Stainable Laminate Wood Products With Porous Resin Binders
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Solution Overview
Problem
Laminated engineered wood products are not reliably stainable, limiting color choice and flexibility for consumers, and they rely on factory-fixed colors, leading to unsold stock and unmet consumer demand.
Innovation Solution
Incorporating porosity agents into a resin binder formulation, such as thermosetting acrylic and polymer resins, to create a stainable laminate product that allows on-site staining with wood stains or colorants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If factory-fixed color processes are used for laminated engineered wood products, then manufacturing efficiency is improved, but color choice flexibility deteriorates
Solution Approach 1:
The patent separates the coloring process into two independent stages: (1) factory application of base coating and veneer layer, and (2) on-site application of wood stain by consumer. This segmentation allows manufacturing to maintain high efficiency while consumers gain flexibility to choose and apply different stain colors according to their preferences.
Solution Approach 2:
The patent prepares the laminate surface in advance with a porous veneer layer and base coating that are designed to accept wood stains, but delays the actual coloring action until on-site installation. The preliminary preparation includes applying a porous polymer coating and selecting veneers with appropriate porosity to enable subsequent stain absorption.
2Reliability
If hardwood veneers are used to achieve wood-like appearance and stainability, then staining capability is improved, but cost deteriorates
Solution Approach 1:
The patent applies porous polymer coating only to the surface layer of the laminate that contacts the wood stain, rather than using expensive hardwood veneer throughout. The porous quality is localized to where it is needed (the surface) while the core structure uses more economical engineered wood materials.
Solution Approach 2:
The patent creates a synthetic surface layer that copies the staining properties of hardwood veneer. The porous polymer coating and selected veneer layers replicate the ability to absorb and display wood stains, providing a wood-like appearance and staining capability without using expensive natural hardwood materials.
3Strength
If non-porous resin binder formulations are used for laminate durability, then wear resistance is improved, but stainability deteriorates
Solution Approach 1:
The patent creates a layered structure where the bulk resin binder remains dense and non-porous for durability, while the surface veneer layer and applied porous polymer coating provide the porosity needed for stain absorption. Each layer has optimized properties for its specific function.
Solution Approach 2:
The patent uses a composite structure combining non-porous resin binder for structural integrity and wear resistance with porous veneer layers and porous polymer coatings for stainability. The composite material system integrates materials with different properties to achieve both durability and staining capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables flexible staining options for laminate wood products, reducing manufacturing and consumer costs while providing a professional, high-quality wood-like appearance similar to hardwood veneers.
Implementation Method 1
The resin binder formulation includes one or more porosity agents. The one or more porosity agents enable staining of the laminate product
Implementation Method 2
The one or more porosity agents enable staining of the laminate product
Data Source
AI summary
The present disclosure describes laminate wood or wood products capable of retaining a wood stain or colorant. The unique resin binder formulations and products include porosity-promoting agents that result in the resin binder 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 laminate wood or wood 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 laminate products may include a decorative paper layer sandwiched between a backing layer and a resin binder 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 resin binder layer optionally has a textured top surface.