# US 12,109,794 B2 · Stainable melamine laminate products, compositions, and methods of manufacture > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,109,794 B2 - Document ID: US12109794B2 - Status: Granted - Kind: B2 - Application number: 15/674,510 - Filed: 2017-08-10 - Published: 2018-02-15 - Granted: 2024-10-08 - Earliest claimed: 2016-08-10 - Assignees: Pressing Developments, L.L.C. - Applicants: Pressing Developments, L.L.C. - Inventors: Adam Curtis Fuhr - Web page: https://patentgrep.com/patent/US12109794B2 ## CPC - B32B 5/18: characterised by features of a layer {of} foamed material - B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} - B32B 21/042: {of wood (B32B21/13 takes precedence)} - B32B 21/06: of paper or cardboard - B32B 21/10: Next to a fibrous or filamentary layer - B32B 21/14: comprising wood board or veneer - B32B 27/08: of synthetic resin - B32B 27/10: of paper or cardboard - B32B 27/42: comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines - B32B 29/005: {next to another layer of paper or cardboard layer} - B32B 29/02: next to a fibrous or filamentary layer - C09D 161/28: with melamine - B32B 2260/021: Fibrous or filamentary layer - B32B 2260/026: Wood layer - B32B 2260/028: Paper layer - B32B 2260/046: Synthetic resin - B32B 2264/10: Inorganic particles - B32B 2264/102: Oxide or hydroxide - B32B 2264/104: Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles - B32B 2264/12: Mixture of at least two particles made of different materials - B32B 2266/0285: Condensation resins of aldehydes, e.g. with phenols, ureas, melamines - B32B 2307/4023: on the layer surface, e.g. ink - B32B 2451/00: Decorative or ornamental articles - B32B 2479/00: Furniture - B32B 2607/00: Walls, panels - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D) ## 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. ## Claims ### Claim 1 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. ### Claim 2 (depends on 1) The stainable melamine laminate product of claim 1, wherein the at least two porosity agents comprise 50% to 75% of the weight of the stainable melamine formulation before curing. ### Claim 3 (depends on 2) The stainable melamine laminate product of claim 2, wherein the at least two porosity agents comprise at least about 60% of the weight of the stainable melamine formulation before curing. ### Claim 4 (depends on 2) The stainable melamine laminate product of claim 2, wherein the at least two porosity agents comprise about 60-75% of the weight of the stainable melamine formulation before curing. ### Claim 5 (depends on 1) The stainable melamine laminate product of claim 1, further comprising: a phenolic backing layer having a first side and a second side opposite the first side, the first side being affixed to the substrate; and a decorative design on the phenolic backing layer. ### Claim 6 (depends on 1) The stainable melamine laminate product of claim 1, wherein: the substrate is a phenolic backing layer having a first side and a second side opposite the first side, the first side being affixed to the melamine layer; wherein the melamine-impregnated sheet is non-opaque and the at least two porosity agents in the stainable melamine layer are in an amount between 75 to 145 grams per square meter. ### Claim 7 (depends on 1) The stainable melamine laminate product of claim 1, wherein the stainable melamine formulation further comprises at least a third porosity agent, wherein the combination of porosity agents is at least 65% of the weight of the stainable melamine formulation after curing. ### Claim 8 (depends on 7) The stainable melamine laminate product of claim 7, wherein the at least two porosity agents are at least 70% of the weight of the stainable melamine formulation after curing. ### Claim 9 (depends on 7) The stainable melamine laminate product of claim 7, wherein the at least two porosity agents are about 70-80% of the weight of the stainable melamine formulation after curing. ### Claim 10 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 top 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, wherein the at least two porosity agents are at least 60% of the weight of the melamine formulation after curing or the at least two porosity agents are between 50-75% of the melamine formulation weight before curing; and the amount of porosity agent 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. ### Claim 11 (depends on 10) The stainable melamine laminate product of claim 10, wherein the at least two porosity agents are at least 65% of the weight of the stainable melamine formulation after curing. ### Claim 12 (depends on 11) The stainable melamine laminate product of claim 11, wherein the at least two porosity agents are selected from the group consisting of: talc, calcium carbonate, precipitated calcium carbonate, and combinations thereof. ### Claim 13 (depends on 11) The stainable melamine laminate product of claim 11, wherein the at least two porosity agents are at least 65% of the weight of the stainable melamine formulation after curing. ### Claim 14 (depends on 11) The stainable melamine laminate product of claim 11, wherein the at least two porosity agents are at least 70% of the weight of the stainable melamine formulation after curing. ### Claim 15 (depends on 10) The stainable melamine laminate product of claim 10, wherein the at least two porosity agents comprise: talc; calcium carbonate or precipitated calcium carbonate. ### Claim 16 (depends on 10) The stainable melamine laminate product of claim 10, wherein the at least two porosity agents are between 60-75% of the total melamine formulation weight before curing.