CN101636265A - New composite materials, their methods of manufacture and their applications - Google Patents

Abstract

New composite, their manufacture method and application thereof.The present invention relates to the manufacturing of new composite; particularly be suitable as the material in the internal structure; be used for lining; structure and the composite that is used to make furniture and similar products; and the method for making composite; this method comprises the following steps: a) to provide carrier; b) at least one surface of carrier, apply the fabric face structure; the fabric face structure contains the adhesive of at least a B of being in level state; and contain at least a functional material; c) will under the effect of pressure and heat, carry out lamination according to the structure that step b) obtains; so that accept its final sclerosis, d) apply other protective layer and the drying of one deck at least alternatively with the adhesive that B level state exists.

Description

New composite materials, their methods of manufacture and their applications

The present invention relates to new composite materials, in particular composite materials suitable for use as materials in interior structures, for linings, structures and for the manufacture of furniture and similar products.

Composite materials are increasingly replacing traditional building materials as structural materials and they must be adapted for a wide variety of applications. Therefore, sufficient mechanical stability is required on the one hand, and good working properties and low weight are also required on the other hand. Therefore, there has never been a shortage of attempts to improve existing composite materials.

It is therefore known to mix woody materials produced from ground wood and using adhesives with other such materials. In this regard, the two materials are usually laminated and form a composite. The choice and combination of materials can improve mechanical properties while also achieving, for example, weight savings.

Composite materials based on wood materials and nonwovens reinforced with "B" class adhesives are known from WO 2006/031522. Substrate nonwovens are known from, for example, US-A-5,837,620, US-A-303,207 and US-A-6,331,339. The cited publications disclose in a general manner that further additives can be added to the adhesive and/or the nonwoven, but no more detailed data are given.

Therefore, there is the task of optimizing known products in terms of applied technical properties and manufacturing processes.

The subject of the invention is a method of manufacturing a composite material comprising the steps of:

a) provide the carrier,

b) applying a textile surface structure on at least one surface of the carrier, the textile surface structure containing at least one adhesive in the state of class B and containing at least one functional material,

c) laminating the structure obtained according to step b) under the action of pressure and heat, so that the adhesive present in the B-stage state undergoes its final hardening,

d) Optionally applying at least one further protective layer and drying.

The carriers used in step a) are preferably wooden materials, paper, cork, cardboard, mineral boards and/or so-called honeycombs. Honeycombs are structural components with a three-dimensionally reinforced structure which, thanks to their structure (bee honeycomb structure), makes it possible to have an extraordinary stability and strength combined with a low weight. Such honeycombs have been used for some time in many fields of application, including also as internal reinforcement for structural areas or panel elements in furniture.

Wood-based materials are wood-based materials in the form of boards or long strands produced by mixing different wood particle forms with natural and/or synthetic binders in a heat-pressing process. Wood-based materials used in the present invention preferably comprise plywood or laminated boards, wood chip materials especially particle boards and OSB (oriented strand boards), wood fiber materials especially porous wood fiberboards, open diffused wood fiberboards, rigid (high density) wood fiberboards ( HDF) and Medium Density Fiberboard (MDF), as well as Arboform. Arboform is a thermoplastic working material for lignin and other wooden components.

The paper is preferably paper based on natural, synthetic, inorganic or ceramic fibers, or mixtures of these fiber types.

The paperboard is preferably a paperboard based on natural and/or synthetic fibers, also containing inorganic and/or ceramic fibers and mixtures of these fiber types.

The mineral boards are preferably commercially available mineral paperboards with a paperboard coating on both sides, gypsum fiberboards, ceramic fiberboards, cement boards or limeboards. Optionally, the board can be reinforced with natural and/or synthetic fibers, wherein these fibers can also contain inorganic and/or ceramic fibers. The reinforcing fibers can be present in the form of long fibers, microfilaments or as staple fibers.

In addition to the materials described, the carrier can also consist of cork or other plant material.

The weight per unit area of the carrier contained in the composite material varies with the final application without any specific limitation.

The textile surface structures used in step b) are all structures made of fibers from which the textile surface is produced by surface forming techniques.

Textile surface structures provided with B-stage adhesives can basically also be used without adhesives, in particular chemical adhesives. However, in order to ensure the required strength of the surface structure in further work, adhesives can be introduced and/or known needling methods can be used. In addition to the possibility of mechanical reinforcement, for example by calendering or needling, hydraulic needling is particularly noteworthy here. Chemical and/or thermoplastic adhesives are suitable as adhesives.

However, the fabric surface structure provided with B-stage adhesive is preferably pre-reinforced with a chemical adhesive. The adhesive used may be the same or different, but must be selected from an adhesive system compatible with the B-stage adhesive. The additional binder component is at most 25% by weight, preferably 10% by weight or less; the minimum content is 0.5% by weight, preferably at least 1% by weight.

The fiber-forming material is preferably natural fibers and/or fibers of synthetic or natural polymers, ceramic fibers, inorganic fibers or glass fibers, which can also be used in the form of mixtures. Textile surfaces that come into consideration are tissues, pads, knitted fabrics, knitted fabrics and nonwovens, preferably nonwovens.

