CN101175634A - Non-combustible high pressure laminate - Google Patents

Non-combustible high pressure laminate Download PDF

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Publication number
CN101175634A
CN101175634A CNA2006800164734A CN200680016473A CN101175634A CN 101175634 A CN101175634 A CN 101175634A CN A2006800164734 A CNA2006800164734 A CN A2006800164734A CN 200680016473 A CN200680016473 A CN 200680016473A CN 101175634 A CN101175634 A CN 101175634A
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CN
China
Prior art keywords
laminate
curtain
fiber reinforcement
resin
glass
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Pending
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CNA2006800164734A
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Chinese (zh)
Inventor
R·W·M·胡斯肯
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Owens Corning Intellectual Capital LLC
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Owens Corning Intellectual Capital LLC
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Publication date
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Publication of CN101175634A publication Critical patent/CN101175634A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/06—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
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    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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Abstract

A high pressure laminate includes a first layer (12) of resin impregnated paper and at least one layer (14,16) of fiber reinforced veil. Each layer of fiber reinforced veil includes binder and filler. The laminate is characterized by having a caloric value of lower than 3.0 MJ/kg when tested in accordance with ISO 1716. A method for producing this high pressure laminate is also provided.

Description

Non-combustible high pressure laminate
Technical field of the present invention and industrial applicibility
Generality of the present invention relates to fire-retardant, high-pressure laminated plate, relates in particular to follow prEN 13823 and have high-pressure laminated plate less than the calorific value of 3.0MJ/kg when according to ISO 1716 test.
Background of invention
High-pressure laminated plate (HPL) is known in this area, and the HPL plate for example is used as the wall liner of furniture, wall body decorative panel, table top etc.
One of most important parameters of HPL plate in the HPL plate, particularly building industry is a combustibility.Since 2003, all construction materials in Europe must be followed prEN 13823 (reaction of the combustion test of building products).This specification description individual event firing method (SBI) test.A1 and the A2 grade measured according to the additional calorific value of ISO 1716 are requirements.
Under the prior art, by using fire-retardant brown paper or by using fire-retardant phenol-formaldehyde resin to make the HPL plate become fire-retardant.Under the prior art, the FR-HPL product has been realized the SBI grade up to B (when with ISO 1716 test greater than 3.0MJ/kg).
HPL manufacturer wishes the HPL plate of SBI A2 grade strongly.This kind grade will allow manufacturer to enlarge the range of application of their product and therefore permeate additional market.So far this does not also realize, because also there is not product can satisfy the calorific value requirement, and still reaches required mechanical performance and characteristics of flame.The present invention relates to satisfy first kind of HPL plate of all these requirements, comprise those requirements of A2 grade (when the time less than 3.0MJ/kg) needs with ISO 1716 test.
The present invention relates to improved fire-resistant and resistance to impact is the novel laminate of feature.
Summary of the invention
High-pressure laminated plate of the present invention comprises the ground floor of Tetefol and one deck fiber reinforcement curtain (veil) at least.Each layer of fiber reinforcement curtain comprises secondary binding agent (secondary binder) and filler.Described high-pressure laminated plate is characterised in that the calorific value that has less than about 3.0MJ/kg when according to ISO 1716 tests.
Described laminate can also comprise the second layer of Tetefol.In such embodiment, one or more layers of fiber reinforcement curtain is sandwiched between the ground floor and the second layer of Tetefol.
In any possible embodiment, the secondary binding agent is the thermal curable resin.The binding agent that is fit to includes but not limited to the polyacrylate of self-crosslinkable, polyamide-amide epichlorohydrin resins (PAE), polyvinyl alcohol, acrylate, styrene-acrylate, carbamide, melocol, P-F, epoxy resin, unsaturated polyester (UP), crosslinkable acrylic resin, polyurethane resin, chloropropylene oxide-poly-amino polyamide (epichlorohydrin-polyaminopolyamide resin), chloropropylene oxide-polyamino resin, chloropropylene oxide-polyamide and their mixture.
Described filler is selected from metal hydroxides, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin (kaolin clay), chlorite, diatomite, feldspar, mica, nepheline syenite, pyrophyllite (alumina silicate), silica, talcum, wollastonite, imvite (bentonite), hectorite, saponite, calcium carbonate, magnesium carbonate, aluminium oxide, iron oxide, magnesium hydroxide, glass microballoon and their mixture usually.
In one embodiment, described filler is selected from metal hydroxides, metal carbonate and their mixture.For the present invention, the mixture of calcium carbonate and aluminium hydroxide is the filler that is particularly useful.Situation is especially true when binding agent is carbamide.
Other filler comprises: aluminum trihydrate, magnesium hydroxide, melamine cyanurate, halogenate additive, antimony trioxide, metal hydroxides, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin, chlorite, diatomite, feldspar, mica, nepheline syenite, pyrophyllite, silica, talcum, wollastonite, imvite, hectorite, saponite, magnesium carbonate, aluminium oxide, iron oxide, glass microballoon, the phosphoric acid ethylenediamine, phosphoguanidine, the boric acid melamine, (single, burnt, many) melamine phosphate, (single, burnt, many) ammonium phosphate, the dicyandiamide condensation product, common intumescent system (therefore foaming also produces the system of insulating barrier on the spot in combustion process) and their mixture.
In a possible embodiment, each layer of fiber reinforcement curtain comprises the about 95wt% fortifying fibre of about 1-, approximately the about 50wt% carbamide of 5-, the approximately about 80wt% calcium carbonate of 10-and about about 90wt% aluminium hydroxide of 20-.
The fiber reinforcement curtain can be weaven goods or non-woven fabric.When providing multi-layer fiber to strengthen curtain, they can all be weaven goods, and they also can all be that non-woven fabric or these layers can be the mixtures of weaven goods and non-woven fabric.The fiber reinforcement curtain comprises the fiber that is selected from glass fibre, basalt fibre (basalt fiber), metallic fiber, inorfil, silicon dioxide fibre, carbide fibre, nitride fiber, carbon fiber and their mixture.The glass fibre that the fiber reinforcement curtain uses can be selected from boron-free glass, E-glass, ECR-glass, C-glass, AR-glass, S2-glass and their mixture.
When the ground floor of Tetefol is the facing paper (decor paper) of melamine-impregnated, can make high-pressure laminated plate of the present invention have more aesthstic attractive force.In addition, this product can comprise the paint film that the paint film of radiation curing or coating such as UV solidify or the paint film of electronic beam curing on the exposure of the ground floor of Tetefol.In another possibility, this product can comprise the urethane acrylate enamelled coating of heat cross-linking on the exposure of the ground floor of this Tetefol.
