invention

In order to overcome the above-mentioned drawbacks of the prior art, the present invention provides a method for manufacturing a substantially equiaxed thermosetting decorative laminate comprising an equiaxed core, a major surface layer, wherein i) 85 parts by weight of particles having an average particle size of 5-3000 microns are mixed together with 15-85 parts by weight of a powdered thermosetting resin selected from the group consisting of phenol-formaldehyde resins, melamine-formaldehyde resins, urea-formaldehyde resins and mixtures thereof, the mixture being subjected to vigorous agitation so as to generate a frictional heat without causing the frictional heat to exceed 150 ℃, whereby the thermosetting resin becomes soft to bind or impregnate the particles, the particles connected by the thermosetting resin are separated and form agglomerates of the thermosetting resin and the particles, the agglomerates having an average particle size of 200-3000 microns and a resin content by weight percentage are formed 10% -50%; ii) drying the particle/resin mixture to an extent that the water content is below 10% by weight; iii) the dried particle/resin mixture is uniformly spread on a support, a press belt of a continuous laminator, and then continuously pressed at a temperature of 60 ℃ to 120 ℃ and a pressure of 15 bar to 400 bar, so that the particle/resin mixture flows out without complete curing of the resin, thereby obtaining a preformed isometric core, which is fed together with a main surface layer having a decorative layer between the press belts of the continuous laminator, and then continuously pressed at a temperature of 120 ℃ to 200 ℃ and a pressure of 15 bar to 300 bar, so that the resin is cured and thereby a thermosetting decorative laminate having an isometric core is obtained.

The present invention also provides a method for making a substantially equiaxed thermosetting decorative laminate comprising an isometric core, a major surface layer, wherein i) 85 parts by weight of particles having an average particle diameter of 5 to 3000 microns are mixed with 15 to 85 parts by weight of a powdered thermosetting resin, the resin is selected from the group consisting of phenol-formaldehyde resins, melamine-formaldehyde resins, urea-formaldehyde resins and mixtures thereof, the mixture is vigorously stirred to generate frictional heat, not to make the frictional heat exceed 150 ℃, whereby the thermosetting resin becomes soft to bind with or impregnate the particles, the particles connected by the thermosetting resin are separated and agglomerates of the thermosetting resin and the particles are formed, the average particle size of the agglomerates is 200-3000 microns and the resin content is 10-50% by weight; ii) drying the particle/resin mixture to an extent that the water content is below 10% by weight; iii) the dried particle/resin mixture is uniformly spread on a support, on a press plate of a discontinuous laminator, and is then intermittently pressed at a temperature of 60 ℃ to 120 ℃ and a pressure of 15 bar to 400 bar, whereby the particle/resin mixture flows out without complete curing of the resin, thereby obtaining a preformed isometric core, which is placed on the press plate of the discontinuous laminator together with a main surface layer having a decorative layer, and is then intermittently pressed at a temperature of 120 ℃ to 200 ℃ and a pressure of 15 bar to 300 bar, whereby the resin is cured and thereby a thermosetting decorative laminate having an isometric core is obtained.

The present invention also provides a method for making a substantially equiaxed thermosetting decorative laminate comprising an isometric core, a major surface layer, wherein i) 85 parts by weight of particles having an average particle diameter of 5 to 3000 microns are mixed with 15 to 85 parts by weight of a powdered thermosetting resin, the resin is selected from the group consisting of phenol-formaldehyde resins, melamine-formaldehyde resins, urea-formaldehyde resins and mixtures thereof, the mixture is vigorously stirred to generate frictional heat, not to make the frictional heat exceed 150 ℃, whereby the thermosetting resin becomes soft to bind with or impregnate the particles, the particles connected by the thermosetting resin are separated and agglomerates of the thermosetting resin and the particles are formed, the average particle size of the agglomerates is 200-3000 microns and the resin content is 10-50% by weight; ii) drying the particle/resin mixture to an extent that the water content is below 10% by weight; iii) the dried particle/resin mixture is uniformly spread on a carrier, a press belt of a continuous laminator and subsequently continuously pressed at a temperature of 120 ℃ to 200 ℃ and a pressure of 15 bar to 300 bar, whereby the resin is cured and thereby an isometric core is formed, which is provided with a main surface layer.

The present invention also provides a method for making a substantially equiaxed thermosetting decorative laminate comprising an isometric core, a major surface layer, wherein i) 85 parts by weight of particles having an average particle diameter of 5 to 3000 microns are mixed together with 15 to 85 parts by weight of a powdered thermosetting resin, the resin is selected from the group consisting of phenol-formaldehyde resins, melamine-formaldehyde resins, urea-formaldehyde resins and mixtures thereof, the mixture is vigorously stirred to generate frictional heat, not to make the frictional heat exceed 150 ℃, whereby the thermosetting resin becomes soft to bind with or impregnate the particles, the particles connected by the thermosetting resin are separated and agglomerates of the thermosetting resin and the particles are formed, the average particle size of the agglomerates is 200-3000 microns and the resin content is 10-50% by weight; ii) drying the particle/resin mixture to an extent that the water content is below 10% by weight; iii) the dried particle/resin mixture is uniformly spread on a support, a platen of a discontinuous laminator, and then intermittently pressed at a temperature of 120 ℃ to 200 ℃ and a pressure of 15 bar to 300 bar, whereby the resin is cured and thereby an isometric core is formed, which is provided with a main surface layer.

According to the present invention the above problems are solved by providing a flexible manufacturing process of a thermosetting laminate, mainly equiaxed, which can be adjusted according to investment effect, impact resistance, stiffness, density, moisture absorption capacity, swelling, mould resistance and fire resistance. The present invention relates to a method for manufacturing a mainly equiaxed thermosetting decorative laminate having an equiaxed core, a major surface layer and possibly a minor surface layer. The invention is characterized in that preferably organic particles having a weight percentage of 85 parts and an average particle diameter of 5-3000 microns, preferably 5-2000 microns, are mixed together with 15-85 parts, preferably 22-37 parts, by weight of a thermosetting resin powder selected from the group comprising phenol-formaldehyde resins, melamine-formaldehyde resins, urea-formaldehyde resins or mixtures thereof. Mixing takes place, for example, in an extruder, in which the mixture is subjected to vigorous stirring and frictional heat is generated. For this purpose, calenders may also be used. The frictional heat is not allowed to exceed 150 c and is preferably below 110 c and most preferably below 90 c. Whereby the thermosetting resin binds to or impregnates the particles by softening. The particles possibly joined together by the thermosetting resin are separated and form agglomerates of thermoplastic resin and particles, the agglomerates having an average particle size of between 200 and 3000 microns and a content of resin of between 10% and 50% by weight, and preferably between 20% and 30%.

The pellet/resin mixture is then dried to a moisture content of less than 10% by weight, and preferably less than 5%.

The dried particle/resin mixture is then uniformly cast onto a support, a press belt of a continuous laminator, or a press plate of a discontinuous laminator. Thereafter, the dried pellet/resin mixture is continuously or intermittently pressed at a temperature of 60 ℃ to 120 ℃ and preferably 80 ℃ to 100 ℃ and at a pressure of 15 bar to 400 bar and preferably 30 bar to 120 bar, so that pellet/resin agglomerates flow out without complete curing of the resin, thereby obtaining an equiaxial core preform. The core preform is then fed, together with a main surface layer with a decorative layer and possibly a secondary surface layer, between the press belts of a continuous laminator or on the press plates of a discontinuous laminator. Subsequently, it is continuously or intermittently pressed at a temperature of 120 ℃ to 200 ℃ and preferably 140 ℃ to 180 ℃ and at a pressure of 15 bar to 300 bar and preferably 30 bar to 150 bar, so that the resin cures and a thermosetting decorative laminate having an isometric core is obtained.

According to another alternative, the dried particle/resin mixture obtained above is homogeneously distributed on a support, a press belt of a continuous laminator or a press plate of a discontinuous laminator and then pressed continuously or intermittently at a temperature of 120 ℃ to 200 ℃ and preferably 140 ℃ to 180 ℃ and at a pressure of 15 bar to 300 bar and preferably 30 bar to 150 bar, whereby the resin is cured and thereby an isometric core is formed. Before or in connection with the pressing, the core is provided with a main surface layer and possibly a secondary surface layer.

A pressure of 15-70 bar is normally used in a continuous pressing process, whereas a pressure of 50-400 bar is used in a discontinuous pressing.

The particles are suitably constituted wholly or partly by fruit parts or wood parts of the plant, whereby the wood parts comprise, for example, sawdust, wood flour or shredded stalks, while the fruit parts are suitably constituted by some kind of powdery grain, such as corn kernels, wheat flour or flour. The particles may also consist wholly or partly of manufacturing waste of recycled material, such as waste paper, cardboard or thermosetting laminate. The granules may also consist entirely or partly of lime. The particles are therefore selected according to the properties imparted to the final laminate. Mixtures of different particles will also give satisfactory properties. Prior to mixing, the granules are suitably dried to a moisture content of less than 10%, and preferably less than 6% by weight.

Preferably, the dried particle/resin mixture is dosed such that the difference in particle weight per unit area of the core material is not more than 10%, and preferably not more than 3%. The particle/resin mixture is for example thrown onto the press platens of a discontinuous multi-layer press. The press plate may be provided with a removable frame surrounding the desired core. Alternatively, the frame may be connected to the platen, whereby the frame and platen form a carrier. In an alternative to using a frame, a second platen having a size smaller than the size inside the frame is placed over the dosed particle/resin mixture. A plurality of platens having a frame with a pellet/resin mixture and a second platen on top of the mixture are stacked and fed into a laminator. In the case where a framed platen is not used, the second platen is eliminated. Otherwise, the work program will correspond to the framed work program described above.

The dried pellet/resin mixture may also be pressed in a continuous lamination process. The particle/resin mixture is then, for example, cast on a support in the form of a coil, which is fed continuously between two steel belts of a continuous laminator. The support is removed after passing through the laminator. The carrier may also be formed of a major surface layer or a minor surface layer, whereby the carrier is not separated from the laminate, as it forms part of the laminate.

The pressing process is suitably started at a low initial pressure, preferably equal to 10-50% of the final pressure, at which the pellet/resin mixture is allowed to flow, as the resin softens due to the high temperature. The pressure is gradually increased before curing begins, and curing occurs for about 5 seconds to 120 seconds depending on the curing agent composition, pressure and temperature. In the discontinuous pressing process, the temperature is suitably equal to 100-200 ℃ and preferably equal to 140-170 ℃ and the pressure is 10-500 bar and preferably 10-300 bar, the final pressure being 100-300 bar. In the continuous pressing process, the temperature is suitably equal to 120-200 ℃ and preferably equal to 140-180 ℃ and the pressure is 10-300 bar and preferably 10-150 bar, the final pressure being 50-150 bar. The initial pressure, final pressure and temperature in both continuous and discontinuous pressing processes depend on the particle size, particle composition and resin composition.

