CN101636265A - New composite, their manufacture method and application thereof - Google Patents

New composite, their manufacture method and application thereof Download PDF

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Publication number
CN101636265A
CN101636265A CN200880005755A CN200880005755A CN101636265A CN 101636265 A CN101636265 A CN 101636265A CN 200880005755 A CN200880005755 A CN 200880005755A CN 200880005755 A CN200880005755 A CN 200880005755A CN 101636265 A CN101636265 A CN 101636265A
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CN
China
Prior art keywords
adhesive
face structure
fabric face
fiber
fabric
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Pending
Application number
CN200880005755A
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Chinese (zh)
Inventor
迈克尔·凯泽尔
克劳斯·弗雷迪克·格雷奇
伯恩德·克里斯提恩森
阿兰·甲斐
菲尔·梅勒
格兰达·本纳特
伯恩哈德·埃克特
安娜特·阿尔伯雷特
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Johns Manville Europe GmbH
Johns Manville
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Johns Manville Europe GmbH
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Publication of CN101636265A publication Critical patent/CN101636265A/en
Pending legal-status Critical Current

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Classifications

    • 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
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • 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
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/024—Honeycomb
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/07—Parts immersed or impregnated in a matrix
    • B32B2305/076—Prepregs
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/18—Fabrics, textiles
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/21—Anti-static
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/744—Non-slip, anti-slip
    • 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
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/18—Plaster
    • 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
    • B32B2317/00—Animal or vegetable based
    • B32B2317/02—Cork
    • 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
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • 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
    • B32B2317/00—Animal or vegetable based
    • B32B2317/16—Wood, e.g. woodboard, fibreboard, woodchips
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations

Landscapes

  • Laminated Bodies (AREA)

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, their manufacture method and application thereof
The present invention relates to new composite, particularly be suitable as the material in the internal structure, be used for lining, structure and be used to make the composite of furniture and similar products.
Composite replaces traditional construction material as structural material just more and more, and they must be adapted to various application.Therefore, need enough mechanical stabilities on the one hand, on the other hand, good working performance and low weight also are essential.Therefore, for improving existing composite, never lack trial.
Therefore, will mix mutually from this type of material of wood materials and other that the timber of pulverizing is made with using adhesive, known.Thus, two kinds of materials are usually by lamination and form composite.The selection of material and combination can improve mechanical performance, can also realize for example alleviating of weight simultaneously.
Can from WO2006/031522, recognize by the composite that " B " level adhesive is strengthened based on wood materials and nonwoven.The matrix nonwoven can be from for example US-A-5, recognizes in 837,620, US-A-303,207 and US-A-6,331,339.The publication of quoting discloses and other additive can have been joined in adhesive and/or the nonwoven in general mode, but does not provide more detailed data.
Therefore, exist the task of aspect application technology character and manufacturing process, known product being carried out optimization.
Subject content of the present invention is to make the method for composite, comprises 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.
The carrier that uses in step a) is preferably wood materials, paper, cork, cardboard, mineral board and/or so-called cellular thing.Cellular thing is to have the three-dimensional structure member that strengthens structure, because their structure (honeybee honeycomb structure) makes them might have unusual stability and intensity, and has low weight simultaneously.Cellular thing has so used a period of time in many applications, wherein also comprises the internal reinforcement as plank model component in structural region or the furniture.
Wood materials is by in hot pressing different wooden particle form being mixed the wood materials of making template or microscler wood shavings shape with natural and/or synthetic adhesive.The wood materials of Shi Yonging preferably comprises glued board or laminate in the present invention, the wood chip material is particieboard and OSB (oriented wood chipboard) particularly, wood fiber material is porous wood-fiber board, opening diffusion wood-fiber board, hard (high density) wood-fiber board (HDF) and middle density wood-fiber board (MDF) particularly, and Arboform.But Arboform is the material of the thermoplasticity work of lignin and other wooden composition.
Paper is preferably based on natural, paper synthetic, mixtures inorganic or ceramic fibre or these fiber types.
Cardboard is preferably the cardboard that based on natural and/or synthetic fiber, also comprises mixtures inorganic and/or ceramic fibre and these fiber types.
Described mineral board is preferably commercially available mineral cardboard, and it all has pressboard coating in both sides, plaster board, ceramic beaverboard, cement plate or lime plate.Alternatively, plate can be with natural and/or synthetic fiber reinforced, and wherein these fibers also can comprise inorganic and/or ceramic fibre.Reinforced fibers can exist with the form of long fibre, microfilament or as staple fiber.