The preparation method of high-pressure laminated plate is provided according to a further aspect of the invention.This method is included in about 525N/m 2-about 15,750N/m 2Pressure under with the ground floor of Tetefol with one deck fiber reinforcement curtain is compressed together at least, simultaneously these layers are heated to about 120 ℃-about 220 ℃ temperature to form laminate.In addition, this method may further comprise the steps: provide when according to ISO 1716 these laminates of test calorific value less than 3.0MJ/kg with the bond of secondary binding agent and filler.
Described method can also comprise selects described secondary binding agent from following material: carbamide, P-F, melocol, epoxy resin, unsaturated polyester (UP), crosslinkable acrylic resin, polyurethane resin, chloropropylene oxide-poly-amino polyamide, chloropropylene oxide-polyamino resin, chloropropylene oxide-polyamide and their mixture.Described filler can be selected from metal hydroxides, metal carbonate and their mixture.In the embodiment that is particularly useful, filler is selected from the mixture of calcium carbonate and aluminium hydroxide.
In a possible embodiment, described method comprises that the facing paper by melamine-impregnated forms the ground floor of described Tetefol.In addition, described method can comprise that the paint with radiation curing is the exposure japanning of the ground floor of this Tetefol.In another possible embodiment, described method can comprise with the urethane acrylate paint of heat cross-linking paints for the exposure of the ground floor of this Tetefol.
In another embodiment, the laminate of the present invention flame retardant bed and the fibrolamellar that comprise the decorative layer of resin dipping, form by the fiber reinforcement curtain.
This fibrolamellar in the laminate can be described as the plate based on timber usually.Described fiberboard can be made of the material that is selected from high density fiberboard, medium density fibre board (MDF), directional fiber plate, particieboard and their mixture.In addition, laminate can comprise the facing paper that covers described resin dipping the resin dipping the covering ply of paper and/or be positioned at the backing layer of the resin dipping of described fibrolamellar below.The backing layer of the decorative layer of described resin dipping and resin dipping can be made by the facing paper of known type in this area.
In this embodiment, the fiber reinforcement curtain comprises the about 95wt% fortifying fibre of about 5-, the approximately about 75wt% binding agent of 5-and the approximately about 80wt% filler of 0-.After dipping and before suppressing, the fiber reinforcement curtain has the about 500g/m of about 20- 2Per unit area weight.
The preparation method of fibrolamellar pressing plate comprises: at about 1050N/m 2-about 5250N/m 2Pressure under backing layer that the decorative layer of the cover layer of resin dipping, resin dipping, the flame retardant bed, fibrolamellar and the resin that are formed by the fiber reinforcement curtain are flooded compressed together, be heated to the about 225 ℃ temperature of about 150-simultaneously and kept about 10-about 50 seconds.This method can further describe to may further comprise the steps: the binding agent that is selected from polyvinyl alcohol, acrylate, styrene-acrylate, carbamide, melocol, P-F, epoxy resin, unsaturated polyester (UP), crosslinkable acrylic resin, polyurethane resin, polyamide-amide epichlorohydrin resins and their mixture is provided in the fiber reinforcement curtain.
Described laminate can be used for laminate flooring to be used, and wherein said laminate is formed by the plate with timber base-material such as particieboard, fiberboard (comprising high density and medium density fibre board (MDF)) and directional fiber plate.Other application of laminate includes, but are not limited to wall liner, ceiling, indoor accessory and decorative panel as being used for those of boats and ships, train and building.
In the following description, simply by way of example the explanation mode that is very suitable for implementing one of pattern of the present invention show and described a possible embodiment of the present invention.It should be understood that the present invention can realize with other different embodiment, and all various without departing from the invention tangible aspect in the some details of the present invention can correct.Therefore, should to regard as be illustrative and not restrictive in nature for accompanying drawing and describe.
The accompanying drawing summary
The accompanying drawing of incorporating into and forming this specification part shows several aspects of the present invention, and together is used for illustrating some principle of the present invention with description of the invention.In the accompanying drawings:
Fig. 1 is the side view of a possible embodiment of the present invention.
Fig. 2 is the side view of first alternative embodiment of the present invention.
Fig. 3 is the side view of another possible embodiment of the present invention.
Fig. 4 a is with two representative embodiment of the present invention and two total exotherm figure that representational prior art products compares.
Fig. 4 b is with described identical two representative embodiment and two heat liberation rate, heat release rate curve maps that representational prior art products compares of the present invention.
Fig. 5 is the side view of a possible embodiment of the present invention.
Fig. 6 shows the impact size classification grade of using bead impact test and big pellet impact test.
Now will be in detail with reference to the preferred embodiments of the invention, the example of this embodiment is shown in the drawings.
Detailed Description Of The Invention
Three embodiments of high-pressure laminated plate 10 of the present invention are shown in Fig. 1-3.High-pressure laminated plate 10 can generality be described as comprising the ground floor of Tetefol and one deck fiber reinforcement curtain at least.
Each layer of fiber reinforcement curtain also comprises secondary binding agent and filler, so that this high-pressure laminated plate is characterised in that the calorific value that has less than 3.0MJ/kg when according to ISO 1716 tests.Term " secondary binding agent " is defined as below with the binding agent of using in second procedure of processing discussed in detail.
As shown in Fig. 1 embodiment, high-pressure laminated plate 10 comprises the ground floor 12 of the facing paper of Tetefol such as melamine-impregnated.In addition, this laminate 10 comprises two layers 14,16 of fiber reinforcement curtain.
Each layer 14,16 of fiber reinforcement curtain adopts the composition dipping of secondary binding agent and filler.This secondary binding agent is the thermal curable resin.Usually, this secondary binding agent is selected from carbamide, P-F, melocol, epoxy resin, unsaturated polyester (UP), crosslinkable acrylic resin, polyurethane resin, chloropropylene oxide-poly-amino polyamide, chloropropylene oxide-polyamino resin, chloropropylene oxide-polyamide and their mixture.
This filler is selected from metal hydroxides, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin, chlorite, diatomite, feldspar, mica, nepheline syenite, pyrophyllite (alumina silicate), silica, talcum, wollastonite, imvite (bentonite), hectorite, saponite, calcium carbonate, magnesium carbonate, aluminium oxide, iron oxide, magnesium hydroxide, glass microballoon and their mixture.Usually, this filler is selected from metal hydroxides, metal carbonate and their mixture.The mixture of calcium carbonate and aluminium hydroxide especially can be used for the present invention.Situation is especially true when being used in combination with the carbamide binding agent.The granularity of filler is typically about the about 150 μ m of 0.3 μ m-, the about 75 μ m of more preferably about 1 μ m-, the about 50 μ m of most preferably about 4 μ m-.
