US4046937A
Expired / Lapsed
US
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Melamine-aldehyde resin and postformable laminate made therefrom
Assignee: Westinghouse Electric Corp
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Filing: 1974-10-10
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Granted: 1977-09-06
•
Expires: 1994-10-10
Abstract
Abstract A melamine-aldehyde resin is disclosed of a composition of melamine-aldehyde, a water-soluble, aliphatic diglycidyl ether, and water. The composition is cured to the A-stage and an absorbent sheet is impregnated with the resin which is then cured to the B-stage. At least one B-staged sheet is stacked with a postformable core stock and heated and pressed to form a C-staged postformable laminate. The laminate can be heated and pressed to postform it. The postformed laminate can be adhesively bonded to a substrate to form a counter top or other article.
Inventors
- 👤 Harold O. McCaskey, Jr.
- 👤 Lenon G. Brooker
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 04:49
CPC Classifications
B; B32; B32B; B32B27/00; B32B27/04; B32B29/00; B32B29/002; B32B29/005; B32B38/00; B32B38/08; C; C08; C08L; C08L61/00; C08L61/20; C08L61/26; C08L61/28; D; D21; D21H; D21H17/00; D21H17/03; D21H17/05; D21H17/06; D21H17/20; D21H17/33; D21H17/46; D21H17/47; D21H17/49; D21H17/51; D21H17/52; B32B2038/0052; B32B2038/0076; B32B2307/00; B32B2307/40; B32B2307/406; B32B2317/00; B32B2317/12; B32B2317/125; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24802; Y10T428/24934; Y10T428/31504; Y10T428/31511; Y10T428/31678; Y10T428/31688; Y10T428/31692; Y10T428/31703; Y10T428/31942; Y10T428/31946; Y10T428/31949; Y10T428/31953; Y10T428/31964; Y10T428/31967; Y10T442/00; Y10T442/30; Y10T442/3472; Y10T442/3528; Y10T442/3569
Claims Analysis
Total Claims: 72
Claim 1
Independent Claim
51 words
A composition comprising 1. an aldehyde and melamine in a mole ratio of about 1.5 to about 6; 2. about 1 to about 50% (by weight based on melamine weight) of a water-soluble, aliphatic diglycidyl ether; and 3. sufficient water to form a solution of about 15 to about 65% solids.
Claim 2
Dependent Claim
51 words
A composition comprising 1. an aldehyde and melamine in a mole ratio of about 1.5 to about 6; 2. about 1 to about 50% (by weight based on melamine weight) of a water-soluble, aliphatic diglycidyl ether; and 3. sufficient water to form a solution of about 15 to about 65% solids.
Claim 3
Dependent Claim
11 words
A composition according to claim 1 wherein said aldehyde is formaldehyde.
Claim 4
Dependent Claim
22 words
A composition according to claim 1 wherein the mole ratio of said aldehyde to said melamine is about 1.5 to about 2.5.
Claim 5
Dependent Claim
27 words
A composition according to claim 1 wherein the amount of said water-soluble, aliphatic diglycidyl ether is about 5 to about 15% (by weight based on melamine weight).
Claim 6
Dependent Claim
99 words
A composition according to claim 1 wherein said water-soluble, aliphatic diglycidyl ether has the general formula: ##STR7## where R is selected from the group consisting of --CR'-- x , --CH 2 --CH 2 --O-- x CH 2 CH 2 --, --CH(CH 3 )--CH 2 O-- x CH(CH 3 )--CH 2 --, --CH--CH 2 -- y CH--, and mixtures thereof, were each R' is independently selected from hydrogen and alkyl to about C 5 , y is 3 or 4, and x has a lower limit of 0 and an upper limit determined by the solubility of the diglycidyl ether.
Claim 7
Dependent Claim
20 words
A composition according to claim 5 wherein R is --CH 2 --CH 2 --O-- x CH 2 CH 2 .
Claim 8
Dependent Claim
20 words
A composition according to claim 5 wherein R is --CH(CH 3 )CH 2 0-- x CH(CH 3 --CH 2 .
Claim 9
Dependent Claim
19 words
A composition according to claim 1 wherein said water-soluble, aliphatic diglycidyl ether is a diglycidyl ether of a polyglycol.
