DE10065550A1 - Process for adhesive-free preparation of a laminate useful for covering walls or ceilings, for a variety of uses comprises pressing a decorative layer onto a polymeric support and has at least one film like layer in between - Google Patents

Abstract

A process for preparation of a laminate with a support from at least one thermoplastic or thermoelastic polymer, and at least one decorative layer of open pore structure, especially wood veneer, in which the layer is pressed to the support at high temperature and pressure, or is back sprayed with the polymer, and having at least one film-like layer between the support and decorative layer is new. An Independent claim is included for a laminate (1) as described above.

Description

The invention relates to a method for producing a Composite body with a carrier made of at least one ther plastic or thermoelastic polymer and at least a decorative layer with an open-pore structure, in particular a wood veneer, the decorative layer with increased Pressure and increased temperature pressed with the carrier or is injected with the polymer. It is also on egg NEN composite body with a carrier of at least one thermoplastic or thermoelastic polymer and little at least one decorative layer with an open-pore structure, especially special in the form of a wood veneer, as well as on the use direction of such a composite body.

Composite bodies of this type are known and are found in particular re as a replacement for entirely made of wood or wood-based materials existing molded parts for various uses. While the Decorative layer in many cases made from a wood veneer det, are often also for other applications  visible layers of leather, imitation leather, imitation wood ten or the like is desired. On the one hand is an advantage the carrier material, which is considerably cheaper than wood rial, on the other hand, the carrier material enables ko Cost-effective and especially adhesive-free production using known methods in the field of polymer technology technology.

If the carrier consists of a thermosetting polymer, so the composite body is usually produced by low pressure casting process by putting the decorative layer in a mold arranged under static or small in contact with reactive synthetic resin components brought and the resin is cured. The disadvantage is on the one hand compared to thermoplastic polymers poor recyclability, on the other hand, in particular re natural decorative layers made of wood, leather or the like have a low affinity for synthetic resins that there is an untimely separation of the decorative layer from can come to the wearer.

EP 0 943 410 A1 describes a generic method ren to produce a decorative molding by the decor layer of wood, imitation wood, leather or paper with one thermoplastic natural polymer is injected. When injecting, the polymer melt penetrates into the oven fenporige structure of the decorative layer and thus forms one permanent and firm positive connection. additionally can the decorative layer with a Glue layer to be provided after the back injection to form a predominantly thermosetting composite is cured. On the one hand, a disadvantage is a common one Penetration of the polymer melt to the visible side of the De Coating layer during the spraying process, on the other hand  especially with thin decorative layers made of wood or the like the risk of breaking when injecting.

DE 198 52 035 A1 is a method for producing egg Composite body with a thermoplastic or thermo elastic straps and a decorative layer from a natural union material, e.g. B. a wooden veneer can be removed by the open-pore decorative layer in the carrier with increased Pressure and elevated temperature is injected. To a Pressure hammering of the polymer melt during the pressing process is the arrangement of a fiber layer, such as one Braid, woven, knitted, knitted, laid, fleece or the like, between the support and the wood veneer provided, the fiber layer additionally as a bonding agent serves between the carrier and the wood veneer. On in this way there can be an optical impairment of the Decorative layer due to penetration of polymer melt prevent as much as possible, but there is also one here Risk of breakage of the wood veneer during the pressing process. This applies in particular to relatively thin veneers a thickness less than about 0.8 cm.

The invention has for its object a method of type mentioned to the extent that each impairment of the decorative layer during the manufacturing process position of the composite body safely and reliably that will. It is also made in such a way th composite body and directed to its use.

The procedural part of this task is invented in accordance with a method of the type mentioned solved in that between the carrier and the decor layer at least one film-like layer arranged becomes.  

On the one hand, by the method according to the invention Penetration of the polymer melt to the visible side of the De cork layer even with very thin decorative layers on simple reliably and inexpensively prevented. While the connection between the film-like layer and the Carrier in particular by melting the at least upper surface plasticized polymer of the carrier ensured the connection between the film-like Layer and the decorative layer mainly through Form fit is achieved by the film-like layer under the pressure of the at least superficially plasticized poly mers of the carrier in the open-pore structure of the decor layer intervenes and gets caught there, for example. On this way is permanent, firm and adhesive-free Connection guaranteed. On the other hand, it was found that the film-like layer breaks the decorative layer, like a wood veneer or the like, during the fro position of the composite is reliably prevented by the pressure of the polymer of the carrier evenly on the surface of the De cork layer is distributed. The film-like layer increases thus the drapability of the decorative layer such that the Production of composite bodies with very thin decorative layers possible with any avoidance of committee, which is accompanied by considerable cost savings.

