Laminate basics: The invention of laminate. How is laminate made? What is laminate made of?
In essence, laminate is a skin, supplying a supplemental finish that is both ornamental and lasting. In this way, it is a veneer: a thin surface that cannot be used without a substrate. Laminates are usually applied to a substrate of inferior aesthetic and economic value. In the architectural and interior design trades, laminates are categorized as a “surfacing material” or a non-essential overlay, a material applied to achieve an aesthetic effect or to serve a durable function.
- EDITOR’s NOTE: This story on laminate history and design is written by Grace Jeffers on behalf of Wilsonart. I’m really thrilled about it — because I consider Grace Jeffers to be America’s foremost expert on laminate history. But I also want to make it clear: This is not a typical”product placement” or “sponsored post” — Wilsonart is not paying me anything to run these stories. I accepted the series proposal because I thought the content would be great for Retro Renovation — and because I’m thrilled to be working closely on this project with Grace. Read Grace’s complete bio here.
Story continues:
It surprises many people to learn that laminate, the material commonly found on kitchen counter tops, has been around for more than 100 years. The first laminates were what we call industrial laminates. They were not decorative — instead of being patterned or brightly colored they came only in a caramel brown color, a result of the polymer resin that was used to make them. These first laminates were made using only phenolic resin, the same polymer used in Bakelite jewelry. Not surprising, as the man who developed phenolic resin in 1906, Dr. Leo Baeckelund also invented Bakelite. By 1907, laminates were being made at Westinghouse in Pittsburgh, Pennsylvania. The first laminates were made as casing for electrical parts, mostly in the form of gears and tubes. Two employees at Westinghouse championed sheet laminates, but the company did not see any benefit to producing them. In 1913 those two employees left to form the company we know today as Formica.
The invention of melamine makes bright colors possible
Why, when we think of laminate, do we think of America in the mid-20th century? Initially, laminate was made purely with phenolic, which could only be used to produce a caramel brown colored finish. It wasn’t until 1938 — following the invention of a new kind of resin, melamine — that laminate could be engineered with a top layer of colored paper. Melamine bakes, or “flows”, to create a hard, clear, topcoat finish, which bonds and protects the “decorative” paper layer beneath. This important invention made the brightly colored laminates we associate with kitchen counter tops of the 1950s possible — and opened up a brand new world of design possibilities for American kitchens and bathrooms. Given the state of the American economy in the late 30s, laminates were not marketed to the consumer until the very end of the 1940s, after the Second World War. Consumers ate this new “modern” material up — laminate became simultaneously popular in commercial settings, such as diners and bars, and in the home as dinette tables, cabinetry and counter tops.
Laminate was seen as a modern marvel. It was bright and cheerful, impervious to stains, easy to clean and never required polishing. Think about the other materials that were used for the same purposes: Marble was porous, stained and was cold to the touch. Wood stained, scratched and required polishing. Linoleum could be scored, it stained, and it yellowed with time and sunlight.
Lots of names for laminate
Today, laminate is called by many names: laminate, plastic laminate, p-lam, and yes, sometimes it is called generically by the brand name Formica®. In Canada, it is often generically called Arborite® because in the post-World War II era that was the name of the company that made and popularized it there. There are currently five main brands of laminate manufactured in the United States: Wilsonart®, Formica, Pionite®, Nevamar® and Lamin-Art®. Of these five companies, only Wilsonart and Formica are available to consumers through home centers. Some additional laminate brands are imported for sale in the U.S., including the Italian manufacturer Abet Laminati, the company that supplied the colorful laminate to the Memphis Group and Studio Alchimaya. Laminate is a misleading word because it literally means made of layers, layers that are also called laminae (plural) or lamina (singular). By this definition, plywood is a laminate and so is chocolate-layered cake. The laminate we know and love as a surfacing material – used most often for kitchen and bathroom counter tops — is more accurately called High Pressure Laminate (HPL) or specifically decorative high pressure laminate, since there are also industrial high pressure laminates which are not decorative.
How laminate is made
The decorative high pressure laminates in our homes consist of sheets of paper that have been coated or impregnated with two types of resin, stacked on top of each other and placed into a press where they are cooked at a minimum of 265 degrees F. at a pressure of approximately 1,200 pound per square inch (psi) for about an hour. Under this pressure and heat, the resins flow and the stack and the resins transform into a single sheet of homogenous composite material. It surprises most people to learn that plastic laminate is approximately 70% paper and 30% polymer (phenolic and melamine) resin.
