HK1085166B - Fiber-reinforced decorative laminate - Google Patents

Description

Fiber reinforced decorative laminate

Technical Field

The present invention relates generally to decorative laminates, and more particularly to decorative laminates having fiber reinforced layers. The invention further relates to a method for producing such a decorative laminate.

Background

High pressure decorative laminates are commonly used in the construction of kitchen and bathroom cabinets, furniture, storage fixtures, and other building products. Decorative laminates which are consolidated under heat and pressure are typically produced using a core comprising a plurality of layers of phenolic resin impregnated kraft paper sheets, a melamine-formaldehyde resin impregnated face sheet, and optionally a melamine resin impregnated overlay sheet. These high pressure laminates are accepted worldwide as building materials in homes and offices, i.e., wall panels, countertops, etc., examples of which are described in U.S. patent No.3418189 to Grosheim et al, U.S. patent No.4311748 to Casey et al, and U.S. patent No.4473613 to Jaisle et al. They can be prepared for a variety of uses and can be produced, for example, as a surface with a high gloss, matte finish or an embossed finish. There is a great consumer demand for decorative laminates of various colors, styles and textures. Furthermore, in applications such as hallway areas where traffic is frequent in shops, restaurants, hotels, schools and hospitals, high pressure decorative laminates that can withstand very frequent use are also highly desirable.

The decorative laminate is typically laminated or bonded to a structural substrate or substrate in a separate operation. Typically, the structural matrix is formed from plywood, particle board, coarse paper, hardboard, wood waste, medium or high density fiberboard. Structural matrices composed of recycled plastics, ABS/PC, nylon and/or PVC are also known, however they are not common.

U.S. patent No.4871596 to Kamiya et al discloses an artificial marble laminate formed of a plurality of layers of porous cellulose sheets impregnated with melamine resin. These resin impregnated cellulosic sheets, while each consisting primarily of alpha cellulose or lint fibers by weight, may include a limited amount of non-cellulosic fibers, such as glass, carbon, polyester, or nylon fibers. Kamiya discloses a two-step process for forming a finished laminate. In a first step, the resin-impregnated cellulose sheet is cured together with the decorative layer, thereby forming a decorative laminate. In a second step, the decorative laminate is bonded to a structural substrate material, such as plywood.

Composite structural panels formed of woven, nonwoven or chopped fibers bonded together with thermosetting or thermoplastic resins have been available for some time. The high modulus or high strength fibers generally include glass, graphite, Kevlar^®Or aramid, boron, polyethylene, polyimide, or silicon carbide fibers.

Generally, composite fibre reinforced panels are formed from a plurality of layers or sheets of resin impregnated fibre reinforced sheet. The individual layers in a multi-layer composite fiber-reinforced panel need not be identical, but may vary in the pattern of the fiber-reinforced sheet, the fiber material, thickness and orientation, and the particular resin material, resin additives and amounts of impregnation used.

Currently available composite fiber reinforced panels lack the desired decorative qualities, such as color or style.

Disclosure of Invention

According to the invention, a method for producing a fiber-reinforced decorative laminate is provided. The method comprises the following steps: stacking in superimposed relationship a decorative layer comprising one or more decorative sheets and a fiber-reinforced core layer comprising at least one fiber-reinforced sheet and at least one cellulose sheet, the decorative layer being at least partially resin-impregnated and at least partially cured, the at least one fiber-reinforced sheet being substantially cellulose-free and at least partially resin-impregnated and at least partially cured; simultaneously curing the decorative layer and the core layer under the action of heat and pressure to produce a fiber-reinforced decorative laminate; and cooling the laminate under pressure. The invention also provides a fiber-reinforced decorative laminate produced according to the method.

Further in accordance with the present invention, there is provided a heat press consolidated laminate comprising, in superimposed relationship, a decorative layer comprising one or more cellulose colored sheets impregnated with a transparent thermosetting resin, a core layer comprising at least one fiber reinforced sheet substantially free of cellulose and impregnated with a thermosetting resin, and an optional backing layer comprising one or more cellulose sheets impregnated with a thermosetting resin. The decorative layer, core layer, and optional backing layer are consolidated by heat and pressure to provide a fiber reinforced decorative laminate ("fiber reinforced decorative laminate") having the desired flexural strength and impact resistance, and having the desired water absorption, fire resistance, and crush resistance properties, and which is easy to manufacture.

