Support carrier material with a modified resin layer, and the production thereof

Abstract

A carrier material has a resin layer arranged on a side of the carrier material. The resin layer includes a formaldehyde resin, a polymer selected from a group containing polyacrylates, polyepoxides, polyesters, polyurethanes, and long-chain silanols, and at least one silane-containing compound of general formula (I), R.sub.a SiX.sub.(4-a), and/or the hydrolysis product thereof, where X is H, OH, or a hydrolyzable residue selected from the group comprising halogen, alkoxy, carboxy, amino, monoalkylamino or dialkylamino, aryloxy, acyloxy, alkylcarbonyl; R is a non-hydrolyzable organic residue R selected from the group comprising alkyl, aryl, alkenyl, substituted and unsubstituted alkynyl, cycloalkyl, which can be interrupted by O or NH; and where R can have a functional group Q selected from a group containing a hydroxy, ether, amino, monoalkylamino, dialkylamino, anilino, amide, carboxy, mercapto, alkoxy, aldehyde, alkylcarbonyl, epoxide, alkenyl, alkynyl, acryl, acryloxy, methacryl, methacryloxy, cyano, and isocyano group, and a is 0-3.

Claims

1. A support material comprising: an overlay paper layer partially or completely impregnated with a modified resin, wherein the modified resin comprises: at least one formaldehyde resin; at least one polymer selected from the group consisting of polyacrylates, polyepoxides, polyesters, polyurethanes and long-chain silanols, wherein an amount of polymer in the modified resin is at least 20 wt %; and at least one silane-containing compound of the general formula
R.sub.aSiX.sub.(4-a) and/or a hydrolysis product thereof, where X is alkoxy, R is an alkyl, and a is 0, 1, 2 or 3, wherein the overlay paper layer partially or completely impregnated with the modified resin is provided as an exposed outermost layer in a laminate with at least one paper layer not impregnated with the modified resin, at least one kraft paper layer partially or completely impregnated with the modified resin, and at least one transparent paper layer, and an upper surface of the partially or completely impregnated overlay paper layer is exposed.

2. The support material as claimed in claim 1, wherein the at least one formaldehyde resin is a melamine-formaldehyde resin, a melamine-urea-formaldehyde resin, or a urea-formaldehyde resin.

3. The support material as claimed in claim 1, wherein the polyacrylate is a poly(meth)acrylate, the polyepoxide is an aliphatic polyepoxide (polyalkyldiepoxide) or an aromatic polyepoxide, and the polyurethane is an aliphatic polyurethane.

4. The support material as claimed in claim 1, wherein the mass ratio of formaldehyde resin and polymer is from 20:80 to 80:20.

5. The support material as claimed in claim 1, wherein the modified resin comprises nanoparticles of a size less than 500 nm, fillers, wetting agents, or other additives.

6. The support material as claimed in claim 1, wherein a is 0, 1, or 2.

7. A sheet comprising a support sheet with at least one support material according to claim 1 provided on at least one surface of the support sheet.

8. The sheet of claim 7, wherein the support sheet is a wood-based material, a plastic, or a composite material.

9. The sheet of claim 8, wherein the composite material is a particleboard, a medium-density fiberboard (MDF), a high-density fiberboard (HDF), an oriented-strand board (OSB), a plywood sheet, a cement fiberboard, a plasterboard, or a wood-plastic composite sheet.

10. The support material of claim 1, further comprising a resin layer comprising the modified resin, the resin layer coating at least one surface of the overlay paper layer partially or completely impregnated by the modified resin.

11. A support material comprising: an overlay paper layer partially or completely impregnated with a modified resin, wherein the modified resin comprises: at least one formaldehyde resin; at least one polymer selected from the group consisting of polyacrylates, polyepoxides, polyesters, polyurethanes and long-chain silanols, wherein an amount of polymer in the modified resin is at least 20 wt %; and at least one silane-containing compound of the general formula
R.sub.aSiX.sub.(4-a) and/or a hydrolysis product thereof, where X is alkoxy, R is an alkyl, and a is 0, 1, 2 or 3, wherein the overlay paper layer partially or completely impregnated with the modified resin is provided as an exposed outermost layer in a laminate with at least one paper layer not impregnated with the modified resin, the at least one paper layer not impregnated with the modified resin is a decorative paper layer, and the laminate further comprises at least one kraft paper layer impregnated with the modified resin, and an upper surface of the partially or completely impregnated overlay paper layer is exposed.

12. The support material of claim 11, wherein the laminate further comprises at least one transparent paper.

13. The support material of claim 11, wherein the laminate comprises two transparent paper layers, and, optionally, a backing.