The top layer: A special clear, tough combination
The top layer of this laminated stack of paper is a sheet of melamine-impregnated alpha cellulose overlay paper. This special type of paper is made with very high-grade wood fibers (‘alpha’ meaning ‘first’, and ‘cellulose’ meaning ‘insoluble substance that is the main constituent of plant cell walls’; both cotton and wood produce cellulose). The paper is white in color when dry but very porous, not unlike very thin toilet paper. Between the paper and the melamine, this layer becomes completely clear in the pressing.
The second layer: The decorative design or color
The clear, tough melamine/alpha cellulose top overlay lies on top of the second layer of the laminate — the decorative layer. The decorative layer of laminate gives the counter top (for example) its design or color — its aesthetic appeal. The decorative layer also is permeated with melamine, which is pushed through the overlay sheet and penetrates into the decorative layer. The decorative layer can be created in three different ways: It can be a digital print (white paper which is printed with a wood grain, stone or abstract pattern); it can be a solid sheet of color; or it can be a solid sheet with “inclusions” (such as gold glitter, a Retro Renovation favorite not currently available in North America).
The core underneath: Kraft paper
The core consists of layers of kraft paper treated with phenolic resin. There are three basic grades of laminate: vertical, horizontal and post-forming. The main difference between the three is the number of layers of kraft paper. Kraft paper is the same kind of brown paper used for grocery bags. The word kraft comes from German and means strength. The kraft paper used in laminate is often made of recycled material. Since it is only the backing material and will not be seen once the laminate is installed, it is possible to use a thicker, less aesthetically pleasing paper, as opposed to the thin alpha cellulose paper used in the top layer, which is milled thin enough to “disappear” when imbued with resin. All three layers together equal one of the most popular counter top innovations ever. The melamine overlay of the top sheet and the kraft paper layers underneath work in tandem to create a laminated material that is stronger than each material on its own. Scientists and engineers sometimes refer to laminate as a composite material because composites work the same way: Two materials combine to make a third, even stronger, material. High Pressure Decorative Laminate (HPDL) meets an industry standard for wearability, scuff resistance, stain resistance to 29 different agents, radiant heat resistance, conductive heat resistance, UV light resistance, blister resistance, cleanability, appearance and post-forming capabilities (its ability to wrap around a radius). Because of its early use as an electrical insulator, laminate was associated with standards set by the National Electrical Manufacturers Association (NEMA). ASTM International, formerly known as the American Society for Testing and Materials (ASTM), is now associated with test methods for laminate and most other materials in our homes, such as textiles and vinyl flooring.
Laminate today — compared to laminate in the 1950s
Laminate today is produced in the same was as it was in the 1950s, with some differences. In that period, laminate had a higher percentage of polymer (phenolic and melamine) resin. The exact percentage is unknown but it is estimated that mid century laminate was 40% polymer and perhaps as high as 50% depending on the grade. Interestingly in today’s laminate, the paper-to-polymer ratio makes for a stronger material. It has been said that gram per gram, laminate is actually as strong as steel. Mid century laminate also has a different hand-feel than today’s laminate. It feels almost oilier, slippery in a different way. Part of this texture is due to the finishing technique.
Plastics. Polymers. Resins. Phenolic. Melamine. Chem 101 time:
Let’s get to know how to use our terms correctly.
Plastic is a word that means “capable of shaping or molding,” from the Greek plastikos meaning “able to be molded”. Horn is a natural plastic, it can be heated and bent into a shape. Tortoise shell is as well. Phenolic and melamine are synthetic plastics. All plastics are polymers.
The word polymer comes from the Greek polymeres meaning “having many parts”. Polymers are categorized by how they are constructed on the molecular level; they are made up of strands of connected units of the same size, like a beaded necklace, or many, many beaded necklaces all mixed together. It is the organization of the molecules that ultimately determines what material is, and polymers are the only material that demonstrates this “beaded necklace” order.
Plastic or Polymer? The general public uses the words interchangeably, but an engineer or a material scientist would only refer to polymers.
Resin is another word that we commonly confuse. Merriam Webster Dictionary defines resin as a group of natural, flammable, fusible organic substances that are formed as secretions in plants. They are soluble in organic solvents, but are not water-soluble. Resins can be solid or semi- solid, and are usually transparent or translucent and yellowish-brown in color.