The method according to the invention enables the adhesive free production of composite bodies with different types Decorative materials such as wood veneer, cork, leather or others by the viewer as aesthetically perceived materials, where in the decorative layer, if desired, considerably thinner than 0.8 cm, e.g. B. can be chosen between about 0.2 and 0.8 cm can. The carrier can for example also with or several, in particular different colored wood veneers to achieve ornamental or figurative patterns  be layered, the veneers being flat or professional can form a lined surface, or the veneers forming a three-dimensional surface in ver different levels arranged parallel to the beam. The Carrier can be essentially plate-shaped, but also have any other shape, e.g. B. cuboid, cylindrical etc. be trained.

While the film-like layer basically from any conditions materials, e.g. B. polymers, metals, etc. exist can, according to a preferred embodiment of the inventions method according to the invention as a film-like layer a film from at least one polymer, in particular a thermopla static or thermoelastic polymer film, used. On this way it is possible to use the film during the Production of the prevailing temperature and Printing conditions at least superficially in the plastic Condition to transfer so that between the carrier and the Foil a double-sided fusion connection and between the Foil and the decorative layer in addition to the positive gene connection by engaging the film in the open-pore Structure of the decorative layer creates a fusion comes. This way the strength of the connection still increased, without that at least superficially plastifi graced polymer of the carrier and / or the film the decor layer penetrates.

For reasons of environmental compatibility, one is preferred containing or consisting of natural polymers Foil inserted.

For the greatest possible durability for the highest Ge to meet the requirements of the composite body provided that a cross-linkable functional group containing pointing polymers or consisting of such  Foil is used, preferably polymers with acid functional and / or nitrogen-containing functional group pen, e.g. B. from the group hydroxy, carboxy, aldehyde, Acetate, carbonate, ketone, ester, ether, amine and amide groups. Such films have proven to be excellent bonding agent between the carrier and one Decorative layer of wood proved by the film with the Wood and - when using such groups carrier polymer - also with this chemical bin the untimely loosening of the bond make practically impossible. With preference z. B. a pro Fo containing or consisting entirely of such fo lie used.

According to another preferred embodiment of the Invention According to the method it is provided that as a film Layer of paper is used. With advantage one coated with at least one polymer and / or in embossed paper layer used, in the case of a with a thermoplastic or thermoelastic polymer layers of paper in turn in addition to the form conclusive connection by engaging the paper layer in the open-pore structure of the decorative layer is a fusion bond the coated paper layer with the decorative layer is possible is. It can e.g. B. one with natural or cross-linked bare functional group-containing polymers tete or impregnated paper layer are used, from which the advantages mentioned above result. As before one with at least one egg has also participated resin, e.g. B. Japanese paint, coated and / or imprä gnier paper layer proved.

In a development of the method according to the invention, a Film-like layer containing fibers are used, so that especially when using a thermopla  static or thermoelastic polymer film on the surface melting the same partially free the fibers be laid and so the strength of the connection with both the carrier as well as with the open-pore decorative layer Increase bridging mechanically. While as fibers basically also synthetic or mineral fibers, such as glass, polyamide, carbon, aramid fibers or the like for environmental reasons attracts natural fibers.

In particular, when using Wood veneers also have a surface structure be shaped by z. B. a profile on the veneer assigned inner surface of a mold when closing penetrates into the veneer. Thus, e.g. B. by modifying the inner surface assigned to the veneer of the mold rough or leathery surfaces of the Decorative layer can be achieved without an additional Ver driving step is required.

