NOVEL COATED ARTICLES AND THEIR METHOD OF MANUFACTURING AND USE

Abstract

The present invention relates to a coated article, comprising a carrier material and a resin composition, preferably a B-stage resin composition. The invention further relates to the method of preparing said coated article and in particular to the use of said coated articles for the manufacture of shuttering boards.

Claims

1. A coated article comprising a) a carrier material and b) a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate or a mixture of a melamine-formaldehyde (MF)-resin, a urea-formaldehyde (UF)-resin and a phenol-formaldehyde (PF)-resin, or a mixture of the co-condensate and the mixture of the MF-resin, the UF-resin and the PF-resin, wherein the resin composition has a molar ratio of phenol to total formaldehyde in the range from 1:5 up to 1:30 a molar ratio of melamine to total formaldehyde in the range of at least 1:1, and a molar ratio of urea to total formaldehyde in the range of at least 1:1.

2. The coated article according to claim 1, wherein the carrier material is a paper.

3. The coated article according to claim 1, wherein the resin composition has a molar ratio of phenol to total formaldehyde in the range from 1:13 to 1:15, a molar ratio of melamine to total formaldehyde in the range of at least 1:3 and a molar ratio of urea to total formaldehyde in the range of at least 1:4.

4. The coated article according to claim 1, wherein the resin composition has a molar ratio of melamine to total formaldehyde in the range up to a maximum of 1:20, and a molar ratio of urea to total formaldehyde in the range up to a maximum of 1:20.

5. The coated article according to claim 1, wherein the resin composition is a B-stage resin characterized by a degree of crosslinking which is less than 100%.

6. The coated article according to claim 1, wherein the resin composition is characterized by a total content of residual volatiles of at least 3% by weight.

7. The coated article according to claim 1, wherein the article comprises more than 50% by weight of resin based on the weight of the dried coated article.

8. The coated article according to claim 1, wherein the article exhibits a 7 day COBB value of 300 g/m.sup.2 or less.

9. The coated article according to claim 1, wherein the carrier material comprises a second resin composition, which differs from the first resin composition.

10. A method of manufacturing a shuttering board comprising the following steps a) providing a carrier material b) applying a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate or a mixture of a melamine-formaldehyde (MF)-resin, a urea-formaldehyde (UF)-resin and a phenol-formaldehyde (PF)-resin, or a mixture of the co-condensate and the mixture of the MF-resin, the UF-resin and the PF-resin, to the carrier material, wherein the resin composition has a molar ratio of phenol to total formaldehyde in the range from 1:5 up to 1:30, a molar ratio of melamine to total formaldehyde in the range of at least 1:1, and a molar ratio of urea to total formaldehyde in the range of at least 1:1, c) curing the resin composition therewith resulting in a resin composition, wherein the degree of crosslinking is less than 100%.

11. A method of manufacturing a shuttering board according to claim 10, wherein step b) comprises the steps of i. applying a first resin composition to the carrier material and ii. applying a second resin composition to the carrier material, wherein the first resin composition differs from the second resin composition.

12. A shuttering board comprising a) a carrier material, and b) at least one resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate or a mixture of a melamine-formaldehyde (MF)-resin, a urea-formaldehyde (UF)-resin and a phenol-formaldehyde (PF)-resin, or a mixture of the co-condensate and the mixture of the MF-resin, the UF-resin and the PF-resin, wherein the resin composition has a molar ratio of phenol to total formaldehyde in the range from 1:5 up to 1:30, a molar ratio of melamine to total formaldehyde in the range of at least 1:1, a molar ratio of urea to total formaldehyde in the range of at least 1:1, and optionally additives c) a wood.

13. The shuttering board according to claim 12, wherein the carrier material is a paper.

14. The shuttering board according to claim 12, wherein the resin composition has a molar ratio of phenol to total formaldehyde in the range from 1:13 to 1:15, a molar ratio of melamine to total formaldehyde in the range of at least 1:3, and a molar ratio of urea to total formaldehyde in the range of at least 1:4.

