NO OVERLAY DECORATIVE LAMINATES COATED WITH MELAMINE-FORMALDEHYDE RESIN AND METHODS FOR PRODUCING THE SAME

Abstract: The use of a fully-hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resin coating for the print sheet in a decorative laminate eliminates the necessity for an overlay sheet without thereby imparting any deleterious effects to the laminate itself.

Description: NO-OVERLAY DECORATIVE LAMINATES BACKGROUND This invention generally relates to decorative laminates and methods of producing the same. More particularly, this invention relates to high-wear, no-overlay decorative laminates employing a fully hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resin coating in place of an overlay sheet. Conventionally, decorative laminates are made of three essential layers: a core layer, a print layer, and a surface layer, The core layer constitutes a bottom or supporting layer onto which the other layers are bonded. In normal high-pressure laminate manufacture the core layer consists of a plurality of cellulosic sheets. The core sheets are generally made from-a kraft paper impregnated with a laminating resin. Laminating resins commonly used for the core layer include phenolic, amino, epoxy, polyester, silicone, and diallyl phthalate resins to nave but a few. The industrially preferred laminating resin for decorative laminates appears to be a phenolic resin made from the reaction of phenols with formaldehyde. In low-pressure laminate manufacture the core layer is generally comprised of a sheet of particleboard ranging from 3/8" to 1"' in thickness. Placed above the core layer is the print layer which is generally an alpha cellulose pigmented paper containing a print, pattern, or design't'hat.has been impregnated with a melamine-formaldehyde resin. Typically, the printing is performed prior to impregnation by a high-speed rotogravure. The cured melamine-formaldehyde resins are colorless and resistant to light; they are resistant to a variety of solvents and stains; and their heat resistance makes them immune to burning cigarettes, boiling water and heated containers up to about 325 F. Without these melamine-formaldehyde resins the decorative laminate industry would not exist as it is known today. However, because these resins are extremely brittle, they sometimes require. reinforcement. The surface layer, or overlay as it is commonly referred to, is a bjh--quaiity alpha cellulose paper im.preg- nated with a melamine-formaldehyde resin. This layer protects the print sheet from external abuse such as abrasive wear and tear, harsh chemicals, burns, spills and the like. It is primarily the melamine-formaldehyde resin which accounts, for these protective properties. The alpha-cellulose paper acts as a translucent carrier for water-thin resin, imparts strength to the rather brittle melamine-formaldehyde resin, maintains a uniform resin thickness in the overlay by acting as a shim, and controls resin flow. The core layer, print layer and surface layer are stacked in a superimposed relationship, usually between polished steel plates, and subjected to a pressure and temperature for a time sufficiently long enough to cure the laminating resins impregnating the respective layers. The elevated -temperatures'and pressure actually cause the impregnated resins within the sheets to flow'which consolidates the whole into an integral mass, known as the laminate. These laminates find use as counter tops, table tops, furniture, store fixtures and the like. Employment of the overlay sheet has, however, generated a host of unwanted problems. The overlay contributes substantial material cost.to the manufactured laminate. -Not only are there raw material costs involved, such as expensive high-quality alpha cellulose paper and melamine -formaldehyde resins, but there exists substantial processing costs, such as collating sheets, scrap losses generated by the brittle and difficult-to-handle impregnated sheets, as well as the cost of impregnation itself. In-addition to these unwanted expenditures and processing steps, the translucent character of the overlay sheet becomes visually disturbing in decorative laminates when, through the use of more advanced printing techniques, a sharper, more intricate design is employed. Thus, there exists the need for substitution of the overlay sheet by a tough and transparent thermoset layer that will eliminate haze or blur, incur fewer processing steps and lower costs, and yet maintain sufficient resistance to external abuse to be commercially acceptable. The provision for such a layer would fulfill a long-felt need and constitute a significant advance in--the art. SUMMARY OF THE INVENTION The present invention provides for a fully hydrolyzed polyvinyl alcohol (PVA) modified melamine-formaldehyde resin coating to be employed as a substitute for the conventional overlay sheet as the, protective surface layer in laminates. The application of this modified thermosetting resin allows for the elimination of the overlay sheet thereby providing substantial processing and cost savings in the manufacture of laminates. In addition, the requirements of the National Electrical Manufacturers Association (hereinafter referred to as NEMA) for high-pressure decorative laminates are still satisfied when this resin is employed. Finally, the transparent nature of this resin provides for a clear and undistorted appearance of the print, pattern or design in the decorative laminate. DETAILED DESCRIPTION OF THE INVENTION In accordance with the present invention there is provided a heat-and-pressure consolidated laminate consisting essentially of, in superimposed relationship, a core layer comprised of a self-supporting substrate, a print layer consisting of an opaque alpha cellulose paper sheet, and a surface coating of a fully hydrolyzed polyvinyl alcohol (PVA) modified melamine-formaldehyde resin wherein the surface coating weight is from about 60 to about 140 grams per square meter and the amount of fully hydrolyzed PVA in the surface coating is from about 5 to about 30 percent by weight of the total weight of the melamine-formaldehyde reaction product solids. The fully hydrolyzed polyvinyl alcohol modified melamine-±'ormaldehydc resin employed as the surface coating in the laminates of the present invention comprises the reaction product of melamine, formaldehyde and fully hydrolyzed pol'vinvl alcohol wherein the molar ratio of melamine to *nrmaldehE is abOzzt 1:1 to about 1:3, respectively, and the fully 'hydrolyzed polyvinyl alcohol comprises from about 5 to about 30 percent by weight of the total weight of the melamine-formaldehyde reaction product solids. The heat-and-pressure consolidated laminate of then present invention is produced according to the method which comprises positioning the consolidated laminate assembly between press plates, applying sufficient temperature and pressure to the laminate assembly to cure tile resins impregnating the laminate assembly, thereby providing the decora tive.laminate, and recovering the resultant laminate. The core layer of the laminate may, for example, contain either a plurality of sheets impregnated with a laminating resin or a commercially available pressed particleboard. In high-pressure lamina,tes, the core layer is typically provided by a plurality of impregnated sheets. These sheets can be varied in their nature in accordance with the particular properties desired in the decorative laminate. Typically, the core layer is made from paper, woven fabrics, mats, felts, or the like. Paper is by far the most widely used and thus constitutes the preferred stock for the core layer in high-pressure laminate. More particularly, a kraft paper of about a 60 to about a 130 pound basis weight per 3000 square foot ream is preferred as the stock from which the core layer sheets are prepared for high-pressure laminates because of its strong, cheap and plentiful nature. In lowpressure laminates, a particleboard of from about 3/8 to about 1 inch in thickness is preferred as the self-supporting substrate comprising the core layer. Suitable particleboards are commercially available in plentiful quantities at moderate cost. The laminating resins used for impregnating the sheets of the core layer can be any of those thermosetting resins conventionally used in the production of laminates. Laminating resins conventionally used include, but are not limited to, phenolic, .amino, epoxy, polyester, silicone and diallyl phthalate resins. The most commonyl employed laminating