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 with at least one resin layer provided on at least one side of the support material wherein the at least one resin layer comprises a modified resin made of at least one formaldehyde resin, at least one polymer selected from a group containing polyacrylates, polyepoxides, polyesters, polyurethanes and long-chain silanols, and at least one silane-containing compound of the general formula (I)
R.sub.aSiX.sub.(4-a)(I), and/or a hydrolysis product thereof, where X is H, OH, or a hydrolysable moiety selected from the group containing halogen, alkoxy, carboxy, amino, monoalkylamino, dialkylamino, aryloxy, acyloxy, and alkylcarbonyl, R is a non-hydrolysable organic moiety R-selected from the group containing alkyl, aryl, alkenyl, substituted and unsubstituted alkynyl, and cycloalkyl, all of which can be interrupted by O or NH, and where R can have at least one functional group Q selected from a group containing a hydroxy, ether, amino, monoalkylamino, dialkylamino, anilino, amide, carboxy, mercapto, alkoxy, aldehyde, alkylcarbonyl, epoxide, alkenyl, alkynyl, acrylic, acryloxy, methacrylic, methacryloxy, cyano and isocyano group, and a is 0, 1, 2 or 3.

2. The support material as claimed in claim 1, wherein the support material takes the form of a support sheet, paper layer, film layer, or fabric layer.

3. The support material as claimed in claim 1, wherein the support material has been impregnated to some extent or completely by the resin layer.

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

5. The support material as claimed in claim 1, wherein poly(meth)acrylates are used as polyacrylate, aliphatic polyepoxides (polyalkyldiepoxides) or aromatic polyepoxides are used as polyepoxides, and aliphatic polyurethanes are used as polyurethanes.

6. The support material as claimed in claim 1, wherein the mass ratio of formaldehyde resin and polymer is in a range between 20:80.

7. The support material as claimed in claim 1, wherein the number of resin layers arranged on the support material is more than one.

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

9. A flexible laminate comprising at least one support material as claimed in claim 1, where the support material is a decorative paper layer, overlay paper layer, or kraft paper layer impregnated by the modified resin.

10. The laminate as claimed in claim 9, wherein, in addition to the at least one paper layer impregnated by the modified resin, there is at least one paper layer not impregnated by the modified resin, at least one transparent paper layer (parchmentized paper), and/or at least one plastics film layer provided.

11. The laminate as claimed in claim 9, comprising at least two paper layers impregnated by the modified resin.

12. The laminate as claimed in claim 11, comprising at least one overlay paper layer impregnated by the modified resin and at least one kraft paper layer impregnated by the modified resin, or at least one decorative paper layer impregnated by the modified resin and at least one kraft paper layer impregnated by the modified resin.

13. A process for the production of a laminate as claimed in claim 9 comprising: provision of at least one paper layer impregnated by the resin, provision of at least one paper layer not impregnated by the resin, and/or at least one transparent paper layer, and/or one plastics film layer, production of a layer system made of a paper layer impregnated by the resin, a paper layer not impregnated by the resin, a transparent paper layer, and/or a plastics film layer, and pressing of the layer system in a hot press.

14. A sheet comprising a support sheet with at least one laminate as claimed in claim 9 provided on at least one side of the support sheet.

15. The sheet as claimed in claim 14, wherein the support sheet used is a sheet consisting of a wood-based material, of plastic, of a wood-based material/plastic blend, or of a composite material, a cement fiberboard, a plasterboard, and/or a wood-plastic composite sheet.

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

17. The support material as claimed in claim 2, wherein the paper layer comprises an overlay paper layer, kraft paper layer, or decorative paper layer.

18. The support material as claimed in claim 6, wherein the mass ratio is in a range between 30:70.

19. The process as claimed in claim 13, wherein the hot press comprises a continuous press, a batch press, or a twin-belt press.

20. The sheet as claimed in claim 15, wherein the composite material comprises particleboard, medium-density fiberboard, high-density fiberboard, oriented-strand board, or plywood sheet.

Description

[0119] The invention is explained in more detail below on the basis of a number of inventive examples, with reference to the figures, which show:

[0120] In FIG. 1, MDF/HDF, on the upper side of which there is a modified resin layer provided;

[0121] In FIG. 2, a first embodiment of the flexible laminate;

[0122] In FIG. 3, a second embodiment of the flexible laminate; and

[0123] In FIG. 4, a third embodiment of the flexible laminate.

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

[0124] 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.

[0125] Thermal conductivity is adjusted by adding 3 g of hollow beads (K20 from 3M). Acronal DS 3591 is used here to increase resilience.

[0126] 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.

[0127] 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.

[0128] 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

[0129] 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.

[0130] 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.

[0131] 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.

[0132] 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

[0133] FIG. 2 shows the layer structure of a first embodiment of the laminate of the invention.

[0134] 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.

[0135] 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.

[0136] 50 g of a melamine resin mixture (without initiator) are heated to 50? C. 1.78 g of methyltriethoxysilane are then added thereto.

[0137] 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.

[0138] 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).

[0139] 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

[0140] FIG. 3 shows the layer structure of a second embodiment of the laminate of the invention.

[0141] 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.

[0142] 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.

[0143] 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).

[0144] 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

[0145] FIG. 4 shows the layer structure of a third embodiment of the laminate of the invention.

[0146] 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.

[0147] 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.

[0148] 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).

[0149] 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.