The fiber reinforcement curtain comprises the fortifying fibre that is selected from glass fibre, basalt fibre, inorfil (carbide, nitride etc.) and their mixture.Especially can be used for glass fibre of the present invention and comprise E-glass (as Advantex glass), ECR-glass, AR-glass, C-glass, M-glass, D-glass, S-glass, S2-glass and their mixture.Fiber is prescinded the length to about 0.1mm-100mm usually, and can be short bundle (chopped strand), the short form of cutting rove or upright fiber (individual fiber) of short cutting or their mixture of cutting.When using discrete fibers, those fibers typically have a diameter from about about 50 microns of 3-.
Before the dipping of secondary binding agent and filler, the fiber reinforcement curtain comprises at the most approximately 95wt% glass fibre, the about 95wt% glass fibre of 75-preferably approximately, the more preferably about about 93wt% glass fibre of 78-, the most preferably about about 92.5wt% glass fibre of 80-.Preferably, fiber reinforcement curtain layer comprises the E-glass fibre.
Before the dipping of secondary adhesive composition and filler, the fiber reinforcement curtain can comprise binding agent, and is aforesaid, and this binding agent is polyvinyl alcohol preferably.Preferably, this binding agent is present in this curtain with the content of the about 25wt% of about 5-.
In the embodiment depicted in fig. 1, laminate 10 comprises two layers 14,16 of curtain.Each act layer 14,16 can be weaven goods or non-woven fabric.In the embodiment depicted in fig. 1, curtain layer 14,16 can be a weaven goods, can be non-woven fabric, or one deck can be a weaven goods and another layer is a non-woven fabric.
An embodiment that is particularly useful of the present invention comprises one or more acts of layers 14,16, before the dipping of secondary adhesive composition and filler, described curtain layer comprises the about 95wt% fortifying fibre of about 1-, the about 95wt% fortifying fibre of 75-preferably approximately, more preferably about about 93wt% fortifying fibre of 78-, most preferably about about 92.5wt% fortifying fibre of 80-.This act layer also comprises the about 50wt% of about 2-, the preferably approximately about 25wt% carbamide of 5-secondary binding agent and at least a filler, described filler uses with following amount: about about 80wt% of 10-, the preferably approximately about 65wt% calcium carbonate of 17.5-and the approximately about 90wt% of 20-, the preferably approximately about 70wt% aluminium hydroxide of 35-.
As Fig. 1 further shown in, can followingly make this laminate 10 pleasant more aesthetically: on the other exposure of the ground floor 12 of Tetefol, comprise the paint film 18 that the paint of radiation-curable such as electronic beam curing or UV solidify.Perhaps, layer 18 can comprise the urethane acrylate paint of heat cross-linking.
An alternative embodiment of the present invention is shown in Figure 2.In this embodiment, high-pressure laminated plate 10 comprises the ground floor that is clipped in Tetefol and the single fiber reinforcement curtain layer 20 between the second layer 22,24.The laminate 10 of Fig. 2 also can comprise the enamelled coating 26 of radiation curing, as the paint film of electronic beam curing or UV curing or the urethane acrylate paint of heat cross-linking.Yet this layer 26 chosen wantonly.
In another embodiment shown in Figure 3, laminate 10 can comprise the ground floor 28 of Tetefol, six intermediate layers 30,32,34,36,38,40 of fiber reinforcement curtain and the second layer 42 of Tetefol.Fig. 3 embodiment also can comprise optional layer 44, and it comprises the paint of the radiation curing of the aesthetic appearance that is used to strengthen, as electronic beam curing or the paint film of UV curing or the urethane acrylate enamelled coating of heat cross-linking.
The Tetefol layer 22,24,28 that should be appreciated that Fig. 2 and the embodiment shown in 3 is similar or identical with the Tetefol layer 12 of first embodiment shown in Fig. 1 with 42.Similarly, also the curtain layer 14,16 with Fig. 1 embodiment is identical or similar for the fiber reinforcement curtain layer 20,30,32,34,36,38,40 of Fig. 2 and the embodiment shown in 3.As shown, laminate 10 of the present invention can comprise the fiber reinforcement curtain layer of any number, still satisfies flame propagation, calorific value and mechanical performance that any specific final products are used simultaneously.
Usually, each fiber reinforcement curtain layer is the sheet material that adopts resinoid bond dipping and storage to be used for the pre-preg material (prepreg) of weaving of subsequent applications (as by the final techonosphere laminate product of manufacturer) or non-woven fortifying fibre or be prepared for molding.
Can use any water base wet strength binding agent as known in the art.Useful binding agent includes but not limited to following: polyvinyl alcohol, (partial hydrolysis) polyvinyl acetate, acrylic polymer and copolymer, crosslinkable acrylic polymer and copolymer, polymerisable multiple functionalized N-methylol compound, particularly N-methylolurea such as dimethylol urea and N-melamine methylol type resin, melamino-formaldehyde, phenol formaldehyde (PF), furfuryl group formaldehyde, resorcinol formaldehyde, styrene-butadiene-copolymer latex, cationic polyamide chloropropylene oxide, amino resins, epoxy resin, polystyrene emulsion binding agent, the polycarboxylic acids based binder, other latex and/or acrylic polymer or copolymer such as acrylamide, ethane-acetic acid ethyenyl ester/vinyl chloride, acrylic acid alkyl ester polymer, SBR styrene butadiene rubbers, acrylonitrile polymer, polyurethane resin, polyvinyl chloride, polyvinylidene chloride, the copolymer of vinylidene chloride and other monomer, polyvinyl acetate, PVP, mylar, the acrylic acid ester emulsion resin, styrene-acrylate.More preferably, binding agent is a polyvinyl alcohol.
Composition with described secondary binding agent and filler floods described pre-preg material.Except the glass in the pre-preg material Already in, the composition of described secondary binding agent and filler preferably includes the about 30wt% glass of about 2-, the more preferably about about 25wt% glass of 3-, the most preferably about about 20wt% glass of 4-.Described pre-preg material also comprises the about 25wt% secondary of about 5-binding agent, the about 20wt% secondary of 7-binding agent preferably approximately, the most preferably about about 18wt% secondary of 8-binding agent.This pre-preg material also comprises the about 93wt% filler of about 50-, more preferably about about 90wt% filler of 55-, most preferably about about 88wt% total filler of 60-.