In one embodiment, the fiber reinforced decorative laminate further comprises a second decorative layer consisting of one or more cellulose colored sheets impregnated with a transparent thermosetting resin, stacked in overlying relationship with the decorative layer and the core layer in place of the optional backing layer. The decorative layer, core layer and second decorative layer are consolidated by heat and pressure to provide a fiber reinforced decorative laminate having desirable flexural strength and impact resistance, and having desirable water absorption, fire resistance and crush resistance properties, and which is easy to manufacture.

In another embodiment, the decorative layer of the fiber-reinforced decorative laminate of the present invention may comprise one or more cellulose sheets, wherein at least one of the cellulose sheets is colored in its entirety or has a pattern printed on its surface. The decorative layer may also include one or more overlay sheets, a top coat with or without abrasive particles, and one or more barrier sheets. The fiber-reinforced sheets of the core layer may comprise one or more sheets made of woven glass fibers, non-woven glass fibers and/or chopped glass fibers. Additionally, the fiber-reinforced sheets may include glass fibers, graphite fibers, aramid fibers, boron fibers, high modulus fibers, and/or combinations of these fibers.

An advantage of the present invention is that it provides an impact resistant fiber reinforced decorative laminate. Another advantage of the present invention is that it can provide a lightweight decorative laminate that has desirable flexural strength when used under conditions where the laminate may be subjected to impact loading. Another advantage of the invention is that the presence of the decorative layer does not negatively affect the flammability of the fibre-reinforced laminate. In addition, the flammability of fiber-reinforced decorative laminates is superior to conventional high pressure decorative laminates. Another advantage of the present invention is that a complete fiber reinforced decorative laminate can be formed in one curing operation.

According to another aspect of the present invention, there is provided a fiber reinforced decorative laminate comprising: a decorative layer at least partially impregnated with a thermosetting resin; and a core layer comprising at least one cellulosic sheet and a plurality of non-cellulosic fiber-reinforced sheets at least partially impregnated with a thermosetting resin, wherein at least one of the plurality of fiber-reinforced sheets is selected from one of a woven glass fiber sheet, a non-woven glass fiber sheet, and a chopped glass fiber sheet.

According to another aspect of the present invention, there is provided a fiber reinforced decorative laminate comprising: a decorative layer comprising one or more cellulose sheets at least partially impregnated with a thermosetting resin; and a core layer comprising at least one cellulosic sheet and a plurality of non-cellulosic fiber reinforced sheets at least partially impregnated with a thermosetting resin, wherein at least one of the plurality of fiber reinforced sheets is selected from one of glass fibers, graphite fibers, aramid fibers, boron fibers, and high modulus fibers or a combination of these fibers.

According to another aspect of the present invention, there is provided a fiber reinforced decorative laminate comprising: a decorative layer which is a cellulose sheet at least partially impregnated with a thermosetting resin; and a core layer comprising at least one fiber-reinforced cellulosic sheet and at least one non-cellulosic fiber-reinforced sheet at least partially impregnated with a thermosetting resin, wherein the fiber-reinforced sheet is one selected from the group consisting of a woven glass fiber sheet, a non-woven glass fiber sheet, and a chopped glass fiber sheet.

These and other features and advantages of the present invention will be apparent from the accompanying drawings and from the detailed description of the invention provided below.

Drawings

FIG. 1 is a cross-sectional view (not to scale) of overlapping constituent layers according to a first embodiment of the invention.

FIG. 2 is a cross-sectional view (not to scale) of overlapping constituent layers according to another embodiment of the invention.

FIG. 3 is a cross-sectional view (not to scale) of overlapping constituent layers according to yet another embodiment of the invention.

FIG. 4 is a cross-sectional view (not to scale) of overlapping constituent layers according to yet another embodiment of the invention.

Detailed Description

Turning now to fig. 1 and 2, the decorative laminate structure of the present invention is generally indicated by the reference numeral 10. Decorative laminate structure 10 includes a decorative layer 20, a fiber-reinforced layer 30, and an optional backing layer 40 or decorative layer 20'. The decorative layer 20 is laminated on the fiber reinforced layer 30. The backing layer 40 or decorative layer 20' may be laminated to the fiber-reinforced layer 30 on the opposite side of the first decorative layer 20.