The main surface layer is preferably constituted by at least one decorative paper, for example made of alpha cellulose impregnated with a thermosetting resin, and preferably impregnated with a melamine-formaldehyde resin and/or a urea-formaldehyde resin. At least one so-called overlay board impregnated with melamine-formaldehyde resin or urea-formaldehyde resin may be placed on top of the decorative paper. A base paper impregnated with a thermosetting resin, preferably with a melamine-formaldehyde resin, a urea-formaldehyde resin, a phenol-formaldehyde resin or a mixture thereof, is optionally placed under the decor paper. Optionally a diffusion barrier foil is placed under the decorative paper closest to the core material.

In some cases it may be desirable to provide the secondary surface layers on opposite sides of the core material. The sub-surface layer is thus suitably composed of at least one so-called base paper, which is conventional and impregnated with a thermosetting resin, and preferably a melamine-formaldehyde resin or a urea-formaldehyde resin. The base paper is used to prevent the laminate from buckling which might otherwise be caused by the difference in expansion between the core material and the surface layer in relation to moisture and temperature. Alternatively, the secondary surface layer may be constituted by at least one decorative paper made, for example, of alpha cellulose impregnated with a thermosetting resin, and preferably with a melamine-formaldehyde resin or a urea-formaldehyde resin. According to a further embodiment the secondary surface layer is constituted by the anti-diffusion foil closest to the core material.

The diffusion-preventing foil is preferably made of metal, such as aluminum, steel, copper, zinc, or plastic, such as polyethylene, polypropylene, polyalkylene terephthalate, acrylic polymers, polyvinyl chloride, fluorinated thermoplastics, and the like. The surface of the diffusion-preventing foil is suitably treated by coating with a primer, microetching, sandblasting, corona treatment, spark-grinding, brush-plating, electroplating or the like, in order to improve the adhesion to the impregnated paper and the support layer, respectively, by surface expansion or surface activation. The anti-diffusion foil suitably has a thickness of 5-2000 μm, preferably 10-1000 μm. The metal foil suitably has a thickness of 5-200 μm and preferably 10-100 μm, while the plastic foil has a thickness of 0.2-2mm, preferably 0.3-1 mm. The foil suitably has a coefficient of thermal expansion of 15 x 10^-6/° K to 100 × 10^-6Preferably in the range of 15X 10/° K^-6/° K and 50 × 10^-6Between/° K. It is desirable to use a foil having a coefficient of thermal expansion as close as possible to that of the thermosetting resin impregnated paper, since large differences will cause internal tensions upon temperature changesWhich may cause delamination between the foils or between the foil and other layers. These inconveniences are particularly pronounced during lamination and cooling of the laminate after lamination. However, in some applications it may be desirable to select a foil that expands a significantly different amount depending on the temperature than the other materials of the laminate. One such application may be, for example, an asymmetric laminate, where the foil may prevent temperature-dependent bending that would otherwise occur in an asymmetric laminate. The common type of phenol-formaldehyde based laminates have a coefficient of thermal expansion of 15 x 10^-6/°K-40×10^-6Within the range of/° K. This value can be varied by varying, among other things, the resin composition, the paper quality and the fibre orientation, as well as the pressing time and its pressure and temperature. Even in asymmetrical laminates, the difference in expansion between the various materials in the laminate can be adjusted by selecting foils of appropriate thickness and coefficient of thermal expansion, whereby temperature-dependent bending can be completely avoided.

The thermosetting laminate may suitably be provided with three-dimensional structures such as tongues, grooves and/or laths in a discontinuous press. Subsequent processing can be avoided completely or partly by providing the laminate with functional components during pressing. The laminate may also be provided with a stiffener condition on its rear side. It has not been possible to obtain such features by conventional methods. If a diffusion-preventing foil is applied to such a rear side, the foil must be flexible and of an extensible type. As examples of such foil, it may be the above-mentioned ductile aluminum foil, annealed copper foil or thermoplastic film.

The invention also relates to a thermosetting laminate made by the method. Thermoset laminates are predominantly equiaxed, with the difference in expansion coefficients between the length and width directions of the laminate being less than 10%. The thermosetting laminate suitably has a water absorption capacity of less than 10% (by weight) and preferably less than 6% after 100 hours in water at 23 ℃.

The thermoset laminate also has an impact resistance greater than 2 kilojoules per square meter and preferably greater than 3 kilojoules per square meter. In the case where it is desired to produce a thermoset laminate with high abrasion resistance, at least one thermoset resin impregnated paper, and preferably the uppermost layer of such paper, is coated with hard particles, such as silica, alumina and/or silicon carbide, having an average particle size of from 1 micron to 100 microns and preferably from 5 microns to 60 microns.

The invention also relates to the use of the thermosetting laminate obtained by the method. The thermoset laminate material may be used herein as floor lining, interior walls, ceilings and doors in dry and wet rooms. The thermoset laminates may also be used as table tops, article surfaces, building facades and roofing panels.

Drawings

The invention will be further described with reference to the drawings and examples in which

Figure 1 schematically illustrates the discontinuous method of the present invention;

FIG. 2 schematically illustrates a continuous process of the present invention;

FIG. 3 schematically illustrates an alternative continuous process of the present invention;

FIG. 4 schematically illustrates an alternative discontinuous method of the present invention;

figure 5 shows a part of a panel obtained by the method of the invention;

FIG. 6 shows a part of a laminate flooring obtained by the method of the invention;

7.1-7.2 show a part of a building facade panel obtained by the method of the invention;

Detailed Description

Example 1 describes the manufacture of laminated panels;

example 2 describes the manufacture of laminate flooring;

example 3 describes the manufacture of a laminated building facade panel;

example 4 describes an alternative manufacturing method of laminated panels;

example 5 describes an alternative manufacturing method of a laminated panel.

Figure 1 schematically illustrates the discontinuous process of the present invention wherein a predominantly equiaxed thermosetting decorative laminate is produced comprising an equiaxed core, a major surface layer and possibly a minor surface layer. In a dry state, the pellets are mixed with the thermosetting resin powder under vigorous stirring in the extruder 100, thereby generating frictional heat. Extruder 100 is cooled. The thermosetting resin will soften as a result of the heat whereby it will bond with and impregnate the particles. Particles that may stick to each other will be separated in the grinder 101, whereby lumps of resin and particles are formed. The pellet/resin mixture is then dried in a dryer 102. The dried particle/resin mixture is then uniformly distributed onto the platen 51 of a discontinuous laminator 50. The platen 51 is provided with a frame. Thereafter, a second platen 51' having an outer dimension less than the inner dimension of the frame is placed over the pellet/resin mixture. Subsequently, a number of such press plates 51 are placed in a laminator 50 in the form of a multi-layer press, in which the particle/resin mixture is compressed under the influence of heat and pressure, whereby the resin solidifies and thereby an equiaxed core 2 is formed. After leaving the press and being cooled, the surface of the core 2 is treated and covered with a primary surface layer 10 (fig. 6) in the form of a decorative paper 12 (fig. 6). The decorative paper 12 is usually made of alpha cellulose impregnated with melamine-formaldehyde resin, which is then dried and the solvent is thereby evaporated, while the resin is partially cured to the so-called B-stage. Such papers are commonly referred to as prepregs. The prepreg and core are joined together by compression in a laminator. The secondary surface layer may be adhered to the core in the same manner. It is of course laid on the other side of the core.

According to an alternative embodiment, at least one such prepreg constituting the main surface layer may be placed directly on the press plate, whereby the particle/resin mixture is distributed on top of the main surface layer. A lamination process is saved here. The secondary surface layer may be integrated with the core in the same manner. The secondary surface layer is then laid on top of the dosed particle/resin mixture.

Fig. 2 schematically shows a continuous process according to the invention, in which a predominantly equiaxed thermosetting decorative laminate comprising an equiaxed core, a major surface layer and a minor surface layer is produced. In the dry state, the pellets are mixed with the thermosetting resin powder in the extruder 100 with strong agitation and thus frictional heat is generated. Extruder 100 is cooled. The thermosetting resin will soften as a result of the heat whereby it will bond with and impregnate the particles. Particles that may stick to each other will be separated in the grinder 101, whereby lumps of resin and particles are formed. The pellet/resin mixture is then dried in dryer 102. The dried particle/resin mixture is then uniformly distributed onto a support 30, which is composed of a base paper 21 in the form of a roll of tape. The base paper 21 forms the sub-surface layer 20. The base paper tape 21 is generally composed of kraft paper impregnated with phenol-formaldehyde resin and then dried. The strip of base paper 21 with the particle/resin mixture on its surface is then fed together with the uppermost main surface layer 10 between two steel belts 41 of a continuous laminator 40. The main surface layer 10 is, starting from the upper surface, composed of two overlay papers 11, so-called in the form of rolls, which are impregnated with a melamine-formaldehyde resin which is subsequently dried. The decorative paper 12 in the form of a threading is fed under the overlay paper 11, closest to the particle/resin mixture. The decor paper tape 12 is typically composed of alpha cellulose impregnated with melamine-formaldehyde resin and then dried. The particle/resin mixture and the paper tape are compressed under heat and pressure so that the resin cures, thereby forming a thermosetting laminate having an equiaxial core, a decorative wear surface layer 10 and a non-decorative sub-surface layer 20. The pellet/resin mixture will be thinned during pressing to approximately one-third of its original thickness.

Hard particles such as silicon carbide or alumina may be sprayed onto one or both sides of the overlay paper tape 11 where additional wear resistance is desired.