Except the material of describing, carrier also can be made of cork or other vegetable material.
The weight of the per unit area of the carrier that comprises in the composite changes along with final application, without any concrete restriction.
The fabric face structure of using in step b) is all structures of being made by fiber, and fabric face produces by surperficial formation technology from fiber.
Be provided with the fabric face structure of B level adhesive, also can not use basically with adhesive, particularly chemical adhesive.But,, can introduce adhesive and/or can use known needle-punching method in order to ensure surface texture required intensity in further working.Except possibility for example, also what is particularly worth mentioning is that the waterpower needle point method here by the calendering or the mechanical consolidation of acupuncture.Chemical and/or thermoplastic adhesives are suitable as adhesive.
But, be provided with under the fabric face structure optimization situation of B level adhesive and reinforce in advance with chemical adhesive.The adhesive that uses can be identical or different, but must be selected from and the compatible adhesive system of B level adhesive.Additional adhesive ingredients mostly is 25% weight ratio most, is preferably 10% weight ratio or following; Minimum content is 0.5% weight ratio, and preferred minimum is 1% weight ratio.
The material that forms fiber is preferably fiber, ceramic fibre, inorganic matter fiber or the glass fibre of natural fiber and/or synthetic or natural polymer, also can use with the form of mixture.Admissible fabric face is cotton paper, liner, looped fabric, knit goods and nonwoven, is preferably nonwoven.
The fabric face of mineral and ceramic fibre is alumina silicate fibre, ceramic fibre, dolomite fiber, wollastonite fibre or vulcanie fiber, preferred basalt fibre, diabase fiber and/or melaphyre fiber, especially basalt fibre.Diabase and melaphyre are combined and are appointed as paleobasalts and diabase also through being often specified to greenstone.
Described mineral fibres adhesive-bonded fabric can form by long fibre or by staple fiber, and described long fibre is the endless fiber.The average length of the staple fiber in the adhesive-bonded fabric of used in the present invention mineral fibres is 5 to 120mm, and preferred 10 to 90mm.In other embodiments of the present invention, described mineral fibres adhesive-bonded fabric contains the mixture of circular fiber and staple fiber.The fiber diameter of described mineral fibres is 5 to 30 μ m, preferred 8 to 24 μ m, especially preferred 8 to 15 μ m.
The weight of per unit area inorganic salts fabric surface structure is 15 to 500g/m 2Between, preferably 40 to 250g/m 2Between, wherein these data are meant the surface texture that does not have adhesive.
Under the situation of glass fabric fiber, nonwoven is particularly preferred.They by long fibre, be that the fiber or the staple fiber of endless constitutes.The average length of staple fiber is preferably 10 to 90mm between 5 to 120mm.In another embodiment of the invention, glass fibre non-woven contains the fiber of endless and the mixture of staple fiber.
The fiber diameter of glass fibre is between 5 to 30 μ m, preferably between 8 to 24 μ m, between 10 to 21 μ m.
Except the diameter of quoting previously, can also use so-called glass microfiber.The preferred average diameter of glass microfiber is between 0.1 to 5 μ m.The microfibre that forms described fabric face also may reside in the mixture with other fiber, described other fiber preferred glass fibers.In addition, the layer structure of microfibre and glass fibre also is possible.
In addition, the fabric face structure also can have fiber, line or long fibre and reinforces.Gut threads is preferably multiply long fibre or the rove based on glass, polyester, carbon or metal.Gut threads can be used as it is, and perhaps also can use with the form of fabric face structure, for example fabric, liner, looped fabric, knit goods or nonwoven.Reinforce and preferably comprise parallel line layer or liner.
The weight of per unit area glass fabric surface texture is 15 to 500g/m 2Between, preferably 40 to 250g/m 2Between, wherein these data are meant the surface texture that does not have adhesive.
The glass fibre that is fit to comprises the fiber of making from A-glass, E-glass, S-glass, T-glass or R-glass.
Fabric face can be made according to any known method.For the glass nonwoven, be preferably and do or the soak equipment, method.