The decorative layer 20 comprises one or more sheets. In its simplest configuration, the decorative layer 20 includes one or more decorative sheets 22. The decorative layer 20 may also include one or more overlay sheets 24, and one or more barrier sheets 26 (see, e.g., fig. 1 and 3). The decorative layer 20 may be fully or partially impregnated with a thermosetting resin.

The term "lamina" as used herein generally refers to a well-defined lamina. The sheet may be flat, but the sheet may also adopt a non-planar structure, for example a sheet conforming to a three-dimensional structure. The decorative sheet 22 may be a cellulose sheet. Cellulosic sheets include any lamina formed substantially of plant fibers or treated plant fibers such as paper, alpha cellulose or cotton linters products. Alternatively, the decorative sheet 22 may be formed from a fabric, a polymeric sheet such as a nonwoven of polyester, and any other continuous, discontinuous, or particulate material or combination of materials capable of applying a color or pattern to the finished laminate. The decorative sheet 22 may be fully colored, may have a pattern woven into its structure, or may have a pattern printed onto its surface. Alternatively, the top coat 25 may be applied to the decorative sheet 22 (FIG. 4) or to the veil 24 (FIG. 1). Top coat 25 may include abrasive particles. The decorative layer 20 may be fully or partially impregnated with resin. The resin is typically a thermosetting resin.

Referring to fig. 1 and 3, the laminated upper layer 24 may comprise one or more sheets of cellulose, and in particular, the laminated upper layer 24 may comprise sheets of alpha cellulose. The laminated upper layer 24 may also include abrasive particles to provide enhanced abrasion resistance to the layer, as is known in the art. The laminated upper layer 24 may be fully or partially impregnated with resin. For example, the laminated upper layer 24 may be formed from high quality alpha cellulose paper impregnated with a thermosetting resin. Generally, alpha cellulose paper can be used as a translucent resin carrier, imparting strength to the resin, promoting maintenance of a uniform resin thickness, and providing some measure of abrasion resistance of the decorative layer 20.

The barrier sheet 26 may comprise a cellulosic sheet, which may or may not be impregnated with a thermosetting resin or other suitable resin, such as a melamine-formaldehyde resin, a phenolic resin, or other thermosetting or thermoplastic resins.

The fiber-reinforced layer 30 comprises at least one fiber-reinforced sheet that is substantially cellulose-free. The use of the term "cellulose-free" means that the sheet does not comprise plant fibres or treated plant fibre products. The use of the term "substantially cellulose free" means that the sheet has some small amount of vegetable fibre product, however the majority of the sheet by weight is made up of material other than vegetable fibre. For example, layer 30 may comprise a plurality of sheets or plies reinforced solely with glass, carbon, aramid, boron, and other known synthetic reinforcing fibers. These sheets of reinforcing fibers may be provided in the form of woven or nonwoven sheets and continuous or discontinuous fibers, as is well known in the art. For example, as shown in FIG. 1, aramid (Kevlar) woven in two pieces can be used^®) Between the fibrous sheets 34 sheets 32 of chopped glass fibers are provided.

The fibrous reinforcement layer 30 may also comprise a non-fibrous reinforced sheet, such as a sheet of solid or foamed polymeric material, or a sheet of resin filled with particulate matter. These non-fiber reinforced sheets may be interspersed with fiber reinforced layers. Alternatively, it is within the scope of the present invention that the fibrous reinforcement layer 30 may comprise a cellulosic sheet in addition to the at least one substantially cellulose-free fiber-reinforced sheet. In addition, it is within the scope of the present invention that layer 30 may include one or more fiber-reinforced cellulose sheets in addition to at least one substantially cellulose-free fiber-reinforced sheet.

The fibrous reinforcement layer 30 may be impregnated with a thermosetting or thermoplastic resin, as is known in the art. The impregnation may be full or partial and the resin may be partially cured.

The decorative laminate structure 10 may include a backing layer 40. As best shown in fig. 2, the backing layer 40 is disposed adjacent the fiber-reinforced layer 30 on the side opposite the decorative layer 20. The backing layer 40 may be formed from one or more sheets 42, and the sheets 42 may or may not be coated or impregnated with resin. The sheet typically comprises a cellulosic material. In one embodiment of the invention, the backing layer 40 may be coated or impregnated with a thermosetting resin and partially cured. Exemplary backing products include fire resistant kraft paper, or decorative paper impregnated with thermosetting resins. During curing of the decorative laminate structure 10, the backing layer 40 is heat fused together with the fiber-reinforced layer 30.

