CN100374501C - 蜜胺树脂薄片和/或薄膜用于涂覆三维结构表面和/或模制品的用途 - Google Patents

蜜胺树脂薄片和/或薄膜用于涂覆三维结构表面和/或模制品的用途 Download PDF

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CN100374501C
CN100374501C CNB2004800023169A CN200480002316A CN100374501C CN 100374501 C CN100374501 C CN 100374501C CN B2004800023169 A CNB2004800023169 A CN B2004800023169A CN 200480002316 A CN200480002316 A CN 200480002316A CN 100374501 C CN100374501 C CN 100374501C
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J·德歇尔
M·马丁-波图格斯
G·施尔
S·魏因克茨
K·菲舍尔
R·A·格罗斯
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Abstract

本发明涉及由含有纤维素的纤维材料制成的蜜胺树脂薄片和/或薄膜用于涂覆三维结构表面和/或模制品的用途,该纤维材料用含有(i)蜜胺-甲醛缩合物、(ii)醚化的蜜胺-甲醛缩合物和(iii)聚合物分散体的水溶液进行后浸渍或预浸渍和后浸渍。

Description

蜜胺树脂薄片和/或薄膜用于涂覆三维结构表面和/或模制品的用途
本发明涉及由纤维素纤维材料生产的蜜胺树脂薄片和/或薄膜用于涂覆三维结构表面和/或模制品(3D涂覆)的用途,该纤维素纤维材料用含有下列成分的水溶液进行后浸渍或预浸渍和后浸渍:
(i)蜜胺-甲醛缩合物,
(ii)醚化的蜜胺-甲醛缩合物,和
(iii)聚合物分散体。
本发明进一步涉及特定的含水合成树脂混合物。
对于材料的3D涂覆,通常使用热塑性薄片,例如为了涂覆家具工业的木基材料。目前这些热塑性薄片的显著优势是它们的弹性;缺点包括尤其是由于另外使用粘合剂而产生的高生产成本以及预期的高处理成本。人们希望使用自粘的便宜蜜胺树脂薄膜,例如用于家具工业以提高平滑表面的级别,以及用于涂覆三维结构区域。纯的蜜胺树脂太脆而不能用于该应用。按照DE-A 23 09 334使用带有醚化羟甲基的蜜胺树脂获得了改进的柔韧性。这些树脂主要用于生产复合材料如蜜胺树脂薄片。为了生产这些复合材料,用蜜胺树脂浸渍例如纸、机织物或非织造布并且在100-180℃的温度下固化。这些蜜胺树脂薄膜尤其用于增强木基材料如碎料板、硬质纤维板和木块芯板(blockboard)的表面。为此目的,使用适当的粘合剂将蜜胺树脂薄片粘合到木基材料的表面或边缘上,并在适当的情况下施加热和压力。用蜜胺树脂薄片进行涂覆是为了改进木基材料对机械应力的抵抗力及其防水性。
为了获得例如涂覆圆边所要求的弹性和柔韧性,对蜜胺树脂进行改性:例如通过加入如DE-A 44 39 156所述的胍胺树脂或通过加入如DE-A 38 37965所述的少量含水合成树脂分散体。DE-A 37 00 344指出氨基树脂和丙烯酸酯分散体的组合在生产的薄片中产生了特定的弹性。上述专利专门公开了称为软边缘的那些的生产。当使用这些蜜胺树脂薄片涂覆软边缘时,如实施例所述,需要粘合剂以将树脂薄片固定到边缘上。