In principle, any known synthetic thermoplastic or thermoelastic polymers such as polyolefins, polyamides, polyesters, polyacetates, polycarbonates, polyurethanes, vinyl polymers or copolymers thereof are suitable for the carrier. As already indicated, however, the need to conserve mineral oil resources, from which the basic materials of plastic synthesis are obtained, results in the need for synthetic polymers to be substituted by natural polymers. This need is all the more so since the often only option for waste disposal, namely incineration, synthetic plastics produce significant CO ₂ emissions, often accompanied by toxic emissions. For this reason, it is provided in a preferred embodiment that natural polymers are used for the carrier. Polymers made from renewable natural raw materials are characterized by an ecologically neutral CO ₂ balance, since when the natural polymers are burned, no more CO _{2 is} fed into the atmosphere than was withdrawn during the growth of the raw materials. Furthermore, biodegradable or compostable natural polymers are of primary interest, since they are degraded in a much shorter period of time and generally without residues in comparison with most synthetic polymers.

In a preferred embodiment it is provided that for the Trä ger natural polymers based on lignin or Li Polymer blends containing gnin can be used. While many plastics based on natural polymers or by oxidation, enzyme treatment or the like mo differentiated natural polymers poorer materialsi exhibit properties as synthetic plastics, lignin is characterized by high strength, rigidity, Impact resistance and high resistance to over UV radiation. Lignin is also a suitable one Insulating material for heat and sound insulation. Lignin is a high molecular polyphenolic macromolecule, which ver woody plants the spaces between the cell membranes fills out and turns into wood, with a mixing body pressure-resistant lignin and tensile cellulose. lignin falls in large quantities as a by-product of the pulp extraction and is therefore available in large quantities. This creates lignin sulfone when the wood is digested acids as part of the liquor in which the Li Gninsulfonic acids dissolved as phenates ("alkali lignin") through treatment with sulfuric acid and carbon dioxide the lignic acid can be precipitated. To make the Composite body according to the invention can because of its high Availability, for example, alkali lignin as a powder, such as it in the treatment of waste water from the cellulose ver  work received by evaporation and so far predominantly is burned, or z. B. dissolved in alcohols such as glycol ster form are used.

It can also be a lignin-containing natural product granulate of EP 0 720 634 B1 can be used, which consists of alkali Lignin and proteins or protein derivatives produced and from a stereochemical modification by treatment with organic acids, especially acetic acid and can be processed thermoplastically into molded parts. This Material is rot and compostable.

As the carrier material of the composite body according to the invention can also be a polymer blend of at least one synthetic and at least one natural polymer, in particular re lignin. By combining under different polymers, it is in particular possible for the intended use of the composite body in each case favorable properties of the two polymer components to use binatorial or the desired material highlight a polymer component, while the undesirable material properties of this component ever according to the mixing ratio to a certain extent from the other components are covered. This allows Provide composite bodies whose properties are targeted adjusted to the respective technical purpose can be.

The carrier can be used to achieve increased dimensional stability with reinforcing fibers are added, from the ge mentioned reasons the use of natural reinforcements tion fibers such as hemp, cellulose, flax, sisal, mis canthus, coconut, ramie and wood fibers or the like, is preferred. In many cases, the use of Hemp fibers are beneficial as they compare to others  Natural fibers have high-quality material properties, such as have high tensile strength. Of course come the fiber types mentioned also in the case of a with Naturfa layered film-like layer.

The pressure when injecting the decorative layer or when Pressing the same with the carrier depends on the use detem polymer or depending on the polymer mixture used Carrier preferably between 5 bar and 2000 bar, in particular between 15 bar and 1500 bar. The temperature is preferably between 100 ° C and 200 ° C, especially between rule 120 ° C and 180 ° C, and suitably corresponds at least the temperature of the melt transition range for the Carrier used polymer.

The invention also relates to a composite body with a Carrier made from at least one thermoelastic or thermo elastic polymer and at least one decorative layer with open-pore structure, especially in the form of a wooden door niers, which is one between the carrier and the decor has layer-like film-like layer. The fo lien-like layer enables a compared to the state of the Technology very thin decorative layer, e.g. B. with a thickness up to about 0.2 cm, with a visual impairment the decorative layer through penetrated polymer melt as well especially in the case of a decorative layer in the form of a Wood, cork veneer or similar materials are broken Chen the decorative layer during the manufacture of the composite is reliably avoided.

According to a preferred embodiment, the film-like layer has guide a film from at least one polymer, in particular re from at least one thermoplastic or thermoela tical polymer, so that between the film and the Carrier or the decorative layer both a form-fitting  also an at least superficial fusion connection is posed. The film preferably contains natural buttocks polymers or consists entirely of such polymers, wherein the film, for example, with the decorative layer and / or the Polymers having carrier-crosslinked functional groups contains or consists of the largest possible Durability of the composite body according to the invention for ensure high usage requirements. The functio nelle groups preferably contain oxygen and / or Nitrogen and are, for example, from the group of hydroxy, Carboxy, aldehyde, acetate, carbonate, ketone, ester, Ether, amine and amide groups selected. So can the slide advantageously contain or consist entirely of proteins Proteins are formed.