Also alternatively, as best shown in fig. 1, the decorative laminate structure 10 may include a second decorative layer 20' instead of the backing layer 40. Such a second decorative layer 20' is laminated on the opposite side of the fiber-reinforced layer 30 to the first decorative layer 20. Generally, the second decorative layer 20' is a mirror image of the first decorative layer 20 (with the possible exception of a special pattern incorporated into the decorative sheet). However, the second decorative layer does not need to comprise the same sheet as in the laminate of the first decorative layer.

In the partially cured state, the sheet of the decorative layer, the sheet of the fiber-reinforced layer and the sheet of the backing/decorative layer are drapeable. The term "drapeable" as used herein to describe the various sheets of the invention means that the material is substantially flaccid and has the ability to conform to two-dimensional or three-dimensional features in a substantially uniform manner. In the cured state, the decorative laminate structure is quasi-flexible or substantially rigid. The term "quasi-flexible" as used herein means that the rigid features of the structure have worked and only a limited amount of bending is possible without causing permanent damage. For substantially rigid decorative laminate structures, the structure as a whole exhibits rigid characteristics, yet the individual plies or groups of plies may remain flexible or quasi-flexible. In addition, by altering or modifying the thickness of the resin and/or structure, the flexibility of the structure can be modified to suit a particular application.

In a preferred embodiment, the decorative laminate structure is impact resistant. As used herein, the term "impact resistant" means the ability to withstand relatively low energy and/or low velocity blunt objects impacting or striking the surface of a structure with no or minimal damage. In general, an impact-resistant structure can resist crack formation radiating from the point of impact, as well as ply delamination below the point of impact.

Before curing, the decorative layer, fiber-reinforced layer or backing/decorative layer may be processed to improve its operability. This may include, for example, partially drying the sheet to remove certain more volatile elements from the resin, thereby reducing the tackiness of the sheet.

Thermosetting resins, thermoplastic resins, and various additives thereof are well known in the art and are commercially available. The properties of a particular resin will not be described in detail unless specific parameters of the resin must be selected to best suit the application in question. For example, certain resins and additives may be selected for their ability to provide impact resistance, reliance on fiber-reinforced adhesive strength, fire resistance, overall flexibility of the panel, resistance to performance degradation due to heat, moisture, or radiation cycling, etc.

A first process for making the fiber-reinforced decorative laminate 10 of the present invention involves laminating the decorative layer 20, the fiber-reinforced layer 30, and the optional backing/decorative layer 40 in an overlapping relationship (i.e., "lay-up") between the backing sheets. The laminate is then subjected to a predetermined pressure and temperature for a period of time sufficient to consolidate the layers.

A second process for making the fiber-reinforced decorative laminate 10 of the present invention involves continuously or semi-continuously feeding the decorative layer 20, the fiber-reinforced layer 30, and the optional backing/decorative layer 40 in the aforementioned overlapping relationship for a continuous press from an upstream source of the continuous press. The continuous press is set to establish the temperature and pressure environment required to thermally fuse the layers into the final laminated product. The operating speed of the continuous press is selected to be capable of staying in the press for a period of time sufficient to ensure adequate bonding of the layers. A release sheet may be placed on each side of the laminate prior to entering the press. These release sheets are typically drawn out after the laminate exits the press. Continuous presses are advantageous because they shorten the processing time of the laminate, whereas the use of continuous presses requires that the sheets fed into the press must be continuous (or semi-continuous) and have a certain operability.

In both of the above manufacturing processes, the elevated temperature and pressure are meant to cause the resin in the sheets to flow between the sheets so that once the sheets are cooled, they have consolidated and formed a monolithic panel. In a discontinuous curing process, the present invention is typically processed at a temperature in the range of from about 110 ℃ to about 170 ℃ and at a pressure in the range of from about 500psi to about 1600 psi. In a continuous curing process, the present invention is typically processed at temperatures above 120 ℃ and in a range dependent on the residence time of the laminate in the press and at pressures in the range of from about 300psi to about 1000 psi. The curing temperature and pressure are generally selected based on the particular resin in use and the final desired characteristics of the cured laminate. The curing temperature can also be controlled to adapt to the processing speed; for example, higher curing temperatures may be used at higher processing speeds, while lower curing temperatures may be used at lower processing speeds.