In the fabric face of the fiber of synthetic polymer, preferred adhesive-bonded fabric, especially so-called spunbond cloth (spun bonds), the i.e. spunbond adhesive-bonded fabric for preparing by the deposition melt-spun long fibre that tangles.But they are made up of the annular synthetic fibers of the polymeric material of melt-spun.The suitable polymers material is for example polyamide, for example polyhexamethylene two adipamides, polycaprolactam, the polyamide of armaticity or part armaticity (" aromatic polyamides "), fatty polyamide, nylon for example, the part armaticity or the polyester of armaticity fully, polyphenylene sulfide (PPS), polymer with ether and ketone groups, for example polyether-ketone (PEK) and polyether-ether-ketone (PEEK), polyolefin, for example polyethylene or polypropylene, cellulose or polybenzimidazoles.Except above-mentioned synthetic polymer, even spun those polymer also are suitable from solution.
But described spunbond adhesive-bonded fabric preferably is made up of the polyester of melt-spun.In principle, the polyester material that is suitable for making fiber of all known types all is considered to polyester material.Particularly preferred polyester contains the PETG (PET) of at least 95 moles of %, especially those unmodified PET.
If composite of the present invention should have fire retardation in addition, advantageously they are spun from the polyester with fire-retardant mode modification.These polyester with fire-retardant mode modification are known.
The long stapled independent fiber number of polyester in described spunbond adhesive-bonded fabric is 1 to 16 dtex, preferred 2 to 10 dtexs.
In other embodiments of the present invention, described spunbond adhesive-bonded fabric can also be the binder fibre fabric by the sclerosis of melt binding agent, and it contains carrier fibre and merges fiber.Described carrier fibre and fusion fiber can form the property polymer derived from any thermoplastic fibre.These spunbond adhesive-bonded fabrics by melt binding agent sclerosis are described in EP-A-0, in 446,822 and EP-A-0,590,629.
Except annular long fibre (spun-bond process), described fabric face can also be by staple fiber or staple fiber and annular long stapled mixture structure.The independent fiber number of the staple fiber in described adhesive-bonded fabric is 1 to 16 dtex, preferred 2 to 10 dtexs.Fibre length is 1 to 100mm, and preferred 2 to 500mm, and especially preferred 2 to 30mm.Described fabric face structure can also be by the fibrous structure of different materials, can obtain special performances.
In addition, the fabric face structure also can have fiber, line or long fibre and reinforces.Gut threads is preferably multiply long fibre or the rove based on glass, polyester, carbon or metal.Gut threads can be used as it is, and perhaps also can use with the form of fabric face structure, for example fabric, liner, looped fabric, knit goods or nonwoven.Reinforce and preferably comprise parallel line layer or liner.
Construct the long fibre of described binder fibre fabric and/or cross section or other shape that staple fiber can have actual circle, for example cross section of dumb-bell shape, kidney shape, triangle or trilobal or leafy shape.Even can use fiber and the two components or the multicomponent fibre of hollow.In addition, described fusion fiber can use with the form of two components or multicomponent fibre.
Form additive agent modified that the fiber of described fabric face structure can be by routine, for example by the antistatic additive modification, described antistatic additive is carbon black for example.
The per unit area weight of the fabric face structure of the fiber of synthetic polymer is 10 to 500g/m 2, preferred 20 to 250g/m 2
Described natural fiber is a string, is derived from the fiber of grass, straw, timber, bamboo, reed and bast, perhaps zoogenous fiber.String is a total notion and representative species subbundle, for example cotton, kapok or poplar fine hair, bast fiber is bamboo fiber, hemp, jute, flax or ramie, hart fiber for example, for example sisal hemp or abaca, perhaps fruit fiber, for example coconut.Zoogenous fiber is wool, animal hair, feather and silk.
The per unit area weight of the fabric face structure of natural fiber is 20 to 500g/m 2, preferred 40 to 250g/m 2
The fabric face of the fiber of natural polymer is a cellulose fibre, for example viscose glue or vegetalitas or animal protein fiber.
In the fabric face of cellulose fibre, adhesive-bonded fabric is particularly preferred.They are by long fibre and/or staple fiber structure, and described long fibre is the endless fiber.The average length of described staple fiber is 1 to 25mm, and preferred 2 to 5mm.
The average diameter of described cellulose fibre is 5 to 50 μ m, preferred 15 to 30 μ m.
Fabric face structure at least one side that is applied to carrier of using in step b) contains the adhesive of at least a B of being in level state.
