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High Pressure Laminates

HPL is the direct descendent of the original plastic laminate. It is considered to be one of the most durable decorative surface materials and is available with special performance properties including chemical, fire and wear resistance. Special grades of HPL can be postformed around curved edges by application of heat and restraint.

HPL is produced by saturating multiple layers of kraft paper with phenolic resin. A layer of printed décor paper is placed on top of the kraft paper before pressing. The resulting sandwich is fused together under heat and pressure (more than 1,000 PSI). Because phenolic and melamine resins are thermoset plastics, the curing process transforms the resin into plastic by a cross linking process that converts the paper sheets into a single, rigid laminated sheet. Thermosetting creates strong, irreversible bonds that contribute to HPL’s durability.

HPL is laminated to a panel utilizing a variety of adhesives. Particleboard or MDF are the preferred substrate because they provide a stable, durable, consistent and economical foundation. Due to its durability, HPL is a common choice for horizontal surfaces including flooring, countertops and desktops. It also performs well in horizontal and vertical applications for high traffic settings such as hospitality, office furniture, healthcare, retail casework, commercial interiors and educational facilities. A relatively new development in HPL technology is Double Belt Press (DBP) for the production of Continuous Pressed Laminate (CPL). CPL is decorative paper impregnated with resins and fused under heat and high pressure with resin-impregnated backer(s). Laminate properties are similar to standard HPL and typical thickness range is .4 mm to 1mm. CPL is available in desired sheet lengths or continuous rolls.

Flexible CPL is decorative paper impregnated with flexible thermosetting resins and fused under heat and high pressure with resin-impregnated backer(s). This engineered CPL offers a unique range of formable decorative laminates suitable for profile wrapping and edgebanding applications. Common thickness range is .2 mm through .4 mm. Surface properties are similar to vertical grade HPL and are used significantly to complement HPL and TFM laminates.

 There are many types or grades of high pressure laminates engineered for specific performance requirements:

General Purpose - Most widely used HPL and suitable for horizontal and vertical surface applications. Typical thickness range from 0.028” to 0.048” (0.71 to 1.22 mm).

Postforming - Can be formed around curved edges by application of heat and restraint. Maximum thickness is approximately 0.038” (0.97 mm) and can normally be formed to radii as small as 3/8” (9.5 mm).

Backer - HPL produced without a decorative face. Available as standard (most common; slightly thinner than decorative HPL) or regrind (reclaimed HPL with decorative sheet sanded off).

Special Products - Special purpose high pressure laminates include cabinet liners, high-wear, fire-rated, electrostatic dissipative and chemical resistant laminates.