Patent ID: 6841023

Claim:
A process for the manufacturing of a core forming a carrying structure for decorative laminates, the core comprises particles of cured resin, the particles being bonded to each other in a pressing procedure with a bonding agent, wherein; i) the particles are achieved by grinding cured resin so that it passes through a 2 mm screen, ii) mixing 100 parts per weight of particles with 1-100 parts per weight of fiber, the fiber additive having an average length in the range 1-15 mm. iii) allowing the particle-fiber mixture to absorb a selected amount of water, the amount of water being in the range 1-15% by weight, the water either being added at any stage before the adding of bonding agent, and/or being used as a solvent in the bonding agent, and that, iv) mixing 85 parts per weight of the particle-fiber mixture with 2-15 parts per weight of a bonding agent, the bonding agent selected from the group consisting of, a) a mixture of polyols, crude methylene diphenyl disocyanate and possibly a small amount of blowing agent in a ratio forming a polymeric resin with a density in the range 600-1400 kgm/ 3 ; b) a formaldehyde resin; and c) polyvinyl acetate resin, and that, v) applying the mixture between the belts of the continuous belt press or the press plates of a static press, the belts or press plates allowing a mainly uniform and specified material thickness to form, whereby a slightly porous and preconditioned core with a selected water content in the range 0.8-12% is achieved.