A process for the manufacturing of a core forming a carrying structure for decorative laminates. The core comprises particles of cured, and optionally foamed, rigid,
polyurethane,
polyisocyanurate and / or phenolic resin. The particles are bonded to each other in a pressing procedure with a bonding agent comprising an
adhesive such as a polymerizing
monomer.i) The particles are achieved by
grinding cured, and optionally foamed, rigid,
polyurethane,
polyisocyanurate and / or phenolic resin so that it passes through a 2 mm screen, preferably a 1 mm screen,ii) 100 parts per weight of particles is mixed with 1-100 parts per weight of
fiber, the
fiber additive having an average length in the range 1-15 mm.iii) The particle-
fiber mixture is allowed to absorb a selected amount of water, the amount of water being in the range 1-15% by weight, The water is either added at any stage before the adding of bonding agent, and / or being used as a
solvent in the bonding agent, and that,iv) 85 parts per weight of the particle mixture is mixed with 2-15 parts per weight of a bonding agent, the bonding agent selected from the group consisting of,a) A mixture of polyols, such as
polyester or polyether, crude
methylene diphenyl diisocyanate and possibly a small amount of
blowing agent in a ratio forming a polymeric resin with a density in the range 600-1400 kg / m3.b) A
formaldehyde based resin such as
phenol-
formaldehyde resin,
urea-
formaldehyde resin,
melamine-
urea-formaldehyde resin,
melamine-
urea-
phenol-formaldehyde resin or
phenol-
resorcinol-formaldehyde resin, orc)
Polyvinyl acetate resin.v)The mixture is applied between the belts of the continuos belt press or the press plates of a static press, optionally with at least one intermediate carrier web, the belts or press plates allowing a mainly uniform and specified material thickness to form. A slightly porous and preconditioned core with a selected
water content in the range 0.8-12% is hereby achieved. The invention also relates to a
decorative laminate achieved through the process.