Textile surfaces of mineral and ceramic fibers are aluminum silicate fibers, ceramic fibers, dolomite fibers, wollastonite fibers or hard rubber fibers, preferably basalt fibers, diabase fibers and/or porphyrite fibers, especially basalt fibers . Diabase and porphyrite are collectively designated as paleobasalts and diabase is also often designated as greenstone.

The mineral fiber nonwoven may be formed from long fibers, ie infinitely long fibers, or from staple fibers. The average length of the staple fibers in the nonwoven of mineral fibers used in the present invention is 5 to 120 mm, preferably 10 to 90 mm. In a further embodiment of the invention, the mineral fiber nonwoven contains a mixture of endless fibers and staple fibers. The mineral fibers have an average fiber diameter of 5 to 30 μm, preferably 8 to 24 μm, particularly preferably 8 to 15 μm.

The weight per unit area of the surface structure of the inorganic salt fiber fabric is between 15 and 500 g/m ² , preferably between 40 and 250 g/m ² , where these figures refer to the surface structure without binder.

In the case of glass fiber fabric fibers, nonwovens are particularly preferred. They consist of long fibres, ie fibers of infinite length or staple fibres. The average length of the staple fibers is between 5 and 120 mm, preferably 10 to 90 mm. In another embodiment of the present invention, the glass fiber nonwoven comprises a mixture of infinitely long fibers and staple fibers.

The average fiber diameter of the glass fibers is between 5 and 30 μm, preferably between 8 and 24 μm, particularly preferably between 10 and 21 μm.

In addition to the previously cited diameters, so-called glass microfibers can also be used. The preferred average diameter of the glass microfibers is between 0.1 and 5 μm. The microfibres forming the surface of the fabric may also be present in admixture with other fibers, preferably glass fibres. Furthermore, layered structures of microfibers and glass fibers are also possible.

In addition, the textile surface structure can also be reinforced with fibres, threads or long fibres. The reinforcing threads are preferably multi-strand filaments or rovings based on glass, polyester, carbon or metal. The reinforcing threads can be used as such or also in the form of textile surface structures, such as fabrics, padding, knits, knits or nonwovens. The reinforcement preferably comprises parallel layers of threads or pads.

The weight per unit area of the glass fiber fabric surface structure is between 15 and 500 g/m ² , preferably between 40 and 250 g/m ² , where these figures refer to the surface structure without binder.

Suitable glass fibers include fibers made from A-glass, E-glass, S-glass, T-glass or R-glass.

The fabric surface can be produced according to any known method. For glass nonwovens, dry or wet lay-up methods are preferred.

Among the fabric surfaces of fibers of synthetic polymers, preference is given to nonwovens, especially so-called spun bonds, ie spunbond nonwovens produced by entangling deposited melt-spun long fibers. They consist of endless synthetic fibers of melt-spinnable polymer material. Suitable polymeric materials are, for example, polyamides, such as polyhexamethylene diadipamide, polycaprolactam, aromatic or partially aromatic polyamides (“aromatic polyamides”), aliphatic polyamides, such as Nylon, partially aromatic or fully aromatic polyesters, polyphenylene sulfide (PPS), polymers with ether and ketone groups such as polyetherketone (PEK) and polyetheretherketone (PEEK), polyolefins, For example polyethylene or polypropylene, cellulose or polybenzimidazole. In addition to the synthetic polymers described above, even those spun from solution are suitable.

The spunbond nonwoven preferably consists of melt-spinnable polyester. In principle, all known types of polyester materials suitable for producing fibers are considered to be polyester materials. Particularly preferred polyesters contain at least 95 mole percent polyethylene terephthalate (PET), especially those unmodified PETs.

If the composite materials according to the invention should additionally have a flame-retardant effect, they are advantageously spun from polyesters modified in a flame-retardant manner. These polyesters modified in a flame-retardant manner are known.

The individual titers of the polyester filaments in the spunbonded nonwoven fabric are 1 to 16 dtex, preferably 2 to 10 dtex.

In a further embodiment of the present invention, the spunbonded nonwoven fabric can also be a bonded fiber fabric hardened by a melt binder and which contains carrier fibers and fusion fibers. The carrier fibers and fusion fibers may be derived from any thermoplastic fiber-forming polymer. These spunbonded nonwovens hardened by means of melt binders are described in EP-A-0,446,822 and EP-A-0,590,629.

In addition to endless endless fibers (spunbonding), the textile surface can also be constructed of staple fibers or a mixture of staple fibers and endless endless fibers. The individual titer of the staple fibers in the nonwoven is 1 to 16 decitex, preferably 2 to 10 decitex. The fiber length is 1 to 100 mm, preferably 2 to 500 mm, particularly preferably 2 to 30 mm. The textile surface structure can also be constructed from fibers of different materials in order to be able to obtain special properties.

In addition, the textile surface structure can also be reinforced with fibres, threads or long fibres. The reinforcing threads are preferably multi-strand filaments or rovings based on glass, polyester, carbon or metal. The reinforcing threads can be used as such or also in the form of textile surface structures, such as fabrics, padding, knits, knits or nonwovens. The reinforcement preferably comprises parallel layers of threads or pads.