As you can see, following the strict definition, resins are natural. Pine resin is the original “resin”; the Greeks called it rhetine, which is the root of our English word. Amber is pine resin hardened into a semi- precious stone-like nugget. Any plant that produces sap is producing resin. Resins are also polymers, polymeric in their structure. They are used in varnishes, printing inks, in medicine, and in plastics.
But our modern definition of laminate is broader and more confusing, because we have added the concept of synthetic resins into the mix. Natural resins are natural plastics—they are moldable polymers found in nature. Rubber is a natural resin, the sap of the rubber tree—it is also a natural plastic. We call the liquid state of polymers before they cure “resin”; when cured, they form plastics.
Now — don’t you feel much smarter already today!
db says
Huh, I never associated melamine w/ laminate, melamine was always that white particle board stuff at the big box store. I guess Ikea figured out what a great cabinet and shelving material it could be if you just offered it in a variety of finishes.
Is there any difference in the process of making plain white melamine board and say, the pre-laminated countertops?
Bob says
The “plain white melamine shelves” at the big boxes and some of the components in the furniture at IKEA are actually called Thermally Fused Laminate. The decorative paper is saturated in the melamine resin opposed to the alpha cellulose overlay. The are no kraft papers used in TFL and so that product does not have the impact resistance needed for a horizontal surface such as a countertop.
Grace Jeffers says
Bravo to you both for spotting the difference and knowing the difference. Db you have inspired me to write a future post about what all of these different look-alike materials actually are. Thank you!
Rita@thissortaoldlife says
This is awesome, Pam! We were saying just this weekend that it’s about time for laminate to come back into style. Said, in part, because we just scored a great old cabinet with an orange laminate countertop! Going to play a big role in our family room. Which would probably be called a rec room back in its original day.
Kate says
Sounds awesome Rita…we love orange here at Retro Renovation!
scb says
We still call it the rec room (when we don’t just call it “downstairs” — I live in a tri-level built in 1964).
Jay says
Great back story for those interested in the hows and whys of manufacturing an ordinary household item everyone takes for granted. I think plastic laminate is here to stay. It’s affordable and economical for main street America, myself included. Plus it’s tough and will last years if you don’t tire of it. Certainly easier to change out then granite.
Chicago Mel says
How much bigger is the commercial market for laminate over the residential market? Just curious. Thanks for the history lesson. I have on occasion thought it was strange that I had no idea what laminate was even though I have lived with it my whole life.
I am starting my retro renovation next month and the laminate should be delivered tomorrow actually! I love telling people how much it cost and see their eyes widen in disbelief. Then I laugh gleefully!
Grace Jeffers says
Great question Mel! The commercial market outsells the residential almost 3:1. In a home, laminate is generally used for the countertop. We call this a “horizontal application”. In the commercial market, laminate is used for furniture, cabinetry, elevator cabs, toilet partitions, columns, even the jetway from the gate to the airplane is surfaced in high pressure laminate. Laminate is a choice material in hotels, restaurants, retail stores, hospitals, doctors offices and other healthcare settings, classrooms, lab, and dorms. It’s everywhere and yet we know so little about it.
Robin, NV says
I love this story, thank you so much. As a historian and archaeologist, all of this information is very helpful. On a side note – I’ve actually excavated linoleum from mining and ranching sites dating to the 1880s. I was amazed to learn that linoleum has a long, long history. Haven’t found any historic laminate yet.
I totally agree with Lynne – why can’t the big companies like Wilsonart and Formica manufacture some of the old designs? For my kitchen, I’ve settled on a solid color in buttery yellow but I’d love to have something with some sparkles or pattern. Why are the laminate companies producing so many faux wood and stone designs? They look, well, faux and, quite frankly, cheap. Laminate companies should focus on what laminate does best – brilliant colors and imaginative designs.
Jay says
I think Pam can speak to this but probably the market isn’t big enough to support runs of retro laminate on a national scale. Faux wood finishes on laminate have been around a long time. The big box stores stock the faux wood and stone laminates because they sell. Most DIYers are not going to seek out custom cabinet makers to fabricate their countertops. At work I currently work at a brand new Knoll office desk unit topped in red oak. For years I worked on a top that was covered in white oak. These are finishes chosen by architects / designers.