15. The shuttering board according to claim 12, wherein the wood is spruce, birch, and/or meranti wood.

16. A shuttering board according to claim 12, obtainable by applying a coated article comprising a carrier and a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate or a mixture of a melamine-formaldehyde (MF)-resin, a urea-formaldehyde (UF)-resin and a phenol-formaldehyde (PF)-resin, or a mixture of the co-condensate and the mixture of the MF-resin, the UF-resin and the PF-resin, to a wood board.

17. A shuttering board according to claim 12, comprising wood and a coated carrier material comprising at least two differing resin compositions each containing phenol, melamine, urea, formaldehyde and optionally additives.

18. A shuttering board according to claim 12, wherein at least one resin composition has a molar ratio of melamine to total formaldehyde in the range up to a maximum of 1:20, and a molar ratio of urea to total formaldehyde in the range up to a maximum of 1:20.

19. The shuttering board according to claim 12, wherein at least one resin composition has a molar ratio of phenol to total formaldehyde in the range from 1:10 up to 1:15, a molar ratio of melamine to total formaldehyde in the range from 1:4 up to 1:8 and a molar ratio of urea to total formaldehyde in the range from 1:3 up to 1:8.

20-23. (canceled)

Description

EXAMPLES

Example 1: Preparation of Resin Compositions and Coated Articles According to the Invention and Comparison of their Free Formaldehyde Emission with a Coated Article Comprising a Phenolic Resin Composition

1.1 Objective

[0187] The objective was to evaluate and compare the free formaldehyde emission of a coated article according to the invention comprising the resin composition A, with the emission of a coated article comprising a phenolic resin composition (composition B).

1.2 Test Setup

[0188] The resin compositions A and B were prepared and utilized to prepare a coated article.

[0189] Composition A is a resin composition comprising a mixture of melamine-formaldehyde, urea-formaldehyde and phenol-formaldehyde. Such a resin composition is described for example in US 2005/0136276.

[0190] The reference composition B is a standard phenolic resin known in the art with a phenol to formaldehyde proportion of 1:1.5.

Preparation of the Test Substrates:

[0191] Coated articles were prepared by impregnating paper or different weight (40 g/m.sup.2, 60 g/m.sup.2 or 80 g/m.sup.2) with either resin composition A or B. The coating step was performed by dipping the paper into a bath.

[0192] The coated articles comprising either composition A or B were prepared by dipping the paper into a resin bath and consecutively dipping the wet paper in a second resin bath. The coated article according to the invention comprises composition A only and the reference coated article comprises a phenolic resin (composition B) only. After applying the resin compositions, the paper was dried.

Free Formaldehyde Emission Test:

[0193] The free formaldehyde emission test specification is based on VDA 275 and was conducted to determine the free formaldehyde emission of the respective films in relation to a blank feed comprising either resin composition A or B.

[0194] A PET bottle filled only with water was part of the measuring as a blank feed.

1.3 Results

[0195] The results of the formaldehyde free emission test are presented in table 1:

TABLE-US-00001 TABLE 1 Results of the free formaldehyde emission test coated article Base paper [g/m.sup.2] Emission [mg/kg] Composition A 40 366 60 495 80 492 Composition B 40 1700 60 1316 80 1502

[0196] The test shows a lower free formaldehyde emission for the coated articles comprising composition A (invention) compared to the coated articles comprising composition B (reference).

Example 2: Testing of Surface Properties of the Coated Article According to the Invention

2.1 Objective

[0197] The objective was to evaluate and compare three different types of coated articles, which were either coated with a resin composition A (invention) or the known phenolic resin (composition B; as above).

2.2 Test Setup

[0198] The following tests have been made to determine and show the surface properties of the coated articles of the invention.

[0199] The coated articles were prepared as described in example 1. In order to evaluate the surface properties of the wood-products resulting from the lamination of different wood bases with the coated article according to the invention, the coated articles were laminated onto a wood base by hot-pressing.

[0200] Further specification of the pressing conditions and the wood bases are listed in the sections below:

Crack Test:

[0201] To establish the risk of cracks of coated articles according to the invention, plywood was laminated under different test conditions, notched with a suitable template and dried under fixed test conditions.

[0202] Cracking (number of cracks, length of cracks) was evaluated after cooling.