The long fibers and/or staple fibers making up the bonded fiber web may have a substantially circular cross-section or other shapes, such as dumbbell, kidney, triangular or trilobal or multilobal cross-sections. Even hollow fibers and bicomponent or multicomponent fibers can be used. Additionally, the fusion fibers may be used in the form of bicomponent or multicomponent fibers.

The fibers forming the surface structure of the textile may be modified with conventional additives, for example with antistatic agents, such as carbon black.

The fabric surface structure of the fibers of the synthetic polymer has a weight per unit area of 10 to 500 g/m ² , preferably 20 to 250 g/m ² .

The natural fibers are plant fibers, fibers derived from grass, straw, wood, bamboo, reed and bast, or fibers of animal origin. Vegetable fiber is a general term and represents seed fibers such as cotton, kapok or poplar fluff, bast fibers such as bamboo, hemp, jute, flax or ramie, hart fibers such as sisal or abaca, or fruit fibers , such as coconut. Fibers of animal origin are wool, animal hair, feathers and silk.

The weight per unit area of the textile surface structure of natural fibers is from 20 to 500 g/m ² , preferably from 40 to 250 g/m ² .

The fabric surface of fibers of natural polymers is cellulosic fibers such as viscose or vegetable or animal protein fibers.

Among the fabric surfaces of cellulose fibers, nonwoven fabrics are particularly preferred. They are constructed from long fibers, ie infinitely long fibers, and/or staple fibers. The average length of the staple fibers is 1 to 25 mm, preferably 2 to 5 mm.

The average diameter of the cellulose fibers is 5 to 50 μm, preferably 15 to 30 μm.

The textile surface structure applied to at least one side of the carrier used in step b) contains at least one adhesive in the B-stage state.

Class B adhesives represent adhesives which are only partially strengthened or hardened, but which can still be finally hardened by, for example, thermal post-treatment. Such B-stage adhesives are described in detail in US-A-5,837,620, US-A-6,303,207 and US-A-6,331,339. The B-stage adhesives disclosed there are also the subject matter of this specification. B-stage binders are preferably binders based on furfuryl alcohol formaldehyde, phenol formaldehyde, melamine formaldehyde, urea formaldehyde and mixtures thereof. Preferably an aqueous system is involved. Other preferred binder systems are formaldehyde-free binders. B-grade adhesives are distinguished in that they can be multi-stage hardened, that is, after the first hardening or first batch of hardening, they still have sufficient adhesive capacity to make them suitable for further processing. Such adhesives typically cure in one step with the addition of a catalyst at a temperature of about 350°F.

These binders are optionally cured upon addition of a catalyst in order to form a B-stage state. The amount of hardening catalyst is at most 10% by weight, preferably 0.25 to 7% by weight (relative to the total amount of binder). For example, ammonium nitrate and organic aromatic acids such as maleic acid and p-toluenesulfonic acid are suitable as hardening catalysts because it allows the B-stage state to be reached more quickly. With the exception of ammonium nitrate, maleic acid and p-toluenesulfonic acid, all materials with comparable acidic functionality are suitable as hardening catalysts. To achieve the B-stage condition, the fabric surface structure impregnated with the adhesive is dried under the influence of a temperature that does not produce complete hardening. The required processing parameters depend on the chosen binder system.

The lower and upper temperature limits can be influenced by the choice of length of time, and/or by adding or avoiding too large or too strong an acid hardening catalyst and/or optionally by using stabilizers.

The application of the B-stage adhesive to the textile surface structure specified in b) can be carried out by means of all known methods. In addition to being sprayed on, dipped and pressed into, the binder can also be applied by coating or by rotating nozzle heads.

Another preferred method is to apply the B-stage adhesive by applying foam. In the foam application, the adhesive foam is generated by means of a blowing agent in the foam mixture, ie applied to the nonwoven by means of a suitable coating aggregate. In this case, the application can also take place by means of a rotating nozzle head.

In foamed coatings of possibly B-staged binders, there are essentially no restrictions with regard to the blowing agent. A preferred blowing agent is ammonium stearate or succinate added to the binder in an amount of 1 to 5 wt% in dry matter state. In addition, the catalysts already described are mixed therein, if necessary. The foam has a solids content of at least 40%, preferably at least 50%.

The process of foam application allows very flexible process control and allows a wide variety of different product properties to be achieved. In addition to the targeted adjustment of the penetration depth of the foam into the fabric surface, the binder charge and porosity can be varied within wide limits. In addition, the application of foam offers great advantages in terms of process control, especially in terms of the constancy of the solids content during impregnation or coating of the fabric surface, as well as the required control of the manufacturing process on the adhesive surface. Compatibility requirements.

The functional material used according to b) can be applied together with the B-stage binder, for example simultaneously as a mixture or as a separate component, or before or after application of the binder. If the B-stage adhesive is applied by foam application, it is advantageous to apply the functional material together with the foam, or distributed in the foam, or to either on fresh foam.

The functional materials used in step b) are preferably fireproofing agents, materials for the discharge of electrostatic charges, materials for shielding electromagnetic radiation, organic or inorganic pigments, especially colored pigments, which increase the resistance to abrasion and/or sliding Sexual materials, or decorative layers, etc. The functional material is preferably arranged on the side of the textile surface structure facing away from the carrier, and can penetrate at least partially through the nonwoven.