Claim 10
Dependent Claim
38 words
A composition according to claim 1 which includes about 0.1 to about 1 phr of a mold release agent and about 0.25 to about 3% (based on the diglycidyl ether) of a curing agent for the diglycidyl ether.
Claim 11
Dependent Claim
23 words
A composition according to claim 1 which includes about 1 to about 40% (by weight based on the melamine) of an internal plasticizer.
Claim 12
Dependent Claim
18 words
A composition according to claim 1 wherein said aldehyde and said melamine have been reacted to the A-stage.
Claim 13
Dependent Claim
10 words
A composition according to claim 1 reacted to the A-stage.
Claim 14
Dependent Claim
61 words
An article comprising an absorbent sheet impregnated with an A-staged composition which comprises: 1. an aldehyde and melamine in a mole ratio of about 1.5 to about 6; 2. about 1 to about 50% by weight based on melamine weight of a water-soluble, aliphatic diglycidyl ether; and 3. sufficient water to form a solution of about 15 to about 65% solids.
Claim 15
Dependent Claim
61 words
An article comprising an absorbent sheet impregnated with an A-staged composition which comprises: 1. an aldehyde and melamine in a mole ratio of about 1.5 to about 6; 2. about 1 to about 50% by weight based on melamine weight of a water-soluble, aliphatic diglycidyl ether; and 3. sufficient water to form a solution of about 15 to about 65% solids.
Claim 16
Dependent Claim
23 words
An article according to claim 13 wherein said aldehyde and said melamine are A-stage after their addition to the remainder of said composition.
Claim 17
Dependent Claim
13 words
A sheet according to claim 13 wherein said absorbent sheet is alpha-cellulose paper.
Claim 18
Dependent Claim
24 words
An article according to claim 13 wherein said aldehyde and said melamine are A-staged prior to their addition to the remainder of said composition.
Claim 19
Dependent Claim
9 words
An article according to claim 13 which is B-staged.
Claim 20
Dependent Claim
11 words
An article according to claim 13 wherein said aldehyde is formaldehyde.
Claim 21
Dependent Claim
22 words
An article according to claim 13 wherein the mole ratio of said aldehyde to said melamine is about 1.5 to about 2.5.
Claim 22
Dependent Claim
27 words
An article according to claim 13 wherein the amount of said water-soluble, aliphatic diglycidyl ether is about 5 to about 15% by weight based on melamine weight.
Claim 23
Dependent Claim
99 words
An article according to claim 13 wherein said water-soluble, aliphatic diglycidyl ether has the general formula: ##STR8## where R is selected from the group consisting of --CR'-- x , --CH 2 --CH 2 --O-- x CH 2 CH 2 --, --CH(CH 3 )--CH 2 O-- x CH(CH 3 )--CH 2 --, --CH--CH 2 -- y CH--, and mixtures thereof, where each R' is independently selected from hydrogen and alkyl to about C 5 , y is 3 or 4, and x has a lower limit of 0 and an upper limit determined by the solubility of the diglycidyl ether.
Claim 24
Dependent Claim
20 words
An article according to claim 21 wherein R is --CH 2 --CH 2 --O-- x CH 2 CH 2 .
Claim 25
Dependent Claim
20 words
An article according to claim 21 wherein R is --CH(CH 3 )CH 2 O-- x CH(CH 3 --CH 2 .
Claim 26
Dependent Claim
19 words
An article according to claim 13 wherein said water-soluble, aliphatic diglycidyl ether is a diglycidyl ether of a polyglycol.
Claim 27
Dependent Claim
38 words
An article according to claim 13 which includes about 0.1 to about 1 phr of a mold release agent and about 0.25 to about 3% based on the diglycidyl ether of a curing agent for the diglycidyl ether.
Claim 28
Dependent Claim
23 words
An article according to claim 13 which includes about 1 to about 40% by weight based on the melamine of an internal plasticizer.
Claim 29
Dependent Claim
13 words
An article according to claim 26 wherein said internal plasticizer is toluene sulfonamide.
Claim 30
Dependent Claim
19 words
An article according to claim 13 wherein said composition includes about 1 to about 10 phr of a solvent.
Claim 31
Dependent Claim
20 words
An article according to claim 13 wherein the amount of water in said composition is about 40 to about 60%.
Claim 32
Dependent Claim
13 words
An article according to claim 13 which has been cured to the C-stage.