Usually, this filler is that ratio is about 1: the metal hydroxides that 0.01-is about 1: 100 and the mixture of metal carbonate.Preferably, metal hydroxides is an aluminium hydroxide, and with the about 90wt% of about 20-, more preferably about about 80wt% of 30-, most preferably approximately the amount of the about 70wt% of 35-is present in the pre-preg material.Preferred metal carbonate is a calcium carbonate, and with the about 80wt% of about 10-, more preferably about about 70wt% of 15-, most preferably approximately the amount of the about 65wt% of 17.5-is present in the pre-preg material.
The granularity of filler is typically about the about 150 μ m of 0.3 μ m-, the about 75 μ m of more preferably about 1 μ m-, the about 50 μ m of most preferably about 4 μ m-.
After dipping and before compacting, typical fiber reinforcement curtain pre-preg material will have about 250g/m 2-about 2000g/m 2Per unit area gross weight and about 500kg/m 3-about 2000kg/m 3Density.
High-pressure laminated plate 10 following structures form: at about 525N/m 2-about 15,750N/m 2With the ground floor of Tetefol with one deck fiber reinforcement curtain is compressed together at least, simultaneously these layers are heated to about 120 ℃-about 220 ℃ temperature under the pressure of (approximately 5-about 150 crust) with the formation laminate.In addition, this method may further comprise the steps: provide when according to ISO 1716 these laminates of test calorific value less than 3.0MJ/kg with the bond of binding agent and filler.The product that this makes it possible to prepare the HPL plate or has SBI A2 grade.
In order to reach this purpose, this secondary binding agent is selected from carbamide, P-F, melocol, epoxy resin, unsaturated polyester (UP), crosslinkable acrylic resin, polyurethane resin, chloropropylene oxide-poly-amino polyamide, chloropropylene oxide-polyamino resin, chloropropylene oxide-polyamide and their mixture.This filler is selected from the one group of material that is made of following material: metal hydroxides, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin, chlorite, diatomite, feldspar, mica, nepheline syenite, pyrophyllite (alumina silicate), silica, talcum, wollastonite, imvite (bentonite), hectorite, saponite, calcium carbonate, magnesium carbonate, aluminium oxide, iron oxide, magnesium hydroxide, glass microballoon and their mixture.
Usually, described filler is selected from metal hydroxides, metal carbonate and their mixture.Calcium carbonate and aluminium hydroxide especially can be used for this method.
In order further to strengthen the aesthstic attractive force of product, described method can also comprise that the facing paper by melamine-impregnated forms the ground floor of described Tetefol.In addition, described method can comprise that the paint with electronic beam curing is the exposure japanning of the ground floor of described Tetefol.Perhaps, this method can comprise that the urethane acrylate paint with heat cross-linking is the exposure japanning of the ground floor of described Tetefol.
Embodiment 1
Five samples that prepared high-pressure laminated plate of the present invention.In first embodiment (embodiment 1), five layers of fibre-reinforced glass curtain are clipped between two layers of facing paper of melamino-formaldehyde dipping.
The glass fibre that uses in this glass curtain is that fibre diameter is 11 microns, and length is 10 millimeters E-glass.The glass curtain has 100g/m separately 2Per unit area weight.The glass curtain comprises polyvinyl alcohol adhesive with the content of 16wt%.
Decorative paper layer has 160g/m separately 2Per unit area weight, comprise 80g/m 2Basic weight paper and 80g/m 2Melamine resin.
Flood the stack layer of glass curtain then with the preparaton of secondary binding agent and filler, this preparaton comprises 21wt% phenol formaldehyde (PF), 26wt% calcium carbonate and 53wt% aluminium hydroxide.Final glass curtain weight is 1000g/m 2
At 100kg/cm 2Pressure and 150 ℃ temperature under with this stack layer maintenance compressed together 20 minutes with the thick laminate of preparation 2.96mm.
In second embodiment (embodiment 2), five layers of fibre-reinforced glass curtain are clipped between the layers of kraft paper of melamino-formaldehyde decorative paper layer and phenol formaldehyde (PF) dipping.
The glass fibre that uses in embodiment 2 products is that fibre diameter is 13 microns, and length is 11 millimeters E-glass.This glass curtain has 50g/m separately 2Per unit area weight and comprise polyvinyl alcohol adhesive with the content of 14wt%.
Stack layer with the preparaton dipping glass curtain of the secondary binding agent of 15wt% melamino-formaldehyde, 20wt% calcium carbonate and 65wt% aluminium hydroxide and filler.Final glass curtain weight is 900g/m 2
At 50kg/cm 2Pressure and 145 ℃ temperature under with the stack layer of embodiment 2 products maintenance compressed together 20 minutes with the thick laminate of preparation 3mm.
Other embodiments of the invention 3,4 and 5 provide in following table 1 with embodiment 1 and 2.In addition, in order to contrast, this table also comprises the corresponding measured value of representational prior art HPL (standard HPL) and prior art FR-HPL (fire-retardant HPL) product.The result of the test of the standard HPL of these embodiment 1-5 and prior art products and each among the FR-HPL provides (in the time can obtaining) in table 2.Relevant total heat release (THR) and heat liberation rate, heat release rate (HRR) curve are respectively shown in Fig. 4 a and the 4b.