Fig. 3 schematically shows a continuous process according to the invention, in which a predominantly equiaxed thermosetting decorative laminate comprising an equiaxed core, a major surface layer and a minor surface layer is produced. In the dry state, the pellets are mixed with the thermosetting resin powder in the extruder 100 with strong agitation and thus frictional heat is generated. Extruder 100 is cooled. The thermosetting resin will soften as a result of the heat whereby it will bond with and impregnate the particles. Particles that may stick to each other will be separated in the grinder 101, whereby lumps of resin and particles are formed. The pellet/resin mixture is then dried in a dryer 102. The dried particle/resin mixture is then uniformly distributed onto a support 30, which is composed of a base paper 21 in the form of a roll of tape. The base paper 21 forms the sub-surface layer 20. The base paper tape 21 is generally composed of kraft paper impregnated with phenol-formaldehyde resin and then dried. The base paper strip 21 with the particle/resin mixture on its surface is then fed between two steel strips 41 of a continuous laminator 40' where it is pressed together under heat and pressure without curing resin. A preform core 2 with a sub-surface layer 20 attached is thus obtained. The pellet/resin mixture will be thinned during pressing to approximately one-third of its original thickness. The core 2 with the attached secondary surface layer 20 is fed after the first laminator 40' together with the primary surface layer 10 placed on the upper surface between two steel belts 41 "of a second continuous laminator 40". The main surface layer 10 is formed from two so-called overlay papers 11 in the form of a web of paper from the upper side. The overlay paper tape 11 made of alpha cellulose is impregnated with melamine-formaldehyde resin which is then dried. The decorative paper 12 in the form of a threading is fed under the overlay paper strip 11 closest to the particle/resin mixture. The decor paper tape 12 is typically composed of alpha cellulose impregnated with melamine-formaldehyde resin and then dried. The core 2 and the paper tape are pressed together under heat and pressure so that the resin cures and thereby forms a thermosetting laminate having an equiaxial core 2, a decorative wear resistant primary surface layer 10 and a non-decorative secondary surface layer 20.

Alternatively, the preformed core 2 may be cut into sheets after the first pressing in which the resin is spread only. These sheet-shaped cores 2 can then be placed together with the cardboard that will constitute the surface layer 10 on the press plates 51 of the discontinuous laminator 50. Subsequently, the sheets are pressed together under heat and pressure so that the resin cures. Here, the second laminator 40 "is omitted.

In the event that additional wear resistance is desired, hard particles such as silicon carbide or alumina may be sprayed onto one or both sides of the overlay paper strap 11.

FIG. 4 schematically illustrates an alternative non-continuous method according to the present invention wherein a predominantly equiaxed thermosetting decorative laminate comprising an equiaxed core, a major surface layer and an optional minor surface layer is produced. In a dry state, the pellets are mixed together with the thermosetting resin powder in the extruder 100 under vigorous stirring, thereby generating frictional heat. Extruder 100 is cooled. The thermosetting resin will soften as a result of the heat whereby it will bond with and impregnate the particles. Particles that may stick to each other will be separated in the grinder 101, whereby lumps of resin and particles are formed. The pellet/resin mixture is then dried in a dryer 102. The dried particle/resin mixture is then uniformly dispensed onto the platen 51 of a discontinuous laminator 50. The platen 51 is provided with a frame. Thereafter, a second platen 51' having an outer dimension less than the inner dimension of the frame is placed over the pellet/resin mixture. A number of such platens 51 are then placed in a laminator 50 in the form of a multi-layer press, and the particle/resin mixture is compressed in the laminator under the influence of heat and pressure, whereby the resin solidifies and thus forms the pre-fabricated equiaxed core 2. After leaving the press and preferably after being cooled, the prefabricated equiaxed core 2 is again placed on the press plate 51 together with the main surface layer 10 in the form of the decorative paper 12. The decorative paper 12 is usually made of alpha cellulose impregnated with melamine-formaldehyde resin, which is then dried and the solvent is thereby evaporated, the resin partially curing to the so-called B-stage. Such impregnated papers are commonly referred to as prepregs. The prepreg is pressed together with the core 2 in a laminating machine under the action of pressure and heat, whereby the resin is cured. The secondary surface layer may be joined to the core in the same manner. Subsequently, it is of course laid on the other side of the core.

Fig. 5 shows a part of a panel 70 obtained by the method described in connection with fig. 4. The panel 70 comprises a core 2 and a main surface layer 10. The main surface layer 10 is composed of two layers. The uppermost layer is a decorative thermosetting resin impregnated paper 12. The non-decorative base paper 14 is placed under it closest to the core 2. The rear side of the panel 70 is provided with a lower strip member 75. The panel is substantially rectangular when viewed from the front. A slot 73 is provided for the short side 71 and the long side 72 (not shown). The remaining edge is provided with a tongue 74. The groove 73, tongue 74 and batten 75 are made prior to pressing.

Fig. 6 shows a part of a laminate flooring 60 obtained by the method described in connection with fig. 3. The laminate flooring 60 comprises a core 2, a primary surface layer 10 and a secondary surface layer 20. The main surface layer 10 is composed of three layers of thermosetting resin impregnated paper. The decorative paper 12 is disposed closest to the core 12. Two layers of overlay paper 11 are placed on top of the decor paper. The sub-surface layer 20 is constituted by a conventional so-called base paper 21. The laminate flooring 60 is substantially rectangular when viewed from the front. A groove 63 is machined along a short side 61 and a long side 62. The tongue 64 is machined along the remaining two edges.

Fig. 7.1 and 7.2 show different parts of a building front panel 80 obtained by the method described in connection with fig. 1. The building facade panel 80 comprises a core 2, a primary surface layer 10 and a secondary surface layer 20. The main surface layer 10 is composed of four layers. The two uppermost layers are the so-called alpha cellulose overlay paper. The decorative thermosetting resin impregnated paper is placed under the overlay paper. Below them, closest to the core 2, a diffusion-preventing foil 13 is placed. The sub-surface layer 20 is constituted by a diffusion-preventing foil 23. The diffusion-preventing foil 13, 23 may be made of aluminium, for example. The major part of the rear side of the front panel 80 of the building covered by the sub-surface layer 20 is provided with a lower panel member 85. Therefore, the ductility of the aluminium foil is adapted to the rear side when the rear side is to be given the desired shape during pressing. The building front panel 80 is substantially rectangular when viewed from the front. Along one short side 81, a first connecting formation 83 is provided (fig. 7.1). A second attachment formation 82 is provided along the other long side 84. These two connection configurations will interact with each other. An outer notch 87 is formed along a first short side 86 and an inner notch 89 is formed along the other short side 88. The outer notch 87 is used for downward positioning. The attachment formations 83, 84, the recesses 87, 89 and the plate member 85 are each made in a pressing process.

Example 1

A predominantly equiaxed thermosetting decorative laminate 1 is produced comprising an equiaxed core 2 and a major surface layer 10. The structure of the laminate corresponds to the structure shown in fig. 5. The laminate was made in the manner described in connection with figure 1.

In an extruder 100, a mixture of 84 parts by weight of wood flour having an average particle size of 400 μm and 1 part by weight of lime flour having an average particle size of 10 μm was mixed in the dry state with 21 parts by weight of a powdery melamine-formaldehyde resin. The mixing is performed under vigorous stirring, thereby generating frictional heat. The extruder 100 was allowed to cool so that the pellet/resin mixture temperature did not exceed 100 c. The thermosetting resin thus binds with the lime powder and with and impregnates the wood flour. The particles bound together by the thermosetting resin are separated in the grinder 101, whereby lumps of resin and particles are formed. The particle size of the agglomerates was 200 microns and the resin content was 20% by weight. The pellet/resin mixture is then dried in dryer 102 to the point where the water content is only 4% by weight. The dried particle/resin mixture is then uniformly distributed onto the major surface layer 10 which has been placed on the platen 51. The main surface layer 10 consists of a decorative paper 12 in sheet form, which is placed with the decorative side facing downwards closest to the press plate 51, and a base paper 14 in sheet form is placed on top. The base paper 14 will be located between the decorative paper 12 and the particle/resin mixture in the final laminate. The base paper 14 is made of kraft paper having a surface weight of 150 grams per square meter and impregnated with a phenol-formaldehyde resin solution until the dry resin content is 30% by weight. The base paper 14 is then dried, thereby partially curing the resin to a so-called B-stage. The decorative paper 12 made of alpha cellulose with a surface weight of 80g/m is impregnated with melamine-formaldehyde resin until the dry resin content is 50% by weight. The decorative paper 12 is then dried, whereby the resin is partially cured to a so-called B-stage. Next, a number of blocks of a press plate 51 having a particle/resin mixture and paperboard are stacked in a discontinuous laminator 50 in the form of a multi-layer press, in which the particle/resin mixture is compressed under heat and pressure, whereby the resin is cured and thereby a thermosetting laminate 1 having an isometric core 2 and a major surface layer 10 is formed. The temperature in laminator 50 was 150 ℃ during pressing and the pressure was gradually increased to a final pressure of 200 bar over the first 20 seconds, which pressure would last for 3 minutes. The pellet/resin mixture is reduced to about one-third of its original thickness during pressing. The thickness of the final laminate measured on the upper surface of the panel was 5.2 mm. The height of the plate condition was measured to be 1.5 mm.

The following properties were obtained in the final laminate:

wear resistance: more than 350 turns;

bending strength: 100N/mm²；

The elastic coefficient: 10kN/mm²；

Impact resistance: 10kJ/m²；

water absorption capacity after 100 hours in water at 23 ℃: 2 percent.

The wear resistance of 300 turns is fully satisfactory, since high wear resistance is not necessary in the panel. The panels are often installed as self-supporting units, which is why up to 100N/mm is required²Because a high bending strength will make the installed panel look stronger. 10kJ/m²The impact resistance of (a) will reduce the risk of cracking of the laminate. Such cracks will be mainly caused by handling when assembling the laminate. Such panels 70 made according to this example are normally used in wet premises. It is therefore important that the moisture absorption capacity is not too high, as this will cause the laminate to swell. In conventional panels made solely of impregnated cardboard the direction of the fibres is always oriented for practical reasons in such a way that the fibres point in the vertical direction once the panel has been assembled. This means that when the horizontal side of the wall is usually longer than the vertical side, a panel of the conventional type will have the greatest increase in relation to water absorption on the longest side. A water absorption capacity of 2% after 100 hours in water with room temperature is sufficient. The panel according to the present example was compared with conventional panels in terms of dimensional stability, with the same resin content and composition, laminate thickness and temperature and pressure during manufacture. Both panels are made to absorb moisture until the panel according to the present example has expanded 0.1% along the fibres of the decorative paper. Both panels are then stopped from absorbing water. The amount of expansion of both panels was then measured. In the panel according to the example, the decorative paper fibres expand 0.12% in the transverse direction and 0.1% in the longitudinal direction. Laminates made by conventional methods have a corresponding value of 0.3% expansion in the cross direction and 0.07% expansion in the machine direction of the fibers. This of course is troublesome, since one has to take such expansion into account when assembling the panels. One will also find the maximum amount of expansion along the longest side in conventional panels. The expansion of a conventional panel 5 meters wide will then be around 15 mm whereas the inventive panelCorresponding measurement of (d) is about 5 mm. The water absorption capacity can of course be further reduced by using a diffusion barrier. But this would make the product more expensive. Thus, it is possible to obtain panels with properties that are superior to those of conventional laminates and at the same time reduce the manufacturing costs.