resin and that preferred in the instant invention, is the condensation product of a phenol and an aldehyde, generally referred to as a phenolic resin. In particular, it is preferable to employ an alkaline catalyzed phenol -formaldehyde condensation product as the laminating resin employed in the core layer. These resins can be purchased commercially or prepared according to conventional proce durex The alpha cellulose sheet used in the print layer of ;wÀe la-slinate generally runs from about 50 to about 120 pound basis weight per 3000 square foot ream. Upon this alpha cellulose sheet is displayed a print, pattern or design suitable for the intended use of the laminate. The decorative print, pattern or design is typically applied by a high -speed rotogravure before the sheet is impregnated with the melamine-formaldehyde resin. Recently, photogravure reproductions of natural materials such as wood, marble and leather have been applied to-these alpha cellulose Sheets as well. Typically, a three-ink system is employed with the alpha cellulose sheet itself being highly pigmented to provide a fourth color as background and as an opaque base by which the core layer is accordingly obscured. Although printing can be accomplished at any time prior to impregnation of the melamine-formaldehyde resin, printing is often done immediately before the impregnation. Printing houses make available, for those laminators not equioped with printing equipment, already printed alpha cellulose paper of various prints, patterns, or designs. In some applications, abrasive materials have been employed in the overlay in order to improve abrasion resistance. There the abrasive materials are generally deposited upon the alpha cellulose matrix or, in other applications, mixed with cellulosic fibers or microcrystalline materials replacing the alpha cellulose sheet. Incorporation of these abrasive materials into the overlay often results in severe damage to the delicate, highly polished or intricately etched surfaces of the press plates when the abrasive particles deposited in the overlay come into contact therewith. To avoid these unwanted problems, the finely divided abrasive materials which lend to the laminate increased abrasion resistance may be incorporated into the alpha cellar lose sheet of the present invention in various methods. For example, the abrasive material may be added in the pulper or in the head box during the paper-making process. This method causes uniform distribution of the abrasive particles throughout the sheet, the individual sheet fibers holding the particles through the formation of a matrix network around each particle. Additionally, the abrasive material may be added to the impregnating thermosetting resin. In this latter approach, a thin layer of abrasive particles is deposited on the surface of the opaque alpha cellulose paper during impregnation. In both instances, the abrasive materials become an integral part of the print layer. Suitable abrasive materials should be clear, highly translucent materials with a refractive index which is substantially identical to that of the thermosetting resin. Such materials include, but are not limited to, silica, silicates, glass fibers, clear asbestos, quartz, corundum, alumina, and other suitable natural or synthetic abrasive materials. Preferably, finely divided silica having particles ranging in size up to 40 microns with an average size of approximately 5 to 10 microns are employed. The abrasive material added constitutes approximately 10 to 20 percent by weight of the impregnating melamine-formaldehyde thermosetting resin, preferably about 15 percent by weight of said resin. Suitable melamine-formaldehyde resins for impregnation of the print layer are prepared by reacting melamine with formaldehyde in an aqueous dispersion or solution. The mole ratio of the melamine to formaldehyde may be varied from about 1:1 to about 1:3, respectively. It is preferred that the mole ratio be controlled from about 1:1.3 to about 1:2, melamine to formaldehyde, respectively. The reaction occurs under alkaline conditions at a temperature ranging from about 700 to the reflux temperature until a clear reaction product is obtained. The fully hydrolyzed PVA modified melamine-formaldehyde resin used as a coating over the print layer not only obviates the need for an overlay sheet but provides a high-wear, clear, craze-free decorative laminate that is aesthetically more pleasing. The polyvinyl alcohol is employed as a plasticizer with considerable ductility whose particles in the brittle matrix of the melamine-formaldehyde resin provide for a toughening of the thus-modified resin. The substantially one hundred percent or fully hydrolyzed PVA is required over the partially hydrolyzed PVA for use in the melamine-formaldehyde resin because the partially hydrolyzed PVA modified melamine-formaldehyde has exhibited too short of a shelf-like (time elapse before gelation) for practical purposes, even when stabilizers such as o,p-toluene sulfonamide h.ave been added. Fully hydrolyzed PVA is commercially availabe for use in the present invention. The fully hydrolyzed PVA employed in the coating layer generally will not be prepared by hydrolysis of polyvinyl alcohols. Instead, the fully hydrolyzed PVA is the product of fully hydrolyzing a polyvinyl ester, such as polyvinyl acetate or polyvinyl formate. This procedure is more efficient and less costly. 'However, the term "fully hydrolyzed PVA" is generally recognized in the trade to apply to the fully hydrolyzed polyvinyl ester, and as such will continue to be applied herein. In preparing the fully hydrolyzed PVA modified melamine-formaldehyde resin of the present invention, the first stage in the preparation of this coating is the reaction between melamine and formaldehyde. Although the fully hydrolyzed PVA may be added after the reaction of the melamine and formaldehyde forms a clear resin product, it is preferable to add the fully hydrolyzed PVA to the initial stage. The mole ratio of melamine to formaldehyde can be varied from about 1:1 to about 1:3, respectively. The reaction is to be carried out in an aqueous dispersion or solution. To facilitate this aqueous phase reaction, aqueous formaldehyde solutions commercially available are usually employed in the preparation of the modified resin. The reaction between melamine and formaldehyde should occur under alkaline conditions. The preferred pH range of the reaction is 7.5 to 10. For this purpose, a buffering material to control the pH is traditionally employed. One such buffering agent that may be advantageously used is triethanolamine, although the present invention is not limited to this particular buffering material. The buffering agent may be employed during the initial stages of the reaction, during both the initial stage and the modification stage, or not at all. During the initial stage of the -melamine-formal- dehyde reaction, the reaction temperature is not critical although lower temperatures, such as room temperature, cause the reaction to progress rather slowly. At this point, the fully hydrolyzed PVA may be added to the reaction. The amount of fully hydrolyzed PVA to be employed may vary from about 5% to 30% on a weight basis of the total weight of the melamine-formaldehyde reaction product solids. It is generally preferred, however, that the fully hydrolyzed PVA added be in an amount of from about 10% to 20% on a weight basis of the total weight of the melamine-formaldehyde reaction product solids. It is likewise preferred that during the reaction between the fully hydrolyzed PVA and the melamine -formaldehyde resin, a reaction temperature ranging from about 700C to the reflux temperature should be maintained, preferably about 800C to 900C. The reaction should continue until the percent water tolerance of the reaction ranges from about 300% to about 1000 in 50C water. The expression, percent water tolerance, is a well-known term in the resin art and simply means that a sample of resin can be diluted in a certain percent of its volume without displaying any milkiness, i.e. 300% water tolerance at 50C indicates that the given sample can be diluted in three times its volume of 50C water without displaying any milkiness. After the reaction product has reached the desired endpoint, it is cooled to ambient temperature and stored for coating use. If the resin product is not viscous enough for coating purposes and penetrates the print paper during subsequent coating operations