In a modified version of the method, additional binders are added to fix the functional material on the textile surface structure. Here, preference is given to selecting the same binder (B-stage binder) as is present in the surface structure of the textile. The amount of functional material is determined by the subsequent application.

The fire retardant is an inorganic fire retardant, an organophosphorous fire retardant, a nitrogen-based fire retardant or an intumescent fire retardant. Halogenated (brominated and chlorinated) fire retardants can also be used but are not preferred due to their risk assessment. Examples of such halogenated fire retardants are polybrominated diphenyl ethers such as decaBDE, tetrabromobisphenol A and HBCD (hexabromocyclododecane).

Nitrogen based fire retardants are melamine and urea.

Organophosphorus fire retardants are typically aromatic and alkyl phosphoric acid esters. Preference is given to using TCEP (tris(chloroethyl)phosphate), TCCP (tris(chloropropyl)phosphate), TDCCP (tris(dichloroisopropyl)phosphate), triphenylphosphate, trioctylphosphate ester (tris-(2-ethylhexyl) phosphate).

Inorganic fire retardants are typically hydroxides such as aluminum hydroxide and magnesium hydroxide, borates such as zinc borate, ammonium compounds such as ammonium sulfate, red phosphorus, antimony oxides such as antimony trioxide and antimony pentoxide, and/or laminated Silicates such as vermiculite.

Antistatic and electromagnetic shielding effects can be achieved through the use of conductivity-enhancing agents.

Antistatic agents are usually conductive particles. Suitable materials are conductive carbons such as carbon black, graphite and carbon nanotubes (C-nanotubes), conductive plastics, or metals or fibers with metallic components.

Materials used for shielding against electromagnetic radiation are generally electrically conductive materials. They can be built up in the form of foils, granules, fibers or threads of the aforementioned materials and/or textile surface structures.

Inorganic or organic pigments are particulate materials. In addition to fillers such as CaCO ₃ , talc, gypsum or silica, pigments, in particular pigments which are supposed to increase the value of the composite material, can be used in colour.

In addition to adding value, materials that increase suitability for the application are used. Specifically, this is to be understood as an anti-slip cladding as well as a cladding ensuring increased wear protection. Sic and/or _SiO2 particles are preferably used for the anti-slip cladding, the particle size used is preferably 2-5mm. The content is 1-40%, preferably 10-30%. To increase the effectiveness of the cladding and reduce the amount of cladding used, the surface can be further textured.

Similar materials are used for surface reinforcement to improve wear and hardness. However, a particle size of less than 1 mm is used, which can produce a very hard surface.

In case the functional layer is an anti-slip coating, it is advantageous if it or the primary particles exhibit a complete or at least partial function in the textile surface structure and/or in the B-stage binder. Especially in the case of anti-slip coatings and maintenance reinforcements to improve wear and hardness, it is advantageous if the particles are applied to the textile surface structure such that the particles protrude at least partially from the textile surface structure. The roughness obtained, especially for anti-slip claddings, must comply with the requirements of the applicable national standards and regulations.

The decorative layer is a decorative component. This should be understood to include decorative layers and forms that add value to the composite. Examples of such forms are veneer, cork, decorative paper, foil with lacquered wood grain, overlay paper, HPL, CPL (laminates built into layers) or also known as decorative semi-finished products with different colors. pieces of paper or plastic. For their parts, the decorative semi-finished products may contain a B-stage adhesive and/or one or more textile surfaces, preferably nonwovens or nonwoven layers.

The application of the functional material used in step b) is performed by known techniques, depending on the nature of the particular functional material. The application here can also be carried out by means of a rotating spray head.

The lamination of the structure obtained in step b) is carried out in step c) under the action of pressure and heat in such a way that the adhesive, present in the B-stage state, undergoes its final hardening. Lamination can be performed by discontinuous or continuous pressing or by rolling. The parameters of pressure, temperature and dwell time are selected according to the B-stage adhesive used.

The application of the at least one further protective layer and its drying in step d) takes place by known pressure, spraying and painting techniques. The application here can also be carried out by means of a rotating spray head. Drying of the protective layer varies according to the system chosen.

The protective layer is generally a lacquer, such as powder paint, varnish or clear lacquer, preferably a scratch-resistant lacquer which protects the functional layer against mechanical influence or against UV aging.

In a modified version of the method according to the invention, in step b) even only the textile surface structure can be applied together with at least one adhesive in the B-stage state, while the application of the at least one functional material follows step b) in the steps.

The present invention also includes such a method, comprising the steps of:

I) Provide a carrier;

II) applying a textile surface structure on at least one surface of the carrier, the textile surface structure containing at least one binder in the B-stage state;

III) optionally laminating the structure obtained according to step II) under the action of pressure and heat, so that the adhesive present in the B-stage state is partially or completely hardened;

IV) applying at least one functional material on the side of the fabric surface structure away from the carrier;

V) optionally laminating the structure obtained according to step IV) under the action of pressure and heat, so that the adhesive present in the B-stage state undergoes its final hardening,

VI) Optionally applying at least one further protective layer and drying.