Cobb Test:

[0203] The water permeability of article surfaces was determined by the absorbed water quantity through the surface (i.e. COBB values) of the test samples.

[0204] The coated article was pressed on both sides of a plywood and cut to a 12.5×12.5 cm square. After storage of the samples for three weeks in an air-conditioned room the COBB-values were determined as follows:

[0205] The initial weight of the samples was measured and documented and the sample was subsequently strained in the COBB apparatus. The cylinders of the apparatus were filled with deionized water. After 7 days the samples were dried, weighted and the final weight was documented. From the difference between the initial weight and the final weight the COBB value was calculated.

2.3 Results of Tests

Crack Test:

[0206] The results of the crack test are presented in table 2:

TABLE-US-00002 TABLE 2 Results of the crack test Paperweight Crack-index at presstime* Wood material resin [g/m.sup.2] 4 min 6 min 8 min Birch Composition A 40 4 0 0 60 1 1 7,5 80 0 4 41,5 Composition B 40 0 0 8 60 0 0 0 80 0 17 29 Meranti Composition A 40 0 0 0 60 0 0 0 80 0 0 0 Composition B 40 0 0 1,4 60 1,4 0 0 80 0 1,4 0 Composition B 40 83,3 95,8 66,7 *under hot press conditions: 130° C. and 1,8 N/mm.sup.2

[0207] As evident from table 2, the test results reveal that the coated article according to the invention (composition A) shows results comparable to a state-of-the-art phenolic resin composition (composition B). A satisfying crack-index can be obtained in all cases independent from the wood product, the pressing time or the weight of paper used during the test.

Cobb Test:

[0208] The results of the COBB test are depicted in table 4:

TABLE-US-00003 TABLE 4 Results of the COBB test Paperweight COBB value at presstime* Date resin [g/m.sup.2] 4 min 6 min 8 min 24.01.2018 Composition A 40 96 99 77 60 63 43 78 25.01.2018 Composition B 40 488 352 235 60 332 226 165 01.02.2018 Composition A 40 139 130 73 60 79 62 80 01.02.2018 Composition B 40 481 241 165 60 126 123 78 *under hot press conditions: 130° C. and 1,8 N/mm.sup.2

[0209] The evaluation of the COBB test results show clearly that the water permeability of the articles comprising composition A (invention) according to the invention give superior results compared to articles comprising composition B (reference).

Example 3—Testing of Residual Volatiles of the Coated Article According to the Invention

Determination of Residual Volatiles

3.1 Objective

[0210] The residual volatiles of a coated article are determined under fixed drying conditions. The underlying test method can be elaborated following DIN EN ISO 287.

3.2 Test Setup

[0211] The coated article is cut to 20×25 cm. After the preparation of the sample the weight is determined immediately with a precision scale (max. 0.05% tolerance). The initial weight is documented.

[0212] The prepared test sample is placed in a ventilated drying oven at 170±2° C. for 2 minutes. After cooling to room temperature, its dry weight is determined.

3.3 Evaluation

[0213] The volatile content is determined with the following formula:

Volatile content(%)=(initial weight−end weight)×100/initial weight.

[0214] The average value is determined and documented as the residual volatile content.

Example 4—Testing of the Flow of the Resin Compositions in the Coated Article of the Invention

Flow Test

4.1 Objective

[0215] For quantification of the flow after drying the coated article is subjected to pressure at a predetermined temperature in a flow press for a predetermined pressing time.

4.2 Test Setup

[0216] The coated article is cut to 10×10 cm to result in a cubic test sample. After the preparation of the sample its initial weight is determined. The prepared test sample is placed consecutively between two press plates (15×15 cm) at room temperature (25° C.) in a standard flow press. The test sample is pressed at 2.0 N/mm.sup.2 and 160° C. for two minutes and the resulting weight (end weight) is determined after the pressing.