a small amount of a thickening agent, such as carboxyl methyl cellulose, -sodium alginate or the like may be added with the other constituents during the reaction to correct this result. Additionally, stabilizers such as o,p-toluene sulfonamide may be added to extend the shelf like of the resin coating. To further increase the resin viscosity, a small amount of a catalyst may be added before impregnation or coating operations. The catalyst should not be added earlier, however, because to do so adversely affects the shelf-life of the modified resin so produced. The fully hydrolyzed PVA modified melamine-formaldehyde resin is coated upon the print layer to a weight of from about 60 to about 140 grams per square meter, preferably about 70 to about 120 grams per square meter. The coating operation may be performed by a knife coater, reverse roll coater, or similar technique. The preferred coating process is the knife coater wherein the knife and resin dam are mounted on a roller, adjustment of the gap between the print sheet and the knife coater varies the coating thickness to its desired amount. The coating operation may be a separate operation or part of the impregnation operation. As a separate operation, the print sheet is first impregnated with a melamine-formaldehyde resin and subsequently dried before the coating operation is commenced. As part of the impregnation operation coating is performed on the wet print sheet immediately subsequent to impregnation on a single apparatus. In the present invention a combination of these two methods is preferred wherein the entire impregnation and coating processes are performed on a single apparatus which is provided with the means to impart a partial drying to the wet print sheet subsequent to impregnation yet prior to coating, preferably by passing the impregnated print sheet through a hot air oven before the coating operation. After coating, the print sheet undergoes a terminal drying operation in which the coating print sheet is dried to a volatile content of from about 4% to about 9%, preferably about 6%. The terminal drying imparts upon the coated print sheet, the necessary flow characteristics for good bonding to take place in the subsequent heat-pressing operation. In other applications a three dimensional textured or embossed laminate may be desirable. For these applications there is added to the fully hydrolyzed PVA modified melamine -formaldehyde resin any one of, or a combination of, inorganic or organic color pigments, extender pigments, metallic pigments, etc. The amount of pigment added to the resin will vary from 0.5% to 20%, based on the total weight of the resin, and dependent upon the pigment used and¯resultant color contrast desired. Typical inorganic pigments useful include those iron pigments ranging in color from yellow through red, reddish-brown, brown, brown to black, Such iron pigments include yellow ocher, raw and burnt sienna, and raw and burnt umber. Other useful inorganic color pigments include chrome yellow, cadmium sulfide, zinc yellow, cobalt blue, ultramarine blue, iron oxide, chrome green, chromium oxide green, chromium hydroxide green, lamp black, and white pigments such as titanium dioxide, titanium calcium, zinc oxide, zinc sulfide, antimony oxide, lithopone, etc. Although lead pigments may be used, they are preferably avoided because of the safety hazard involved in their use. Organic pigments which may be used include toluidine red, phthalocyanine blue and green, Vandyke brown, alizarin,' madder lake, lithol red, and the like. Useful metallic pigments include aluminum powder, copper powder, bronze powders available in vario.us shades depending upon the alloy composition, zinc powder, gold and gold-like powders, and the like. Any of the pigments, and particularly the metallic pigments, may be used alone or in combination with each other or in combination with other pigments. To this pigmented fully hydrolyzed PVA modified melamine-formaldehyde resin is added varying amounts of thinners, solvents, fillers, etc. so as to vary its viscosities and thereby cause the pigmented material to flow more than the resin in the decor sheet during the consolidation procedure. The fully hydrolyzed PVA modified melamine-formaldehyde resin is coated upon the print layer and the embossed laminate assembly to a weight of from about 0.5 to about 20 grams per square foot, preferably about 5 to about 10 grams per square foot. The coating operation may be performed by a knife coater, reverse roll coater, or similar technique. The preferred coating process is the knife coater wherein the knife and resin dam are mounted on a roller, adjustment of the gap between the print sheet and the knife coater varies the coating thickness to its desired amount. The coating operation may be a separate operation or part of the impregnation operation. As a separate operation, the print sheet is first impregnated with a melamine-formaldehyde resin and subsequently dried before the coating operation is commenced. As part of the impregnation operation coating is performed on the wet print sheet immediately subsequent to impregnation on a single apparatus. In the present invention a combination of these two methods is preferred wherein the entire impregnation and coating processes are performed on a single apparatus which is provided with the means to impart a partial drying to the wet print sheet subsequent to impregnation yet prior to coasting, preferably by passing the impregnated print sheet through a hot air oven before the coating operation. After coating, the print sheet undergoes a terminal drying operation in which the coated print sheet is dried to a volatile content of from about 4% to about 9%, preferably about 6%. The terminal drying imparts upon the coated print sheet the necessary flow characteristics for good bonding to take place in the subsequent heat-pressing operation. In yet other applications a docorative metallic laminate may be desired. In these applications, the print layer is no longer employed, rather, the fully hydrolyzed PVA modified melamine-formaldehyde resin containing finely divided metallic powders is employed directly onto the core layer. After the fully hydrolyzed PVA modified melamine -formaldehyde resin has been prepared according to this invention, finely divided metallic powders. or pigments are added to the resin. The metallic powder or pigments constitutes from about 2 to 8 percent by weight of the fully hydrolyzed PVA modified melamine-formaldehyde resin, preferably about 5 percent by weight. The metallic particles employed range in size from about 25 to 75 microns. Suitable metals for this purpose include, but are not limited to, aluminum, copper, zinc, nickel, tin, etc., and combinations of the same. Suitable pigments include TiO2, lamp black, etc. Typically, these metallic powders or pigments are vigorously mixed with the modified resin until a uniform dispersion is achieved. The resin provides for a transparent, noncorrosive coating for the particles as well as a medium through which the metallic finish may easily be applied. A preferred process for manufacturing a high-pressure laminate of the present invention is one in which 3 to 9 core sheets consisting of 6-20 mil, kraft paper have been impregnated with a 30% to 60% solution of phenol-formaldehyde resin so that the final resin solids content of the core sheets is about 20% to about 40% of the total weight of the core. Typically, these core sheets are oven dried after impregnation for a period of about one to two minutes at temperatures ranging from 1400C to 1700C. The print layer, when employed, consisting of a 50 to 120 pound basis weight per 3,000 square foot ream alpha cellulose pigmented sheet optionally displaying a print, pattern, design, or color is impregnated with the melamine-formaldehyde resin so that the final resin solids content of the print sheet is from about 10% to about 40% of the print sheet, then partially dried, coated on its print bearing side with a fully hydrolyzed PVA modified melamine-formaldehyde resin and then terminally dried. When the print layer is not employed, the top most sheet of the core layer is so coated. The sheets are then stacked such that the print sheet is the top most sheet with its print bearing the coated side facing outward. The stacked sheets are placed between polished stainless steel plates upon which there is exerted a pressure of from about 800 to 1600 psi at temperatures from about 1200C to 1800C for