B level adhesive is represented only partial reinforment or sclerosis, the adhesive that still can harden at last by for example hot post processing.Such B level adhesive is at US-A-5, carried out detailed description in 837,620, US-A-6,303,207 and US-A-6,331,339.Disclosed there B-level adhesive also is the subject content of this specification.B-level adhesive is preferably the adhesive based on furfuryl alcohol formaldehyde, phenol formaldehyde (PF), melamine formaldehyde (MF), ureaformaldehyde and composition thereof.Relate to aqueous systems under the preferable case.Other preferred adhesive system is formaldehydeless adhesive.The difference of B level adhesive is that they can carry out multistage sclerosis, that is to say, they still have enough adhesive powers after sclerosis for the first time or first sclerosis, make them can be used for further processing.Such adhesive adds the catalyst after-hardening usually under about 350 temperature in a step.
In order to form B level state, these adhesives are adding the catalyst after-hardening alternatively.The amount of hardening catalyst mostly is 10% weight ratio most, is preferably 0.25 to 7% weight ratio (with respect to the adhesive total amount).For example, ammonium nitrate and organic aromatic acid for example maleic acid and p-methyl benzenesulfonic acid are suitable as hardening catalyst, and state reaches quickly because its allows the B level.Except ammonium nitrate, maleic acid and p-methyl benzenesulfonic acid, all materials with suitable acid function all are suitable as hardening catalyst.In order to reach B level state, that the fabric face structure that is impregnated with adhesive is dry under the Temperature Influence that does not produce sclerosis fully.Required machined parameters depends on selected adhesive system.
The lowest temperature and the upper limit can be subjected to the influence of the selection of time length, and/or by adding or avoiding excessive or strong excessively acid hardening catalyst and/or alternatively by using stabilizing agent to influence.
Described B-stage binding agent is applied at b) in can carry out by means of all known methods on the fabric face structure of appointment.Except being sprayed on it, flooding and being pressed into wherein, described binding agent can also be by applying or applying by the swivel nozzle head.
Other preferable methods is to apply described B-stage binding agent by applying foam.In the applying of foam, the binding agent foam generates by means of the blowing agent in foam mixture, promptly is applied on the described adhesive-bonded fabric by suitable coating aggregate.At this, described applying can also be undertaken by the swivel nozzle head.
In may foam coating, basically without limits about described blowing agent for the binding agent in B-stage.Preferred blowing agent is for joining ammonium stearate or the succinate in the described binding agent with the amount of 1wt% to 5wt% under the dry state.In addition, if desired, the catalyst mix of having described is arrived wherein.The solid content of described foam is at least 40%, preferably at least 50%.
The technology that foam applies makes that technology controlling and process can be very flexible, and makes it possible to achieve multiple different product property.Except be penetrated into the length of penetration in the described fabric face as the described foam of the conciliation of target, described binding agent charging and porosity can change in grace period.In addition, foam apply the advantage that provides very big aspect technology controlling and process, especially at dipping or apply aspect the constancy of solid content in the described fabric face process, and required compatibility demand in described binding agent upper surface manufacturing process.
According to b) functional material that uses can for example apply simultaneously as mixture or apply as component separately, perhaps apply before or after applying described binding agent with described B-stage binding agent.If described B-stage binding agent applies method by foam and applies, so advantageously with described foam, perhaps be distributed in and apply described functional material in the described foam, perhaps described functional material is applied on the foam of still new system.
The functional material that uses in step b) is preferably fireproof agent, be used for the material of discharge electrostatic charges, be used to shield electromagnetic radiation the particularly coloured pigment of material, organic or inorganic pigment, can increase the material of the wearing and tearing and/or the resistance of sliding or decorative layer etc.The functional material preferred arrangement can pass nonwoven to small part on the side of fabric face structure away from carrier.
In the revision of method, the adhesive that adds other is to be fixed on functional material on the fabric face structure.Here preferred select with the fabric face structure in the identical adhesive (B level adhesive) that exists.The amount of functional material is determined by application subsequently.
Fireproof agent is inorganic fire agent, organophosphor fireproof agent, based on the fireproof agent or the expansible fireproof agent of nitrogen.(bromo and chloro) fireproof agent of halo also can use, but because their risk assessment rather than preferred.The example of such halo fireproof agent is poly-bromo diphenyl ether, for example decaBDE, tetrabromobisphenol A and HBCD (HBCD).
Fireproof agent based on nitrogen is melamine and urea.