Table 1
Figure S2006800164734D00111
Table 2
Test Standard Embodiment 1 Standard HPL Fire-retardant HPL Embodiment 2 Embodiment 3 Embodiment 4 Embodiment 5
Thickness (mm) 2.96 2.99 2.75 3 2.2 2.4 2.3
Density (kg/m 3) 1849 1442 1500 1750 1847 1845 1870
The test of 2hr water boil EN 438
Visual observations ok ok ok ok ok ok ok
Thickness increases (%) 1,6 4,9 7 1.4 1.6 3 1.7
Water absorptivity (%) 5,84 1,34 5 3.5 8.5 9.4 7.1
Dimensional stability EN 438
70 ± 2 ℃; Vertically (%) 0,32 0,20 1.1
70 ± 2 ℃; Laterally (%) 0,32 0,45 2.3
20 ± 2 ℃ vertical (%) 0,15 0,13 0.65
20 ± 2 ℃; Laterally (%) 0,18 0,30 0.98
Flexural strength (Mpa) ISO 178 87 180 179 54 62 86
Flexural modulus (Mpa) ISO 178 14809 17652 23155 12200 11400 13600
Amount of deflection (%) ISO 178 0.7 1.11 0.8
Hot strength (Mpa) ISO 3268 39 131 113
Stretch modulus (Mpa) ISO 3268 12410 18996 17634
Percentage elongation (%) ISO 3268 0.4 0.74 0.68
Impact F maximum (kN) ISO 6603-2 1.9 1.9 1.2
Impact energy (J) ISO 6603-2 7.8 6.2 4.9
The cone calorimetry method is measured ISO 5660 Referring to THR HRR curve Referring to THR HRR curve Referring to THR HRR curve Referring to THR HRR curve
Calorific value (MJ/kg) ISO 1716 2.95 20.4 19.4 2.35 2.29 2.37 2
Limited oxygen index (%) ISO 4589 100 40 46 100 100 100 100
Refer now to Fig. 5, it shows a possible embodiment of laminate 46 of the present invention.As shown, this laminate 46 comprises the covering paper 48 that the resin of the decorative layer 50 of covering resin dipping floods.Decorative layer 50 covers first flame retardant bed that is formed by fiber reinforcement curtain 52.This curtain 52 covers fibrolamellar 54.At last, backing layer 56 is positioned at fiberboard 54 belows.Laminate 46 can also be included in second flame retardant bed between fiberboard 54 and the backing layer 56, and it is formed by fiber reinforcement curtain 58.Described act 2 58 has further strengthened the fire resistance of laminate 46, and guarantee heat from the top or the bottom with much at one speed transmission.
Fiber reinforcement curtain 52 can comprise the fiber that is selected from glass fibre, basalt fibre, metallic fiber, inorfil, silicon dioxide fibre, carbide fibre, nitride fiber, carbon fiber and their mixture.When using glass fibre in the fiber reinforcement curtain, for example, they can be selected from the one group of fiber that comprises boron-free glass, E-glass, ECR-glass, C-glass, AR-glass, S2-glass and their mixture.Can use Advantex  glass fibre, it can (Toledo OH) be purchased from Owens Corning.
Fiber reinforcement curtain 52 and 58 comprises the about 95wt% fortifying fibre of about 5-after the resin dipping, approximately about 75wt% resin/binding agent of 5-and the about 80wt% filler of 0-.The binding agent that uses can be B b stage resin b (B-stageable resin), this resin can be during pressing step reactivation to reach its final performance.This binding agent can be selected from following resin: polyvinyl alcohol, acrylate, styrene-acrylate, carbamide, melocol, P-F, epoxy resin, unsaturated polyester (UP), crosslinkable acrylic resin, polyurethane resin, polyamide-amide epichlorohydrin resins and their mixture.The filler that uses in the fiber reinforcement curtain 16 can be selected from following material: aluminum trihydrate, magnesium hydroxide, melamine cyanurate, halogenate additive, antimony trioxide, metal hydroxides, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin, chlorite, diatomite, feldspar, mica, nepheline syenite, pyrophyllite, silica, talcum, wollastonite, imvite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminium oxide, iron oxide, glass microballoon, the phosphoric acid ethylenediamine, phosphoguanidine, the boric acid melamine, (single, burnt, many) melamine phosphate, (single, burnt, many) ammonium phosphate, the dicyandiamide condensation product, common intumescent system (therefore foaming also produces the system of insulating barrier on the spot in combustion process) and their mixture.Advantageously, the flame retardant bed that is formed by fiber reinforcement curtain 16 is that laminate has been given improved fire-retardant and impact characteristics, and described improvement performance is better than and far surpasses the performance that the plate based on timber of the flame retardant bed that does not comprise the fiber reinforcement curtain of prior art is realized.
Fiber reinforcement curtain 52 and 58 is formed by non-woven fiberglass or composite fibre structure usually.If necessary, curtain 52,58 can comprise the fiber of orientation.Can use continuous fiber and chopped strand.Continuous fiber has the diameter of about 3-about 30 usually.Chopped strand has the length of the about 100mm of about 2-and the diameter of about about 30 μ m of 3-usually.Fiber reinforcement curtain 52 has the about 500g/m of about 20-usually after dipping and before compacting 2Per unit area weight.
The fiberboard 54 that is used for laminate of the present invention is based on the plate of timber.For example, this fiberboard 54 can be made by the material that comprises high density fiberboard, medium density fibre board (MDF), directional fiber plate, particieboard and their mixture.
Decorative layer 50 and backing layer 56 can be made by facing paper as known in the art.Covering paper 48 can be made by cellulose as known in the art.Cover paper 48, decorative layer 50 and backing layer 56 and can all adopt the resin/binder-impregnated identical with fiber reinforcement curtain 46.
Laminate 46 following making: at about 1050N/m 2-about 5250N/m 2Pressure under the backing layer 56 that floods of first flame retardant bed, fibrolamellar 54, second flame retardant bed (if existence) that forms by the fiber reinforcement curtain 58 of resin dipping and the resin that form with the decorative layer 50 of the cover layer 48 of resin dipping, resin dipping, by the fiber reinforcement curtain 52 of resin dipping compressed together, be heated to the about 225 ℃ temperature of about 150-simultaneously and kept about 10-about 50 seconds.Can use that the current equipment that can obtain is online finishes such processing in market.
Embodiment 2
Table 3 shows 15 at the sample with the glass curtain before additional binding agent and the fire retardant dipping.All samples contains poly-(vinyl alcohol) (PVA) binding agent.Glass fibre in the curtain comprises the Corning by Owens, Toledo, OH, the Advantex  glass fibre that USA makes.
Table 3
Sample Fiber type Glass Ni weight g/m 2 Binding agent percentage %
1 Advantex；11um-6mm 47 15
2 Advantex；11um-6mm 46 15
3 Advantex；11un-6mm 47 15
4 Advantex；11um-6mm 47 15
5 Advantex；11um-6mm 46 15
6 Advantex；11um-6mm 46 15
7 Advantex；11um-6mm 47 15
8 Advantex/ silica (85: 15) 33 10
9 Advantex/ silica (85: 15) 54 10
10 Advantex/ silica (85: 15) 76 10
11 Advantex/ silica (85: 15) 48 10
12 Advantex/ silica (85: 15) 47 10
13 Silica 1 00% 81 12
14 Advantex；11um-6mm 35 15
15 Advantex；11um-6mm 35 15
Table 4 shows the sample 1-15 after flooding with additional binding agent and fire retardant." additional amount " hurdle shows the every m that is impregnated in each sample 2Fire retardant/amount of filler.