Steps I), V) and VI) are identical to the aforementioned steps a), c) and d). The application of the textile surface structure comprising at least one binder in the B-stage state in step II) is carried out according to the same step II) as described above under step b), in which no functional material is present.

The lamination in steps III) and VI) is carried out under pressure and heat, so that the adhesive present in the B-stage state undergoes its partial or final hardening. Lamination can be performed by discontinuous or continuous pressing or by rolling. The parameters of pressure, temperature and dwell time are selected according to the B-stage adhesive used.

The functional materials used in step IV) are those initially described under b), preferably the mentioned fireproof materials, materials for electrostatic charge discharge, materials for shielding against electromagnetic rays, organic or inorganic pigments In particular colored pigments, materials capable of increasing the resistance to abrasion and/or sliding, or decorative layers.

In order to fix the functional material, adhesives can additionally be added to fix the functional material to the textile surface structure. Here, preference is given to selecting the same binder (B-stage binder) as is present in the surface structure of the textile. The content of functional materials is determined by the subsequent application.

The application of the functional material in step IV) is performed by known techniques, depending on the nature of the particular functional material. The application here can also be carried out by means of a rotating spray head.

In the case of B-stage adhesives or other adhesives applied by applying foam, the functional material in step IV) is applied together with or distributed in the foam, or the functional material is applied on the still fresh foam , will be beneficial.

Even the composite material itself is unknown in the prior art, other than the methods described above.

Therefore, other subject matter of the present invention are composite materials, comprising:

a) carrier,

b) at least one textile surface structure applied to at least one of the two sides of the carrier, the surface structure containing at least one final hardened B-stage adhesive,

c) at least one functional material applied on top of or introduced into the textile surface structure provided with the B-stage adhesive, and

d) Optional further protective layers applied on the functional material.

Variations and modifications to the method of the invention are also possible by using selected fabric surface structures.

A further subject-matter of the invention is a method for producing a composite material comprising the steps of:

a) provide the carrier,

b) applying a textile surface structure on at least one surface of the carrier, the textile surface structure containing at least one adhesive in the B-stage state, and wherein the textile surface structure was consolidated before being provided with the B-stage adhesive,

c) optionally applying at least one functional material

d) laminating the structure obtained according to step b) or step c) under the action of pressure and heat, so that the adhesive present in the B-stage state undergoes its final hardening,

e) Optionally applying at least one further protective layer and drying.

The reinforcement of the textile surface structure mentioned in step b) can be effected by mechanical influence of forces, preferably by needling and/or calendering and/or pressing, and/or by chemical and/or thermoplastic adhesives. The adhesive used may be the same or different, but must be selected from an adhesive system compatible with the B-stage adhesive. The additional binder component, ie the binder component distributed to the pre-consolidation, is about 25% by weight, preferably 10% by weight or less; the minimum content is 0.5% by weight, preferably 1% by weight.

The fabric surface structure provided with a B-stage adhesive is preferably pre-reinforced with a chemical adhesive.

The application of the functional material optionally used in step c) is carried out using known techniques, varying according to the nature of the specific functional material. The application or introduction here can also take place by means of rotating spray heads.

Steps d) and e) are then carried out as previously described under steps c) and d).

Given the choice of a pre-reinforced textile surface structure, these composites can be further processed more easily and reduce manufacturing costs.

Therefore, other subject matter of the present invention are semi-finished products, including:

a) the carrier, and

b) At least one textile surface structure applied on at least one of the two sides of the carrier, the surface structure containing at least one adhesive in the state of class B, wherein the textile surface structure has additional reinforcement.

The additional reinforcement of the fabric surface structure mentioned in step b) can take place by mechanical action of forces, preferably by needling and/or calendering and/or pressing, and/or by chemical and/or thermoplastic adhesives. The additional binder used may be the same or different, but must be selected from a binder system compatible with the B-stage binder. The additional binder component, ie the binder component allocated to the pre-consolidation, is a maximum of 25% by weight, preferably 10% by weight or less; a minimum content of 0.5% by weight, preferably a minimum of 1% by weight. Additional reinforcement of the fabric surface structure is preferably performed prior to application of the B-stage adhesive. The fabric surface structure provided with B-stage adhesive is preferably pre-secured with a chemical adhesive.

With a high degree of pre-reinforcement, changeovers in production can be realized more easily and quickly and thus more economically. This flexibility results in significant economic advantages.

Where the aforementioned semi-finished products have been provided with functional materials, they have become finished composite materials.

A further subject-matter of the invention is therefore a semi-finished product comprising at least one textile surface structure with at least one adhesive in the B-class state and with additional reinforcement of the textile surface structure.

Therefore, a further subject matter of the present invention is a composite material comprising:

a) carrier,

b) at least one textile surface structure applied on at least one of the two sides of the carrier, the surface structure containing at least one final hardened B-stage adhesive, and wherein the textile surface structure has additional reinforcement,

c) at least one functional material applied on top of or introduced into the textile surface structure provided with the B-stage adhesive, and

d) Optional further protective layers applied on the functional material.