approximately 20 minutes to effect the cure and thereby provide the high-pressure laminate. When a three dimensional textured or embossed laminate is preferred, the stacked sheets are placed between embossing press plates. The embossing press plates used in the novel process of the instant invention can be prepared by etching or machining a design,on a metal plate. Alternatively, and more preferably, the plate can be prepared as disclosed in U.S. Patent No. 3,718,496, which patent is hereby incorporated by reference. Still further, the raised printed design technique, as taught by Grosheim in U.S. 3,373,068 will also work well as an embossing medium in the instant invention. There is exerted upon these plates a pressure of from 800 to 1600 psi at temperatures from about 1200C to 1800C for approximately 20 minutes to effect the cure embossment and thereby provide the high-pressure laminate. The embossed areas of the resultant laminate, i.e. those formed from the protuberances of the embossing plate and forming the valleys of the final embossment in the finished laminate surface should preferably be at least .007 inch deep. Depths of less than .007 inch are possible but not preferred because the color contrast is not as evident. Laminates of muted color differentials can be produced using embossments of these lesser depths however. A preferred process for manufacturing a low-pressure laminate of the present invention is one in which a pressed particleboard of from about 3/8 to about 1 inch has stacked above it, in a manner identical to that employed in the high-pressure laminate, the print sheet. The print sheet, if employed, being identical to the one employed in the high-pressure laminate. The stack is placed between press plates upon which there is exerted a pressure of from about 200 to about 600 psi at temperatures from 1200C to about 1800C for approximately 20 minutes to effect the cure and thereby provide the low-pressure laminate. The release sheets used in the pressing of laminate of this invention, if necessary, are well known in the art and may be any non-adherable paper or non-adherable aluminum foil. The non-adherable paper may be a parchment type of paper of which a plurality are available commercially. The non-adherable metal foils, as well as the laminate of paper and the non-adherable foils, are also commercially available. Also suitable for this purpose are papers coated, treated or impregnated with polypropylene or the polyfluorocarbons and the like. Films of polypropylene may also be used. Silicone oil treated papers may be used and are also commercially available. Papers coated with sodium alginate and other salts of alginic acid are also suitable for this purpose and are available commercially. When "low pressure" laminates are being formed, no release sheet at all is necessary if the press plate has a releasing surface thereon. The following specific examples illustrate certain aspects of the present invention and, more particularly, point out methods of evaluating the unique advantages the decorative laminate of the present invention provides. However, the examples are set forth for illustration only and are not to be construed as limitations on the present invention except as set forth in the appended claims. All parts and percentages are by weight unless otherwise specified. EXAMPLE 1 Into a suitable reaction vessel equipped with a thermometer, stirrer and reflux condenser there are introduced 221.5 parts of melamine and 256.6 parts of a 37% aqueous solution of formaldehyde. The mixture is adjusted to a pH of 9.0 by the addition of 9.75 parts of triethanolamine. The charge is subjected to constant agitation as it is concurrently heated to 850C. The temperature is held constant at this point until the resin so produced appears clear. Upon the resin appearing clear there is added 278.9 parts of a 20% solution of fully hydrolyzed polyvinyl alcqhol in water. The temperature is maintained at 850C while water tolerance is constantly monitored in 50C water. Upon achieving a water tolerance of 500%, the mixture is cooled to room temperature and is ready for laminating use. EXAMPLE 2 An alpha-cellulose print paper is impregnated with a conventional melamine-formaldehyde resin to 20% resin solids of the impregnated sheet and immediately thereafter the wet print sheet is coated, by a knife coater, with a layer of the fully hydrolyzed polyvinyl alcohol modified melamine -formaldehyde resin of Example 1. The coating weight of the resinous layer is 70.0 grams per square meter. The coated print paper is dried to a 6.0% volatile content and cut into sheets of suitable size. EXAMPLE 3 The procedure of Example 2 is followed in every material detail except that after the print sheet is impregnated with the conventional melamine-formaldehyde resin, it is passed through a hot air oven to effect drying on the impregnated sheet. The dry sheet is then coated with the fully hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resin in accordance with the procedures of Example 2. The coating weight of the resinous layer is 93.0 grams per square meter. -EXAMPLE 4 The procedure of Example 3 is followed in every material detail except that the fully hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resin of Example 1 has 6.0% of o,p-toluenesulfonamide added to it to improve resin shelf life. EXAMPLE 5 The procedure of Example 3 is followed in every material detail except that the fully hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resin of Example 1 has 0.06% of a commercially available wetting agent added to it to prevent a surface "fisheye" appearance. EXAMPLE 6 A commercially available kraft paper is impregnated with a conventional phenol-formaldehyde laminating resin to a resin content of 29%. The impregnated paper is then dried to a volatile content of 6.0% and cut into sheets of suitable size. Five such sheets are assembled together to form a core layer. An alpha cellulose print paper impregnated with a conventional melamine-formaldehyde resin to 40% resin solids is coated following the procedure of Example 3 in every material detail This coated print paper is then laid upon the laminate core with the coated side facing upwardly. The entire assembly is then pressed between polished stainless steel plates for 21 minutes at 1450C and 1400 psi. The pressed laminate is cooled and removed from the press. Test results of the laminate's physical properties are given in Table I. EXAMPLE 7 The procedure of Example 6 is followed in every material detail except that the alpha cellulose print paper is impregnated with a conventional melamine-formaldehyde resin to 118 resin solids and thereafter coated following the procedure of Example 3 in every material detail. Test results of the laminates physical properties are given in Table I. EXXMPLE 8 The procedure of Example 7 is followed in every material detail except that the coating weight is 110.0 grams per square meter. Test results of the laminate's physical properties are given in Table I. COM?ARATIVE 'EXAMPliE A The procedure of Example 7 is followed in every material detail except that the coating weight is 176.0 grams per square meter. Test results of the laminate's physical properties are given in Table I. COMPARATIVE EXAMPLE B A commercially available kraft paper is impregnated with a conventional phenol-formaldehyde laminating resin to a resin content of 29%. The impregnated paper is then dried to a volatile content of 6.0% and cut into sheets of suitable size. Five such sheets are assembled together to form the core layer. An alpha cellulose print paper impregnated with a conventional melamine-formaldehyde resin to 40% resin solids is lain upon the laminate core layer with the print side facing upward. A highly refined alpha cellulose overlay paper impregnated with a conventional melamine-formaldehyde resin to a resin content of 60% is then lain upon the print sheet. The entire assembly is then pressed between polished stainless steel plates for 21 minutes at 1450C and 1400 psi. The pressed laminate is cooled and removed from the press. Test results of the laminate's physical properties are given in Table I. TABLE I EXAMPLE: NEMA Comparative Comparative Test Name Test &num; 6 7 8 A B Abrasion Wear 3-3.01 0.060 0.056 0.054 0.044 0.072 (grams/100 cycles) Abrasion Wear 3-3.01 300 424 484* 401* 326 (Cycles) High Temperature 3-3.06 NE NE NE Severe Cracking NE Resistance Boiling Water 3-3.05 NE NE NE NE NE Resistance Cigarette Resis- 153 136 179 