Table 4
Glass curtain dipping
Sample number Types of binder Fire retardant Additional amount (g/M 2) Final weight (g/M 2)
1 PVA Melamine phosphate 26 73
2 PVA Melamine pyrophosphate 25 71
3 PVA Melamine cyanurate 26 73
4 PVA Ammonium polyphosphate 25 72
5 The chloro-acrylate Aluminum trihydrate 25 71
6 The chloro-acrylate ATH+APP 24 70
7 PVA Do not have 0 47
8 Do not have Do not have 0 33
9 Do not have Do not have 0 54
10 Do not have Do not have 0 76
11 PVA APP 23 71
12 PVA The polyphosphoric acid melamine 24 71
13 Do not have Do not have 0 81
14 PVA ATH 7 42
15 PVA The intumescent preparaton 7 42
Table 5 shows the combustibility of sample 1-15 when each sample is exposed to flame.When flame temperature reached about 950 ℃, sample 1-15 was lighted on Bunsen burner.Being exposed under the identical temperature in order to ensure sample, is about 20mm with the fixed distance of all samples and flame.Observe smoldering of sample, then this sample is removed and observed from putting out behavior from flame.
Table 5
Combustibility
Sample number Smolder * From putting out ** Burn through time (s)
1 + +++ 40
2 + +++ 20
3 ++ +++ 3
4 + +++ 159
5 + ++ 3
6 + +++ 130
7 - + 1
8 -- +++ 600
9 -- +++ 170
10 -- +++ 300
11 + +++ 250
12 + +++ 26
13 -- +++ ＞600
14 + +++ 1
15 ++ +++ 250
* smolder: * * is from putting out behavior:
--: do not smolder+: the self-extinguishment energy of difference
-: almost do not smolder ++: medium self-extinguishment energy
+: medium smolders +++: significant self-extinguishment energy
++: smolder significantly
On Bunsen burner (about 950 ℃ of flame temperature), place sample then, and write down the time (unit is second) when flame burns described act of sample with fixed range (about 10mm).
Floor layer pressing plate embodiment
Sample 7 and 14 is be evaluated as the effective flame retardant bed in the laminate flooring.With unmodified floor layer pressing plate as reference.Estimate these laminate floorings based on resistance to impact and fire resistance.
The preparation method of laminate flooring:
With melmac dipping sample 7 and 14 to guarantee the bonds well with facing paper and fiberboard.Sample 7 and 14 is impregnated into about 150g/m 2Final weight.
The sample 7 and 14 (playing the effect of the flame retardant bed between facing paper and the fiberboard) of this melamine-impregnated is pressed into (pressing conditions: 180 ℃ on the 8mm high density fiberboard; 40kg/cm 220s) with the preparation laminate flooring.Final laminate flooring is carried out two marginal tests; Resistance to impact and fire resistance, and test with the reference laminate flooring, referring to table 6.
Table 6
Standard Coding A: unmodified standard laminate flooring Coding B: sample 7 back-fire relief laminate floorings Coding C: sample 14 back-fire relief laminate floorings
Little pellet impact (N) EN 438 ＜15 16.82 18.84
Big pellet impact (mm) EN 438 ＜1600 ＞1600 ＞1600
Fire resistance NF P 92-501 M3 M2 M2
Impact grade (referring to Fig. 6) IC1 or IC2 IC3 IC3
As shown in table 6, use following bead and big pellet impact test test laminate flooring A, B and C.In the bead impact test, allow the ostentatious plate that has them stand the impact of 5mm steel ball, this steel ball is installed in an end of spring-loaded bolt.Use causes that the needed minimum spring force of visible damage (N) measures resistance to impact.In big pellet impact test, with carbon paper overlaminate floor A, a B and a C and allow them stand big steel ball (324g; Diameter is 42.8mm) impact, this steel ball is fallen from known height.In big ball test, increase height at interval up to the impact marking of this ball generation greater than 10mm with 50mm.This has highly determined anti-big pellet impact (unit is mm).Resistance to impact be expressed as do not cause visible surface break or produce greater than the marking of 10mm diameter under the maximum drop (mm) that can reach.
Fire resistance
Epiradiateur test (NF P 92-501) is the national standard combustion test of France, and is that many construction materials and engineering material are mandatory.
The sample of being tested (7 and 14) is of a size of 300mm * 400mm * maximum 120mm, and with the inclination of 45 degree sample is placed on the fixing self-supporting frame of 8mm.The electric radiator (tilting) that use is in 500W with 45 degree from top and below light this sample.Use two butane ignite fiery combustion will on this sample and under fiberboard lighted 20 minutes.
Fig. 6 shows the impact size classification grade of using bead impact test and big pellet impact test.
The foregoing description of the preferred embodiment of the invention is in order to illustrate and to describe and propose.Do not wish the detailed description of the present invention or be restricted to disclosed precise forms.Consider above-mentioned instruction, it is possible significantly revising or change.For example, if necessary, second flame retardant bed and backing layer can be merged into individual layer.
These embodiments are chosen and are described for explaining principle of the present invention best, so its practical application allows those of ordinary skills to use the present invention in the various embodiments of the special-purpose that is suitable for expecting and various modification.All such modifications and changing within the scope of the present invention, scope of the present invention by claims when according to their justices, definite when width legal and that rationally give is explained.Accompanying drawing and embodiment preferred are in no case planned and are not wished to limit the explanation of the common meaning of claim and its justice and wide region.

Claims (60)

1. high-pressure laminated plate (10) comprising:
The ground floor of Tetefol (12); With
At least one deck fiber reinforcement curtain (14), each layer of fiber reinforcement curtain adopts secondary binding agent and at least a filler dipping;
Described high-pressure laminated plate is characterised in that the calorific value that has less than about 3.0MJ/kg when according to ISO 1716 tests.
2. the laminate of claim 1 comprises the second layer (24) of Tetefol, and the described fiber reinforcement of one deck at least curtain is sandwiched between the ground floor and the second layer (22,24) of described Tetefol.
3. the laminate of claim 1, wherein said secondary binding agent is the thermal curable resin.
4. the laminate of claim 3, wherein said secondary binding agent are selected from carbamide, P-F, melocol, epoxy resin, unsaturated polyester (UP), crosslinkable acrylic resin, polyurethane resin, chloropropylene oxide-poly-amino polyamide, chloropropylene oxide-polyamino resin, chloropropylene oxide-polyamide and their mixture.
5. the laminate of claim 3, wherein said filler is selected from metal hydroxides, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin, chlorite, diatomite, feldspar, mica, nepheline syenite, pyrophyllite, silica, talcum, wollastonite, imvite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminium oxide, iron oxide, magnesium hydroxide, glass microballoon and their mixture.