The additional reinforcement of the textile surface structure mentioned in step b) has already been described above. The same is true for the carrier, B-stage adhesive, functional material and protective layer.

Furthermore, the invention also encompasses decorative semi-finished products, in particular CPL and HPL, comprising at least one textile surface structure comprising B-stage adhesive, preferably a nonwoven comprising at least one functional layer.

CPL and HPL are typically constructed of several layers, usually 2-50, of kraft paper impregnated with melamine, MUF or phenol B-grade binders. In cases where these CPL's and/or HPL's contain at least one nonwoven fabric containing a B-stage binder, the number of layers of kraft paper used to completely replace the paper layers can be significantly reduced.

The use of a nonwoven with B-stage binder reduces the number of kraft paper layers by at least one, but preferably by at least 50%, while maintaining the same properties of the laminate. The reduction in the amount of binder-impregnated kraft paper allows for an increase in the fire rating, which can be extended to the "non-combustible" category.

A further subject matter of the present invention is therefore decorative semi-finished products, in particular comprising at least one textile surface structure, preferably nonwoven CPL and/or HPL, containing a B-stage adhesive, wherein the textile surface structure can also be Pre-reinforced. This can lead to a further reduction in the number of kraft paper layers.

The CPL's and/or HPL's of the present invention preferably have from 1 to 25 layers of nonwoven containing B-stage binder. Additionally, the CPL's and/or HPL's of the present invention may have more layers of kraft paper impregnated with melamine, MUF, or phenol B-grade binders.

The manufacture of decorative semi-finished products is carried out by lamination under the action of pressure and heat in such a way that the adhesive present in the B-stage state is partially or completely hardened. Lamination can be performed by discontinuous or continuous pressing or by rolling. Pressure, temperature and dwell time parameters are selected according to the B-stage adhesive used.

The aforementioned materials are suitable as carriers, textile surface structures, B-class adhesives, functional materials and protective layers. The preferred embodiments disclosed within the scope of the method according to the invention also apply to the composite material according to the invention.

The aforementioned functional material can be present in the form of a separate layer in the B-stage adhesive applied on the side of the textile surface structure facing away from the carrier, or can also completely or partially penetrate the textile surface structure. These embodiments are suitable for functional materials such as fireproofing agents, materials for electrostatic charge discharge, materials for shielding electromagnetic charges, materials for shielding electromagnetic rays, organic or inorganic pigments, especially colored pigments, or decorative layers, etc. .

In a preferred embodiment, the functional material forms a separate layer in the composite material of the invention. This embodiment is particularly suitable for functional materials that have increased resistance to abrasion and/or sliding, and/or that have added value through optical effects on the surface. It is particularly advantageous if the primary particles protrude at least partially from the surface structure of the textile provided with the B-stage adhesive, so that the functional material is produced as an anti-slip material or with increased resistance to abrasion.

The functional material is present in the carrier and/or on the side of the textile surface structure facing away from the carrier.

The composite material according to the invention makes it possible to use it directly for subsequent applications, since the composite material already contains the necessary stocks of functional materials.

In a variant, the application of the textile surface structure equipped in step b) can also take place during the production of the carrier. In other words, instead of the finished support in step a), the support is formed in step a). The formed carrier is pressed together with the equipped textile surface structure, wherein the textile surface structure is suitably introduced into a pressing and/or drying device for the carrier. The manufacture of the carrier-nonwoven composite can be carried out continuously or discontinuously.

Claims (73)

1. make the method for composite, comprise the following steps:

A) provide carrier,

B) apply the fabric face structure at least one surface of carrier, the fabric face structure contains the adhesive of at least a B of being in level state and contains at least a functional material,

C) structure that will obtain according to step b) be carried out lamination under the effect of pressure and heat, so that the adhesive that exists with B level state is accepted its final sclerosis,

D) apply other protective layer and the drying of one deck at least alternatively.

2. the method for claim 1 is characterized in that not providing carrier in step a), but forms carrier.

3. claim 1 or 2 method is characterized in that carrier is wood materials, paper, cork, cardboard, mineral board and/or cellular thing.

4. the method for claim 3 is characterized in that described wood materials is the wood materials of wood shavings shape plate shape or microscler.

5. the method for claim 4, it is characterized in that described wood materials is glued board or laminate, the wood floral material, preferred particieboard and OSB (oriented structure chipboard), wood fiber material, preferred porous wood-fiber board, opening diffusion wood-fiber board, hard (high density) wood-fiber board (HDF) and middle density wood-fiber board (MDF), and Arboform.

6. the method for claim 3 is characterized in that described paper and cardboard are based on the material of following material, and described material is natural, synthetic, mineral or the fiber of pottery or the mixture of these fiber types.

7. the method for claim 3, it is characterized in that described mineral board is the plate that all has pressboard coating two sides, especially plaster board, ceramic beaverboard, cement plate or lime plate, it is optional with natural and/or synthetic fiber reinforcement, and wherein said fiber natural and/or that synthesize can also comprise fiber mineral and/or pottery.

8. each method of claim 1 to 7 is characterized in that described fabric face structure is fabric, lays thing, braid, knitted fabric and/or adhesive-bonded fabric.

