Low pressure melamine/veneer panel
View Patent ↗A layered composite product for use as a floorboard, a door, a cabinet, a wall, etc. is disclosed. The product is a layered structure that includes a rigid substrate layer having two substantially planar sides, a resin-saturated sheet layer disposed on each of the substantially flat sides, and a veneer layer disposed on at least one of the sheet layers. Also provided is a method of making the aforementioned product, the method comprising the steps of forming the layered structure, and then compressing the structure in a pressing apparatus for a time sufficient to cure the resin at under heat and pressure.
1. A warpage resistant laminated composite wood product comprising a rigid substrate layer having two substantially flat sides, a melamine resin-saturated alpha cellulose sheet layer on each of said substantially flat sides, and a wood veneer layer on only one of said sheet layers.
2. The product of claim 1 , wherein said resin of said resin-saturated sheet is a material comprising about 98 wt. % melamine.
3. The product of claim 1 , wherein said resin comprises about 45 wt. % to about 65 wt. % of the resin-saturated sheet.
4. The product of claim 1 , wherein said sheet of said resin-saturated sheet is an alpha cellulose sheet having a basis weight of about 40 pounds per ream to about 100 pounds per ream.
5. The product of claim 1 , wherein said rigid substrate layer is a material selected from the group consisting of particleboard, low-density fiberboard, medium-density fiberboard, and high-density fiberboard.
6. The product of claim 1 , wherein said veneer layer has a moisture content of about 7 wt. % to about 10 wt. % based on the weight of the veneer.
7. The product of claim 1 , wherein said resin of said resin-saturated sheet is a material comprising a melamine/urea blend.
8. The product of claim 7 , wherein said resin of said resin-saturated sheet is a material comprising about 60 wt. % of melamine and about 40 wt. % of urea.
9. A warpage resistant laminated composite wood product made by a method comprising the steps of:
(a) forming a layered structure comprising a rigid substrate layer having two substantially flat sides, a resin-saturated alpha cellulose sheet layer disposed on each of said sides, and a wood veneer layer disposed on only one of said sheet layers, wherein the alpha cellulose layers are simultaneously laminated to both sides of the substrate; and
(b) subjecting said structure to elevated temperature and pressure in a pressing apparatus for a time sufficient to cure said resin at said temperature and pressure, said pressing apparatus comprising a first platen and a second platen, said first platen operating at a temperature different from an operating temperature of said second platen, to provide an unwarped, laminated composite wood product.
10. The laminated composite wood product of claim 9 , wherein said operating temperature of said first platen is in a range of about 350° F. to about 405° F., and said operating temperature of said second platen is in a range of about 320° F. to about 350° F.
11. The laminated composite wood product of claim 9 , wherein said pressing apparatus subjects the structure of step (a) to a pressure of about 325 psi to about 425 psi.
12. The laminated composite wood product of claim 9 , wherein said time is about one minute or less.
13. The laminated composite wood product of claim 9 , wherein said time is about 30 seconds to about 40 seconds.
14. The laminated composite wood product of claim 9 , wherein said rigid substrate layer is a material selected from the group consisting of particleboard, low-density fiberboard, medium-density fiberboard, and high-density fiberboard.
15. The laminated composite wood product of claim 9 , wherein said veneer layer has a moisture content of about 7 wt. % to about 10 wt. % based on the weight of the veneer.
16. The laminated composite wood product of claim 9 , wherein said veneer layer is disposed on only one of said sheet layers.
17. The laminated composite wood product of claim 9 , wherein said resin of said resin-saturated sheet is a material comprising melamine.
18. The laminated composite wood product of claim 17 , wherein said resin comprises about 45 wt. % to about 65 wt. % of the resin-saturated sheet.
19. The laminated composite wood product of claim 17 , wherein said sheet of said resin-saturated sheet is an alpha cellulose sheet having a basis weight of about 40 pounds per ream to about 100 pounds per ream.
20. The laminated composite wood product of claim 17 , wherein said resin of said resin-saturated sheet is a material comprising about 98 wt. % melamine.
21. The laminated composite wood product of claim 17 , wherein said resin of said resin-saturated sheet is a material comprising a melamine/urea blend.
22. The laminated composite wood product of claim 21 , wherein said resin of said resin-saturated sheet is a material comprising about 60 wt. % of melamine and about 40 wt. % of urea.
23. A warpage resistant laminated composite wood product consisting essentially of a rigid substrate layer having two substantially flat sides, a melamine resin-saturated alpha cellulose sheet layer on each of said substantially flat sides, and a wood veneer layer on only one of said sheet layers.