关于可变形性的性质,已知的蜜胺树脂薄片还需要改进。尤其在家具生产方面为了均匀涂覆三维结构体的表面(如某些家具风格(乡村风格的家具)所面临的情况)和/或均匀涂覆模制品存在的需要是能够使用蜜胺树脂薄片或蜜胺树脂薄膜,该薄片或薄膜与其已知的同等产品相比具有改进的弹性并且具有至少相等(如果没有同样得到改进)的其它性能。此外,还需要能够由一种材料对带有锋利边缘部分的三维结构体进行二维涂覆。应当指出优选3D涂覆用于改性引起的自粘的蜜胺树脂薄膜,目前这些薄膜仅适合平滑表面的涂覆。从审美的角度且同时为了简化生产,涂覆操作应该以单一压制操作进行。该类薄片和薄膜的主要特征在于它们在压制操作过程中的可变形性。
本发明的目的是具体说明适合对三维结构表面、模制品和具有锋利边缘部分的三维结构物品进行二维涂覆,但同时呈现蜜胺树脂薄片或薄膜的通常性质特征的蜜胺树脂薄片和/或薄膜。本发明进一步提供了一种特别有利地适合用于浸渍纤维素纤维材料以生产用于3D涂覆的蜜胺树脂薄膜的合成树脂混合物。
我们发现此目的通过将由纤维素纤维材料或机织物制得的蜜胺树脂薄片和/或薄膜用于涂覆三维结构表面和/或模制品(3D涂覆)而实现,其中纤维素纤维材料或机织物用含有下列成分的水溶液进行后浸渍或预浸渍和后浸渍:
(i)蜜胺-甲醛缩合物,
(ii)醚化的蜜胺-甲醛缩合物,和
(iii)聚合物分散体。
已经发现如果所述水溶液包含下列物质:
(i)5-50重量%,特别是10-30重量%的蜜胺-甲醛缩合物,
(ii)5-50重量%,特别是10-40重量%的醚化蜜胺-甲醛缩合物,和
(iii)20-90重量%,特别是30-80重量%的聚合物分散体,则该水溶液特别适合对纤维素纤维材料进行后浸渍或预浸渍和后浸渍。
组分(i)、(ii)和(iii)的量总和为100重量%,并且基于液体树脂混合物。
还可向本发明的蜜胺树脂混合物中加入助剂和添加剂,实例是0.1-50重量%,优选0.2-30重量%,特别是0.5-20重量%的脲、己内酰胺、苯基二甘醇、丁二醇和/或蔗糖,基于100重量%的(i)-(iii)的混合物。其还可以进一步包含常规添加剂如润湿剂、固化剂和催化剂。
还发现了特别有利地适合生产用于3D涂覆的蜜胺树脂薄膜和薄片的新型合成树脂混合物。该混合物的组成如下:
(i)5-50重量%,特别是10-20重量%的蜜胺-甲醛缩合物,
(ii)5-50重量%,特别是10-30重量%的醚化蜜胺-甲醛缩合物,和
(iii)40-90重量%,特别是50-80重量%的水分散体形式的共聚物,该共聚物可通过缩合反应交联,并且是优选含有羧基、羟基、酰胺基、缩水甘油基、羰基、N-羟甲基、N-烷氧基甲基、氨基和/或联亚氨基的丙烯酸酯的共聚物。
组分(i)、(ii)和(iii)的量总和为100重量%,并且基于液体树脂混合物。
下面是各合成组分的细节:
将蜜胺-甲醛缩合物用作合成组分(i)。合成组分(i)的制备是公知知识。通常首先使1mol蜜胺与1.4-2mol甲醛在pH为7-9和温度为40-100℃下缩合直到达到适当的缩合程度。