9. each method of claim 1 to 8 is characterized in that the fabric face structure can also have fiber, line or long stapled reinforcing.

10. the method for claim 9 is characterized in that gut threads is based on the multiply long fibre or the rove of glass, polyester, carbon or metal, and preferably to be present in the form in the fabric face structure or to exist as parallel line layer.

11. the method for claim 10 is characterized in that gut threads uses with fabric, liner, looped fabric, knit goods or as the form of nonwoven.

12. each method of claim 1 to 11, it is characterized in that described fabric face structure is that fiber, ceramic fibre, mineral fibres or glass fibre by natural fiber and/or synthetic or natural polymer forms, wherein these fibers can also be with the form use of mixture.

13. each method of claim 1 to 11 is characterized in that the mineral fibres nonwoven that described fabric face structure is long fibre and/or staple fiber.

14. the method for claim 13, the average length that it is characterized in that staple fiber is between 5 to 120mm.

15. the method for claim 13 or 14, the fiber diameter that it is characterized in that described mineral fibres are 5 to 30 μ m.

16. each method of claim 1 to 11 is characterized in that described fabric face structure is the fiberglass nonwoven of long fibre and/or staple fiber.

17. the method for claim 16, the average length that it is characterized in that described staple fiber are 5 to 120mm.

18. the method for claim 16 or 17, the average diameter that it is characterized in that described glass fibre are 5 to 30 μ m.

19. the method for claim 16 is characterized in that described fiberglass nonwoven comprises glass microfiber, the average diameter of this glass microfiber is 0.1 to 5 μ m.

20. each method of claim 16 to 19 is characterized in that per unit area weight that described fiberglass nonwoven has is 15 to 500g/m ², wherein these data relate to the surface texture that does not have binding agent.

21. each method of claim 16 to 20 is characterized in that described fiberglass nonwoven is by dry method or wet-laying manufactured.

22. each method of claim 1 to 21 is characterized in that described fabric face structure has the fiber of synthetic polymer.

23. the method for claim 22 is characterized in that described fabric face structure comprises adhesive-bonded fabric, particularly spunbond adhesive-bonded fabric.

24. the method for claim 23 is characterized in that described spunbond adhesive-bonded fabric also comprises staple fiber, preferably has independent fiber number between 1 to 16 dtex and/or the staple fiber of staple length between 1 to 100mm.

25. the method for claim 22, it is characterized in that described adhesive-bonded fabric comprises the fiber of following material, described material is polyester, polyphenylene sulfide (PPS), the polymer with ether and ketone groups, polyolefin, cellulose or the polybenzimidazoles of polyamide (" aromatic polyamides "), fatty polyamide, part armaticity or the complete armaticity of polyamide, polycaprolactam, armaticity or part armaticity.

26. each method of claim 1 to 25 is characterized in that described fabric face structure comprises natural fiber.

27. each method of claim 1 to 13 is characterized in that described fabric face structure has cellulose fibre, preferred form is to have the cellulose fibre that average length is 1 to 25mm staple fiber.

28. the method for claim 1 is characterized in that described B-stage binding agent still can for example experience final sclerosis by hot post processing.

29. the method for claim 28 is characterized in that B level adhesive applies as foam, preferably by rotary nozzle, wherein the latter is contained functional material alternatively.

30. the method for claim 28 is characterized in that described binding agent is the binding agent based on furfuryl alcohol formaldehyde, phenol formaldehyde (PF), melamino-formaldehyde, urea-formaldehyde and their mixture.

31. the method for claim 1, it is characterized in that functional material be fire retardant, the material that is used for discharge electrostatic charges, be used to shield electromagnetic radiation the particularly coloured pigment of material, organic or inorganic pigment, can increase material or decorative layer to the wearing and tearing and/or the resistance of sliding.

32. the method for claim 31, it is characterized in that fireproof agent be inorganic fire agent, organophosphor fireproof agent, based on the fireproof agent or the expansible fireproof agent of nitrogen.

33. the method for claim 31 is characterized in that the material that antistatic additive and being used to shields electromagnetic radiation is the particle with electric conductivity.

34. the method for claim 31 is characterized in that inorganic or organic pigment is a means of particulate material, is preferably CaCO ₃, talcum, gypsum or tripoli.

35. the method for claim 31 is characterized in that functional material is moving covering of antiskid and/or the covering with abrasion protection of increase.

36. the method for claim 35 is characterized in that the moving covering of antiskid comprises SiC and/or SiO ₂Particle, preferred particle size is between 2 to 5mm.

37. the method for claim 35, the covering that it is characterized in that having the abrasion protection of increase comprises SiC and/or the SiO of particle size less than 1mm ₂Particle.

38. the method for claim 31 is characterized in that decorative layer is frosting, the paillon foil with grainer, covering paper, cork, facing paper, HPL (high-pressure laminated plate), CPL (continuous pressure laminate) or the scraps of paper and/or plastic sheet.

39. the method for claim 38 is characterized in that HPL ' s and CPL ' s are ornamental semi-finished product, comprises at least one the fabric face structure that contains B level adhesive, is preferably the nonwoven that contains at least one functional layer.