Example 2

A predominantly equiaxed thermosetting decorative laminate 1 is produced comprising an equiaxed core 2, a major surface layer 10 and a minor surface layer 20. The structure of the laminate corresponds to the structure shown in fig. 6. The laminate was made in the manner described in connection with figure 2.

In an extruder 100, a mixture of 51 parts by weight of wood flour having an average particle size of 200 micrometers and 34 parts by weight of corn flour having an average particle size of 10 micrometers is mixed in the dry state with 18 parts by weight of urea-formaldehyde resin and 12 parts by weight of phenol-formaldehyde resin. The mixing is performed with vigorous stirring, thereby generating frictional heat. The extruder 100 was allowed to cool so that the pellet/resin mixture temperature did not exceed 100 c. The thermosetting resin thus binds with the flour and with and impregnates the wood flour. The particles bound together by the thermosetting resin are separated in the grinder 101, whereby lumps of resin and particles are formed. The particle size of the agglomerates was 200 microns and the resin content was 29% by weight. The pellet/resin mixture is then dried in dryer 102 to a point where the water content is only 4.2% by weight. The dried particle/resin mixture is then uniformly cast onto the base paper 21. The base paper 21 constitutes the sub-surface layer 20. The base paper 21 is made of kraft paper and has a surface weight of 150g/m²And impregnating it with a solution containing a phenol-formaldehyde resin so that the content of the dry resin is 30% by weight. The base paper tape is then dried, thereby partially curing the resin to the so-called B-stage. The base paper strip 21 with the particle/resin mixture layer on top of the base paper is then fed between two steel belts 41 of a continuous laminator 40 with the main surface layer 10 on top of the resin particle layer. Main surface layer10 are made up of two so-called overlay papers 11 in the form of webs. The overlay paper tape 11 is made of alpha cellulose and has a surface weight of 30g/m²And impregnated with a melamine-formaldehyde resin solution having a dry resin content of up to 60% by weight. Before the resin is dried, the uppermost facing paper 11 is sprayed with 2g/m in the form of alumina²The hard particles of (2), having an average particle diameter of 20 μm. The lower overlay paper tape 11 is sprayed with 8g/m in the form of alumina before drying the resin²The hard particles of (2), having an average particle diameter of 100 μm. The laminating paper tape 11 is then dried, whereby the resin is partially cured to a so-called B-stage. Below the overlay paper strip 11 closest to the particle/resin mixture is a decorative paper 12 in the form of a draw. The surface weight was 80g/m²And the decoration paper tape 12 made of alpha cellulose is impregnated with melamine-formaldehyde resin, so that the content of the resin is 50% by weight. Subsequently, the decor paper tape is dried and thereby part of the resin is cured to the so-called B-stage. The particle/resin mixture is then compressed under heat and pressure so that the resin cures and thereby forms a thermosetting laminate 1 having an equiaxial core 2, a decorative wear resistant primary surface layer 10 and a non-decorative secondary surface layer. The temperature in the laminator 40 was 155 ℃ during pressing, while the pressure was gradually increased to a final pressure of 70 bar during the first 5 seconds, such final pressure lasting 1 minute. The pellet/resin mixture is reduced to about one-third of its original thickness during pressing. The thickness of the final laminate was measured to be 6 mm.

The following properties were obtained in the final laminate:

wear resistance: the number is more than 7200 turns;

bending strength: 80N/mm²；

The elastic coefficient: 8kN/mm²；

Impact resistance: 8kJ/m²；

water absorption capacity after 100 hours in water at 23 ℃: 5.2 percent.

Since high wear resistance is necessary for laminate flooring, a wear resistance of more than 7000 revolutions is required. Low bending strength should be avoided because the difference in expansion between the core and the surface layer may otherwise cause warping. It has been found that 80N/mm²The bending strength of (2) is sufficient. 8kJ/m²Impact resistance and 8kN/mm²Will reduce the risk of cracking of the laminate. Such cracks are mainly caused by falling hard heavy objects such as flat irons. Particleboard cores are often used in laminate flooring of the traditional type, because dense laminates made of impregnated paper are too expensive to manufacture. Conventional types of laminate flooring typically have 3-5kJ/m²Impact resistance of (2). The laminate flooring according to the invention is thus significantly better. Such a laminate floor manufactured according to the present example is not susceptible to moisture. Thus allowing a relatively high moisture absorption capacity. At the same moisture level, a laminate flooring made according to this example will have an expansion of less than 30% of the expansion of a conventional laminate flooring. This will allow a larger area to be covered than before without the need for expansion means. The water absorption capacity can of course be reduced by using a diffusion barrier, whereby laminate floors can also be used in wet rooms. However, such a floor is extremely expensive to manufacture. Thus, it is possible to obtain a laminate flooring having better performance than the conventional laminate flooring while reducing the manufacturing cost.

Example 3

A predominantly equiaxed thermosetting decorative laminate 1 is produced comprising an equiaxed core 2, a major surface layer 10 and a minor surface layer 20. The structure of the laminate corresponds to the structure shown in fig. 7.1 and 7.2. The laminate was made in the manner described in connection with figure 1.

In an extruder 100, a mixture of 40 parts by weight) A mixture of wood flour with an average particle size of 400 micrometres, 10 parts (in weight%) of waste material produced in the manufacture of laminates in the form of 60% cellulose and 40% cured melamine-formaldehyde resin with an average particle size of 400 micrometres, 10 parts (in weight%) of rubber particles with an average particle size of 100 micrometres and 24 parts (in weight%) of stone flour with an average particle size of 30 micrometres is mixed in the dry state with 37 parts (in weight%) of the melamine-formaldehyde resin mixture. The mixing is performed with vigorous stirring, thereby generating frictional heat. The extruder 100 was allowed to cool so that the temperature in the pellet/resin mixture did not exceed 100 c. The thermosetting resin thus binds with the stone dust, rubber particles and waste and impregnates and binds with the wood flour. The particles bound together by the thermosetting resin are separated in the grinder 101, whereby lumps of resin and particles are formed. The agglomerate had a particle size of 200 microns and a resin content of 33% by weight, of which 3% was cured resin. The pellet/resin mixture is then dried in dryer 102 to the point where the water content is only 4% by weight. The dried particle/resin mixture is then uniformly distributed onto a major surface layer 10 which is placed on a platen 51. The main surface layer 10 consists of a decorative paper 12 in the form of a sheet closest to the press plate with the decorative side facing downwards and a diffusion barrier 13 in the form of an aluminium foil. The diffusion barrier layer is closest to the particle/resin mixture in the final laminate. Made of alpha cellulose and having a surface weight of 80g/m²The decorative paper 12 of (a) is impregnated with melamine-formaldehyde resin in such a way that the dry resin content is 50% by weight. Next, the decorative paper 12 is dried, thereby partially curing the resin to a so-called B-stage. The diffusion barrier layer 13 comprises a 40 micron thick aluminum foil which is brush plated on both sides for greater adhesion. A sub-surface layer 20 in the form of a diffusion barrier 23 is placed on top of the particle/resin mixture. The secondary surface layer comprises a 40 μm thick malleable aluminum foil and is brush plated on one side for stronger adhesion. Next, a plurality of pieces having the particle/resin mixture are stacked in a discontinuous laminator 50 in the form of a multi-layer pressA laminate 51 of a laminate and paperboard, in which press the particle/resin mixture is compressed under heat and pressure, whereby the resin is cured and thereby a thermosetting laminate 1 having an isometric core 2 and a main surface layer is formed. The temperature in laminator 50 was 150 ℃ during pressing and the pressure was gradually increased to a final pressure of 200 bar over the first 20 seconds, which pressure would last for 3 minutes. The pellet/resin mixture is reduced to about one-third of its original thickness during pressing. The thickness of the final laminate measured on the upper surface of the panel was 5.2 mm. The height of the plate condition was measured to be 1.5 mm.

The following properties were obtained in the final laminate:

wear resistance: more than 300 turns;

bending strength: 160N/mm²；

The elastic coefficient: 18kN/mm²；

Impact resistance: 25kJ/m²；

Water absorption capacity after 100 hours in water at 23 ℃: 0.5 percent.

The wear resistance of 300 revolutions is completely satisfactory, since the building facade panels do not require high wear resistance. Building facade panels are usually installed as self-supporting units, which is why 160N/mm is required²The bending strength of (a) is due to the high bending strength making the assembled building facade panel look stronger while at the same time reducing the risk of the building facade panel falling off, for example in a storm. 18kJ/m²The impact resistance of (a) will reduce the risk of cracking of the laminate. Such cracks may be caused by unforeseen impacts, such as from criminals, in addition to handling when assembling the laminate. Of the kind made according to the present exampleThe building front panel 80 will be subjected to a wide variety of weather types when it is placed outdoors. It is therefore important that the ability to absorb moisture is not too strong, since absorbed moisture will cause swelling or will change the dimensions of the laminate. A water absorption capacity of 0.5% after 100 hours in water with room temperature is sufficient. The direction of the fibres in conventional building facade panels made solely of impregnated cardboard is for practical reasons almost always vertical, which means that such building facade panels will have the largest dimension increase in relation to moisture along the longest side of the normal facade. This means that when the horizontal side of the wall is usually longer than the vertical side, a panel of the conventional type will have the largest dimension increase related to moisture on the longest side.

The building front panel according to the present example was compared with a panel made in a conventional manner in terms of dimensional stability, with the same resin composition, content and laminate thickness, pressure and temperature in manufacture. The two building facade panels are allowed to absorb water until the building facade panel according to the example has expanded 0.05% along the fibres of the decorative panel, whereafter the water absorption of the two laminates is interrupted. The expansion measurements were then performed on both sheets. The expansion of the fibers in the building facade panel according to this example was 0.05% in the transverse direction and 0.05% in the longitudinal direction. The corresponding value for the conventional laminate is 0.15% expansion in the cross direction of the fibers and 0.04% expansion in the machine direction of the fibers. A conventional building facade panel of 15 metres length then expands by approximately 25 millimetres whereas the corresponding measurement for the building facade panel according to the present example is around 7 millimetres. Thus, a better performance of the building front panel compared to conventional laminates can be obtained and at the same time the manufacturing costs are reduced.

Example 4

A predominantly equiaxed thermosetting decorative laminate 1 is produced comprising an equiaxed core 2 and a major surface layer 10. The structure of this laminate corresponds to the structure shown in fig. 5. The laminate was made in the manner described in connection with fig. 4.