6. the laminate of claim 1, wherein said filler is selected from metal hydroxides, metal carbonate and their mixture.
7. the laminate of claim 6, wherein with about 1: the ratio of the relative metal carbonate of metal hydroxides that 0.01-is about 1: 100 provides the described mixture of metal hydroxides and metal carbonate.
8. the laminate of claim 1, wherein said filler is selected from the mixture of calcium carbonate and aluminium hydroxide.
9. the laminate of claim 8, wherein said secondary binding agent is a carbamide.
10. the laminate of claim 9, wherein every layer of described fiber reinforcement curtain comprises the about 95wt% fortifying fibre of about 1-after dipping, about about 50wt% carbamide of 2-, the approximately about 85wt% calcium carbonate of 1-and the approximately about 85wt% aluminium hydroxide of 1-.
11. the laminate of claim 10, wherein every layer of described fiber reinforcement curtain has about 250g/m after dipping and before compacting 2-about 2000g/m 2Per unit area weight and about 500kg/m 3-about 2000kg/m 3Density.
12. the laminate of claim 10, wherein said fortifying fibre are the glass fibres that is selected from E-glass, ECR-glass, AR-glass, M-glass, D-glass, C-glass, S-glass, S2-glass and their mixture.
13. the laminate of claim 1, the wherein said fiber reinforcement of one deck at least curtain is a weaven goods.
14. the laminate of claim 1, the wherein said fiber reinforcement of one deck at least curtain is a non-woven fabric.
15. the laminate of claim 1 comprises that at least bilaminar fiber strengthens curtain, wherein said ground floor in two-layer is a weaven goods, and the described second layer in two-layer is a non-woven fabric.
16. the laminate of claim 1, the wherein said fiber reinforcement of one deck at least curtain comprises the fortifying fibre that is selected from glass fibre, basalt fibre, inorfil and their mixture.
17. the laminate of claim 1, the wherein said fiber reinforcement of one deck at least curtain comprises short glass fiber.
18. the laminate of claim 17, wherein said short glass fiber comprise chopped glass fiber bundles, short glass fiber rove, discrete short glass fiber and their mixture.
19. the laminate of claim 1, the ground floor of wherein said Tetefol is the facing paper of melamine-impregnated.
20. the laminate of claim 1 also is included in the paint film of the radiation curing on the exposure of ground floor of described Tetefol.
21. the laminate of claim 1 also is included in the urethane acrylate enamelled coating of the heat cross-linking on the exposure of ground floor of described Tetefol.
22. comprise the fiber reinforcement curtain of secondary binding agent and at least a filler, wherein said curtain has the calorific value less than about 3.0MJ/kg when according to ISO 1716 tests.
23. the fiber reinforcement curtain of claim 22, wherein said secondary binding agent are selected from carbamide, P-F, melocol, epoxy resin, unsaturated polyester (UP), crosslinkable acrylic resin, polyurethane resin, chloropropylene oxide-poly-amino polyamide, chloropropylene oxide-polyamino resin, chloropropylene oxide-polyamide and their mixture.
24. the fiber reinforcement curtain of claim 22, also comprise the binding agent that is selected from following material: polyvinyl alcohol, (partial hydrolysis) polyvinyl acetate, acrylic polymer and copolymer, crosslinkable acrylic polymer and copolymer, polymerisable multiple functionalized N-methylol compound, particularly N-methylolurea such as dimethylol urea and N-melamine methylol type resin, melamino-formaldehyde, phenol formaldehyde (PF), furfuryl group formaldehyde, resorcinol formaldehyde, styrene-butadiene-copolymer latex, cationic polyamide chloropropylene oxide, amino resins, epoxy resin, the polystyrene emulsion binding agent, polycarboxylic acids based binder, other latex and/or acrylic polymer or copolymer such as acrylamide, ethane-acetic acid ethyenyl ester/vinyl chloride, the acrylic acid alkyl ester polymer, SBR styrene butadiene rubbers, acrylonitrile polymer, polyurethane resin, polyvinyl chloride, polyvinylidene chloride, the copolymer of vinylidene chloride and other monomer, polyvinyl acetate, PVP, mylar, acrylic acid ester emulsion resin and styrene-acrylate.
25. the fiber reinforcement curtain of claim 22, wherein said filler are selected from metal hydroxides, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin, chlorite, diatomite, feldspar, mica, nepheline syenite, pyrophyllite, silica, talcum, wollastonite, imvite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminium oxide, iron oxide, magnesium hydroxide, glass microballoon and their mixture.
26. the fiber reinforcement curtain of claim 22, wherein said fiber reinforcement curtain comprises the fortifying fibre that is selected from glass fibre, basalt fibre, inorfil and their mixture.
27. the preparation method of high-pressure laminated plate comprises:
Be enough to Tetefol and the ground floor and the described fiber reinforcement of one deck at least curtain of described Tetefol is compressed together under one deck fiber reinforcement curtain pressure and temperature laminated together at least; With
Flood described paper and described fiber reinforcement curtain so that the calorific value less than 3.0MJ/kg to be provided when according to the described laminate of ISO 1716 tests with secondary binding agent and at least a filler.
28. the method for claim 27 wherein also is included in about 525N/m with described paper and described curtain described step compressed together 2-about 15,750N/m 2Pressure under described paper and described curtain is compressed together, described paper of heating and described curtain under about 120 ℃-about 220 ℃ temperature simultaneously.
29. the method for claim 27 comprises and select described secondary binding agent from following material: carbamide, P-F, melocol, epoxy resin, unsaturated polyester (UP), crosslinkable acrylic resin, polyurethane resin, chloropropylene oxide-poly-amino polyamide, chloropropylene oxide-polyamino resin, chloropropylene oxide-polyamide and their mixture.
30. the method for claim 29 comprises and select described filler from following material: metal hydroxides, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin, chlorite, diatomite, feldspar, mica, nepheline syenite, pyrophyllite, silica, talcum, wollastonite, imvite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminium oxide, iron oxide, magnesium hydroxide, glass microballoon and their mixture.
31. the method for claim 29 comprises and select described filler from metal hydroxides, metal carbonate and their mixture.
32. the method for claim 29 comprises and select described filler from the mixture of calcium carbonate and aluminium hydroxide.
33. the method for claim 27 comprises and select described filler from metal hydroxides, metal carbonate and their mixture.
34. the method for claim 27 comprises and select described filler from the mixture of calcium carbonate and aluminium hydroxide.
35. the method for claim 27 comprises that also the facing paper by melamine-impregnated forms the ground floor of described Tetefol.