164 182 tance (Seconds) Impact Resistance 3-3.03 79 80 59 62 78 (Inches) Stain Resistance 3-3.09 NE NE NE NE NE (Cont'd) TABLE I EXAMPLE: NEMA Comparative Comparative Test Name Test &num; 6 7 8 A B Cleanability 3-3.12 NE NE NE NE NE Dimensional 3-3.04 - - - 0.239 MD 0.155 MD Change (%) 0.628 CD 0.425 CD Steam Resistance - - NE after - Crack after NE after 23 hours 5 hours 24 hours * Non-uniform surface wear due to thick coating warping the laminate NE: No Effect MD: Machine Direction CD: Cross Direction EXAMPLE 9 When the procedure of Example 9 is followed in every material detail except that the print sheet is coated according to Example 4, substantially equivalent results are obtained. EXAMPLE 10 When the procedure of Example 7 is followed in every material detail except that the print sheet is coated according to Example 5, substantially equivalent results are obtained. EXAMPLE 11 When the procedure of Example 7 is followed in every material detail except that the coating weight is 135.0 grams per square meter substantially equivalent results ore obtained. EXAMPLE 12 When the procedure of Example 7 is followed in every material detail except that the fully hydrolyzed PVA constitutes 5% by weight of the total weight of the melamine-, -formaldehyde reaction product solids substantially equivalent results are obtained. EXAMPLE 13 When the procedure of Example 7 is followed in every material detail except that the fully hydrolyzed PVA constitutes 25% by weight of the total weight of the melamine-formaldehyde reaction product solids substantially equivalent results are obtained. EXAMPLES 14-21 When the procedure of Examples 6-13 are followed in every material detail, except that a 1/2 inch pressed particleboard constitutes the core layer and the pressure and temperature are 300 psi and 1450C respectively, substantially equivalent results are obtained for a low -pressure laminate. COMPARATIVE EXAMPLE C A commercially available kraft paper is impregnated with a conventional phenol-formaldehyde laminating resin to a resin content of 29%. The impregnated paper is then dried to a volatile content of 6.0% and cut into sheets of suitable size. Five such sheets are assembled together to form the core layer. An alpha cellulose print paper is impregnated with a conventional melamine-formaldehyde resin to 20% resin solids of the impregnated sheet and immediately thereafter the wet print sheet is coated, by a knife coater, with a layer of conventional melamine-formaldehyde resin. The coating weight of the resinous layer is 93.0 grams per square meter. The coated print paper is dried to a 6.0% volatile content and cut into a sheet of suitable size which is laid upon'the laminate core layer with the print size facing upward. The entire assembly is then pressed between polished stainless steal plates for 21 minutes at 1450C and 1400 psi. The pressed laminate is cooled and removed from the press. Comparative test results of the laminate's crack/craze resistance are given in Table II. TABLE II Comp, Comp. Exam. Exam. Exam. Exam. Exam. 6 7 8 B C Crack/Craze NE NE NE NE Extreme Resistance cracking (at low rela- and craze tive humidity exposure) Test results indicate that a melamine-formaldehyde resin coating.without a cellulose or synthetic reinforcement produces poor crack and craze resistant properties. COMPARATIVE EXAMPLE D Partially (88%) hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resins prepared according to the procedure of the British Patent No. 855,536 were employed as the coating layer in a no-overlay laminate similar to the one prepared in Example 6, above, and tested for color tint and flexural strength. Test results are given in Tables III and IV. EXAMPLE 22 Fully hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resins, prepared according to the pro cedure set forth in Example 1, were employed as the coating laver in a no-overlay laminate similar to the one prepared in Example 6, above, and tested in comparison with the laminates of Comparative Examples D for color tint and flex ural strength. Test results are given in Tables III and IV. TABLE III COLOR TINT: YELLOWNESS INDEX M/F 3 Example Ratio Hydrolysis PVA YI/t(lO )* **Control 1:2.0 -- 0 12 .Comp. D 1:2.0 88% 30% 69-79 22 1:2.0 100% 30% 61 *YI/t: Yellowness Index as measured for overlay-free high pressure laminates divided by the thickness (t) of the resin layer covering a white decorative alpha cellulose print sheet. **Control: An unmodified melamine-formaldehyde overlay-free high pressure laminate. The above data indicate that while laminates prepared employing partially hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resins display a strong yellow tint, those laminates prepared with the fully hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resin are substantially less yellow in tint. TABLE IV FLEXURAL STRENGTH M/F % % Flexural Strength Example Ratio Hydrolysis PVA (psi x 10 )* Comp. D 1:2.0 888 30% 15.7 22 1:2.0 100% 30% 22.3 Comp. D 1:2.5 88% 30% 18.9 22 1:2.5 100t 30% 20.2 average value for several measurements made with the print side in tension The above data indicates that the laminates employing fully hydrolyzed polyvinyl alcohol modified mela mine-formaldehyde resins are superior in strength properties to those prepared using the partially hydrolyzed resin as a coating layer. EXAMPLE 23 Into a suitable reaction -vessel equipped with a thermometer, stirrer and reflux condenser there are intro duced 568 parts of melamine and 658 parts of a 378 aqueous solution of formaldehyde. The mixture is adjusted to a pH of 9.0 by the addition of 25 parts of triethanolamine. The charge is subjected to constant agitation as it is concur rently heated t6 85 C. The temperature is held constant at this point until the resin so produced appears clear. Upon the resin appearing clear there is added 715 parts of a 208 solution of fully hydrolyzed polyvinyl alcohol in water. The temperature is maintained at 850C. while water tolerance is constantly monitored in 50C water. Upon achiev ing a water tolerance of 500%, the mixture is cooled to room temperature and is ready for laminating use. Ob servations are given in Table V. EXAMPLE 24 The procedure of Example 23 is followed in every material detail except that the fully hydrolyzed polyvinyl alcohol is added at the initial stage along with the melamine and formaldehyde. Observations are given in Table I. EXAMPLE 2'5 The procedure of Example 23 is followed in every material detail except that the melamine-formaldehyde resin is allowed to react at room temperature until it is clear. Observations are given in Table I. EXAMPLE 26 The procedure of Example 23 is followed in every material detail except that the magnitudes of the resin constituents are as follows: 504 parts of melamine, 871 parts of a 37% aqueous solution of formaldehyde, 32 parts of triethanolamine and enough water to bring the total solids content to 50%. Observations are given in Table I COMPARATIVE EXAMPLE E The procedure of Example 23 is followed in every material detail except that a partially hydrolyzed polyvinyl alcohol is used in place of the fully hydrolyzed polyvinyl alcohol. Percent hydrolysis was 85.5-88.7%. Observations are given in Table I. TABLE V Example pH Shelf-Life* 23 9.0 14 days 24 ' 9.2 10 days 25 9.0 14 days 26 9.0 14 days *Time lapse before gelation 'EXAMPLE 27 An alpha-cellulose print paper is impregnated with a conventional melamine-formaldehyde resin to 20% resin solids of the impregnated sheet and thereafter the print sheet is coated with a layer of the fully hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resin of Example 23. The coated print paper is dried to a 6.08 volatile content and cut into sheets of suitable size. EXAMPLE 28 The procedure of Example 27 is followed in every material detail except that the fully hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resin of Example 23 has 0.06% of a commercially available surfactant added to it to prevent a surface "fisheye" appearance. EXAMPLE 29 A commercially available kraft paper is impregnated with a conventional phenol-formaldehyde laminating resin content of 29%. The impregnated paper is then dried to a volatile content of 6.08 and cut into sheets of suitable size. Five such sheets are assembled together to form a core layer. An alpha cellulose print paper impregnated with a conventional melamine-formaldehyde resin to 40% resin solids is coated following the procedure of Example 27 in every material detail. This coated print paper