In an extruder 100A mixture of 84 parts by weight of wood flour having an average particle size of 400 μm and 1 part by weight of lime flour having an average particle size of 10 μm is mixed in the dry state with 21 parts by weight of melamine-formaldehyde resin powder. The mixing is performed with vigorous stirring, thereby generating frictional heat. The extruder 100 was allowed to cool so that the pellet/resin mixture temperature did not exceed 85 c. The thermosetting resin thus binds with the lime powder and intermingles and binds with the wood flour. The particles bound together by the thermosetting resin are separated in the grinder 101, whereby lumps of resin and particles are formed. The particle size of the agglomerates was 200 microns and the resin content was 20% by weight. The pellet/resin mixture is then dried in a dryer 102 to the point where the water content is only 4% by weight. The dried pellet/resin mixture is then uniformly distributed onto platen 51. Next, a number of press plates 51 with a particle/resin mixture are stacked in a discontinuous laminator 50 in the form of a multilayer press, in which the particle/resin mixture is compressed under heat and pressure, so that the resin flows uncured and thus forms the preformed isometric core 2. The temperature in the laminator 50 was 100 ℃ during pressing, while the pressure was gradually increased to a final pressure of 200 bar during the first 20 seconds, such final pressure lasting 3 minutes. The pellet/resin mixture is reduced to about one-third of its original thickness during pressing. Next, the laminator 50 is opened, whereby the press plate 51 containing the preform core 2 can be taken out. Thereafter, the precast core 2 is cooled. The pre-core is then placed on the primary surface layer 10 which has been placed on the press plate 51. The main surface layer 10 consists of a decorative paper 12 in sheet form placed with the decorative side facing downwards closest to the press plate 51 and a base paper 14 in sheet form placed on top. The base paper 14 will be located between the decorative paper 12 and the core 2 in the final laminate. The base paper 14 is made of kraft paper and has a surface weight of 150g/m²And impregnating it with a solution containing a phenol-formaldehyde resin in such a way that the dry resin content is 30% by weight. The base paper 14 is then dried, thereby partially curing the resin to a so-called B-stage. Surface weight of805g/m²The decorative paper 12 made of alpha cellulose is impregnated with melamine-formaldehyde resin in such a way that the dry resin content is up to 50% by weight. The decor paper 12 is then dried, whereby the resin is partially cured to a so-called B-stage. Next, a number of press plates 51 having the preformed core 2 and the main surface layers 10 are stacked in a discontinuous laminator 50 in the form of a multilayer press, in which the core 2 and the surface layers are compressed under heat and pressure, whereby the resin is cured and thereby the thermosetting laminate 1 having the equiaxial core 2 is formed. The temperature in the laminator 50 was 150 ℃ during pressing, while the pressure was gradually increased to a final pressure of 80 bar during the first 20 seconds, such final pressure lasting 3 minutes. The thickness of the final laminate, measured on the upper surface of the panel, was 5.2 mm, while the height of the panel condition was measured to be 1.5 mm.

The following properties were obtained in the final laminate:

wear resistance: more than 350 turns;

bending strength: 120N/mm²；

The elastic coefficient: 12kN/mm²；

Impact resistance: 11kJ/m²；

Water absorption capacity after 100 hours in water at 23 ℃: 1 percent of

The wear resistance of 300 turns is fully satisfactory, since high wear resistance is not necessary in the panel. The panels are often installed as self-supporting units, which is why up to 120N/m is required²Because a high bending strength will make the installed panel look stronger. 11kJ/m²The impact resistance of (a) will reduce the risk of cracking of the laminate. Such cracks will primarily be in the assembly laminateThe material is caused by the operation. Such panels 70 made according to this example are typically used in wet rooms. It is therefore important that the ability to absorb moisture is not too strong, as this will cause the laminate to swell. In conventional panels made solely of impregnated cardboard, the direction of the fibres is almost always oriented for practical reasons in such a way that the fibres point in the vertical direction once the panel has been assembled. This means that when the horizontal side of the wall is usually longer than the vertical side, a panel of the conventional type will have the largest dimension increase related to moisture on the longest side. A water absorption capacity of 1% after 100 hours in water with room temperature is sufficient.

The panel according to the present example was compared with conventional panels in terms of dimensional stability, with the same resin content and composition, laminate thickness and temperature and pressure in manufacture. Both panels were allowed to absorb moisture until the panel according to the present example expanded 0.1% along the fibres of the decorative paper. The two laminates were then allowed to cease to absorb water. The amount of expansion of both panels was then measured. In the panel according to the example, the fibers in the decorative board have an expansion of 0.12% in the transverse direction and 0.1% in the longitudinal direction. Laminates made in the conventional manner had a corresponding value of 0.5% expansion in the cross direction of the fibers and 0.12% expansion in the machine direction of the fibers. This of course is troublesome, since one has to take such expansion into account when assembling the panels. It has also been found that the expansion is greatest along the longest side of conventional panels. The expansion of a conventional panel 5 meters wide will then be around 25 mm, whereas the corresponding measurement for the inventive panel is about 5 mm. The water absorption capacity can of course be further reduced by using a diffusion barrier. But this would make the product more expensive. Thus, it is possible to obtain panels with properties that are stronger than conventional laminates and at the same time reduce the manufacturing costs.

Example 5

A predominantly equiaxed thermosetting decorative laminate 1 is produced comprising an equiaxed core 2, a major surface layer 10 and a minor surface layer 20. The structure of the laminate corresponds to the structure shown in fig. 6. The laminate was made in the manner described in connection with fig. 3.

In an extruder 100, a mixture of 51 parts by weight of wood flour having an average particle size of 200 micrometers and 34 parts by weight of corn flour having an average particle size of 10 micrometers is mixed together in the dry state with 6 parts by weight of urea-formaldehyde resin and 24 parts by weight of phenol-formaldehyde resin. The mixing is performed with vigorous stirring, thereby generating frictional heat. The extruder 100 was allowed to cool so that the pellet/resin mixture temperature did not exceed 85 c. The thermosetting resin thus binds with the corn meal and intermingles and binds with the wood flour. The particles bound together by the thermosetting resin are separated in the grinder 101, whereby lumps of resin and particles are formed. The particle size of the agglomerates was 200 microns and the resin content was 29% by weight. The pellet/resin mixture was then dried in a dryer to a point where the water content was only 4.2% by weight. The dried particle/resin mixture is then uniformly cast onto a base paper 21 in the form of a web. The base paper strip 21 constitutes the sub-surface layer 20. The base paper 21 is made of kraft paper and has a surface weight of 150g/m²And impregnating it with a solution containing a phenol-formaldehyde resin until the dry resin content is 30% by weight. The base paper tape is then dried, thereby partially curing the resin to a so-called B-stage. The base paper strip 21 with the layer of the particle/resin mixture thereon is then fed between two steel strips 41 'of a first continuous laminator 40'. Thereafter, the particle/resin mixture and the paper tape are pressed under heat and pressure, whereby the resin flows uncured, thereby forming a prefabricated isometric core 2 having a non-decorative subsurface layer 20. The temperature in the laminator 40' was 90 ℃ during pressing, while the pressure was gradually increased to a final pressure of 70 bar during the first 5 seconds, said final pressure lasting 30 seconds. The pellet/resin mixture is thinned during pressing to approximately one-third of its original thickness. The pre-core 2 with the attached secondary surface layer 20 is fed after the first laminator 40' together with the overlying primary surface layer 10 between two press belts 41 "of a second laminator 40". Main surface layer 1From above, 0 is formed by two so-called overlay webs 11 in the form of webs. The surface weight was 30g/m²The overlay paper tape 11 is made of alpha cellulose and impregnated with a solution of melamine-formaldehyde resin to a dry resin content of up to 60% by weight. Before the resin is dried, the uppermost masking tape 11 is sprayed with 2g/m of alumina having an average particle size of 20 μm²The hard particles of (1). The lower overlay paper tape 11 was sprayed with 8g/m in the form of alumina having an average particle size of 100 microns before drying the resin²The hard particles of (1). Subsequently, the masking tape 11 is dried, thereby partially curing the resin to a so-called B-stage. Underneath the overlay paper strip 11, i.e. closest to the particle/resin mixture, is a decorative paper 12 in the form of a collar. The surface weight was 80g/m²And the decorative paper tape 12 made of alpha cellulose is impregnated with melamine-formaldehyde resin in such a manner that the resin content accounts for 50% by weight. Subsequently, the decor paper tape is dried and thereby the resin is partially cured to a so-called B-stage. The pre-core 2 with the attached secondary surface layer 20 and paper tape is then pressed under heat and pressure so that the resin cures and thereby forms a thermosetting laminate 1 with the equiaxial core 2, the decorative wear-resistant primary surface layer 10 and the non-decorative secondary surface layer 20. The temperature in the laminator 40 was 155 ℃ during pressing and the pressure was 70 bar and this pressure lasted for 1 minute. The thickness of the final laminate was measured to be 6 mm.

The following properties were obtained in the final laminate:

wear resistance: the number is more than 7200 turns;

bending strength: 81N/mm²；

The elastic coefficient: 7kN/mm²；

Impact resistance: 9kJ/m²；

Water absorption capacity after 100 hours in water at 23 ℃: 3.8 percent of

Since high wear resistance is necessary for laminate flooring, a wear resistance of more than 7000 revolutions is required. Low bending strength should be avoided since the difference in expansion between the core and the surface layer may otherwise cause warping. It has been found that 81N/mm²The bending strength of (2) is sufficient. 9kJ/m²Impact resistance and 7kN/mm²Will reduce the risk of cracking of the laminate. Such cracks are mainly caused by falling hard heavy objects such as flat irons. Particleboard cores are often used in laminate flooring of the traditional type, because the manufacturing costs of a dense laminate made of impregnated paper are high. Conventional types of laminate flooring typically have 3-5kJ/m²Impact resistance of (2). The laminate flooring according to the invention is thus significantly better. Such laminate flooring made according to the present example is hardly affected by moisture. Thus allowing a relatively high moisture absorption capacity. At the same moisture level, a laminate flooring made according to the present example will have an expansion of less than 25% of the expansion of a conventional laminate flooring. This will allow a larger area to be covered than before without the need for expansion means. The water absorption capacity can of course be reduced by using a diffusion barrier, whereby laminate floors can also be used in wet rooms. However, such floorboards are expensive to manufacture. Thus, it is possible to obtain a laminate flooring having better performance than the conventional laminate flooring while reducing the manufacturing cost.