4.3 Evaluation

[0217] The flow can be measured by detecting the percentage change in weight before and after the pressing and is calculated as follows:

Flow %=(initial weight−end weight)×100/initial weight

PREFERRED EMBODIMENTS

Embodiment 1

[0218] A coated article comprising: [0219] a) a carrier material, preferably paper, and [0220] b) a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate, a mixture of a melamine-formaldehyde (MF)-resin, a urea-formaldehyde (UF)-resin and a phenol-formaldehyde (PF)-resin, or a mixture thereof, [0221] wherein the resin composition is a B-stage resin composition.

Embodiment 2

[0222] A coated article comprising: [0223] a) a carrier material, preferably paper, and [0224] b) a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate, a mixture of a melamine-formaldehyde (MF)-resin, a urea-formaldehyde (UF)-resin and a phenol-formaldehyde (PF)-resin, or a mixture thereof, [0225] wherein the resin composition is characterized by a degree of crosslinking which is less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80%.

Embodiment 3

[0226] A coated article comprising: [0227] a) a carrier material, preferably paper, and [0228] b) a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate, a mixture of a melamine-formaldehyde (MF)-resin, a urea-formaldehyde (UF)-resin and a phenol-formaldehyde (PF)-resin, or a mixture thereof, [0229] wherein the resin composition is characterized by a total content of residual volatiles of at least 3% by weight, preferably at least 4% by weight and, more preferably 5% by weight, most preferably, at least 7% by weight.

Embodiment 4

[0230] The coated article according to embodiment 1 or 2, wherein the resin composition is characterized by a total content of residual volatiles of at least 3% by weight, preferably at least 4% by weight and, more preferably 5% by weight, most preferably, at least 7% by weight.

Embodiment 5

[0231] The coated article according to embodiment 1 or 3, wherein the resin composition is characterized by a degree of crosslinking which is less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80%.

Embodiment 6

[0232] The coated article according to any one of the preceding embodiments, wherein the total content of residual volatiles of the coating article is lower than 20% by weight, preferably lower than 15% by weight, more preferably lower than 10% by weight, most preferably the total content of residual volatiles is between 3 and 15% by weight, in particular between 3 and 10% by weight.

Embodiment 7

[0233] The coated article according to any one of the preceding embodiments, wherein the resin composition has a has a flow of at least 1%, preferably of at least 2%, of at least 3% or, most preferably of at least 5% when being pressed for 2 min at 160° C. under 2.0 N/mm.sup.2.

Embodiment 8

[0234] The coated article according to any one of the preceding embodiments, wherein the article comprises more than 50% by weight of resin, preferably at least 55% by weight of resin, most preferably at least 60% by weight of resin based on the weight of the dried coated article.

Embodiment 9

[0235] The coated article according to any one of the preceding embodiments, wherein the resin composition is obtainable by matching at least the following components: [0236] a) a melamine, a urea, a phenol and formaldehyde; or [0237] b) a melamine-formaldehyde (MF)-resin, a urea-formaldehyde (UF)-resin and a phenol-formaldehyde (PF)-resin.

Embodiment 10

[0238] The coated article according to any one of the preceding embodiments, wherein the article exhibits a 7 day COBB value of 300 g/m.sup.2 or less, preferably of 250 g/m.sup.2 or less, more preferably of 200 g/m.sup.2 or less.

Embodiment 11

[0239] The coated article according to any one of the preceding embodiments, wherein the resin composition has a molar ratio of phenol to total formaldehyde in the range of at least 1 to 5, preferably of at least 1 to 8, more preferably of at least 1 to 10, most preferably of at least 1 to 13.

Embodiment 12

[0240] The coated article according to any one of the preceding embodiments, wherein the resin composition has a molar ratio of melamine to total formaldehyde in the range of at least 1 to 1, preferably of at least 1 to 2, most preferably of at least 1 to 3.

Embodiment 13

[0241] The coated article according to any one of the preceding embodiments, wherein the resin composition has a molar ratio of urea to total formaldehyde in the range of at least 1 to 1, preferably of at least 1 to 2, more preferably of at least 1 to 3, most preferably of at least 1 to 4.

Embodiment 14

[0242] The coated article according to any one of the preceding embodiments, wherein less than 40% by weight, more preferably less than 35% by weight, further preferably less than 30% by weight and most preferably less than 20% by weight of the coating layer composition penetrates into the material to be coated.

