Impregnating resin composition, resin coating, laminate containing same, impregnation product, and method for producing same

Abstract

The invention relates to an impregnating resin composition containing a) a melamine formaldehyde resin, b) a non-ionic wetting agent, c) a non-ionic release agent, d) a hardener, and e) polyhexamethylene guanidine (PHMG). The invention further relates to a resin coating which can be obtained by condensing the impregnating resin composition and to a resin coating containing a co-condensate made of the melamine formaldehyde resin and polyhexamethylene guanidine (PHMG). The invention further relates to an impregnate containing i) the impregnating resin composition or the resin coating and ii) an impregnate carrier material. Another object of the invention is a laminate containing iii) a laminate carrier material and iv) the impregnate or the impregnating resin composition, or the resin coating. A further object of the invention is a method for producing a laminate having the steps of i) applying the impregnating resin composition or the resin coating or the impregnate onto a carrier material and ii) compressing the component from step i). In addition, the invention concerns the use of the impregnating resin composition or the resin coating in the production of wood-based materials, impregnates, and/or laminates.

Claims

1. An impregnating resin composition comprising a) a melamine-formaldehyde resin; b) a non-ionic wetting agent; c) a non-ionic release agent; d) a hardener; and e) polyhexamethylene guanidine (PHMG), wherein the melamine-formaldehyde resin and polyhexamethylene guanidine (PHMG) form a co-condensate.

2. The impregnating resin composition according to claim 1, characterised in that i. the non-ionic wetting agent is selected from the group consisting of polyalkylene glycol ethers, alkyl polyglucosides, and nonyl phenol ethoxylates and fatty alcohol ethoxylates, and mixtures thereof; ii. the non-ionic release agent is selected from the group consisting of fatty acid glycerides, ethoxylated fatty alcohols, and higher fatty acid phosphate esters, and mixtures thereof; and/or iii. the hardener is selected from the group consisting of para-toluene sulfonic acid, morpholine, para-toluene sulfonic acid morpholine salts, alkylamine salts, ammonium salts, morpholine-p-toluene sulfonate, ethanolamine hydrochloride and mixtures thereof.

3. The impregnating resin composition according to claim 1, characterised in that the impregnating resin composition contains one or more of the components a) to e) in the following amounts: a) the melamine-formaldehyde resin in an amount of 25 to 60 wt.-%, in relation to the total weight of the impregnating resin composition; b) the non-ionic wetting agent in an amount of 0.1 to 3 wt.-%, in relation to the solid resin content of the melamine-formaldehyde resin; c) the non-ionic release agent in an amount of 0.1 to 1.0 wt.-%, in relation to the solid resin content of the melamine-formaldehyde resin; d) the hardener in an amount of 0.1 to 1.0 wt.-%, in relation to the solid resin content of the melamine-formaldehyde resin; and/or e) polyhexamethylene guanidine (PHMG) in an amount of 0.01 to 10 wt.-%, in relation to the solid resin content of the melamine-formaldehyde resin.

4. A resin coating comprising an impregnating resin composition according to claim 1.

5. The resin coating according to claim 4, characterised in that the resin coating has a thickness of 0.01 to 2 mm, preferably from 0.05 to 1 mm, and particularly preferably from 0.1 to 0.3 mm.

6. An impregnate containing i. an impregnating resin composition according to claim 1, and ii. at least one impregnate carrier material.

7. The impregnate according to claim 6, characterised in that the impregnate contains the impregnating resin composition according to claim 1 in an amount of i. 30 to 600 wt.-%, 350 to 550 wt.-%, or 100 to 180 wt.-%, each in relation to the dry weight of the impregnate; or ii. 10 g/m.sup.2 to 250 g/m.sup.2, preferably 50 g/m.sup.2 to 150 g/m.sup.2, and particularly preferably 80 g/m.sup.2 to 120 g/m.sup.2, in relation in each case to one of the two surfaces of the impregnate.

8. The impregnate according to claim 6, characterised in that the at least one impregnate carrier material is selected from the group consisting of paper, fleece, glass fleece, nonwoven fabric, knitted fabric, decorative paper, overlay paper, cardboard, regenerated paper, core cardboard, paperboard and semi-chemical pulps.

9. A laminate comprising the resin coating according to claim 4.

10. The laminate according to claim 9, characterised in that the at least one laminate carrier material is selected from the group consisting of paper, fleece, nonwoven fabric, knitted fabrics, decorative paper, cardboard, core cardboard, paperboard, semi-chemical pulps, wood, wood-based material and solid wood panels or a combination thereof.

11. The laminate according to claim 9 for furniture, floor, wall and/or ceiling construction, characterised in that the surface of the laminate that is directed towards the room interior, contains the resin coating.