Robin, NV says
I completely understand what you’re saying. Big companies like Formica know what sells. But I do wonder if consumer taste is being driven by what people see in the box stores – would people want patterns and color if they were prominantly displayed at Lowe’s or Home Depot? Why are people so afraid of color nowadays anyway? My husband, who is somewhat mistified by my mid century madness, was surprised and even a little dismayed by how hard it is to find just a basic solid color in laminate (something truly colorful, not a washed out greigy version of a color). It seems to me that laminate companies are merely following the trend for granite and quartz and not doing much in the way of innovation. The possibilities with laminate are almost endless yet they continue to produce approximations of what is “popular” today.
This is why I’ll never be a CEO or a business owner – my tastes and values don’t seem to follow popular trends.
Julie L says
Hi Robin,
I feel exactly the same about everything you just said. I’m always baffled about the limited choices available especially since laminate is sooo versatile. I decided for my kitchen reno to paint the old laminate in the color I want since it is IMPOSSIBLE to find anything made of color.
I agree, interior design at the moment is completely afraid of color. I want to make my home happy, cheerful and pleasant. You have to be willing to work to have color in your house. Custom make drapes, furniture, cabinets etc. At least we can still get color in VCT for the floor!
I also wonder if people HAD the options of color would they choose it??? Many will follow trend, and this is why everything is neutral at the moment: it is trend. Innovation and creatively is feared by many big box stores and companies these days. Too risky I guess.
PS I would fail as a CEO too because I would be like: “No, I’m going to produce what I feel is beautiful, not what is trendy”
Bob says
The big box stores typically do not show all of the colors that are available. Countertop fabricators will have most of the available choices and typically can get high pressure decorative laminate within a few days from their distributors. Wilsonart leads the way in design and performance. I would recommend that anyone looking for a new surface for their home or office to look at http://www.countertop.com
tammyCA says
I hear ya! I don’t know if people think color and laminate isn’t “sophisticated” or what, but lack of colors & choices sure is depressing.
Interesting how laminate is made..didn’t know that. I’d choose good old tile or laminate over anything else.
Grace Jeffers says
Robin, you raise some excellent points and I think we will be exploring these issues further in the future. For now, I have two observations: what people like to look at in magazines and design blogs is not always what they like to buy when it comes time to spend their hard earned money. A lot of people think about “resale value” and that means white and beige.
As for the stone comment, I am curious about you saying they look “cheap.” Faux and the history of faux is a topic near and dear to my heart. What does “cheap” mean exactly? In commercial interiors, the new and improved faux woods are actually more popular than genuine wood veneers because they are more consistent and they look so convincingly real.
Lynne says
Thanks for a very informative, interesting post. Since we’re delving into history here, why is it that the old laminate patterns are never reproduced? Its very difficult to bring our mid century kitchens and bathrooms back to their former glory with the meager choices we have available.
I mean, they don’t have to even think up a NEW design! Just reproduce a small line of the most popular styles. Grace? Are you out there????
Tikitacky says
I love this question. We all know that Formica did reproduce their boomerang pattern for years (and still do grey), but I too have wondered why small runs of the old patterns cannot be done as special orders. Yes, there’d be a wait time for the item, but I’d patiently wait for pink with gold glitter laminate! Or (this one is for Grace): is it too involved a process to allow people to submit their own patterns for special order laminates? (In much the same way as candy companies will now do special orders with your name or company colors used). Some of us are willing to pay way more than we should for laminate just because it is exactly what we want. 🙂
Robert Schaefer says
Here is a link to one of several retro designs that can be purchased one sheet at a time: http://assets.wilsonart.com/images/Product/icon/910.jpg
These are great designs that cost a little more but are not mass produced. Good luck!
pam kueber says
Thanks, Robert. We’ve done lots of stories about these. See Kitchen/Countertops category, readers!!!!
Robert Schaefer says
Thanks Pam! That picture came from Wilsonart’s site under “Indie Collection”. 4×8 sheets are the most economical way to get some really good retro designs!
pam kueber says
Yes, lots in the Indie Collection.
Melissa says
I’d like to know if there is a way to refinish or restore old laminate. I have black with gold fleck laminate in my kitchen that in some spots the clear shine has worn off and it looks grey instead of black. Olive oil turned it darker (almost back to the black) and shiny, but after a few cleanings that wore off.
(and yes this is the black and gold counter in my kitchen that was feature in RR’s Design Dilemma- unfortunately the kitchen is STILL not completed- but I promise pics when its done!)