在合成组分(ii)中,蜜胺-甲醛缩合物用C1-C4链烷醇如甲醇、乙醇、丙醇和/或丁醇进行醚化。优选甲醇和乙醇。合成组分(ii)的制备是公知知识。蜜胺-甲醛缩合物通常与20-30mol甲醇混合,并且在pH为1-5和温度为40-80℃下进行醚化。缩合条件受到树脂需要的水稀释度的控制,稀释度为至少1∶6。缩合后,通过蒸馏除去蜜胺树脂中过量的醇和甲醛。任何残留的甲醛通过在室温至90℃,优选60-70℃的温度下加入脲而转化。
将共聚物分散体用作合成组分(iii),所述共聚物优选含有羧基、羟基、酰胺基、缩水甘油基、羰基、N-羟甲基、N-烷氧基甲基、氨基和/或联亚氨基。共聚物中的这些官能团通过共聚带有这些官能团的相应单体以常规方式得到。
共聚物通常以这样的用量含有上述官能团:使所述共聚物可在其共聚形式中含有基于共聚物为0.1-50重量%,优选0.3-20重量%的含有官能团的这些单体。
适于含有上述基团的共聚单体的主要单体包括可以与所述共聚单体共聚合的常规烯属不饱和单体,实例是丙烯酸和甲基丙烯酸的C1-C12烷基酯,优选C1-C8烷基酯,例如丙烯酸甲酯、甲基丙烯酸甲酯、丙烯酸乙酯、甲基丙烯酸乙酯、丙烯酸丙酯、甲基丙烯酸丙酯、丙烯酸丁酯、甲基丙烯酸丁酯、丙烯酸(2-乙基己基)酯、甲基丙烯酸(2-乙基己基)酯、丙烯酸月桂酯和甲基丙烯酸月桂酯;C2-C4羧酸的乙烯基酯,例如乙酸乙烯酯和丙酸乙烯酯,马来酸和富马酸的C1-C4二烷基酯,乙烯基芳族化合物如苯乙烯、α-甲基苯乙烯和乙烯基甲苯;丙烯腈、甲基丙烯腈、丙烯酰胺、甲基丙烯酰胺,还有含3-10个碳原子的乙烯基醚、乙烯基卤化物如氨乙烯和1,1-二氯乙烯;多烯属不饱和化合物如丁二烯和异戊二烯,以及上述单体的混合物,只要它们相互可以共聚合。
为了制备合成树脂混合物,在加入其它组分之前通常将聚合物分散体的pH调整为7.5-10。
在不损害其它性质的情况下,按照本发明使用的蜜胺树脂薄片和/或薄膜具有涂覆三维结构表面和/或模制品和/或具有锋利边缘部分的结构物品所需要的必要高弹性。锋利边缘部分尤其表示相交的两个或更多个平面产生的确定角所形成的边缘、角和点。
按照本发明使用的蜜胺树脂薄片或薄膜使用吸收性的纤维素纤维材料或机织物或装饰性纸以常规方式生产。
纤维素纤维材料用本发明的蜜胺树脂混合物(i)-(iii)或用蜜胺-甲醛浸渍树脂或用蜜胺-甲醛浸渍树脂和涂覆树脂的混合物或用脲-甲醛树脂和蜜胺-脲-甲醛树脂的混合物进行预浸渍。基于蜜胺树脂混合物的固体含量,每100重量份使用25-85重量份蜜胺树脂混合物。浸渍的纤维材料随后例如在140-200℃的温度下在热空气流中以常规方式固化成为蜜胺树脂薄片或蜜胺树脂薄膜。蜜胺树脂薄片或蜜胺树脂薄膜通过用蜜胺树脂混合物(i)-(iii)对其进行后浸渍并且将其粘合在具有待涂覆三维结构表面的材料组份上而进一步加工,若合适的话,粘合操作在加热和加压下进行。优选的材料是木基材料,例如乡村风格的家具和定向纤维板(OSB)。优选以单一加工步骤进行二维粘合,即在一个压制操作中使用单一的蜜胺树脂薄膜或薄片涂覆三维结构表面,该薄膜或薄片覆盖整个结构体。
对本发明而言,蜜胺树脂薄片是非自粘薄片,而蜜胺树脂薄膜是自粘薄膜。
所得表面明显且有效地闭合,并具有良好的可变形性。
本发明的优点还在于避免了目前使用的热塑性薄片的昂贵且麻烦的生产和处理成本。
实施例
组分(i):蜜胺-甲醛缩合物
来自BASF Aktiengesellschaft的Kauramin浸渍树脂753,包含改性蜜胺-甲醛缩合物的水溶液(改性剂:丁二醇)。