is then laid upon the laminate core with the coated side facing upwardly. The entire assembly is then pressed between polished stainless steel plates for 21 minutes at 1450C. and 1400 psi. The pressed laminate is cooled and removed from the press. The resultant laminate meets the requirements of NEMA for high-pressure decorative laminates. EXAMPLES 30 - 32 The procedure of Example 29 is followed in every material detail in each instance, except that the coating resin used was that produced in Examples 24-26; respectively. The resultant laminates meet the requirements of NEMA for high-pressure decorative laminates. EXAMPLES 33 - 36 The procedure of Example 29 is followed in every material detail, in each instance, except that the alpha -cellulose print paper is coated following the procedure of Example 28 and that the coating resin used was that produced in Examples 24-26, respectively. The resultant laminates meet the requirements of NEMA for high-pressure decorative laminates. COMPARATIVE EXAMPLE F A commercially available kraft paper is impregnated with a conventional phenol-formaldehyde laminating resin to a resin content of 29%. The impregnated paper is then dried to a volatile content of 6.0 and cut into sheets of suitable size. Five such sheets are assembled together to form a core layer. An opaque alpha cellulose print paper is impregnated with a conventional melamine-formaldehyde resin to 40% resin solids. The print paper is then passed through a hot-air oven to effect drying of the impregnated sheet. The dry print sheet is then coated with a fully hydrolyzed PVA modified melamine-formaldehyde resin by a knife coater. The coating weight of the resinous layer is 88 grams per square meter. The coated print paper is dried to a 6.0% volatile content and cut into sheets of suitable size. This coated print paper is then laid upon the laminate core with the coated side facing upwardly. The entire assembly is then pressed between polished stainless steel plates at 1450C and 1400 psi. The pressed laminate is cooled and removed from the press. Test results of the laminate's physical properties are given in Table VI. EXAMPLE 37 The procedure of Comparative Example F is followed in every material detail except that finely divided silica of 325 mesh is added to the melamine-formaldehyde resin before impregnating the print layer. The silica constitutes 15% by weight of the melamine-formaldehyde resin. Test results of the laminate's physical properties are given in Table VI. COMPARATIVE EXAMPLE G The procedure of Comparative Example F is followed in every material detail except that immediately after the print layer is impregnated with the conventional melamine -formaldehyde resin it is coated, by a knife coater, with a layer of the fully hydrolyzed PVA modified melamine-formaldehyde resin, no prior drying having been effectuated. Test results of the laminate's physical properties are given in Table VI. EXAMPLE 38 The procedure of Comparative Example G is followed in every material detail except that finely divided silica of 325 mesh is added to the melamine-formaldehyde resin impregnating the print layer. The silica constitutes 15% by weight of the melamine-formaldehyde resin. Test results are given-in Table VI. EXAMPLE 39 The procedure of Comparative Example F is followed in every material detail except that the opaque alpha cellulose print paper contains silica particles. The silica particles of 325 mesh are added to the paper during the manufacturing processes so that the cellulose fibers entrap the silica particles. The amount of silica is such that it equals 15% by weight of the melamine-formaldehyde resin which is later impregnated into the print layer. Additionally, the print layer is impregnated with conventional melamine -formaldehyde to 48% resin solids. Test results are given in Table VI. TABLE VI ABRASION RESISTANCE NEMA Test &num;3-301 NEMA Test &num;3-301 Example Abrasion Wear: Cycles Abrasion Wear: gram/100 Cycles Comparative E 350 0.07 37 * 527 0.032 Comparative F 350 0.07 38 * 443 0.04 39 * 600 0.012 * No evidence of plate despite presence of silica particles. EXAMPLE 40 When the procedure of Example 37 is followed in every material detail except that calcium silicate is employed as the abrasive material in an amount equal to 10% by weight of the melamine-formaldehyde resin, substantially equivalent results are obtained. EXAMPLE 41 When the procedure of Example 37 is followed in every material detail except that glass fibers are employed as the abrasive material in an amount equal to 20% by weight of the melamine-formaldehyde resin, substantially equivalent results are obtained. EXAMPLE 42 When the procedure of Example 37 is followed in every material detail except that alumina is employed as the abrasive material in an amount equal to 15% by weight of the melamine-formaldehyde resin, substantially equivalent results are obtained. EXAMPLES 4-3-48 When the procedure of Examples 37-42 are followed in every material detail except that a 1/2 inch pressed particleboard constitutes the core layer and the pressing pressure and temperature are 300 psi and 145CC respectively, a low-pressure laminate of excellent surface abrasion resistance is obtained. EXAMPLE 49 Part A A pigmented fully hydrolyzed PVA-modified melamine-formaldehyde resin is prepared by reacting melamine and formaldehyde together in a mole ratio of 1:1.8, respectively. The resin is modified with 10% fully hydrolyzed PVA on a weight basis of the total weight of the melamine-formaldehyde reaction product solids and pigmented with 0.5% brown iron-oxide, same basis. Part B An alpha cellulose print sheet exhibiting a tawny rawhide design with a basis weight of 50 pounds per 3000 foot ream is first impregnated with a conventional melamine-formaldehyde resin so that the final resin solids content is 29% of the print sheet. The impregnated sheet is then partially dried by passing through a hot air oven and then coated, on its print bearing side, with the pigmented PVA-modified resin of Part A. The pigmented PVA-modified resin of Part A has flow sufficiently great enough to cause said pigmented resin to flow more than the conventional melamine-formaldehyde resin impregnated print layer. The coating is applied by a knife coater adjusted to place a coating weight of 6.0 grams per square foot upon the print sheet. The coated sheet is then terminally dried to a 4% volatile content and 16% resin flow. Part C Six phenolic impregnated kraft paper sheets having a basis weight of 115 pounds per 3000 foot ream are stacked together. Each kraft sheet is impregnated so that the final resin solids content is 27% of the kraft sheet. The coated print sheet is next placed upon the six assembled kraft sheets such that the print bearing, coated side faces upward. Upon the print sheet is placed a release sheet and a textured leather embossing master plate. This assembly is pressed at 1400 psi at 1450C for 20 minutes, cooled, trimmed and sanded. The resulting laminate gives a leather-like appearance displaying variations in color intensity - high pressure areas being lighter and low pressure areas being darker. EXAMPLE 50 The procedure of Example 49 is followed in every material detail except that the amount of fully hydrolyzed PVA employed in Part A is 30%, the amount of pigment employed is 18%, the pigment employed is Vandyke brown, the coating weight in Part B is 1.0 grams per square foot, and the embossing master employed in Part C is an open weave textured plate. The resulting laminate is a brown open weave embossed sheet having excellent physical and chemical properties. EXAMPLE 51 The procedure of Example 49 is followed in every material detail except that the amount of fully hydrolyzed PVA employed in Part A is 20%, the amount of pigment employed is 6%, the pigment employed is lamp black, the coating weight in Part B is 10 grams per square foot, and the embossing master employed in Part C is a slate textured plate. The resulting laminate is a black slate embossed sheet exhibiting excellent physical and chemical properties. EXAMPLE 52 The procedure of Example 49 is followed in every material detail except that the amount of fully hydrolyzed PVA employed in Part A is 5%, the amount of pigment employed is 1%, the pigment employed is titanium dioxide, the coating weight in Part B is 18 grams per square foot, and the embossing master employed in Part C is a tile textured plate. The resulting laminate is a white tile embossed sheet exhibiting excellent