Embodiment 15

[0243] The coated article according to any one of the preceding embodiments, wherein the carrier material comprises a further resin composition and the resin composition of claim 1b) is not equal to the further resin composition.

Embodiment 16

[0244] The coated article according to any one of the preceding embodiments, wherein the article's overall weight is in the range of at least 80 to 300 g/m.sup.2, preferably of at least 100 to 270 g/m.sup.2, more preferably of at least 115 to 240 g/m.sup.2, most preferably 120 to 220 g/m.sup.2.

Embodiment 17

[0245] The coated article according to any one of the preceding embodiments, wherein the resin composition comprises a further condensation partner of the group consisting of glycol, diamide, sulphonamide, thiourea, lactame, saccharide, guanamine, preferably caprolactame, acetoguanamine, benzoguanamine, dicyandiamide or p-toluene-sulphonamide.

Embodiment 18

[0246] The coated article according to any one of the preceding embodiments, wherein the resin composition comprises a base, preferably a metal hydroxide, more preferably an alkali hydroxide, most preferably sodium hydroxide or potassium hydroxide.

Embodiment 19

[0247] The coated article according to any one of the preceding embodiments, wherein the carrier material is having a weight per square meter of 20 to 100 g/m.sup.2, preferably 30 to 90 g/m.sup.2, most preferably 40 to 80 g/m.sup.2.

Embodiment 20

[0248] The coated article according to any one of the preceding embodiments, wherein the article is further coated with a resin such as an adhesive resin.

Embodiment 21

[0249] A wood-product obtainable by a coated article according to any one of the preceding embodiments 1 to 20.

Embodiment 22

[0250] Wood-product according to embodiment 21, wherein the wood-product is selected from a group consisting of a wood-based panel or a wood-based veneer, more preferably a wood-based panel.

Embodiment 23

[0251] Wood product according to any one of the preceding embodiments 21 or 22, wherein the wood-based panel is selected from a group consisting of wood, plywood, chipboard, blockboard, fibre board, oriented strand board (OSB), glue wood, laminated veneer lumber (LVL), parallel strand lumber (PSL), oriented strand lumber (OSL), 3-layer boards, preferably plywood or blockboard, in particular spruce, birch or meranti plywood.

Embodiment 24

[0252] Method of manufacturing a coated article, in particular a shuttering board for concrete shuttering, comprising the following steps [0253] a) providing a carrier material, [0254] b) applying a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate, a mixture of a melamine-formaldehyde (MF)-resin, a urea-formaldehyde (UF)-resin and a phenol-formaldehyde (PF)-resin, or a mixture thereof to the carrier material. [0255] c) optionally curing the resin composition therewith resulting in a B-stage resin composition.

Embodiment 25

[0256] Method of manufacturing a coated article, in particular a shuttering board for concrete shuttering, comprising the following steps [0257] a) providing a carrier material, [0258] b) applying a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate, a mixture of a melamine-formaldehyde (MF)-resin, a urea-formaldehyde (UF)-resin and a phenol-formaldehyde (PF)-resin, or a mixture thereof to the carrier material. [0259] c) optionally curing the resin composition therewith resulting in a resin composition,
wherein the degree of crosslinking is less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80%.

Embodiment 26

[0260] Method of manufacturing a coated article, in particular a shuttering board for concrete shuttering, comprising the following steps [0261] a) providing a carrier material, [0262] b) applying a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate, a mixture of a melamine-formaldehyde (MF)-resin, a urea-formaldehyde (UF)-resin and a phenol-formaldehyde (PF)-resin, or a mixture thereof to the carrier material. [0263] c) optionally curing the resin composition therewith resulting in a resin composition,
wherein the total content of residual volatiles of the coated article is at least 3% by weight, preferably at least 4% by weight, more preferably at least 5% by weight and, most preferably at least 7% by weight.

Embodiment 27

[0264] Method of manufacturing a coated article according to any of the preceding embodiments 24 to 26,

comprising the following steps [0265] a) providing a paper, [0266] b) applying a first resin composition to the paper, [0267] c) applying a second resin composition to the paper according to the invention described herein, [0268] d) optionally curing the first and second resin composition therewith resulting in a B-stage of the first and second resin composition.

