Decorative laminates are durable flat sheeting flat material used in home and industrial furnishings. Formica is the world's largest manufacturer of plastic laminates Decorative laminates are commonly used to surface kitchen counters, cabinetry and table tops because of its resistance to scratches, stains and heat.
There are three layers in the laminate sheets; the bottom most layer is a brown paper which is coated with phenolic resin, the second layer is basically a paper decorated with desired pattern, and third layer is of clear sheet. Both the second and third layers are coated with melamine resin.
RAW MATERIALS
The laminate sheets of decorative laminates is made of resins that react with aldehydes during the thermosetting process. The resins are laminated on layers of kraft paper topped with a decorative sheet. The first plastic laminates manufactured were made with phenolic resin, a polymer of phenol formaldehyde. Phenolic resins can only produce dark colours. Melamine, a urea-based resin was developed which produced a clear surface.
BY PRODUCTS
When the laminate sheets are manufactured, the entire process produces many by-products and some of them are very hazardous and harmful. Emissions that come out from phenolic resins during the laminating process are toxic. The acrylic resins and hardeners that are used in applying plastic laminates to surfaces are also very hazardous. Decorative laminates are not considered as recycled plastic. Also, the thickness of laminate sheets usually range from 0.6 mm to1.5 mm.