physical and chemical properties. EXAMPLES 53-56 When the procedure of Examples 49-52 is followed in every material detail except that a 1/2 inch pressed particleboard constitutes the core layer and the pressure and temperature are 300 psi and 1450C, respectively, substantially equivalent results are obtained for a low-pressure laminate. EXAMPLE 57 Part A Into a suitable reaction vessel equipped with a thermometer, stirrer and reflux condenser there are introduced 568 parts of melamine, 658 parts of a 37% aqueous solution of formaldehyde and 715 parts of a 20% solution of a fully hydrolyzed polyvinyl alcohol in water. The mixture is adjusted to a pH of 9.0 by the addition of 25 parts of triethanolamine. The charge is subjected to constant agitation as it is concurrently heated to 850C. The temperature is held constant at this point until the resin so pro duced appears clear and a water tolerance of 500% in 50C water is achieved. The mixture is then cooled to room temperature. Part B To the fully hydrolyzed PVA modified melamine-formaldehyde resin prepared in Part A is added a copper powder in an amount equal to 5% by weight of the resin. The copper powder has a mesh size of 359 (particle size of approximately 38 microns). The mixture is vigorously mixed until a uniform dispersion of the powder is achieved. Part C A first commercially available kraft paper is impregnated with a conventional phenol-formaldehyde laminating resin to a resin content of 27%. The impregnated paper is then dried to a volatile content of 6.0% and cut into sheets of suitable size. A second commercially available kraft paper is impregnated with a conventional phenol-formaldehyde resin to a resin content of 27% and then passed through a hot air oven to effect partial drying of the impregnated sheet. The dried sheet is then coated, by a knife coater, with the fully -hydrolyzed PVA modified melamine-formaldehyde resin containing metallic powders prepared in Parts A and B. The coating weight of the resinous layer is 110 grams per square meter. The coated paper is dried to a 6.0% volatile content and cut into sheets of suitable size. Placed upon 5 of said first sheets is one of said second sheets such that the coated side is facing outwardly. The entire assembly is then pressed between polished stainless steel plates for 20 minutes at 1450C and 1400 psi. The pressed laminate is cooled and removed from the press. The laminate so formed exhibit exquisite metallic look and satisfactory physical properties according to NEMA standards. EXAMPLE 58 The procedure of Example 57 was followed in every material detail except that aluminum powder was submitted for the copper powser of Part B. Laminates so produced exhibit excellent silver colored appearance and satisfactory physical properties according to NEMA standards. EXAMPLE 59 The procedure of Example 57 was followed in every material detail except that bronze powder was substituted for the copper powder of Part B. Laminates so produced exhibit excellent bronze appearance and satisfactory physical properties according to NEMA standards. EXAMPLES 60-62 The procedures of Examples 57-59 are followed in every material detail except that the polished stainless steel plates employed in Part C during the pressing operation are replaced by textured stainless steel plates. Laminates so produced exhibit excellent textured metallic appearance and satisfactory physical properties according to NEMA standards. Additionally, additional coatings are not necessary to inhibit corrosion. EXAMPLE 63 When the procedure of Example 57 is followed in every material detail except that the coating weight is 60 grams per square meter substantially equivalent results are obtained. EXAMPLE 64 When the procedure of Example 57 is followed in every material detail except that the coating weight is 85 grams per square meter substantially equivalent results are obtained. EXAMPLE 65 When the procedure of Example 57 is followed in every material detail except that the coating weight is 125 grams per square meter substantially equivalent results are obtained. EXAMPLE 66 When the procedure of Example 57 is followed in every material detail except that the coating weight is 140 grams per square meter substantially equivalent results are obtained. EXAMPLE 67 When the procedure of Example 57 is followed in every material detail except that the fully hydrolyzed PVA constitutes 5% by weight of the total weight of the melamine-formaldehyde reaction product solids substantially equivalent results are obtained. 'EXAMPLE -68 When the procedure of Example 57 is followed in every material detail except that the fully hydrolyzed PVA constitutes 15% by weight of the total weight of the melamine-formaldehyde reaction product solids substantially equivalent results are obtained. EXAMPLE -69 When the procedure of Example 57- is followed in every material detail except that the fully hydrolyzed PVA constitutes 20% by weight of the total weight of the melamine-formaldehyde reaction product solids substantially equivalent results are obtained. EXAMPLE 70 When the procedure of Example 57 is followed in every material detail except that the fully hydrolyzed PVA constitutes 30% by weight of the total weight of the melamine-formaldehyde reaction product solids substantially equivalent results are obtained. EXAMPLE 71 When the procedure of Example 57 is followed in every material detail except that the metallic powder added is equal in amount to 2% by weight of the resin, substantially equivalent results are obtained. EXAMPLE 72 When the procedure of Example 57 is followed in every material detail except that the metallic powder added is equal in amount to 8% by weight of the resin, substantially equivalent results are obtained. EXAMPLE 73 When the procedure of Example 57 is followed in every material detail except that a TiO2 pigment is added in place of the metallic powder, substantially equivalent results are obtained for the pigmented laminate so produced. EXAMPLE 74 When the procedure of Example 57 is followed in every material detail except that a lamp black pigment is added in place of the metallic powder, substantially equivalent results are obtained for the pigmented laminate so produced.

Claims: CLAIMS 1. A heat and pressure consolidated laminate consisting essentially of, in superimposed relationship, (a) a core layer consisting of a self-supporting substrate; (b) a print layer consisting of an opaque alpha cellulose paper shcct impregnated with a melamine-formaldehyde thermoset resin, and (c) a surface coating of a fully hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resin wherein the surface coating weight is from about 60 to about 140 grams per square meter and the amount of fully hydroly-, zed polyvinyl alcohol in the surface coating is from about: 5 to 30 percent by weight of the total weight of the melamine-formaldehyde reaction product solids. 2. A heat-and-pressure consolidated laminate of registered embossment and color contrast comprising, in superimposed relationship, (a) a core layer comprised of a self-supporting substrate; (b) a resin impregnated print layer consisting of an alpha cellulose paper sheet; and (c) a pigmented surface coating of a fully hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resin wherein the surface coating weight is from about 0.5 to about 20.0 grams per square foot, the amount of fully hydrolyzed polyvinyl alcohol in the surface coating is from about 5 to about 30 percent by weight of the melamine -formaldehyde reaction product solids and the pigmented surface coating has a flow sufficient to cause said pigmented surface coating to, flow more than said resin impregnating the print layer, and the surface of said laminate contains an embossment consisting of protuberances and valleys, each of which are of a different color. 3. A heat and pressure consolidated laminate consisting essentially of, in superimposed relationship, (a) a core layer consisting of a self-support ing substrate; (b) a surface coating of a fully hydrolyzed polyvinyl alcohol modified melamine-for maldehyde resin containing a finely di vided metallic powder or pigment wherein the surface coating weight is from about 60 to 140 grams per square meter, the amount of fully hydrolyzed polyvinyl alcohol in the surface coating is from about 5 to 30 percent by weight of the total weight of the melamine-formaldehyde reaction pro duct solids and the amount of metallic powder is from about 2 to 8 percent by weight of the total weight of the melamine -formaldehyde reaction product solids. 