The invention is not limited to the embodiments shown, since various modifications can be made within the scope of the invention.

Claims

1. A method for manufacturing a substantially equiaxed thermosetting decorative laminate (1) comprising an equiaxed core (2), a major surface layer (10),

i) mixing 85 parts by weight of particles having an average particle diameter of 5 to 3000 microns with 15 to 85 parts by weight of a powdered thermosetting resin selected from the group consisting of phenol-formaldehyde resin, melamine-formaldehyde resin, urea-formaldehyde resin and a mixture thereof, the mixture being strongly agitated to generate frictional heat without causing the frictional heat to exceed 150 ℃, whereby the thermosetting resin becomes soft to bind or impregnate the particles, the particles joined by the thermosetting resin being separated and forming agglomerates of the thermosetting resin and the particles, the agglomerates having an average particle diameter of 200 to 3000 microns and a resin content of 10 to 50% by weight;

ii) drying the particle/resin mixture to an extent that the water content is below 10% by weight;

iii) the dried particle/resin mixture is uniformly spread on a carrier (30), pressing belts (41) of a continuous laminator (40) and subsequently continuously pressed at a temperature of 60 ℃ to 120 ℃ and a pressure of 15 bar to 400 bar, whereby the particle/resin mixture flows out without complete curing of the resin, whereby a prefabricated isometric core (2) is obtained, which is fed together with a main surface layer (10) with a decorative layer between the pressing belts (41) of the continuous laminator (40) and subsequently continuously pressed at a temperature of 120 ℃ to 200 ℃ and a pressure of 15 bar to 300 bar, whereby the resin is cured and whereby a thermosetting decorative laminate with an isometric core is obtained.

2. The method of claim 1, wherein the laminate further comprises a primary surface layer (20).

3. The method of claim 1 or 2, wherein the particles are organic and have an average particle size of from 5 microns to 2000 microns.

4. The method according to claim 1 or 2, wherein the powdered thermosetting resin is 22 to 37 parts by weight.

5. A process according to claim 1 or claim 2, wherein in step (i), the mixing takes place in an extruder in which the mixture is vigorously stirred.

6. The method of claim 1 or claim 2, wherein in step (i), the frictional heat is less than 110 ℃.

7. The method of claim 6, wherein the frictional heat is less than 90 ℃.

8. The method of claim 1 or 2, wherein in step (i), the resin content of the mass is 20% to 30% by weight.

9. A process according to claim 1 or claim 2, wherein in step (ii), the particle/resin mixture is dried to a level where the water content is less than 5% by weight.

10. The method according to claim 1 or 2, wherein in step (iii) the dried particle/resin mixture is uniformly spread on the support (30) and the pressing belt (41) of the continuous laminator (40) and continuously pressed at a temperature of 80 ℃ to 100 ℃ and a pressure of 30 bar to 120 bar.

11. A method according to claim 1, wherein in step (iii) the pre-fabricated isometric core is continuously pressed at a temperature of 140 ℃ to 180 ℃ and at a pressure of 30 bar to 150 bar after being fed together with the main surface layer (10) between pressing belts (41) of a continuous laminator (40).

12. A method as claimed in claim 2, wherein in step (iii), said pre-fabricated equiaxial core, together with said primary surface layer (10) and said secondary surface layer (20), is continuously pressed at a temperature of 140 ℃ to 180 ℃ and a pressure of 30 bar to 150 bar after being fed between pressing belts (41) of a continuous laminator (40).

13. The method of claim 1, wherein the particles consist entirely or partially of fruit parts or woody parts of the plant.

14. A method according to claim 13, characterised in that the wood part is constituted by sawdust, wood flour or chopped stalks, while the fruit part is suitably constituted by floury grain.

15. The method of claim 14, wherein the powdered grain is corn flour, wheat flour, or flour.

16. A method according to claim 1, wherein the particles are wholly or partly constituted by recycled material or waste from the manufacturing process of thermosetting laminates.

17. The method of claim 16, wherein the recycled material is waste paper, cardboard.

18. The method of claim 1, wherein the particles consist entirely or partially of lime.

19. A method according to claim 1 or 2, wherein the granules are dried to a moisture content of less than 10% by weight prior to mixing.

20. The method of claim 19, wherein the pellets are dried to a moisture content of less than 6% by weight prior to mixing.

21. A method according to claim 1 or 2, characterized in that the dried particle/resin mixture is dosed such that the difference in weight of particles per surface area of the intended core (2) does not exceed 10%.

22. The method according to claim 21, characterized in that the difference in the weight of the particles per surface area of the intended core (2) is less than 3%.

23. A method as claimed in claim 2, characterized in that the carrier (30) is formed by a primary surface layer (10) or a secondary surface layer (20).

24. A method according to claim 1 or 2, wherein the pressing process is initiated at a low initial pressure at which the particle/resin mixture is allowed to flow as the resin softens due to temperature.

25. The method of claim 24, wherein the pressing process is initiated at an initial pressure equal to 10% to 50% of the final pressure.

26. Method according to claim 1 or 2, characterized in that the main surface layer (10) consists of at least one decor paper (12) made of alpha cellulose impregnated with a thermosetting resin, at least one underlying base paper (14) impregnated with a thermosetting resin, at least one overlying so-called overlay paper (11) impregnated with a melamine-formaldehyde resin or a urea-formaldehyde resin.

27. The method of claim 26, wherein the thermosetting resin is a melamine-formaldehyde resin or a urea-formaldehyde resin.

28. A method as claimed in claim 26 or 27, wherein said main surface layer (10) further comprises an anti-diffusion foil (13) closest to the core (2).

29. A method as claimed in claim 28, characterized in that the diffusion-preventing foil (13) is made of metal or plastic.

30. The method of claim 29, wherein the metal is aluminum, steel, copper, or zinc, and the plastic comprises polyethylene, polypropylene, polyalkylene terephthalate, acrylic polymers, polyvinyl chloride, fluorinated thermoplastics.

31. A method as claimed in claim 2, characterized in that the sub-surface layer (20) consists of at least one or more conventional so-called base papers (21) impregnated with a thermosetting resin.

32. The method of claim 31, wherein the thermosetting resin is a phenol-formaldehyde resin or a urea-formaldehyde resin.

33. The method according to claim 2, characterized in that the secondary surface layer (20) consists of at least one or more decorative papers (22) made of alpha cellulose and impregnated with a thermosetting resin.

34. The method of claim 33, wherein the thermosetting resin is a melamine-formaldehyde resin or a urea-formaldehyde resin.

35. A method as claimed in claim 2, characterized in that the secondary surface layer (20) is constituted by at least one anti-diffusion foil (23) closest to the core (2).

36. A method as claimed in claim 35, characterized in that the diffusion-preventing foil (23) is made of metal or plastic.

37. The method of claim 36, wherein the metal is aluminum, steel, copper, or zinc, and the plastic comprises polyethylene, polypropylene, polyalkylene terephthalate, propylene, polyvinyl chloride, fluorinated thermoplastics.

38. The method according to claim 29 or 36, wherein the surface of the diffusion barrier foil (13, 23) is coated with a primer, microetch, shot blast, corona treatment, spark grinding, brush plating or electroplating treatment to improve the adhesion to the laminate (1) by surface expansion or surface activation.

39. A method as claimed in claim 29 or 36, characterized in that the thickness of the diffusion-preventing foil (13, 23) is 5 micrometers to 2000 micrometers.

40. The method according to claim 39, characterized in that the thickness of the diffusion-preventing foil (13, 23) is 10-1000 microns.

41. A method as claimed in claim 39, characterized in that the diffusion-preventing foil (13, 23) is of metal and has a thickness of 5-200 μm.

42. The method according to claim 41, wherein the diffusion-preventing foil (13, 23) has a thickness of 10-100 microns.

43. A method as claimed in claim 39, characterized in that the diffusion-preventing foil (13, 23) is made of a thermoplastic material and has a thickness of 0.2 mm to 2 mm.

44. The method according to claim 43, wherein the anti-diffusion foil (13, 23) has a thickness of 0.3 mm to 1 mm.

45. Method according to claim 29 or 36, characterized in that the anti-diffusion foil (13, 23) has a thickness of 15 x 10^-6/° K to 100 × 10^-6Heat in the range of/° KCoefficient of expansion.

46. The method according to claim 45, wherein the diffusion barrier foil (13, 23) has a coefficient of thermal expansion of 15 x 10^-6/° K and 50 × 10^-6Between/° K.

47. The method as claimed in claim 1 or 2, characterised in that the thermosetting laminate (1) is provided with three-dimensional functional elements being tongues (3), grooves (4) and/or a grid structure (5).

48. A method for manufacturing a substantially equiaxed thermosetting decorative laminate (1) comprising an equiaxed core (2), a major surface layer (10),

iii) the dried particle/resin mixture is uniformly distributed on a carrier (30), a press plate (51) of a discontinuous laminator (50) and subsequently intermittently pressed at a temperature of 60 ℃ to 120 ℃ and a pressure of 15 bar to 400 bar, whereby the particle/resin mixture flows out without complete curing of the resin, whereby a prefabricated isometric core (2) is obtained, which is placed together with a main surface layer (10) with a decorative layer on the press plate (51) of the discontinuous laminator (50) and subsequently intermittently pressed at a temperature of 120 ℃ to 200 ℃ and a pressure of 15 bar to 300 bar, whereby the resin is cured and whereby a thermosetting decorative laminate with an isometric core is obtained.

49. The method of claim 48, wherein the laminate further comprises a primary surface layer (20).

50. The method of claim 48 or 49, wherein the particles are organic and have an average particle size of from 5 microns to 2000 microns.

51. The method of claim 48 or 49, wherein the powdered thermosetting resin is 22 parts to 37 parts by weight.

52. A process as claimed in claim 48 or 49, wherein in step (i), the mixing takes place in an extruder in which the mixture is vigorously stirred.

53. A process according to claim 48 or claim 49, wherein in step (i), the frictional heat is less than 110 ℃.

54. The method of claim 53, wherein the frictional heat is less than 90 ℃.

55. A method as claimed in claim 48 or claim 49, wherein in step (i), the resin content of the mass is from 20% to 30% by weight.

56. A process according to claim 48 or claim 49, wherein in step (ii), the particle/resin mixture is dried to an extent that the water content is less than 5% by weight.

57. The method according to claim 48 or 49, wherein in step (iii) the dried particle/resin mixture is extruded intermittently at a temperature of 80-100 ℃ and a pressure of 30-120 bar after being evenly spread on the support (30) and the press plates (51) of the discontinuous laminator (50).