12. A method for producing a laminate according to claim 9, comprising the steps of i. applying an impregnate to a laminate carrier material; ii. compressing the components from step i wherein the impregnate contains i. an impregnating resin composition comprising a) a melamine-formaldehyde resin; b) a non-ionic wetting agent; c) a non-ionic release agent; d) a hardener; and e) polyhexamethylene guanidine (PHMG), wherein the melamine-formaldehyde resin and polyhexamethylene guanidine (PHMG) form a co-condensate and ii. at least one impregnate carrier material.

13. The method for manufacturing a laminate according to claim 12, further comprising the step of iii. degreasing at least one of the surfaces of the laminate.

14. A wood-based material comprising an impregnating resin composition of claim 1.

15. The impregnating composition according to claim 1, characterised in that the impregnating resin composition contains one or more of the components a) to e) in the following amounts: a) the melamine-formaldehyde resin in an amount of 25 to 60 wt.-%, in relation to the total weight of the impregnating resin composition; b) the non-ionic wetting agent in an amount of 0.2 to 1.0 wt.-%, in relation to the solid resin content of the melamine-formaldehyde resin; c) the non-ionic release agent in an amount of 0.2 to 0.5 wt.-%, in relation to the solid resin content of the melamine-formaldehyde resin; d) the hardener in an amount of 0.3 to 0.8 wt.-%, in relation to the solid resin content of the melamine-formaldehyde resin; and/or e) polyhexamethylene guanidine (PHMG) in an amount of 1.0 to 5.0 wt.-%, in relation to the solid resin content of the melamine-formaldehyde resin.

16. The impregnating composition according to claim 1, characterised in that the impregnating resin composition contains one or more of the components a) to e) in the following amounts: a) the melamine-formaldehyde resin in an amount of 25 to 60 wt.-%, in relation to the total weight of the impregnating resin composition; b) the non-ionic wetting agent in an amount of 0.2 to 0.4 wt.-%, in relation to the solid resin content of the melamine-formaldehyde resin; c) the non-ionic release agent in an amount of 0.2 to 0.4 wt.-%, in relation to the solid resin content of the melamine-formaldehyde resin; d) the hardener in an amount of 0.5 to 0.6 wt.-%, in relation to the solid resin content of the melamine-formaldehyde resin; and/or e) polyhexamethylene guanidine (PHMG) in an amount of 1.0 to 3.0 wt.-%, in relation to the solid resin content of the melamine-formaldehyde.

Description

EXAMPLE 1: PREPARATION OF AN IMPREGNATING RESIN COMPOSITION

(1) In this example, an impregnating resin composition within the meaning of the invention is prepared as follows:

Materials

(2) TABLE-US-00001 2,780 g of melamine-formaldehyde impregnating resin 62% solid resin content 345 g PHMG-HCl 25% aqueous solution 14.5 g hardener MH836 Fa. INEOS Melamines 5.0 g of non-ionic wetting agent Deurowet MA 21 2.5 g of non-ionic release agent Deurolease PHE

(3) The material listed above were blended together in a 5 l three-necked flask at 25° C. with agitation and intimately mixed for 15 minutes.

(4) The composition had a solids content of 57.9 wt.-% as measured by the oven drying method (1 g sample weight for 2 hours at 120° C. dry) and a turbidity time of 160 s at 100° C. in a boiling water bath.

EXAMPLE 2: PREPARATION OF AN IMPREGNATE

(5) An impregnate was then prepared with the impregnating resin composition from Example 1.

(6) A decorative paper with a grammar of 65 g/m was impregnated with 65 g/m.sup.2 of the impregnating resin composition from Example 1 using a hand squeegee device from CHM GmbH Automatisierungstechnik. After coating with resin, the impregnate was dried for 3 minutes at 120° C. in a convection oven. The residual moisture of the impregnate was 6 wt.-%.

EXAMPLE 3: PREPARATION OF A LAMINATE

(7) The impregnate from Example 2 was compressed onto a 7.4 mm HDF carrier board (50×50 cm) at 192° C. under a pressure of 60 bar within 23 s. A backing layer paper was attached to the underside of the carrier board to ensure flatness.

EXAMPLE 4: ANTIMICROBIAL EFFECT OF THE LAMINATE OF EXAMPLE 3

(8) Checking for antimicrobial effectiveness typically takes place u sing in vitro tests. Since each material has inherently different characteristics in terms of adhesion of germs, the antimicrobial activity is always measured as a difference compared to a corresponding non-antimicrobial zero sample. Common test methods are JIS Z 2801 (ISO 22196, ASTM E 2180 and the Certika test.

(9) To test the antimicrobial effectiveness in the present case laminate samples from Example 3 were investigated using the dry-inoculation method (Rodeo method) in accordance with the Microbiological Quality Standard 22 and compared to an active-substance-free reference.

