Product Identification
MelCor II laminate may be used in any application where a solid color edge is desired. MelCor II is intended for use in applications where the edge of the laminate contributes to the aesthetics of the final product. Pionite's patented manufacturing process provides a second generation color-through laminate that is more flexible and much less likely to chip than other color-through laminate.

Multi-toned edges or sandwich colors provide interesting design options. Grooves, bands, patterns, or lettering may be fashioned with the use of routers, engravers, or sandblasting equipment. Solid color MelCor II is also ideal for high-wear applications since gouges and cuts will not readily show.

Due to its unique composition MelCor II colors will vary from corresponding colors in standard Pionite.

MelCor II laminate is manufactured in a flat press by combining decorative papers saturated in melamine resin with multiple layers of pigmented core paper impregnated in a flexible thermoset resin at pressures exceeding 1000 psi (6895 kPa) and temperatures approaching 300 deg. F (150 deg. C). The panels are trimmed to size and the backs are sanded to facilitate bonding. The thickness of the laminate is determined by the number of pigmented core layers used. The laminating process combines the durability of melamine resins with the aesthetics of decorative papers creating a more flexible color through surfacing material than has been previously possible.

Typical Uses
MelCor II laminate is used in high-end furniture and casework applications where a solid color edge can be incorporated into the total design concept.

Fabrication Tips
When working with MelCor II, these techniques will produce a quality application.

1. Proper conditioning of the laminate, substrate, and backing sheet minimizes possible warping, shrinking, or expansion of assembled panels. Ideally, all components should be conditioned at 70 deg. F to 75 deg. F (21 deg. C to 25 deg. C) and 45 to 50 percent relative humidity for 48 hours prior to assembly.
   
   
2. Always bond laminate to a suitable substrate such as high quality plywood, medium to high density fiberboard, particleboard, or metals. It should not be glued directly to plaster walls, gypsum wallboard, or concrete.
   
   
3. For virtually invisible seams with MelCor II, use a clear drying adhesive such as white glue (PVA) or clear epoxy, spread thinly.
   
   
4. The use of a backing sheet is recommended to minimize warpage. The thickness of the backing sheet should be relatively equal to the thickness of the decorative laminate on the face of the assembly.
   
   
5. All saw blades and router bits used for cutting should be carbide tipped. Feed rate should be slow and tool speed should be high.
   
   
6. Inside corners of cutouts for electrical outlets, sinks, etc., should have a minimum radius of 1/8" (3 mm) and be filed smooth. This reduces the likelihood of stress cracks.
   
   
7. All edges of laminate should be filed smooth with file direction towards substrate to help prevent stress cracks and to minimize chipping.
   
   
8. When nails or screws must be used, it is advisable to first drill an oversized hole through the laminate. This reduces the likelihood of stress cracks.
   
   
9. Two-inch edging strips can be wrapped around a 6" radius without heat. A radius of 3" can be achieved by heating the edging strip to 325 deg. F (165 deg. C).
   
   
10. All laminate is intended for interior use only, and should not be exposed to extreme humidity, continuous sunlight, or temperatures above 275 deg. F (135 deg. C) for extended periods of time.
    
    
11. Although Melcor II is more flexible than other color-through laminates offered in the market, it is not as flexible as standard decorative laminate. Care should be used when rolling or flexing Melcor II.

Technical Information
Physical Properties