58. The method according to claim 48, wherein in step (iii) the pre-fabricated isometric core is intermittently pressed at a temperature of 140 ℃ -180 ℃ and at a pressure of 30 bar-150 bar after being fed together with the primary surface layer (10) onto a platen (51) of the discontinuous laminator (50).

59. The method according to claim 49, wherein in step (iii) the pre-fabricated isometric core is intermittently pressed at a temperature of 140 ℃ -180 ℃ and at a pressure of 30 bar-150 bar after being fed onto the press plates (51) of the discontinuous laminator (50) together with the primary (10) and secondary (20) surface layers.

60. A method according to claim 48, wherein the particles consist wholly or partly of fruit parts or woody parts of the plant.

61. A method as claimed in claim 60, wherein the wood part is constituted by sawdust, wood flour or chopped straw, and the fruit part is suitably constituted by powdered grain.

62. The method of claim 61, wherein the powdered grain is corn flour, wheat flour, or flour.

63. A method according to claim 48, wherein the particles consist wholly or partly of recycled material or waste from the manufacturing process of thermosetting laminates.

64. The method of claim 63, wherein the recycled material is waste paper, cardboard.

65. A method as claimed in claim 48, wherein the particles consist wholly or partly of lime.

66. A method as claimed in claim 48 or 49, wherein the granules are dried to a moisture content of less than 10% by weight prior to mixing.

67. A method as claimed in claim 66 wherein the granules are dried to a moisture content of less than 6% by weight prior to mixing.

68. The method according to claim 48 or 49, characterized in that the dried particle/resin mixture is dosed such that the difference in weight of particles per surface area of the intended core (2) does not exceed 10%.

69. The method according to claim 68, wherein the difference in the weight of the particles per surface area of the intended core (2) is less than 3%.

70. A method as claimed in claim 49, characterized in that the carrier (30) is formed by a primary surface layer (10) or a secondary surface layer (20).

71. A method according to claim 48 or 49, wherein the pressing process is initiated at a low initial pressure at which the particle/resin mixture is allowed to flow as the resin softens due to temperature.

72. The method of claim 71, wherein the pressing process is initiated at an initial pressure equal to 10% to 50% of the final pressure.

73. A method as set forth in claim 48 or 49, characterized in that the main surface layer (10) consists of at least one decor paper (12) made of alpha-cellulose impregnated with a thermosetting resin, at least one underlying base paper (14) impregnated with a thermosetting resin, at least one overlying so-called overlay paper (11) impregnated with a melamine-formaldehyde resin or a urea-formaldehyde resin.

74. The method of claim 73, wherein the thermosetting resin is a melamine-formaldehyde resin or a urea-formaldehyde resin.

75. A method as claimed in claim 73 or 74, characterized in that said main surface layer (10) further comprises an anti-diffusion foil (13) closest to the core (2).

76. A method as claimed in claim 75, characterized in that the diffusion-preventing foil (13) is made of metal or plastic.

77. The method of claim 76, wherein the metal is aluminum, steel, copper, or zinc, and the plastic comprises polyethylene, polypropylene, polyalkylene terephthalate, acrylic polymers, polyvinyl chloride, fluorinated thermoplastics.

78. A method as claimed in claim 49, characterized in that the sub-surface layer (20) consists of at least one or more conventional so-called base papers (21) impregnated with a thermosetting resin.

79. The method of claim 78, wherein the thermosetting resin is a phenol-formaldehyde resin or a urea-formaldehyde resin.

80. A method as set forth in claim 49, characterized in that the secondary surface layer (20) consists of at least one or more decorative papers (22) made of alpha cellulose and impregnated with a thermosetting resin.

81. The method of claim 80, wherein the thermosetting resin is a melamine-formaldehyde resin or a urea-formaldehyde resin.

82. A method as claimed in claim 49, characterized in that the secondary surface layer (20) is constituted by at least one anti-diffusion foil (23) closest to the core (2).

83. A method as claimed in claim 82, characterized in that the diffusion-preventing foil (23) is made of metal or plastic.

84. The method of claim 83, wherein the metal is aluminum, steel, copper, or zinc, and the plastic comprises polyethylene, polypropylene, polyalkylene terephthalate, propylene, polyvinyl chloride, fluorinated thermoplastics.

85. A method according to claim 76 or 83, characterized in that the surface of the diffusion barrier foil (13, 23) is coated with a primer, microetch, shot blast, corona treatment, spark grinding, brush plating or galvanic treatment to improve the adhesion to the laminate (1) by surface expansion or surface activation.

86. A method as claimed in claim 76 or 83, characterized in that the thickness of the diffusion-preventing foil (13, 23) is 5 micrometers to 2000 micrometers.

87. The method according to claim 86, wherein the thickness of the diffusion barrier foil (13, 23) is 10-1000 microns.

88. The method according to claim 86, characterized in that the diffusion-preventing foil (13, 23) is of metal and has a thickness of 5-200 microns.

89. The method according to claim 88, wherein the diffusion-preventing foil (13, 23) has a thickness of 10-100 microns.

90. The method according to claim 86, characterized in that the diffusion-preventing foil (13, 23) is made of a thermoplastic material and has a thickness of 0.2 mm to 2 mm.

91. The method according to claim 90, wherein the anti-diffusion foil (13, 23) has a thickness of 0.3 mm to 1 mm.

92. A method as claimed in claim 76 or 83, characterized in that the diffusion-preventing foil (13, 23) has a thickness of 15 x 10^-6/° K to 100 × 10^-6Coefficient of thermal expansion in the range of/° K.

93. The method according to claim 92, wherein the anti-diffusion foil (13, 23) has a coefficient of thermal expansion of 15 x 10^-6/° K and 50 × 10^-6Between/° K.

94. The method as claimed in claim 48 or 49, characterised in that the thermosetting laminate (1) is provided with three-dimensional functional elements being tongues (3), grooves (4) and/or a grid structure (5).

95. A method for manufacturing a substantially equiaxed thermosetting decorative laminate (1) comprising an equiaxed core (2), a major surface layer (10),

iii) the dried particle/resin mixture is uniformly distributed on a carrier (30), a press belt (41) of a continuous laminator (40) and subsequently continuously pressed at a temperature of 120 ℃ to 200 ℃ and a pressure of 15 bar to 300 bar, whereby the resin is cured and thereby an isometric core (2) is formed, the core (2) being provided with a main surface layer (10).

96. The method of claim 95, wherein the laminate further comprises a primary surface layer (20).

97. The method of claim 95 or 96, wherein the particles are organic and have an average particle size of from 5 microns to 2000 microns.

98. The method of claim 95 or 96, wherein the powdered thermosetting resin is 22 parts to 37 parts by weight.

99. The process of claim 95 or 96, wherein in step (i), said mixing occurs in an extruder in which the mixture is vigorously stirred.

100. The method of claim 95 or 96, wherein in step (i), the frictional heat is less than 110 ℃.

101. The method of claim 100, wherein the frictional heat is less than 90 ℃.

102. The method of claim 95 or 96, wherein in step (i), the resin content of the mass is 20% to 30% by weight.

103. A process according to claim 95 or claim 96, wherein in step (ii), the particle/resin mixture is dried to an extent such that the water content is less than 5% by weight.

104. The method according to claim 95 or 96, wherein in step (iii) the dried particle/resin mixture is uniformly spread onto the support (30) and the press belt (41) of the continuous laminator (40) and continuously pressed at a temperature of 140 ℃ to 180 ℃ and a pressure of 30 bar to 150 bar.

105. A method as claimed in claim 95, wherein said primary surface layer (10) is provided to the core (2) before or after said pressing.

106. A method as claimed in claim 96, wherein said primary (10) and secondary (20) surface layers are provided to the core (2) before or after said pressing.

107. A method according to claim 95, wherein the particles consist wholly or partly of fruit parts or woody parts of the plant.

108. A method as claimed in claim 107, wherein the wood part is constituted by sawdust, wood flour or chopped straw, and the fruit part is suitably constituted by floury grain.

109. The method of claim 108, wherein the powdered grain is corn flour, wheat flour, or wheat flour.

110. The method of claim 95, wherein the particles are comprised in whole or in part of recycled material or waste from the manufacturing process of thermoset laminates.

111. The method of claim 110 wherein the recycled material is waste paper, cardboard.

112. The method of claim 95, wherein the particles are comprised in whole or in part of lime.

113. A method as claimed in claim 95 or 96, wherein prior to mixing, the granules are dried to a moisture content of less than 10% by weight.

114. The method of claim 113, wherein the pellets are dried to a moisture content of less than 6% by weight prior to mixing.

115. The method according to claim 95 or 96, characterized in that the dried particle/resin mixture is dosed such that the difference in the weight of the particles per surface area of the intended core (2) does not exceed 10%.

116. The method according to claim 115, wherein the difference in the weight of particles per surface area of the intended core (2) is less than 3%.

117. The method according to claim 96, wherein the carrier (30) is constituted by the primary surface layer (10) or the secondary surface layer (20).

118. The method of claim 95 or 96, wherein the pressing process is initiated at a low initial pressure at which the pellet/resin mixture is allowed to flow due to softening of the resin by temperature.

119. The method of claim 118, wherein the pressing process is initiated at an initial pressure equal to 10% to 50% of the final pressure.

120. The method according to claim 95 or 96, characterized in that the main surface layer (10) consists of at least one decor paper (12) made of alpha cellulose impregnated with a thermosetting resin, at least one underlying base paper (14) impregnated with a thermosetting resin, at least one overlying so-called overlay paper (11) impregnated with a melamine-formaldehyde resin or a urea-formaldehyde resin.

121. The method of claim 120, wherein the thermosetting resin is a melamine-formaldehyde resin or a urea-formaldehyde resin.

122. A method as claimed in claim 120 or 121, wherein said main surface layer (10) further comprises an anti-diffusion foil (13) closest to the core (2).

123. The method according to claim 122, wherein the anti-diffusion foil (13) is made of metal or plastic.

124. The method of claim 123, wherein the metal is aluminum, steel, copper, or zinc, and the plastic comprises polyethylene, polypropylene, polyalkylene terephthalate, acrylic polymers, polyvinyl chloride, fluorinated thermoplastics.

125. A method as claimed in claim 96, characterized in that the sub-surface layer (20) consists of at least one or more conventional so-called base papers (21) impregnated with a thermosetting resin.

126. The method of claim 125, wherein the thermosetting resin is a phenol-formaldehyde resin or a urea-formaldehyde resin.

127. The method according to claim 96, characterized in that the secondary surface layer (20) consists of at least one or more decorative papers (22) made of alpha cellulose and impregnated with a thermosetting resin.

