US 12,109,794 B2 · Stainable melamine laminate products, compositions, and methods of manufacture

Abstract

The present disclosure describes melamine laminate products capable of retaining a wood stain or colorant. The unique melamine formulations and products include porosity-promoting agents that result in the melamine having a porous surface capable of being stained with a wood stain or other colorant, while still having the favorable properties of traditional laminate products. The methods of the invention produce a melamine laminate product that can be stained with a variety of stains and colorants after manufacturing to suit the individual builder's or homeowner's preference. The stainable melamine laminate products may include a decorative paper layer sandwiched between a backing layer and a melamine layer embedded with a porosity agent, such as, silica, wax, mica, calcium carbonate, silane, kaolin clay, crystalline silica, corn starch, feldspar, talc, or combinations thereof. The stainable melamine layer optionally has a textured top surface.

Claims16

Dependent claims

A stainable melamine laminate product, comprising:

a substrate;
and
a porous, stainable top melamine layer affixed to the substrate, wherein the porous, stainable top melamine layer comprises a stainable melamine formulation and a sheet impregnated with the stainable melamine formulation wherein the sheet is a paper or fiber sheet;
wherein the stainable melamine formulation comprises a melamine resin and at least two porosity agents, wherein the at least two porosity agents are selected from the group consisting of:
kaolin clay;
corn starch;
talc;
mica;
calcium carbonate;
cellulosic particles;
wax particles;
precipitated calcium carbonate;
wollastonite;
and combinations thereof;
the at least two porosity agents are in an amount of between 75 to 150 grams per square meter;
and the amount of porosity agents sufficiently allows deep and even staining of the stainable top melamine layer,
and wherein the at least two porosity agents are stacked one on top of the other to form a path extending from an upper surface to a lower surface of the stainable top melamine layer to allow a stain to seep into, distribute, and hold in the stainable top melamine layer.

14 more elements

Dependencies are inferred from the claim text.

Stainable melamine laminate products, compositions, and methods of manufacture

Life of this patent

Stainable melamine laminate products, compositions, and methods of manufacture

Life of this patent

Abstract

Claims16