In a preferred embodiment, the cured decorative laminate structure 10 described above is designed to be subsequently mounted on another structure. For example, the decorative laminate structure 10 may be adhesively or mechanically secured to a cargo product or a heavily trafficked galley wall to provide protection against impact and other damage. As another example, the laminated structure 10 may be permanently or removably mounted to a finished component of furniture in the case of after-market maintenance.

The following examples are illustrative of the novel decorative laminate and do not constitute any limitation in relation to the spirit of the present invention.

Example I

The decorative laminate structure 10 is manufactured using a continuous press. A laminate of the release sheet, decorative layer 20, fiber-reinforced layer 30 and backing layer 40 is formed in an overlapping relationship and placed between steel backing plates. The decorative layer 20 comprises a melamine resin treated solid-colored decorative paper and an untreated barrier sheet. The fiber-reinforced layer 30 comprises eight layers of glass cloth impregnated with melamine resin. Each glass cloth ply was formed from a model 7628 woven glass fabric having a finish 516. The backing layer was a 65 pound gauge HP balance paper. The laminate was then subjected to a pressure of about 700 psi. Once the predetermined pressure is reached, the press is heated to a predetermined temperature of about 140 ℃. The press is held at a predetermined pressure and temperature for a heating period of about 5 minutes. The pressed laminate is then cooled to below about 60 c under pressure in a press. The pressure is then released and the fiber reinforced decorative laminate is removed from the press. The final laminate is about 0.060 inches thick.

Alternatively, the decorative layer 20 may comprise a printed decorative paper treated with melamine resin and a veneer layer also treated with melamine resin. Alternatively, the fiber-reinforced layer 30 may be formed from twelve layers of glass cloth, in which case the final laminate is about 0.090 inches thick. Alternatively, more or fewer plies of glass cloth or different types of glass cloth plies may be used to provide a pressed laminate of almost any thickness. In still other alternatives, the backing layer may be selected from flame retardant kraft paper or 118 pound kraft paper treated with a fast curing phenolic resin.

Example II

The fiber reinforced decorative laminate 10 is manufactured using a GreCon continuous high pressure lamination press, which includes an inlet section, a heating section and a cooling section. The temperature of each section can be controlled individually. The sum of the heat transferred into the layers of the laminate is controlled by the temperature of the different parts and the dwell time depending on the speed of the operation. This continuous process requires that the various sheets used to make the laminate be fed into the press in a continuous roll. Upstream of the continuous press, a melamine resin treated decor paper roll, an untreated barrier paper roll, a plurality of glass cloth rolls as described in example I above, and a backing paper roll were placed so that they could be fed continuously into the press in the above-described overlapping relationship. The temperature settings of the different press sections were as follows: the inlet portion was set at about 200 deg.C, the heating portion was set at about 186 deg.C, and the cooling portion was set at about 181 deg.C. The pressure was set at about 350 psi. The operating speed of the continuous press was set at about 5 feet/minute, resulting in a dwell time in the press of about 2.4 minutes.

It will be understood by those skilled in the art that various modifications may be made without departing from the scope of the invention and that the invention is not limited to those embodiments described and illustrated in the specification.

Claims (23)

1. A method for producing a fiber-reinforced decorative laminate, comprising:

stacking in superimposed relationship a decorative layer comprising one or more decorative sheets and a fiber-reinforced core layer comprising at least one fiber-reinforced sheet and at least one cellulose sheet, the decorative layer being at least partially resin-impregnated and at least partially cured, the at least one fiber-reinforced sheet being substantially cellulose-free and at least partially resin-impregnated and at least partially cured;

simultaneously curing the decorative layer and core layer under heat and pressure to produce the fiber reinforced decorative laminate; and

the laminate is cooled under pressure.

2. The method of claim 1, further comprising:

stacking in superimposed relationship the decorative layer and core layer with a decorative third layer comprising one or more decorative sheets, the third layer being at least partially resin impregnated and at least partially cured and positioned on the side of the core layer opposite the decorative layer; and

curing the third layer simultaneously with the decorative layer and core layer.

3. The method of claim 1, further comprising:

stacking the decorative layer and core layer in overlying relation with the backing layer; and

the backing layer is simultaneously heat fused to the core layer by the curing step.