组分(ii):醚化的蜜胺-甲醛缩合物
在270g甲醛存在下在pH为8.5和温度为40-70℃下羟甲基化126g蜜胺。所得的加合化合物使用甲酸调节到pH为4并且使用900g甲醇在60℃的温度下醚化15分钟。用氢氧化钠溶液中和后,反应溶液通过浓缩(蒸馏)除去未反应的甲醛和过量甲醇。
组分(iii):聚合物分散体
来自BASF Aktiengeseilschaft的LuhydranS 937 T,包含基于丙烯酸酯和甲基丙烯酸酯以及苯乙烯的共聚物的含羟基含水分散体的共聚物。
实施例1
在pH为7-9和温度为20-30℃下混合20g组分(i)、30g组分(ii)和40g组分(iii)。所得的合成树脂混合物是至少24小时储存稳定的。
应用实施例:
基重为80g/m2的装饰性纸用组分(i)(基于纸重施用70%的树脂)进行预浸渍。来自实施例1的合成树脂混合物与基于合成树脂混合物为0.5重量%的固化剂(例如来自BASF Aktiengesellschaft的Hrter 529 Flüssig[固化剂529,液体])混合,然后通过刮刀式涂布施加到预浸渍的装饰性纸上并随后干燥,从而使装饰性纸具有120-130%的固体含量,并且具有6-10%的残余水分含量。
对比例:
在加入基于组分(i)为0.5重量%的固化剂(例如来自BASFAktiengesellschaft的Hrter 529 Flüssig)后,使用组分(i)浸渍重量为80g/m2的装饰性纸并且干燥,从而使装饰性纸具有120-130%的完全浸渍的固体含量,并且具有6-10%的残余水分含量。
3D涂覆及表征:
将所得的蜜胺树脂薄膜压到直径为16.5cm并包含3D结构的MDF(中密度纤维)板上。3D结构表示具有圆形和平直区域和/或有确定角度的边缘的轮廓。压制操作在45kN的压力下和在150-160℃的实验室压机中进行,且持续时间为30-60秒。
评价压到包含3D结构的MDF板上的蜜胺树脂薄膜的可变形性和粘合性。对良好的可变形性而言,涂层应当完全与结构体相符合并且牢固地粘合到其上而没有撕裂或破裂。
表面的表征:
所得的蜜胺树脂薄膜在160-165℃的温度和25Kp的压力下压到MDF板上,且持续时间为110秒。进行下列测试:
固化
通过使0.004重量%的若丹明B溶液着色的0.2N盐酸作用在涂覆的MDF板上16小时而测定固化的质量。如果表面没有被酸侵蚀,则固化是有效的。可以根据变红的程度评价侵蚀的程度。
评价:
0=没有侵蚀
1=浅粉色着色
2=明显的变红
3=严重变红
4=严重变红且轻微的表面膨胀
5=严重变红且严重的表面膨胀
6=破坏的表面
不渗透性:
涂覆表面的不渗透性或孔隙率用于评价对污物的敏感性。将黑鞋油擦到测试表面上然后再用布擦掉。孔隙中残余的鞋油可评价表面的不渗透性。
按照下面的级别评价表面不渗透性:
0=无孔隙
1=孤立孔隙
2=几个孔隙
3=许多孔隙
4=大量的开放区域
5=很大量的开放区域
6=没有不透性
黑度:
使用带有Tint Sensor亮度测量头的Tint Tester 527按照D 3265测量黑度。测量范围覆盖0-99.99亮度单位,零为最低亮度级别(绝对黑)。即使在>0.8的值也可识别出明显的变灰。
在用标准校准设备之后,对测试样品进行三次测量,并且以平均值报告黑度。