36. the method for claim 27 comprises that also the paint with radiation curing is the exposure japanning of the ground floor of described Tetefol.
37. the method for claim 27 also comprises with the urethane acrylate paint of heat cross-linking and painting for the exposure of the ground floor of described Tetefol.
38. non-combustible high pressure laminate (46) comprising:
The decorative layer (50) of resin dipping;
First flame retardant bed that forms by fiber reinforcement curtain (52); With
Fibrolamellar (54).
39. the laminate of claim 38, the wherein said first fiber reinforcement curtain (52) comprises the fiber that is selected from glass fibre, basalt fibre, metallic fiber, inorfil, silicon dioxide fibre, carbide fibre, nitride fiber, carbon fiber and their mixture.
40. the laminate of claim 38, the wherein said first fiber reinforcement curtain (52) comprises the glass fibre that is selected from boron-free glass, E-glass, ECR-glass, C-glass, AR-glass, S2-glass and their mixture.
41. the laminate of claim 38, the wherein said first fiber reinforcement curtain (52) comprises the binding agent that contains the B b stage resin b.
42. the laminate of claim 38, the wherein said first fiber reinforcement curtain (52) comprises the binding agent that is selected from polyvinyl alcohol, acrylate, styrene-acrylate, carbamide, melocol, P-F, epoxy resin, unsaturated polyester (UP), crosslinkable acrylic resin, polyurethane resin, polyamide-amide epichlorohydrin resins and their mixture.
43. the laminate of claim 38, the wherein said first fiber reinforcement curtain (52) comprises the filler that is selected from following material: aluminum trihydrate, magnesium hydroxide, melamine cyanurate, halogenate additive, antimony trioxide, metal hydroxides, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin, chlorite, diatomite, feldspar, mica, nepheline syenite, pyrophyllite, silica, talcum, wollastonite, imvite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminium oxide, iron oxide, glass microballoon, the phosphoric acid ethylenediamine, phosphoguanidine, the boric acid melamine, (single, burnt, many) melamine phosphate, (single, burnt, many) ammonium phosphate, the dicyandiamide condensation product, common intumescent system and their mixture.
44. the laminate of claim 38, the wherein said first fiber reinforcement curtain (52) is a non-woven fabric.
45. the laminate of claim 38 also comprises second flame retardant bed that is formed by fiber reinforcement curtain (52), described fibrolamellar (54) is sandwiched between described first and second flame retardant beds.
46. the laminate of claim 45, wherein the described fiber reinforcement curtain (52,58) of described first and second flame retardant beds comprises the about 95wt% fortifying fibre of about 5-after the resin dipping, approximately about 75wt% binding agent of 5-and the about 80wt% filler of 0-.
47. the laminate of claim 46, the described fiber reinforcement curtain (52,58) of wherein said first and second flame retardant beds comprises the resinoid bond that is selected from polyvinyl alcohol, acrylate, styrene-acrylate, carbamide, melocol, P-F, epoxy resin, unsaturated polyester (UP), crosslinkable acrylic resin, polyurethane resin, polyamide-amide epichlorohydrin resins and their mixture.
48. the laminate of claim 47, the described fiber reinforcement curtain (52,58) of wherein said first and second flame retardant beds comprises the filler that is selected from following material: aluminum trihydrate, magnesium hydroxide, melamine cyanurate, halogenate additive, antimony trioxide, metal hydroxides, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin, chlorite, diatomite, feldspar, mica, nepheline syenite, pyrophyllite, silica, talcum, wollastonite, imvite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminium oxide, iron oxide, glass microballoon, the phosphoric acid ethylenediamine, phosphoguanidine, the boric acid melamine, (single, burnt, many) melamine phosphate, (single, burnt, many) ammonium phosphate, the dicyandiamide condensation product, common intumescent system and their mixture.
49. the laminate of claim 46, wherein the described fiber reinforcement curtain (52,58) of described first and second flame retardant beds has the about 500g/m of about 20-after dipping and before compacting 2Per unit area weight.
50. the laminate of claim 38, wherein said fibrolamellar (54) is based on the plate of timber.
51. the laminate of claim 38, wherein said fibrolamellar (54) are selected from one group of material that is made of high density fiberboard, medium density fibre board (MDF), directional fiber plate, particieboard and their mixture.
52. the laminate of claim 38, also comprise the decorative layer (50) that covers described resin dipping the resin dipping covering ply of paper (48) and be positioned at the backing layer (56) that the resin of described fibrolamellar (54) below floods.
53. the laminate of claim 52 also comprises the backing layer (56) of the resin dipping that is positioned at described fibrolamellar (54) below.
54. the laminate of claim 53, the backing layer (56) of the decorative layer (50) of wherein said resin dipping and described resin dipping is all made by facing paper.
55. the laminate of claim 38, wherein said laminate (46) is the floor layer pressing plate.
56. the laminate of claim 38, wherein said laminate (46) by classification in impacting grade 3 (IC3).
57. the preparation method of non-combustible high pressure laminate (46) comprising:
At about 1050N/m 2-about 5250N/m 2Pressure under backing layer (56) that the decorative layer (50) of the cover layer (48) of resin dipping, resin dipping, the flame retardant bed, fibrolamellar (54) and the resin that are formed by the fiber reinforcement curtain (52) of resin dipping are flooded compressed together, be heated to the about 225 ℃ temperature of about 150-simultaneously and kept about 10-about 50 seconds.
58. the method for claim 57 also is included in the step that the resinoid bond of selecting is provided in the described fiber reinforcement curtain (52) from following material: polyvinyl alcohol, acrylate, styrene-acrylate, carbamide, melocol, P-F, epoxy resin, unsaturated polyester (UP), crosslinkable acrylic resin, polyurethane resin, polyamide-amide epichlorohydrin resins and their mixture.
59. the method for claim 58 also is included in the step that the filler of selecting is provided in the described fiber reinforcement curtain (52): aluminum trihydrate from following material, magnesium hydroxide, melamine cyanurate, halogenate additive, antimony trioxide, metal hydroxides, metal carbonate, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin, chlorite, diatomite, feldspar, mica, nepheline syenite, pyrophyllite, silica, talcum, wollastonite, imvite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminium oxide, iron oxide, glass microballoon and their mixture.
60. second flame retardant bed that provides the fiber reinforcement curtain (52) by resin dipping to form between the backing layer (56) of described fibrolamellar (54) and described resin dipping is provided the method for claim 57.
CNA2006800164734A 2005-04-18 2006-03-30 Non-combustible high pressure laminate Pending CN101175634A (en)

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