Claim 33
Dependent Claim
70 words
A laminate comprising a postformable core stock to which is bonded at least one absorbent sheet impregnated with a C-staged composition comprising: A. an aldehyde and melamine in a mole ratio of about 1.5 to about 6; B. about 1 to about 50% by weight based on melamine weight of a water-soluble, aliphatic diglycidyl ether; and c. sufficient water to form a solution of about 15 to about 65% solids.
Claim 34
Dependent Claim
70 words
A laminate comprising a postformable core stock to which is bonded at least one absorbent sheet impregnated with a C-staged composition comprising: A. an aldehyde and melamine in a mole ratio of about 1.5 to about 6; B. about 1 to about 50% by weight based on melamine weight of a water-soluble, aliphatic diglycidyl ether; and c. sufficient water to form a solution of about 15 to about 65% solids.
Claim 35
Dependent Claim
24 words
A laminate according to claim 31 wherein said core stock comprises about 1 to about 15 absorbent sheets impregnated with a postformable phenol-aldehyde resin.
Claim 36
Dependent Claim
12 words
A laminate according to claim 32 wherein said phenol-aldehyde resin is phenol-formaldehyde.
Claim 37
Dependent Claim
12 words
A laminate according to claim 31 which is in a postformed condition.
Claim 38
Dependent Claim
10 words
A laminate according to claim 34 adhesively-bonded to a substrate.
Claim 39
Dependent Claim
23 words
A laminate according to claim 31 wherein said aldehyde and said melamine are A-staged after their addition to the remainder of said composition.
Claim 40
Dependent Claim
24 words
A laminate according to claim 31 wherein said aldehyde and said melamin are A-staged prior to their addition to the remainder of said composition.
Claim 41
Dependent Claim
9 words
A laminate according to claim 31 which is B-staged.
Claim 42
Dependent Claim
11 words
A laminate according to claim 31 wherein said aldehyde is formaldehyde.
Claim 43
Dependent Claim
22 words
A laminate according to claim 31 wherein the mole ratio of said aldehyde to said melamine is about 1.5 to about 2.5.
Claim 44
Dependent Claim
27 words
A laminate according to claim 31 wherein the amount of said water-soluble, aliphatic diglycidyl ether is about 5 to about 15% by weight based on melamine weight.
Claim 45
Dependent Claim
99 words
A laminate according to claim 31 wherein said water-soluble, aliphatic diglycidyl ether has the general formula: ##STR9## wherein R is selected from the group consisting to --CR'-- x , --CH 2 --CH 2 --O-- x CH 2 CH 2 --, --CH(CH 3 )--CH 2 O-- x CH(CH 3 )--CH 2 --, --CH--CH 2 -- y CH--, and mixtures thereof, where each R' is independently selected from hydrogen and alkyl to about C 5 , y is 3 or 4, and x has a lower limit of 0 and an upper limit determined by the solubility of the diglycidyl ether.
Claim 46
Dependent Claim
20 words
A laminate according to claim 42 wherein R is --CH 2 --CH 2 --O-- x CH 2 CH 2 .
Claim 47
Dependent Claim
20 words
A laminate according to claim 42 wherein R is --CH(CH 3 )CH 2 O-- x CH(CH 3 --CH 2 .
Claim 48
Dependent Claim
19 words
A laminate according to claim 31 wherein said water-soluble, aliphatic diglycidyl ether is a diglycidyl ether of a polyglycol.
Claim 49
Dependent Claim
38 words
A laminate according to claim 31 which includes about 0.1 to about 1 phr of a mold release agent and about 0.25 to about 3% based on the diglycidyl ether of a curing agent for the diglycidyl ether.
Claim 50
Dependent Claim
23 words
A laminate according to claim 31 which includes about 1 to about 40% by weight based on the melamine of an internal plasticizer.
Claim 51
Dependent Claim
13 words
A laminate according to claim 47 wherein said internal plasticizer is toluene sulfonamide.
Claim 52
Dependent Claim
19 words
An articl according to claim 31 wherein said composition includes about 1 to about 10 phr of a solvent.
Claim 53
Dependent Claim
20 words
A laminate according to claim 31 wherein the amount of water in said composition is about 40 to about 60%.
Claim 54
Dependent Claim
13 words
A laminate according to claim 31 which has been cured to the C-stage.