14. The support material of claim 13 comprising the following layer structure in the following order: the overlay paper layer impregnated with the modified resin, a decorative paper layer not impregnated with the modified resin, one transparent paper layer, the at least one kraft paper layer impregnated with the modified resin, another transparent paper layer, and, optionally, the backing comprising a counterbalancing material.

15. A support material comprising: an overlay paper layer partially or completely impregnated with a modified resin, wherein the modified resin comprises: at least one formaldehyde resin; at least one polymer selected from the group consisting of polyacrylates, polyepoxides, polyesters, polyurethanes and long-chain silanols, wherein an amount of polymer in the modified resin is at least 20 wt %; and at least one silane-containing compound of the general formula
R.sub.aSiX.sub.(4-a) and/or a hydrolysis product thereof, where X is alkoxy, R is an alkyl, and a is 0, 1, 2 or 3, wherein the overlay paper layer partially or completely impregnated with the modified resin is provided as an exposed outermost layer in a laminate with at least one kraft paper layer not impregnated with the modified resin and at least one transparent paper layer, and an upper surface of the partially or completely impregnated overlay paper layer is exposed.

16. The support material as claimed in claim 15, wherein the formaldehyde resin is a melamine-formaldehyde resin, a melamine-urea-formaldehyde resin, or a urea-formaldehyde resin and/or the polyacrylate is a poly(meth)acrylate, the polyepoxide is an aliphatic polyepoxide (polyalkyldiepoxide) or an aromatic polyepoxide, and the polyurethane is an aliphatic polyurethane.

17. A sheet comprising a support sheet with at least one support material according to claim 15 provided on at least one surface of the support sheet.

18. The sheet of claim 17, wherein the support sheet is a wood-based material, a plastic, or a composite material.

19. The support material as claimed in claim 11, wherein the formaldehyde resin is a melamine-formaldehyde resin, a melamine-urea-formaldehyde resin, or a urea-formaldehyde resin and/or the polyacrylate is a poly(meth)acrylate, the polyepoxide is an aliphatic polyepoxide (polyalkyldiepoxide) or an aromatic polyepoxide, and the polyurethane is an aliphatic polyurethane.

20. A sheet comprising a support sheet with at least one support material according to claim 11 provided on at least one surface of the support sheet.

21. The sheet of claim 20, wherein the support sheet is a wood-based material, a plastic, or a composite material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention is explained in more detail below on the basis of a number of inventive examples, with reference to the figures, which show:

(2) In FIG. 1, MDF/HDF, on the upper side of which there is a modified resin layer provided;

(3) In FIG. 2, a first embodiment of the flexible laminate;

(4) In FIG. 3, a second embodiment of the flexible laminate; and

(5) In FIG. 4, a third embodiment of the flexible laminate.

DESCRIPTION OF THE INVENTION

INVENTIVE EXAMPLE 1: DEVELOPMENT OF A SURFACE PROVIDING A REALISTIC IMITATION OF WOOD ON MDF/HDF

(6) 50 g of a melamine resin mixture (without initiator) are heated to 50? C. 2.03 g of tetraethyl orthosilicate are then added thereto. 50 g of an aqueous carboxylated polyacrylate from BASF (Acronal DS 3591) are moreover added thereto, with stirring. After addition of 0.25 g of para-toluenesulfonic acid as catalyst, a hydrolysis and condensation reaction is initiated. The mixture is stirred for a further 30 minutes.

(7) Thermal conductivity is adjusted by adding 3 g of hollow beads (K20 from 3M). Acronal DS 3591 is used here to increase resilience.

(8) The ready-to-use hybrid resin is stable in storage for about one day, and can then be further processed in the same way as conventional melamine resins.

(9) The hybrid resin is applied onto MDF/HDF, which has been surface-treated and basecoated, and is pressed. The surface of the MDF/HDF has warm tactile properties providing a realistic imitation of wood.

(10) FIG. 1 depicts a typical layer structure made of MDF/HDF 1 with modified resin layer 2 arranged on the surface.

INVENTIVE EXAMPLE 2: DEVELOPMENT OF A STONE-TYPE SURFACE ON MDF/HDF

(11) 50 g of a melamine resin mixture (without initiator) are heated to 50? C. 1.78 g of methyltriethoxysilane are then added thereto. 50 g of U 9380 from Alberdingk are moreover added thereto, with stirring. After addition of 0.2 g of sulfuric acid (1 molar) as catalyst, a hydrolysis and condensation reaction is initiated. The mixture is stirred for a further 55 minutes.