128. The method of claim 127, wherein the thermosetting resin is a melamine-formaldehyde resin or a urea-formaldehyde resin.

129. The method according to claim 96, characterized in that the secondary surface layer (20) is constituted by at least one anti-diffusion foil (23) closest to the core (2).

130. The method according to claim 129, wherein the anti-diffusion foil (23) is made of metal or plastic.

131. The method of claim 130, wherein the metal is aluminum, steel, copper, or zinc, and the plastic comprises polyethylene, polypropylene, polyalkylene terephthalate, propylene, polyvinyl chloride, fluorinated thermoplastics.

132. The method according to claim 123 or 130, wherein the surface of the diffusion barrier foil (13, 23) is coated with a primer, microetch, shot blast, corona treatment, spark grinding, brush plating or electroplating treatment to improve the adhesion to the laminate (1) by surface expansion or surface activation.

133. The method according to claim 123 or 130, characterized in that the thickness of the anti-diffusion foil (13, 23) is 5-2000 μm.

134. The method according to claim 133, wherein the thickness of the anti-diffusion foil (13, 23) is 10-1000 microns.

135. The method of claim 133, wherein the anti-diffusion foil (13, 23) is of metal and has a thickness of 5-200 microns.

136. The method according to claim 135, wherein the diffusion-preventing foil (13, 23) has a thickness of 10-100 microns.

137. A method as claimed in claim 133, characterized in that the diffusion-preventing foil (13, 23) is made of a thermoplastic material and has a thickness of 0.2 mm to 2 mm.

138. The method according to claim 137, wherein the anti-diffusion foil (13, 23) has a thickness of 0.3 mm to 1 mm.

139. The method according to claim 123 or 130, wherein the anti-diffusion foil (13, 23) has a thickness of 15 x 10^-6/° K to 100 × 10^-6Coefficient of thermal expansion in the range of/° K.

140. The method according to claim 139, wherein the diffusion barrier foil (13, 23) has a coefficient of thermal expansion of 15 x 10^-6/° K and 50 × 10^-6Between/° K.

141. The method as claimed in claim 95 or 96, wherein the thermosetting laminate (1) is provided with three-dimensional functional elements being tongues (3), grooves (4) and/or a grid structure (5).

142. A method for manufacturing a substantially equiaxed thermosetting decorative laminate (1) comprising an equiaxed core (2), a major surface layer (10),

iii) the dried particle/resin mixture is uniformly distributed on a support (30), a platen (51) of a discontinuous laminator (50) and is then intermittently pressed at a temperature of 120 ℃ to 200 ℃ and a pressure of 15 bar to 300 bar, whereby the resin is cured and thereby an isometric core (2) is formed, the core (2) being provided with a main surface layer (10).

143. The method of claim 142, wherein the laminate further comprises a primary surface layer (20).

144. The method of claim 142 or 143, wherein the particles are organic and have an average particle size of from 5 microns to 2000 microns.

145. The method of claim 142 or 143, wherein the powdered thermosetting resin is 22 parts to 37 parts by weight.

146. The process of claim 142 or 143, wherein in step (i), said mixing occurs in an extruder in which the mixture is vigorously stirred.

147. The method of claim 142 or 143, wherein in step (i), the frictional heat is less than 110 ℃.

148. The method of claim 147, wherein said frictional heat is less than 90 ℃.

149. The method of claim 142 or 143, wherein in step (i), the resin content of the mass is between 20% and 30% by weight.

150. A process according to claim 142 or 143, wherein in step (ii) the particle/resin mixture is dried to a level where the water content is less than 5% by weight.

151. The method according to claim 142 or 143, wherein in step (iii) the dried particle/resin mixture is intermittently extruded at a temperature of 140 ℃ to 180 ℃ and a pressure of 30 bar to 150 bar after being uniformly spread on the support (30) and the press plate (51) of the discontinuous laminator (50).

152. A method as claimed in claim 151, characterized in that said core (2) is provided with said primary surface layer (10) before or after said pressing.

153. A method as claimed in claim 143, wherein said primary (10) and secondary (20) surface layers are provided to said core (2) before or after said pressing.

154. The method of claim 142, wherein the particles consist entirely or partially of fruit parts or woody parts of the plant.

155. The method of claim 154, wherein the wood part is constituted by sawdust, wood flour or chopped straw, and the fruit part is suitably constituted by powdered grain.

156. The method of claim 155, wherein the powdered grain is corn flour, wheat flour, or wheat flour.

157. The method of claim 142, wherein the particles consist entirely or partially of recycled material or waste from the manufacturing process of the thermoset laminate.

158. The method of claim 157, wherein said recycled material is waste paper, cardboard.

159. The method of claim 142, wherein the particles are comprised in whole or in part of lime.

160. The method of claim 142 or 143, wherein the particles are dried to a moisture content of less than 10% by weight prior to mixing.

161. The method of claim 160, wherein the particles are dried to a moisture content of less than 6% by weight prior to mixing.

162. The method according to claim 142 or 143, wherein the dried particle/resin mixture is dosed such that the difference in weight of particles per surface area of the expected core (2) is not more than 10%.

163. The method according to claim 162, wherein the difference in the weight of particles per surface area of the intended core (2) is less than 3%.

164. The method according to claim 143, wherein the carrier (30) is constituted by a primary surface layer (10) or a secondary surface layer (20).

165. The method of claim 142 or 143, wherein the pressing is initiated at a low initial pressure at which the pellet/resin mixture is allowed to flow due to softening of the resin by temperature.

166. The method of claim 165, wherein the pressing process is initiated at an initial pressure equal to 10% -50% of the final pressure.

167. The method according to claim 142 or 143, characterized in that the main surface layer (10) consists of at least one decor paper (12) made of alpha cellulose impregnated with thermosetting resin, at least one underlying base paper (14) impregnated with thermosetting resin, at least one overlying so-called overlay paper (11) impregnated with melamine-formaldehyde resin or urea-formaldehyde resin.

168. The method of claim 167, wherein the thermosetting resin is a melamine-formaldehyde resin or a urea-formaldehyde resin.

169. The method according to claim 167 or 168, wherein the main surface layer (10) further comprises an anti-diffusion foil (13) closest to the core (2).

170. The method according to claim 169, characterized in that the anti-diffusion foil (13) is made of metal or plastic.

171. The method of claim 170, wherein the metal is aluminum, steel, copper, or zinc, and the plastic comprises polyethylene, polypropylene, polyalkylene terephthalate, acrylic polymers, polyvinyl chloride, fluorinated thermoplastics.

172. A method as claimed in claim 143, wherein the sub-surface layer (20) consists of at least one or more conventional so-called base papers (21) impregnated with a thermosetting resin.

173. The method of claim 172, wherein the thermosetting resin is a phenol-formaldehyde resin or a urea-formaldehyde resin.

174. The method according to claim 143, characterized in that the secondary surface layer (20) consists of at least one or more decor papers (22) made of alpha cellulose and impregnated with a thermosetting resin.

175. The method of claim 174, wherein the thermosetting resin is a melamine-formaldehyde resin or a urea-formaldehyde resin.

176. The method according to claim 143, wherein the secondary surface layer (20) is constituted by at least one anti-diffusion foil (23) closest to the core (2).

177. The method of claim 176, wherein the diffusion-preventing foil (23) is made of metal or plastic.

178. The method of claim 177, wherein the metal is aluminum, steel, copper, or zinc, and the plastic comprises polyethylene, polypropylene, polyalkylene terephthalate, propylene, polyvinyl chloride, fluorinated thermoplastics.

179. The method according to claim 170 or 177, wherein the surface of the diffusion barrier foil (13, 23) is coated with a primer, microetch, shot blast, corona treatment, spark grinding, brush plating or electroplating treatment to improve the adhesion to the laminate (1) by surface expansion or surface activation.

180. The method according to claim 170 or 177, wherein the thickness of the anti-diffusion foil (13, 23) is 5-2000 μm.

181. The method according to claim 180, wherein the thickness of the anti-diffusion foil (13, 23) is between 10 microns and 1000 microns.

182. The method of claim 180, wherein the anti-diffusion foil (13, 23) is of metal and has a thickness of 5-200 microns.

183. The method according to claim 182, wherein the diffusion-preventing foil (13, 23) has a thickness of 10-100 microns.

184. The method according to claim 180, wherein the diffusion-preventing foil (13, 23) is made of a thermoplastic material and has a thickness of 0.2 mm to 2 mm.

185. The method according to claim 184, wherein the diffusion-preventing foil (13, 23) has a thickness of 0.3 mm to 1 mm.

186. Method according to claim 170 or 177, wherein the anti-diffusion foil (13, 23) has a thickness of 15 x 10^-6/° K to 100 × 10^-6Coefficient of thermal expansion in the range of/° K.

187. The method of claim 186, wherein said diffusion-preventing foil (13, 23) has a coefficient of thermal expansion of 15 x 10^-6/° K and 50 × 10^-6Between/° K.

188. The method as claimed in claim 142 or 143, wherein the thermosetting laminate (1) is provided with three-dimensional functional elements being tongues (3), grooves (4) and/or a grid structure (5).

189. A thermosetting laminate (1) made by the method of any one of claims 1-188, wherein the thermosetting laminate (1) is substantially equiaxed, and wherein the difference in expansion coefficients between the length and width directions of the laminate is less than 10%.

190. A thermosetting laminate (1) according to claim 189, characterised in that the thermosetting laminate (1) has a water absorption capacity of less than 10% by weight after 100 hours in water at 23 ℃.

191. A thermosetting laminate (1) according to claim 190, characterised in that the water absorption capacity is below 6% by weight.

192. A thermosetting laminate (1) as claimed in claim 189 or 190, characterised in that the thermosetting laminate (1) has more than 2kJ/m²Impact resistance of (2).

193. Thermosetting laminate (1) according to claim 192, characterized in that the impact resistance is higher than 3kJ/m²。

194. A thermosetting laminate (1) as claimed in claim 189 or 190, characterised in that the main surface layer (10) comprises at least one thermosetting resin impregnated paper and is the uppermost layer, coated with hard particles of silica, alumina and/or silicon carbide having an average particle size of 1 micron to 100 microns.

195. A thermosetting laminate (1) according to claim 194, characterised in that the hard particles have an average particle size of 5-60 microns.

196. Use of a thermosetting laminate (1) as claimed in claim 189 or 190 as a covering material for floors, interior walls, ceilings and doors in dry and wet spaces and as a table top, article surfaces, facade panels and roof panels.