Embodiment 28

[0269] The method of manufacturing according to any of the preceding embodiments 24, 25 or 27, wherein the total content of residual volatiles in the coated article is at least 3% by weight, preferably at least 5% by weight and, most preferably, at least 7% by weight.

Embodiment 29

[0270] Use of a coated article according to any of the preceding embodiments 1 to 20, for preparing the wood-product according to any of the preceding embodiments 21 to 23.

Embodiment 30

[0271] Use of a coated article according to any of the preceding embodiments 1 to 20, for preparing a shuttering board for concrete shuttering.

VERY PREFERRED EMBODIMENTS

[0272] 1. A coated article comprising [0273] a) a carrier material, preferably paper, and [0274] b) a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate or a mixture of a melamine-formaldehyde (MF)-resin, a urea-formaldehyde (UF)-resin and a phenol-formaldehyde (PF)-resin, or a mixture of the co-condensate and the mixture of the MF-resin, the UF-resin and the PF-resin, [0275] wherein the resin composition has [0276] a molar ratio of phenol to total formaldehyde in the range of at least 1 to 5, preferably of at least 1 to 8, more preferably of at least 1 to 10, most preferably of at least 1 to 13, [0277] a molar ratio of melamine to total formaldehyde in the range of at least 1 to 1, preferably of at least 1 to 2, most preferably of at least 1 to 3 and [0278] a molar ratio of urea to total formaldehyde in the range of at least 1 to 1, preferably of at least 1 to 2, more preferably of at least 1 to 3, most preferably of at least 1 to 4. [0279] 2. The coated article according to embodiment 1, wherein the resin composition is a B-stage resin composition. [0280] 3. The coated article according to embodiment 1 or 2, wherein the resin composition has [0281] a molar ratio of phenol to total formaldehyde in the range up to a maximum of 1 to 30, preferably up to a maximum of 1 to 25, most preferably up to a maximum of 1 to 20, [0282] a molar ratio of melamine to total formaldehyde in the range up to a maximum of 1 to 20, preferably up to a maximum of 1 to 15, most preferably up to a maximum of 1 to 10 and [0283] a molar ratio of urea to total formaldehyde in the range up to a maximum of 1 to 20, preferably up to a maximum of 1 to 15, most preferably up to a maximum of 1 to 10. [0284] 4. The coated article according to any one of the preceding embodiments, wherein the resin composition is characterized by a degree of crosslinking which is less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80 [0285] 5. The coated article according to any one of the preceding embodiments, wherein the resin composition is characterized by a total content of residual volatiles of at least 3% by weight, preferably of at least 4% by weight, more preferably of at least 5% by weight and, most preferably, of at least 7% by weight. [0286] 6. The coated article according to any one of the preceding embodiments, wherein the article comprises more than 50% by weight of resin, preferably at least 55% by weight of resin, most preferably at least 60% by weight of resin based on the weight of the dried coated article. [0287] 7. The coated article according to any one of the preceding embodiments, wherein the resin composition is obtainable by matching at least the following components: [0288] a) a melamine, a urea, a phenol and formaldehyde; [0289] or [0290] b) an MF-resin, a UF-resin and a PF-resin. [0291] 8. The coated article according to any one of the preceding embodiments, wherein the article exhibits a 7 day COBB value of 300 g/m.sup.2 or less, preferably of 250 g/m.sup.2 or less, more preferably of 200 g/m.sup.2 or less. [0292] 9. The coated article according to any one of the preceding embodiments, wherein the carrier material comprises a further resin composition and the resin composition of embodiment 1b), embodiment 2 or embodiment 3 is not equal to the further resin composition. [0293] 10. The coated article according to any one of the preceding embodiments, wherein the resin composition comprises a base, preferably a metal hydroxide, more preferably an alkali hydroxide, most preferably sodium hydroxide or potassium hydroxide. [0294] 11. A wood product, in particular a shuttering board, obtainable by applying the coated article according to any one of embodiments 1 to 10 to a wood board. [0295] 12. Method of manufacturing a coated article, in particular a shuttering board for concrete shuttering, comprising the following steps [0296] a) providing a carrier material, preferably