-Melissa
Kate says
Can’t wait to see what you’ve been up to Melissa. We are glad you love your vintage laminate. 🙂
Robin, NV says
What about Johnson’s Kitchen Wax – would that work?
Sarah g (roundhouse) says
If you are going to oil up your counter I would suggest mineral oil instead of olive oil since olive oil is plant based and will attract bugs and such and could possibly spoil and cause odors over time
Melissa says
Thanks Sarah. The olive oil was actually an accidental spill… and then we said “Hey, its black and shiny again!” So if one of the next articles doesn’t have any other restoration tips (and if Johnson kitchen wax doesn’t work)- I’ll go with mineral oil 🙂
-M
Grace Jeffers says
Melissa, I can’t wait to see the pictures! I believe I have only ever seen one example of the gold glitter over black. Lucky you! Is your laminate glossy? What is the texture? Does the laminate look grey because the surface is scratched? If it was worn down, it might appear more dark brown in color than grey, but the scratching of a high gloss finish might look grey-ish. I recommend Countertop Magic. It is what I used to restore the Wilson House. There is a catch here. I used the Countertop Magic in the spray can. Now it seems to only be available in a pump bottle and the formulation is not as moisturizing. It’s like wanting deep conditioning shampoo and only getting regular conditioner. But you have inspired me to look into this matter further and report back in the near future.
Grama Robin says
I used Countertop Magic from my local Ace Hardware (home away from home) to restore the boomerang laminate in my 1959 camper. Lots of coats seemed to do the trick. But you’re right; I can’t find it now. Nice to know to look for a pump bottle.
Joel says
There is a product called something like Penetrol which is a paint flow improver… it is easy to find, even sold at Home Depot. It is clear and oil like and added to paint to make brushmarks smooth out. But when used alone, it will dry to a gloss… try some of this on your countertops. I used it to restore fiberglass “Tulip” chairs that had oxidized to a dull powdery surface. Rub it into the surface, wipe it down and allow to dry. Reapply if necessary.
pam kueber says
However: Read the instructions — beware of products that may be poisonous to your food!
Joshua Croff says
How is laminate on the environment? Seems like with all of those polymers that it would be bad for indoor air quality as well as toxic during manufacture.
Grace Jeffers says
Thanks for asking Joshua,
The off-gassing of plastics is a big issue and I am glad you are aware of it. But not all polymers are the same. Perhaps I should write a specific post about this in the future.
In the meantime I can tell you this.
North American manufacturers have worked really hard to ensure they engage in responsible processes and sourcing. As for indoor air quality, many companies have received GREENGUARD® certification on their products (and Wilsonart has achieved the additional SCS Indoor Advantage Gold IAQ certification). Greenguard certification indicates that a product does not contribute of poor indoor air quality.
There are other sustainability issues. Many laminate manufacturers are beginning to source recycled paper fiber in their offerings (you can see Wilsonart’s story here
http://assets.wilsonart.com/productlib/sustainability/laminate/Full%20Circle%20Infographic.pdf). Companies are still researching options for improvements, and they’ll come, but, in my opinion, overall laminate is a pretty responsible choice.
pam kueber says
I fear that this is a very difficult topic to get into without lots and lots of research. There are so many environmental issues to consider: carbon footprint cradle-to-cradle, air quality and off gassing, all consequences of material extraction and processing, and all manufacturing processes and their consequences, to name a few.
Unless a manufacturer can provide a cradle-to-cradle Life Cycle Assessment that is vetted by neutral third parties and then shared in its entirety, transparently, this is so much anecdote.
See my story about FTC requirements for green claims: https://retrorenovation.com/2012/11/14/an-end-to-greenwashing-the-ftc-issues-new-guides-cautioning-marketers-against-making-broad-unsubstantiated-claims/
I may try to take on Joshua’s question myself. Thanks, Grace.
Chase says
Pam, this is a fantastic post; one of the best this year I’d say. Thank you so much for compiling and sharing all of this great information, and a big thank you to Grace for working with you and the blog to bring this to us!
Grace Jeffers says
Chase, thank you so much for the big compliment! It is wonderful that so many people are interested in learning more about laminate and other materials. And there is more to follow. Everyone will become an “expert” this year!
linda h says
When we put quartz in the kitchen, I thought we would use the exact same product when we replaced the fake marble bathroom counters, but lately I have been collecting laminate samples. I don’t know if I can convince my husband, though.