The organophosphor fireproof agent is the aromatic series and the Arrcostab of phosphoric acid in typical case.Preferred TCEP (tricresyl phosphate (chloroethyl) ester), TCCP (tricresyl phosphate (chloropropyl) ester), TDCCP (tricresyl phosphate (two chloro isopropyls) ester), Triphenyl phosphate, the tricresyl phosphate octyl group ester (tricresyl phosphate-(2-ethylhexyl) ester) of using.
The inorganic fire agent is typically hydroxide for example aluminium hydroxide and magnesium hydroxide, and borate is Firebrake ZB for example, and ammonium compounds is ammonium sulfate for example, and red phosphorus, sb oxide is antimony trioxide and antimony pentaoxide for example, and/or the silicate of lamination vermiculite for example.
Antistatic and electromagnetic shielding effect can realize by using the reagent that improves electric conductivity.
The particle that antistatic additive normally conducts electricity.The material that is fit to is carbon for example carbon black, graphite and the CNT (C-nanotube) of electric conductivity, Markite, or metal or the fiber of metal ingredient is arranged.
Be used to shield the material that the material of electromagnetic radiation normally conducts electricity.They can be set up with paillon foil, particle, fiber or the fine rule of above-mentioned material and/or the form of fabric face structure.
Inorganic or organic pigment is a means of particulate material.Except filler CaCO for example 3, outside talcum, gypsum or the tripoli, pigment, with regard to aspect, the especially pigment that can in color, use of the value that should increase composite.
Except increasing value, also having used increases the material of using applicability.Specifically, being construed as here is the covering that antiskid is moved covering and guaranteed to increase abrasion protection.Sic and/or SiO 2Particle is preferred for the moving covering of antiskid, and the granular size of use is preferably 2-5mm.Content is 1-40%, is preferably 10-30%.For validity that increases covering and the amount that reduces the covering that uses, can further construct the surface.
Materials similar is used to the surface and strengthens, to improve wearing and tearing and hardness.But, having used particle size less than 1mm, this can produce stone surface.
In functional layer is under the situation of the moving covering of antiskid, if it or basic granules show in fabric face structure and/or B level adhesive fully or work to small part, will be favourable.Particularly at the moving covering of antiskid with under safeguarding that reinforcement is with the situation of improving wearing and tearing and hardness, if particle is applied on the fabric face structure, making particle outstanding to small part from the fabric face structure, will be favourable.The roughness that obtains, particularly for the moving covering of antiskid, must meet the requirement of suitable national standard and rules.
Decorative layer is an ornamental member.This should be understood to include decorative layer and the form that increases the value of composite.The example of such form is frosting, cork, facing paper, has the paillon foil of grainer, covers paper, HPL, CPL (being built into the laminate of multilayer) or be also referred to as the ornamental half-finished scraps of paper or plastic sheet with different colours.For their parts, ornamental semi-finished product can contain B level adhesive and/or one or more fabric face, are preferably nonwoven or nonwoven layer.
Applying by known technology of the functional material that uses in the step b) undertaken, and changes along with the essence of concrete functional material.Here apply also and can be undertaken by rotary nozzle.
Being laminated in the step c), carrying out by this way under the effect of pressure and heat of the structure that obtains in step b) accepted its last sclerosis even be able to the adhesive that B level state exists.Lamination can carry out by discontinuous or continuous compacting or by rolling.The parameter of pressure, temperature and duty time is selected according to used B level adhesive.
In step d) at least one other protective layer apply and dry, by known pressure, spray and the technology of spraying paint is carried out.Here apply also and can be undertaken by rotary nozzle.The drying of protective layer changes according to selected system.
Protective layer normally coats with lacquer, and for example powder paints, varnish or transparency lacquer are preferably the aging anti-scratch lacquer of defencive function layer opposing mechanical influence or opposing UV.
In the version of the change of the inventive method, in step b) even have only the fabric face structure to apply with the adhesive of at least a B of being in level state, and being applied in the step after the step b) of at least a functional material carried out.
The present invention also comprises such method, comprises the following steps:
I) provide carrier;
II) 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;
III) alternatively will be according to Step II) structure that obtains carries out lamination under the effect of pressure and heat, so that the adhesive that exists with B level state partially or completely hardens;
IV) apply at least a functional material in the fabric face structure away from a side of carrier;
V) alternatively will be according to step IV) structure that obtains carries out lamination under the effect of pressure and heat, so that the adhesive that exists with B level state is accepted its final sclerosis,
VI) apply the other protective layer of one deck at least alternatively, and carry out drying.