Claim 55
Independent Claim
117 words
A method of making a postformable laminate comprising: A. preparing an A-staged composition which comprises 1. an aldehyde and melamine in a mole ratio of about 1.5 to about 6; 2. about 1 to about 50% by weight based on melamine weight of water-soluble, aliphatic diglycidyl ether; and 3. sufficient water to form a solution of about 15 to about 65% solids. B. applying said composition to an absorbent sheet to a weight ratio of composition solids to absorbent sheet of about 1.2 to about 4.0; C. reacting said composition to the B-stage; D. forming a stack of at least one of said sheets with a postformable core stock; and E. curing said stack to the C-stage.
Claim 56
Independent Claim
117 words
A method of making a postformable laminate comprising: A. preparing an A-staged composition which comprises 1. an aldehyde and melamine in a mole ratio of about 1.5 to about 6; 2. about 1 to about 50% by weight based on melamine weight of water-soluble, aliphatic diglycidyl ether; and 3. sufficient water to form a solution of about 15 to about 65% solids. B. applying said composition to an absorbent sheet to a weight ratio of composition solids to absorbent sheet of about 1.2 to about 4.0; C. reacting said composition to the B-stage; D. forming a stack of at least one of said sheets with a postformable core stock; and E. curing said stack to the C-stage.
Claim 57
Dependent Claim
23 words
A method according to claim 52 wherein said aldehyde and said melamine are A-staged after their addition to the remainder of said composition.
Claim 58
Dependent Claim
24 words
A method according to claim 52 wherein said aldehyde and siad melamine are A-staged prior to their addition to the remainder of said composition.
Claim 59
Dependent Claim
9 words
A method according to claim 52 which is B-staged.
Claim 60
Dependent Claim
11 words
A method according to claim 52 wherein said aldehyde is formaldehyde.
Claim 61
Dependent Claim
22 words
A method according to claim 52 wherein the mole ratio of said aldehyde to said melamine is about 1.5 to about 2.5.
Claim 62
Dependent Claim
27 words
A method according to claim 52 wherein the amount of said water-soluble, aliphatic diglycidyl ether is about 5 to about 15% by weight based on melamine weight.
Claim 63
Dependent Claim
99 words
A method according to claim 52 wherein said water-soluble, aliphatic diglycidyl ether has the general formula: ##STR10## where R is selected from the group consisting of --CH'-- x , --CH 2 --CH 2 --O-- x CH 2 CH 2-- , --CH(CH 3 )--CH 2 O-- x CH(CH 3 )--CH 2 --, --CH--CH 2 -- y CH--, and mixtures thereof, where each R' is independently selected from hydrogen and alkyl to about C 5 , y is 3 or 4, and x has a lower limit of 0 and an upper limit determined by the solubility of the diglycidyl ether.
Claim 64
Dependent Claim
20 words
A method according to claim 59 wherein R is --CH 2 --CH 2 --O-- x CH 2 CH 2 .
Claim 65
Dependent Claim
20 words
A method according to claim 59 wherein R is --CH(CH 3 )CH 2 O-- x CH(CH 3 --CH 2 .
Claim 66
Dependent Claim
19 words
A method according to claim 52 wherein said water-soluble, aliphatic diglycidyl ether is a diglycidyl ether of a polyglycol.
Claim 67
Dependent Claim
38 words
A method according to claim 52 which includes about 0.01 to about 1 phr of a mold release agent and about 0.25 to about 3% based on the diglycidyl ether of a curing agent for the diglycidyl ether.
Claim 68
Dependent Claim
23 words
A method according to claim 52 which includes about 1 to about 40% by weight based on the melamine of an internal plasticizer.
Claim 69
Dependent Claim
13 words
A method according to claim 64 wherein said internal plasticizer is toluene sulfonamide.
Claim 70
Dependent Claim
19 words
A method according to claim 52 wherein said composition includes about 1 to about 10 phr of a solvent.
Claim 71
Dependent Claim
20 words
A method according to claim 52 wherein the amount of water in said composition is about 40 to about 60%.
Claim 72
Dependent Claim
13 words
A method according to claim 52 which has been cured to the C-stage.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1980-09-05 | 1981-03-07 | 1981-09-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1984-09-05 | 1985-03-07 | 1985-09-06 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1988-09-05 | 1989-03-07 | 1989-09-06 | $7700.00 | Window Closed / Lapsed |