40. each method of claim 1 to 39 is characterized in that the lamination in the step c) carries out by discontinuous or continuous compacting or by rolling.

41. each method of claim 1 to 40, it is characterized in that in the step d) protective layer by pressure, spray, the technology of spraying paint applies, and preferably passes through rotary nozzle.

42. the manufacturing process of semi-finished comprises:

A) provide carrier,

B) apply the fabric face structure at least one surface of carrier, wherein the fabric face structure contains the adhesive of at least a B of being in level state, and wherein the fabric face structure was reinforced before providing B level adhesive,

C) structure that will obtain according to step b) be carried out lamination under the effect of pressure and heat, so that the adhesive that exists with B level state is accepted its final sclerosis.

43. the method for claim 42 is characterized in that applying in step b) or afterwards at least a functional material.

44. the method for claim 42 is characterized in that applying at least a protective layer and carries out drying after step c).

45. the method for claim 1, it is characterized in that in step b), not existing functional material, apply in its independent step after step b), preferably be right after after step b), and carry out further lamination alternatively, with the fixing functional material that independently applies.

46. composite contains:

A) carrier,

B) be applied at least one fabric face structure in two sides of carrier at least one, described surface texture contains the B level adhesive of at least a final sclerosis,

C) be applied to the top of the fabric face structure that provides B level adhesive or import at least a functional material in the fabric face structure, and

D) be applied to optional other protective layer on the functional material.

47. the composite of claim 46 is characterized in that the fabric face structure has extra reinforcing.

48. the composite of claim 46 or 47 is characterized in that carrier defines in claim 2 to 7.

49. the composite of claim 46 or 47 is characterized in that the fabric face structure defines in claim 8 to 27.

50. the composite of claim 46 or 47 is characterized in that B level adhesive defines in claim 28 to 30.

51. the composite of claim 46 or 47 is characterized in that functional material comprises fire retardant, is used for the material of discharge electrostatic charges, the material that is used to shield electromagnetic radiation, organic or inorganic pigment or decorative layer.

52. the composite of claim 51 is characterized in that functional material further definition in claim 31 to 39.

53. the composite of claim 46 or 47 is characterized in that functional material exists away from the independently form of layer in the B level adhesive on the side of carrier to be applied to the fabric face structure, perhaps also can penetrate the fabric face structure wholly or in part.

54. semi-finished product comprise:

A) carrier, and

B) be applied at least one fabric face structure in two sides of carrier at least one, this fabric face structure contains the adhesive of at least a B of being in level state, and wherein the fabric face structure has extra reinforcing.

55. the semi-finished product of claim 54 is characterized in that carrier defines in claim 2 to 7.

56. the semi-finished product of claim 54 is characterized in that the fabric face structure defines in claim 8 to 27.

57. the semi-finished product of claim 54 is characterized in that B level adhesive defines in claim 28 to 30.

58. the semi-finished product of claim 54 is characterized in that extra reinforcing undertaken by thermoplasticity and/or chemical adhesive, are preferably chemical adhesive.

59. the semi-finished product of claim 54 is characterized in that extra reinforcing by physics needle-punching method, particularly waterpower acupuncture, and/or the effect of pressure, are preferably calendering or compacting is carried out.

60. contain the semi-finished product of at least one fabric face structure, wherein contain the adhesive of at least a B of being in level state, and the fabric face structure have extra reinforcing.

61. the semi-finished product of claim 60 is characterized in that the fabric face structure is defined within the claim 8 to 27.

62. the semi-finished product of claim 60 is characterized in that B level adhesive is defined within the claim 28 to 27.

63. the semi-finished product of claim 60 is characterized in that extra reinforcing undertaken by thermoplasticity and/or chemical adhesive, are preferably chemical adhesive.

64. the semi-finished product of claim 54 is characterized in that extra reinforcing by physics needle-punching method, particularly waterpower acupuncture, and/or the effect of pressure, are preferably calendering or compacting is carried out.

65. ornamental semi-finished product, particularly CPL and HPL comprise at least one the fabric face structure that contains B level adhesive, are preferably to contain at least one ornament as the functional layer and the optional nonwoven of other functional material.

66. the ornamental semi-finished product of claim 65 is characterized in that the fabric face structure, are preferably nonwoven, have extra reinforcing.

67. the ornamental semi-finished product of claim 65 or 67 is characterized in that they contain at least a carrier.

68. the ornamental semi-finished product of claim 65 or 66 is characterized in that they contain fabric face structure between 1 to 25 layer.

69. the ornamental semi-finished product of claim 65 or 66 is characterized in that they also contain several layers with the brown paper of melamine, MUF or phenol B level adhesive-dipping.

70. the ornamental semi-finished product of claim 65 or 66 is characterized in that at least one functional layer is a decorative layer.

71. the composite that uses claim 46 to 53 is as construction material, especially for the cover layer on furniture, wall, ceiling and floor.

72. contain the cover layer on furniture, wall, ceiling and the floor of the composite of claim 46 to 53.

73. use the semi-finished product of definition in the claim 54 to 64, be used for making the ornamental semi-finished product of claim 65 to 70, or be used for making the composite of claim 46 to 53.