Step I), V) with VI) with above-mentioned step a), c) and d) identical.In Step II) in contain the applying of fabric face structure of the adhesive of at least a B of being in level state, according to preceding step b) the identical Step II described down) carry out, wherein do not have functional material.
Step II I) and VI) being laminated to pressure and heat is carried out down, the feasible adhesive that exists with B level state is accepted its part or last sclerosis.Lamination can carry out by discontinuous or continuous compacting or by rolling.The parameter of pressure, temperature and duty time is selected according to used B level adhesive.
At step IV) in the functional material that uses be at first at b) functional material described down, be preferably the fire proofing material of mentioning, the material that is used for discharge electrostatic charges, the material that is used to shield electromagnetic radiation, the particularly coloured pigment of organic or inorganic pigment, can increase material or decorative layer the wearing and tearing and/or the resistance of sliding.
For the fixed function material, can add adhesive in addition so that functional material is fixed on the fabric face structure.Here preferred select with the fabric face structure in the identical adhesive (B level adhesive) that exists.The content of functional material is by follow-up application decision.
Step IV) applying by known technology of functional material undertaken in, changes along with the character of concrete functional material.Here apply also and can be undertaken by rotary nozzle.
B level adhesive or other adhesive by the situation that applies foam and apply under, with step IV) in functional material with foam or be distributed in the foam and apply, or functional material is applied on the still fresh foam, will be favourable.
Except above-described method, even composite also is unknown in existing technology originally.
Therefore, other subject content of the present invention is a composite, comprising:
A) carrier,
B) be applied at least one fabric face structure in two sides of carrier at least one, 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.
By using selected fabric face structure, method of the present invention is changed and revises also is possible.
Other subject content of the present invention is to make the method for composite, comprises 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 wherein the fabric face structure was reinforced before providing B level adhesive,
C) apply at least a functional material alternatively
D) will under the effect of pressure and heat, carry out lamination according to the structure that step b) or step c) obtain, so that the adhesive that exists with B level state is accepted its final sclerosis,
E) apply other protective layer and the drying of one deck at least alternatively.
The reinforcing of the fabric face structure of mentioning in step b) can be undertaken by the mechanical influence of power, preferably by acupuncture and/or calendering and/or compacting, and/or by chemistry and/or thermoplastic adhesives.The adhesive that uses can be identical, also can be different, but must be selected from and the compatible adhesive system of B level adhesive.Additional adhesive ingredients is promptly distributed to the adhesive ingredients of pre-reinforcing, for about 25% weight ratio, is preferably 10% weight ratio or following; Minimum content is 0.5% weight ratio, is preferably 1% weight ratio.
The fabric face structure optimization that is provided with B level adhesive is reinforced in advance with chemical adhesive.
Applying of the functional material of optional use uses known technology to carry out in step c), changes according to the character of concrete functional material.Applying or importing also here can be undertaken by rotary nozzle.
Execution in step d subsequently) and e), according in the past at step c) and d) under description carry out.
Under the condition of selecting pre-fabric face structure of reinforcing, these composites can more easily further be processed, and reduce manufacturing expense.
Therefore, other subject content of the present invention is semi-finished product, comprising:
A) carrier, and
B) be applied at least one fabric face structure in two sides of carrier at least one, surface texture contains the adhesive of at least a B of being in level state, and wherein the fabric face structure has extra reinforcing.
The extra reinforcing of the fabric face structure of mentioning in the step b) can be undertaken by the mechanism of power, preferably by acupuncture and/or calendering and/or compacting, and/or by chemistry and/or thermoplastic adhesives.The extra adhesive that uses can be identical, also can be different, but must be selected from and the compatible adhesive system of B level adhesive.Extra adhesive ingredients is promptly distributed to the adhesive ingredients of pre-reinforcing, is 25% weight ratio to the maximum, is preferably 10% weight ratio or following; Minimum content is 0.5% weight ratio, and preferred minimum is 1% weight ratio.The extra reinforcing of fabric face structure was preferably carried out before applying B level adhesive.The fabric face structure optimization that provides B level adhesive is reinforced in advance with chemical adhesive.
By the pre-reinforcing of high level, the conversion in the production can be easier and realizes more quickly, thereby more economically.This flexibility has caused the remarkable economical advantage.