According to another preferred embodiment, the foil enlike layer on a paper layer, the paper layer preferably coated with at least one polymer and / or is impregnated. The paper layer can e.g. B. with thermoplastic or thermoelastic polymers or especially with at least one resin, e.g. B. Japan lacquer, or a resin mixture coated and / or imprä be decorated.

For a purely mechanical increase in the strength of the composite body contains the film-like layer in training Fibers, preferably natural fibers.

If desired, the decorative layer can have a visible side in particular have embossed surface structure.

For the reasons mentioned, the carrier preferably consists of natural polymers or a poly containing such mer blend, advantageously consisting of natural buttocks lymeren based on lignin or such  tendency polymer blend, which is due to the wood like character of the lignin a woody look like that like a woody feel. The carrier can e.g. B. from a natural polymer blend based on lignin and other natural polymers, such as shellac, polylactide, Po lyhydroxybutyrate or valerate, cellulose acetate or ace topropionate, starch, chitin or the like.

To increase the strength of the carrier, this Ver strengthening fibers, preferably natural reinforcement fa serums, such as hemp, cellulose, flax, sisal, miscanthus, Coconut, ramie and wood fibers or the like. Particulate fillers are also conceivable, whereby how therefore preferably natural substances, e.g. B. particulate chitin, come into question.

The composite body according to the invention is for many uses suitable for use. It is particularly useful in the case a wood veneer and a carrier based on Li Gnin due to its range of properties, its color and its consistency as a substitute for entirely made of wood or wood-based materials to existing composite bodies. So is the composite body, for example for floor coverings, such as Parquet, for wall and ceiling coverings or the like suitable, in the case of a carrier based on Lignin additionally its good heat and sound insulation Properties are beneficial.

The composite body according to the invention is also suitable for interior trim and interior parts for Motor vehicles, such as center consoles, dashboards, doors interior trim parts, sun and decorative covers, steering wheels etc., and housing, especially for electrical and / or electronic devices, such as television and radio housings, according to speaker boxes or the like. It is also suitable for  Furniture and musical instruments, especially for their view page. Finally, the Ver according to the invention bundle body also for everyday objects of any kind, such as Playing fields for board games, e.g. B. chess boards, Coasters for glasses etc.

The invention is based on one embodiment explained in more detail.

embodiment

It becomes an open-pore decorative layer in the form of a wood veneer placed in a hot press and as a foil Layer a thermoplastic polymer film, e.g. B. from Pro complexion. Alternatively, the decorative layer and the film can also be pre-connected, what z. B. by Aufka sheer film can happen on the decorative layer. to finally a thermoplastic base is made of lignin mixed with natural fibers and, if appropriate Fillers and other polymers and / or additives, such as Plasticizers, dyes, pigments, antioxidants or the like, applied, which by means of any thermo plastic processing has been prefabricated. The hot press is closed, with a pressure of about 200 bar and a temperature of about 160 ° C is set and the film both the decorative layer before a break through gene of the plasticized carrier polymer and in particular re protected from breakage. After opening the hot press and cooling The same becomes an intimate and lasting bond hold. The thickness of the decorative layer can be done in this way very low, e.g. B. in the range of about 0.2 cm, who selected the.

If a surface structure of the decorative layer is desired is on this during the manufacture of the composite  at the same time imprinted the desired structure, which is achieved through ent speaking training of one facing the decorative layer Inner surface of the hot press is reached.

Alternatively, the decorative layer can be arranged according to the arrangement of the film of course also with a pla certified polymer or a polymer mixture behind be injected, which is particularly true in the case of use Natural polymers are often beneficial because of the polymer then only needs to be plasticized once and thermal Impairment of the same can be prevented.

Below is an embodiment of one such manufactured composite body with reference to the Drawing explained in more detail. Show it:

Fig. 1 shows a cross section of a composite body and

FIG. 2 shows a detailed view II of the cross section according to FIG. 1.