4. The method of claim 1, further comprising:

at least one of the decorative layer and the core layer is at least partially impregnated with a thermosetting resin.

5. The method of claim 1, wherein the curing step comprises:

inserting the laminated layers between plates of a thermosetting forming press;

applying a predetermined pressure to the laminated layers in the thermosetting forming press;

applying a predetermined temperature to the laminated layers in the thermosetting forming press; and

the laminated layers are held in a heated and pressurized thermoset forming press for a period of time sufficient to form the laminated structure from the layers.

6. The method of claim 5, wherein the predetermined temperature is in a range of 110 ℃ to 170 ℃ and the predetermined pressure is in a range of 500PSI to 1600 PSI.

7. The method of claim 1, wherein the curing step comprises:

setting a temperature of the continuous thermosetting molding press to a predetermined temperature;

setting a pressure of the continuous thermosetting molding press to a predetermined pressure;

transporting the decorative layer and the core layer into the continuous thermosetting forming press, the layer being transported into the press from a location upstream of the press; and

holding the laminated layers in the heated and pressurized continuous thermoset forming press for a period of time sufficient to form the laminated structure from the layers.

8. The method of claim 7, wherein the predetermined temperature is above 120 ℃ and the predetermined pressure is in a range of 300PSI to 1000 PSI.

9. The method of claim 7 wherein at least one of the decorative layer and the core layer comprises a plurality of sheets that are fed into the continuous thermosetting forming press from a continuous roll upstream of the press.

10. A fiber reinforced decorative laminate produced according to the method of claim 1.

11. The laminate of claim 10 wherein the decorative layer comprises one or more cellulose sheets and at least one of the cellulose sheets is fully colored.

12. The laminate of claim 10 wherein the decorative layer comprises one or more cellulose sheets and at least one of the cellulose sheets has a pattern printed on a surface thereof.

13. The laminate of claim 10 wherein the decorative layer further comprises a veneer layer comprising one or more sheets of alpha cellulose.

14. The laminate of claim 10 wherein the decorative layer further comprises a top coat layer comprising abrasive particles.

15. The laminate of claim 10 wherein the decorative layer further comprises a barrier layer comprising one or more sheets of cellulose.

16. A laminate according to claim 10, characterised in that the decorative layer and the core layer are at least partially impregnated with a thermosetting resin.

17. The laminate of claim 10, wherein the core layer comprises at least one of a sheet of woven glass fiber material, a sheet of non-woven glass fiber material, and a sheet of chopped glass fiber material, or a combination thereof.

18. The laminate of claim 10, wherein the core layer comprises at least one of glass fibers, graphite fibers, aramid fibers, boron fibers, or high modulus fiber materials.

19. A fiber reinforced decorative laminate comprising:

a decorative layer at least partially impregnated with a thermosetting resin; and

a core layer comprising at least one sheet of cellulose and a plurality of non-cellulose fiber-reinforced sheets at least partially impregnated with a thermosetting resin, wherein at least one of the plurality of fiber-reinforced sheets is selected from one of a woven glass fiber sheet, a non-woven glass fiber sheet, and a chopped glass fiber sheet.

20. A fiber reinforced decorative laminate comprising:

a decorative layer comprising one or more cellulose sheets at least partially impregnated with a thermosetting resin; and

a core layer comprising at least one sheet of cellulose and a plurality of non-cellulosic fiber reinforced sheets at least partially impregnated with a thermosetting resin, wherein at least one of the plurality of fiber reinforced sheets is selected from one of glass fibers, graphite fibers, aramid fibers, boron fibers, and high modulus fibers or a combination of these fibers.

21. The decorative laminate of claim 20, further comprising a barrier layer between the decorative layer and the core layer, the barrier layer comprising at least one cellulose sheet.

22. A fiber reinforced decorative laminate comprising:

a decorative layer which is a cellulose sheet at least partially impregnated with a thermosetting resin; and

a core layer comprising at least one fiber-reinforced cellulosic sheet and at least one non-cellulosic fiber-reinforced sheet at least partially impregnated with a thermosetting resin, wherein the fiber-reinforced sheet is one selected from the group consisting of a woven glass fiber sheet, a non-woven glass fiber sheet, and a chopped glass fiber sheet.

23. The decorative laminate of claim 22 further comprising a barrier layer between the decorative layer and the core layer, the barrier layer comprising at least one cellulose sheet.