Be provided with at above-mentioned semi-finished product under the situation of functional material, they have become the composite of completion.
Therefore, other subject content of the present invention is the semi-finished product that contain 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 has extra reinforcing.
Therefore, other subject content of the present invention is a composite, comprises:
A) carrier,
B) be applied at least one fabric face structure in two sides of carrier at least one, surface texture contains the B level adhesive of at least a final sclerosis, and wherein the fabric face structure has extra reinforcing,
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.
The extra reinforcing of the fabric face structure of mentioning in step b) was described in the above.For carrier, B level adhesive, functional material and protective layer also is same.
In addition, the present invention also comprises ornamental semi-finished product, particularly CPL and HPL, comprises at least one the fabric face structure that contains B level adhesive, is preferably the nonwoven that contains at least one functional layer.
CPL and HPL typically by which floor, be generally the 2-50 layer and constitute with the brown paper of melamine, MUF or phenol B level adhesive-dipping.Contain at these CPL ' s and/or HPL ' s under the situation of nonwoven of at least a B of containing level adhesive, replace the number of plies of the used brown paper of ply of paper significantly to reduce fully.
Contain the use of the nonwoven of B level adhesive, the number of plies of brown paper has been reduced one deck at least, but preferably reduced by at least 50% the brown paper number of plies, keep laminate to have same character simultaneously.The minimizing of the brown paper amount of adhesive-dipping makes can improve the fire prevention classification, can expand to the classification of " not flammable ".
Therefore, other subject content of the present invention is ornamental semi-finished product, has particularly comprised at least one the fabric face structure that contains B level adhesive, the CPL that is preferably nonwoven and/or HPL, and wherein the fabric face structure also can be reinforced in advance.This can cause the further minimizing of the brown paper number of plies.
CPL ' s of the present invention and/or HPL ' s preferably have 1 to 25 layer of nonwoven that contains B level adhesive.In addition, CPL ' s of the present invention and/or HPL ' s can have the more multi-layered brown paper with melamine, MUF or phenol B level adhesive-dipping.
Ornamental half-finished manufacturing is by carrying out lamination by this way under the effect of pressure and heat, partially or completely harden and carry out even be able to adhesive that B level state exists.Lamination can carry out by discontinuous or continuous compacting or by rolling.Pressure, temperature and duty time parameter are selected according to the B level adhesive that uses.
Above-mentioned material is suitable as carrier, fabric face structure, B level adhesive, functional material and protective layer.Disclosed preferred embodiment also is applicable to composite of the present invention in the scope of method of the present invention.
Above-mentioned functional material can exist 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.These embodiments are suitable for functional material, for example fireproof agent, the material that is used for discharge electrostatic charges, the material that is used to shield the electromagnetism electric charge, the material that is used to shield electromagnetic radiation, the particularly coloured pigment of organic or inorganic pigment or decorative layer etc.
In preferred embodiments, functional material has formed the layer that separates in composite of the present invention.This embodiment is particularly suitable for having increased the resistance to wearing and tearing and/or slip, and/or has increased the functional material that is worth by the optical effect on surface.If basic granules from outstanding to small part on the fabric face structure that provides B level adhesive, makes functional material be manufactured into the moving material of antiskid or wearing and tearing is had the resistance of increase, will be particularly advantageous.
Functional material be present in the carrier and/or the side of fabric face structure away from carrier on.
Composite of the present invention makes the application that directly can be used for subsequently become possibility, because composite has contained essential functional material deposit.
In a kind of version of variation, applying also of the fabric face structure of equipping in the step b) can be carried out in the manufacture process of carrier.In other words, be not the carrier of the completion in the step a), but carrier form in step a).The carrier that forms is suppressed with the fabric face structure of equipment, and wherein the fabric face structure is compatibly imported in the compacting and/or drying device of carrier.The manufacturing of carrier-non-woven fabric compounded material 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.
CN200880005755A 2007-02-21 2008-02-20 New composite, their manufacture method and application thereof Pending CN101636265A (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
DE102007008423.6 2007-02-21
DE102007008423A DE102007008423A1 (en) 2007-02-21 2007-02-21 Making composite for use e.g. in furniture or floor covering, involves applying textile sheet containing a B-stage binder to one side of a support, applying functional material to the textile and then curing the binder
DE102007008424.4 2007-02-21
DE102007012651.6 2007-03-16
DE102007028531.2 2007-06-18

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