4. Rhe laminate of Claims 1, 2 or 3 wherein the core layer comprises a plurality of cellulosic sheets impregnated with a thermoset resin. 5. The laminate of Claim 4 wherein the core layer comprses a plurality of kraft paper sheets impregnated with a thermoset resin. 6. The laminate of Claim 4 wherein the thermosetting resin in the core layer is antalkaline catalyzed phenol-formaldehyde condensation product. 7. The lain,A;na.,te,of Claims 1 or 2 wherein the melamine-formaldehyde zesin impregnating the print layer is the product of'reacting melamine with formaldehyde wherein the mole ratio of melamine to formaldehyde is from about 1:1 to about 1:3, respectively. 8. The laminate of Claims 1 or 2 wherein the print layer contains finely divided abrasive materials. 9. The laminate of Claim 8 wherein the finely divided abrasive material is silica. 10. The laminate of Claims 1, 2 or 3 wherein the fully hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resin comprises the reaction product of melamine, formaldehyde and fully hydrolyzed polyvinyl alcohol wherein the molar ratio of melamine to formaldehyde is about 1:1 to about 1:3, respectively. 11. The laminate of Claim 10 wherein the amount of formaldehyde employed in the surface coating resin is from about 1.3 to about 2.0 moles per mole of melamine employed. 12. The laminate of Claims 1, 2 or 3 wherein the amount of polyvinyl alcohol employed is in the range of from about 10 to about 20 percent by weight of the total weight of the melamine-formaldehyde reaction product solids. 13. The laminate of Claims 1 or 3 wherein the fully hydrolyzed polyvinyl alcohol modified melamine-formaldehyde surface coating weight is from about 70 to about 120 grams per square meter. 14. The laminate of Claim 2 wherein the fully hydrolyzed PVA modified melamine-formaldehyde surface is from about 5 to 10 grams per square foot. 15. The laminate of Claim 2 wherein the amount of pigment added to the surface coating resin is from about 0.5 to 20.0 percent by weight of the total weight of the melamine-formaldehyde reaction product solids. 16. The laminate of Claim 3 wherein the amount of finely divided metallic powder or pigment employed in the surface coating is approximately 5% by weight of the total weight of the melamine-formaldehyde reaction product solids in the surface coating 17. The laminate of Claim 3 wherein the size of the finely divided metallic powder employed ranges from about 25 to 75 microns. 18. A fully hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resin comprising the reaction product of melamine, formaldehyde and fully hydrolyzed polyvinyl alcohol wherein the molar ratio of melamine to formaldehyde is about 1:1 to about 1:3, respectively, and the fully hydrolyzed -polyvinyl alcohol comprises from about 5 to about 30 percent by weight of the total weight of the melamine-formaldehyde reaction product solids, 19. The resin of Claim 18 wherein the amount of formaldehyde employed is from about 1.3 to about 2.0 moles per mole of melamine employed. 20. The resin of Claim 18 wherein the amount of polyvinyl alcohol employed is in the range of from about 10 to about 20 percent by weight of the total weight of the melamine-formaldehyde reaction product solids. 21. The resin of Claim 18 wherein an effective amount of a thickening agent is added, 22. The resin of Claim 18 wherein an effective amount of a surfactant is added. 23. A process for preparation for a fully hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resin which comprises. (a) initiating a reaction between melamine and formaldehyde under alkaline conditions, wherein the mole ratio of melamine to formaldehyde is from about 1:1 to about 1:3, respectively; (b) adding, upon the occurrence of a clear melamine-formaldehyde reaction product, a fully hydrolyzed polyvinyl alcohol in an amount such that the fully hvdrolyzed polyvinyl alcohol constitutes from about 5% to 30%, on a weight basis, of the total weight of the melamine-formaldehyde reaction product solids; - (c) maintaining the reaction at a temperature between 800C to 900C., and (d) terminating the reaction when the reaction products have a water tolerance, in 5"C water, between 300% and 1000%. 24. The process of Claim 23 wherein the fully hydrolyzed polyvinyl alcohol is added together with the melamine and formaldehyde at the initiation stage. 25. A method of producing a heat and pressure consolidated laminate which comprises: (a) positioning a laminate assembly between polished stainless steel press plates wherein said laminate assembly consists essentially of, in superimposed relationship, (1) a core layer consisting of a self-sup porting substrate; (2) a print layer consisting of an opaque alpha cellulose paper sheet impregnated with a melamine-formaldehyde thermoset resin, and (3) a surface coating of a fully hydrolyzed polyvinyl alcohol modified melamine-for maldehyde resin wherein the surface coating weight is from about 60 to about 140 grams per square meter and the amount of fully hydrolyzed polyvinyl alcohol in the surface coating is from about to 30 percent by weight of the total weight of the melamine-for maldehyde reaction product solids. (b) applying sufficient temperature and pressure to the laminate assembly to cure the resins impregnating the laminate assembly, thereby providing the laminate; and (c) recovering the resultant laminate. 26. The method of Claim 25 wherein the print layer contains finely divided abrasive materials. 27. A method of producing a heat and pressure consolidated laminate which comprises: (a) positioning a laminate assembly between press plates, said laminate assembly consisting essentially of, in superimposed relationship, (1) a core layer consisting of a self-support ing substrate; and (2) a surface coating of a fully hydrolyzed polyvinyl alcohol (PVA) modified melamine -formaldehyde resin containing finely¯ divided metallic powders or pigment where in the surface coating weight is from about 60 to 140 grams per square meter and the amount of fully hydrolyzed PVA in the surface coating is from about 5 to about 30 percent by weight of the total weight of the melamine-formaldehyde reaction product solids; (b) applying sufficient temperature and pressure to the laminate assembly to cure the resins impregnating the laminate assembly, thereby providing the laminate; and (c) recovering the resultant laminate. 28. The method of Claims 25 or 27 wherein the press plates have a polished finish, 29. The method of Claims 25 or 27 wherein the press plates have a textured finish. 30. A method of producing a heat-and-pressure consolidated laminate which comprises consolidating a laminate assembly under sufficient heat and pressure wherein said laminate assembly consists essentially of, in superimposed relationship, (a) a core layer comprised of a self-supporting substrate; (b) a resin impregnated print layer consisting of an opaque alpha cellulose paper sheet; ; (c) a pigmented surface coating of a fully hydrolyzed polyvinyl alcohol modified melamine-formaldehyde resin wherein the surface coating weight is from about 0.5 to about 20.0 grams per square foot, the amount of fully hydrolyzed polyvinyl alcohol in the surface coating is from about 5 to about 30 percent by weight of the total weight of the melamine-formaldehyde reaction product solids and said pigmented surface coating has a flow sufficient to cause said pigmented surface coating to flow more than said resin impregnating the print layer; ;- and (d) an embossing press plate having a surface with protuberant and valley areas capable of being impressed into the uppermost surface of said print layer and means for preventing the embossing press plate from sticking to the coated print sheet during lamination, to thereby effect a lamination of said fibrous sheets together, an embossment of the uppermost of the print sheet and a migration of the pigmented resin from the areas of said embossment corresponding to the protuberant areas of the embossed press plates to the valley areas thereof and thereafter removing said embossing press plate from the resultant laminate so as to produce a dense laminate having embossed areas of contrasting color.

Inventors: CASEY, DONALD JAMES, RAGHAVA, RAN SINGH, RICHARDSON, CALVIN, WEST, WINTON WILBUR, ZAVISZA, DANIEL MAXIMILLIAN
Applicants: FORMICA CORPORATION
Application year: 1980
Main classification: B32B31
IPC codes: C08G12, B32B27, C08L61, D21H27, D21H17, B32B38