结果显示在表1中。
表1
外观 固化 不渗透性 黑度
对比例 纸在尖锐点破裂 2  4  0.58
实施例1 纸完全被3D表面覆盖 2  2  0.67

Claims (12)

1.由纤维素纤维材料生产的蜜胺树脂薄片和/或薄膜用于涂覆三维结构表面和/或模制品(3D涂覆)的用途,该纤维素纤维材料使用含有下列成分的水溶液进行后浸渍或预浸渍和后浸渍:
(i)5-50重量%的蜜胺-甲醛缩合物,
(ii)5-50重量%的醚化的蜜胺-甲醛缩合物,和
(iii)20-90重量%的聚合物分散体,
组分(i)、(ii)和(iii)的量总和为100重量%,并且基于液体树脂混合物;其中分散体(iii)包含含有羧基、羟基、酰胺基、缩水甘油基、羰基、N-羟甲基、N-烷氧基甲基、氨基和/或联亚氨基的丙烯酸酯的共聚物。
2.如权利要求1所要求的用途,其中基于100重量%的(i)-(iii)的混合物,水溶液进一步包含0.1-50重量%的脲。
3.如权利要求1所要求的用途,其中水溶液包含
(i)10-30重量%的蜜胺-甲醛缩合物,
(ii)10-40重量%的醚化的蜜胺-甲醛缩合物,和
(iii)30-80重量%的聚合物分散体,
组分(i)、(ii)和(iii)的量总和为100重量%,并且基于液体树脂混合物。
4.如权利要求1-3中任一项所要求的用途,用于涂覆具有3D表面和/或锋利边缘部分的物品。
5.如权利要求1-3中任一项所要求的用途,使用单一蜜胺树脂薄片和/或薄膜进行涂覆。
6.如权利要求1-3中任一项所要求的用途,用于涂覆木基材料。
7.如权利要求1-3中任一项所要求的用途,用于涂覆定向纤维板(OSB)。
8.如权利要求1所要求的用途,其中纤维素纤维材料使用蜜胺-甲醛浸渍树脂或使用蜜胺-甲醛浸渍树脂和涂覆树脂的混合物或使用脲-甲醛树脂和蜜胺-脲-甲醛树脂的混合物进行预浸渍并使用如权利要求1定义的(i)-(iii)的水溶液进行后浸渍。
9.一种用于浸渍纤维素纤维材料的合成树脂混合物,该混合物包含
(i)5-50重量%的蜜胺-甲醛缩合物,
(ii)5-50重量%的醚化的蜜胺-甲醛缩合物,和
(iii)40-90重量%的水分散体形式的共聚物,该共聚物可通过缩合反应交联,
组分(i)、(ii)和(iii)的量总和为100重量%,并且基于液体树脂混合物;其中该混合物将含有羧基、羟基、酰胺基、缩水甘油基、羰基、N-羟甲基、N-烷氧基甲基、氨基和/或联亚氨基的丙烯酸酯的共聚物用作组分(iii)。
10.一种使用如权利要求9所要求的合成树脂混合物浸渍的蜜胺树脂薄片或薄膜。
11.一种3D涂覆的方法,该方法包括在一项操作中将权利要求10所要求的蜜胺树脂薄片和/或薄膜二维涂覆到材料的三维结构上。
12.一种3D涂覆的方法,该方法包括由纤维素纤维材料生产蜜胺树脂薄片和/或薄膜,其中纤维素纤维材料使用权利要求1的水溶液进行后浸渍或预浸渍和后浸渍,以及将蜜胺树脂薄片和/或薄膜涂覆到待涂覆的三维结构表面和/或模制品上。
CNB2004800023169A 2003-01-17 2004-01-10 蜜胺树脂薄片和/或薄膜用于涂覆三维结构表面和/或模制品的用途 Expired - Fee Related CN100374501C (zh)

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