(12) Hardness and thermal conductivity, and also abrasion resistance, is adjusted by adding 7 g of quartz sand and 3 g of corundum (ZWSK 220, Treibacher). The polyurethane added reduces resilience.

(13) The ready-to-use hybrid resin is stable in storage for about one day, and can then be further processed in the same way as conventional melamine resins.

(14) The hybrid resin is applied onto MDF/HDF, which has been surface-treated and basecoated, and is pressed. The surface of the MDF/HDF has cold, stone-like tactile properties.

INVENTIVE EXAMPLE 3: FIRST EMBODIMENT OF A LAMINATE

(15) FIG. 2 shows the layer structure of a first embodiment of the laminate of the invention.

(16) The layer structure is composed of the following, from the top downward: an overlay paper layer 3a impregnated by modified resina decorative paper layer 4b not modified by the modified resin, with corunduma parchmentized paper layer 5a kraft paper layer 6a impregnated by the modified resin a parchmentized paper layer 5, and optionally a counterbalancing material 7.

(17) The modified resin used for the impregnation of the various paper layers in principle comprises a composition similar to resin compositions mentioned in inventive examples 1 and 2.

(18) 50 g of a melamine resin mixture (without initiator) are heated to 50? C. 1.78 g of methyltriethoxysilane are then added thereto.

(19) 50 g of a polyurethane (U058) from Alberdingk are moreover added thereto, with stirring. After addition of 0.2 g of sulfuric acid (1 molar) as catalyst, a hydrolysis and condensation reaction is initiated. The mixture is stirred for a further 55 minutes.

(20) The modified resin is used for the impregnation of the overlay paper layer (10% by weight of resin) and for the impregnation of the kraft paper layer (45% by weight).

(21) The impregnated and non-impregnated paper layers are then mutually superposed in the abovementioned sequence, and pressed together to give a laminate. The laminate is by way of example laminated onto HDF with thickness 4.5 mm and swelling amounting to 5% edge swelling in accordance with EN 13329 (Q5), and is further processed to give a floor panel.

INVENTIVE EXAMPLE 4: SECOND EMBODIMENT OF A LAMINATE

(22) FIG. 3 shows the layer structure of a second embodiment of the laminate of the invention.

(23) The layer structure is composed of the following, from the top downward: an overlay paper layer 3b not impregnated by the modified resina decorative paper layer 4a impregnated by the modified resina parchmentized paper layer 5a kraft paper layer 6a impregnated by the modified resina parchmentized paper layer 5a kraft paper layer 6 impregnated by the modified resin, and optionally a counterbalancing material 7.

(24) 50 g of a melamine resin mixture (without initiator) are heated to 50? C. 2.03 g of tetraethyl orthosilicate are then added thereto. 50 g of a polyurethane (U058) from Alberdingk are moreover added thereto, with stirring. After addition of 0.25 g of para-toluenesulfonic acid as catalyst, a hydrolysis and condensation reaction is initiated. The mixture is stirred for a further 30 minutes.

(25) The modified resin is used for the impregnation of the decorative paper layer (15% by weight of resin) and for the impregnation of the kraft paper layer (45% by weight).

(26) The impregnated and non-impregnated paper layers are then mutually superposed in the abovementioned sequence, and pressed together to give a laminate. The laminate is by way of example laminated onto MDF, and can be used as sheet for furniture.

INVENTIVE EXAMPLE 5: THIRD EMBODIMENT OF A LAMINATE

(27) FIG. 4 shows the layer structure of a third embodiment of the laminate of the invention.

(28) This type of layer structure can be composed of the following, from the top downward: an overlay paper layer 3a impregnated by the modified resina decorative paper layer 4b not impregnated by the modified resina PET layer 8 as plastics film layer, there being a primer 9 (e.g. based on the isocyanate) provided respectively on the two sides of the plastics film layertwo successive kraft paper layers 6a impregnated by the modified resin, and optionally a counterbalancing material 7.

(29) 50 g of a melamine resin mixture (without initiator) are heated to 50? C. 1.78 g of tetramethoxyilane are then added thereto. 50 g of a polyurethane (U058) from Alberdingk are moreover added thereto, with stirring. After addition of 0.2 g of sulfuric acid (1 molar) as catalyst, a hydrolysis and condensation reaction is initiated. The mixture is stirred for a further 55 minutes.

(30) The modified resin is used for the impregnation of the overlay paper layer (10% by weight of resin) and for the impregnation of the kraft paper layer (45% by weight).

(31) The impregnated and non-impregnated paper layers are then mutually superposed in the abovementioned sequence with the PET layer and pressed together to give a laminate.