(10) Rodac method for various surfaces

(11) Material: Test surfaces Test germ: S. aureus ATCC 6538 Sterile water (distilled water) Ethanol 70%, 96% Pure acetone Disposable wipes Sterile swab sticks Densicheok Plus (Fa. bioMerieox). Sterilised spreader rod Pipettes Sterile pipette tips Columbia agar+5% sheep blood agar plates (90 mm) Columbia agar+5% sheep blood contact plates (Fa. Oxoid) BD Columbia Agar with 5% sheep blood is a nutrient-rich multipurpose medium for the isolation and cultivation of demanding and undemandlng microorganisms from clinical samples. The excellent growth-supporting properties of Columbia agar with 5% sheep blood are the result of the combination of two peptones and yeast extract as a source of vitamin E complex. The corn starch also contained absorbs toxic by-products of the sample and serves as an energy source for organisms with alpha-amylase. The sheep blood serves to detect haemolytic reactions and supplies the factor X (heme), essential for the growth of many pathogenic species. The colonies are larger and the growth is more pronounced on this medium than on other blood agar media.

(12) In many European countries BD Columbia III Agar with 5% sheep blood is the most used initial isolation medium for clinical samples.

(13) Reagents of Usable Plate Medium

(14) (Composition per litre of distilled water, pH 7.3±0.2)

(15) TABLE-US-00002 Pancreatic digest of casein 12.0 g Peptic digest of animal tissue 5.0 g Yeast extract 3.0 g Beef extract 3.0 g Corn starch 1.0 g Sodium chloride 5.0 g Agar 13.5 g Growth factors 4.0 g Defibrinated sheep blood 5.0%

(16) Inoculum:

(17) From the agar plate, some material was removed from a 24 h S. aureus culture using a sterile swab rod and a suspension prepared in 10 ml of sterile distilled water. The density of the suspension was adjusted using the “Densicheck lus” device (biomériex) to a turbidity, according, to McFarland, of 0.5 (corresponds to a density of 1.5×10{circumflex over ( )}8 KBE/ml). Then, the suspension was diluted by means of a 1:1000 dilution step to 10{circumflex over ( )}5 CFU/ml with sterile distilled water (test inoculum). The inoculum was checked by plating 10 μl and 100 μl of inoculum onto blood agar plate (extrapolation of CFU).

(18) Test Surfaces:

(19) The test surfaces were each divided into 2 sections. Prior to contamination of the surfaces a portion was treated respectively with sterile distilled water, and 70% ethanol (by wiping with a disposable wipe). Then, the test areas were marked with circles. To each portion respectively at 3 marked positions, 10 μl of test inoculum was pipetted. The droplets were then plated using a sterilised spreader rod on the marked surface.

(20) Incubation and Evaluation

(21) After each plating the sterilised spreader rod was immersed in 96% alcohol and flamed. After drying of the suspension at room temperature (10 min, in the laminar flow) a surface marking of the marked position by means of Columbia sheep blood 5%—agar contact plate (application of the contact plate for 5 seconds) was carried out immediately after drying (0 h) after 3 h and after 5 h.

(22) The contact plates were incubated at 35±2° C. for 24 h (without humidity chamber), and then assessed by counting the colonies or a visual assessment of the growth was carried out.

(23) TABLE-US-00003 TABLE 1 Colony forming units (CFU) S. aureus ATCC 6538 after 24 h of incubation at 35 ± 2° C. of the samples. Samples were taken after 0 h, 1 h, 3 h, and contact time of the germ with the test surface (St. = reference) and PHMG (sample from Example 3). S. aureus CFU/10 μl Time St. PHMG (in hours h) (Reference) (Sample from Example 3) 0 More than 10.sup.4 Fewer than 10.sup.3 1 More than 10.sup.3 109 3 840  90 CFU = colony-forming units.

(24) In the treated PHMG laminate here was a very distinct reduction in bacteria from initially fewer than 10.sup.3 colony forming units to only 90 colony forming units.

(25) TABLE-US-00004 TABLE 2 Colony forming units (CFU) E. coli after 24 h of incubation at 35 ± 2° C. of the samples. Samples were taken after 0 h, 1 h and 3 h contact time of the germ with the test surface (St. = reference) and PHMG (sample from Example 3). E.coli CFU/10 μl Time St. PHMG (in hours h) (Reference) (Sample from Example 3) 0 More than 10.sup.4 More than 10.sup.4 1 More than 10.sup.3 More than 10.sup.3 3 More than 10.sup.3 108 CFU = Colony Forming Units.

(26) In the laminate treated with PHMG there was a very distinct reduction in bacteria from initially more than 10.sup.4 colony forming units to only 108 colony forming units.