paper, [0297] b) applying a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate or a mixture of a melamine-formaldehyde (MF)-resin, a urea-formaldehyde (UF)-resin and a phenol-formaldehyde (PF)-resin, or a mixture of the co-condensate and the mixture of the MF-resin, the UF-resin and the PF-resin, to the carrier material, [0298] c) curing the resin composition therewith resulting in a resin composition, wherein the degree of crosslinking is less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80%. [0299] 13. Method of manufacturing a coated article, in particular a shuttering board for concrete shuttering, comprising the following steps [0300] a) providing a paper, [0301] b) applying a first resin composition to the paper, [0302] c) applying a second resin composition to the paper, wherein the first resin composition differs from the second resin composition [0303] d) curing the first and second resin composition therewith resulting in B-staged resin compositions. [0304] 14. Method of manufacturing a coated article, in particular a shuttering board for concrete shuttering, comprising the following steps [0305] a) providing a paper, [0306] b) applying a first resin composition to the paper, [0307] c) applying a second resin composition to the paper, wherein the first resin composition differs from the second resin composition [0308] d) curing the first and second resin composition therewith resulting in resin compositions, [0309] wherein the degree of crosslinking is less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80%. [0310] 15. Use of a coated article according to any of the preceding embodiments 1 to 10, for preparing a wood product. [0311] 16. The wood product, in particular the shuttering board, according to embodiment 11, wherein the coated article is applied to the wood board by hot pressing. [0312] 17. A shuttering board obtainable by applying a coated article comprising a carrier material, preferably paper, and a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate or a mixture of a melamine-formaldehyde (MF)-resin, a urea-formaldehyde (UF)-resin and a phenol-formaldehyde (PF)-resin, or a mixture of the co-condensate and the mixture of the MF-resin, the UF-resin and the PF-resin, to a wood board. [0313] 18. A shuttering board comprising wood, preferably spruce, birch and/or meranti wood and a coated carrier material, preferably paper comprising at least one resin composition containing phenol, melamine, urea, formaldehyde and optionally additives. [0314] 19. A shuttering board comprising wood, preferably spruce, birch and/or meranti wood and a coated carrier material, preferably paper comprising at least two differing resin compositions each containing phenol, melamine, urea, formaldehyde and optionally additives. [0315] 20. The shuttering board according to embodiment 18 or 19, wherein the at least one resin composition has [0316] a molar ratio of phenol to total formaldehyde in the range of at least 1 to 5, preferably of at least 1 to 8, more preferably of at least 1 to 10, most preferably of at least 1 to 13, [0317] a molar ratio of melamine to total formaldehyde in the range of at least 1 to 1, preferably of at least 1 to 2, most preferably of at least 1 to 3 and [0318] a molar ratio of urea to total formaldehyde in the range of at least 1 to 1, preferably of at least 1 to 2, more preferably of at least 1 to 3, most preferably of at least 1 to 4. [0319] 21. The shuttering board according to embodiment 18, 19 or 20, wherein the at least one resin composition has [0320] a molar ratio of phenol to total formaldehyde in the range up to a maximum of 1 to 30, preferably up to a maximum of 1 to 25, most preferably up to a maximum of 1 to 20, [0321] a molar ratio of melamine to total formaldehyde in the range up to a maximum of 1 to 20, preferably up to a maximum of 1 to 15, most preferably up to a maximum of 1 to 10 and [0322] a molar ratio of urea to total formaldehyde in the range up to a maximum of 1 to 20, preferably up to a maximum of 1 to 15, most preferably up to a maximum of 1 to 10. [0323] 22. The shuttering board according to any one of embodiments 18 to 21, wherein the at least one resin composition has [0324] a molar ratio of phenol to total formaldehyde in the range from 1:10 up to 1:15, [0325] a molar ratio of melamine to total formaldehyde in the range from 1:4 up to 1:8 and [0326] a molar ratio of urea to total formaldehyde in the range from 1:3 up to 1:8. [0327] 23. The shuttering board according to any one of embodiments 18 to 22 for concrete shuttering.