The composite body 1 shown in Fig. 1, example, a thermoplastic substrate 2 made of a noble Lich lignin and shellac-containing polymer blend to that of natural reinforcing fibers and, if appropriate fillers added. The composite body 1 is provided on the visible side with a thin open-pore decorative layer 3 in the form of a wood veneer. Between the carrier 2 and the decorative layer 3 is a film-like layer 4 , for. B. a natural fiber-containing protein film is arranged, which prevents the decorative layer 3 from being impaired during the manufacture of the composite body 1 and additionally serves as an adhesion promoter between the carrier 2 and the decorative layer 3 .

As can be seen from FIG. 2, the connection between the decorative layer 3 and the film-like layer 4 is achieved on the one hand by positive locking, in that the film-like layer 4 engages in the open-pore structure of the decorative layer 3 . On the other hand, by at least superficial melting of the thermoplastic protein film during the production of the composite body, a melt connection between the decorative layer 3 and the film-like layer 4 and a bilateral melt or weld connection between the carrier 2 and the film-like layer 4 can be ensured. In the case of a film mixed with fibers, the mechanical strength of the composite is then increased further by bridging as a result of the fibers being exposed on the surface of the film which is at least superficially plasticized during manufacture. The film material based on proteins also ensures the formation of chemical bonds with both the wood veneer and the poly mer blend of the carrier 2 , so that the composite body has the greatest possible strength under the pressure and temperature conditions that occur during the production of the composite and has durability.

Claims (45)

1. A method for producing a composite body ( 1 ) with a carrier ( 2 ) made of at least one thermoplastic or thermoelastic polymer and at least one decorative layer ( 3 ) with an open-pore structure, in particular a wood veneer, the decorative layer ( 3 ) at elevated pressure and is pressed at elevated temperature with the carrier ( 2 ) or back-injected with the polymer, characterized in that at least one film-like layer ( 4 ) is arranged between the carrier ( 2 ) and the decorative layer ( 3 ). 2. The method according to claim 1, characterized in that a film made of at least one polymer is used as the film-like layer ( 4 ). 3. The method according to claim 1 or 2, characterized net that a thermoplastic or thermoelastic  Polymer film is used. 4. The method according to any one of claims 1 to 3, characterized ge indicates that a natural polymer containing or is used from such existing film. 5. The method according to any one of claims 1 to 4, characterized ge indicates a cross-linkable functional group containing polymers or from such be standing film is used. 6. The method according to claim 5, characterized in that Contain polymers with oxygen and / or nitrogen the functional groups are used. 7. The method according to claim 5 or 6, characterized in net that the functional groups from the group Hydroxy, carboxy, aldehyde, acetate, carbonate, Ke clay, ester, ether, amine and amide groups selected become. 8. The method according to any one of claims 1 to 7, characterized ge indicates that a protein containing or from such existing film is used. 9. The method according to claim 1, characterized in that a paper layer is used as the film-like layer ( 4 ). 10. The method according to claim 9, characterized in that one coated with at least one polymer and / or impregnated paper layer is used. 11. The method according to claim 9 or 10, characterized in net that one coated with at least one resin  and / or impregnated paper layer is used. 12. The method according to any one of claims 1 to 11, characterized in that a film-containing layer containing fibers ( 4 ) is used. 13. The method according to claim 12, characterized in that a film-like layer ( 4 ) containing natural fibers is used. 14. The method according to any one of claims 1 to 13, characterized in that a surface structure is simultaneously impressed on the decorative layer ( 3 ). 15. The method according to any one of claims 1 to 14, characterized in that natural poly mers are used for the carrier ( 2 ). 16. The method according to any one of claims 1 to 15, characterized in that natural poly mers based on lignin or lignin-containing polymer blends are used for the carrier ( 2 ). 17. The method according to any one of claims 1 to 16, characterized in that the carrier ( 2 ) with reinforcing fibers is added. 18. The method according to any one of claims 1 to 17, characterized in that the carrier ( 2 ) is mixed with natural reinforcing fibers. 19. The method according to claim 17 or 18, characterized records that the reinforcing fibers from the group Hemp, cellulose, flax, sisal, miscanthus, ko  Kos, Ramie and wood fibers is chosen. 20. The method according to any one of claims 1 to 19, characterized in that when injecting the decorative layer ( 3 ) or when pressing the same with the carrier ( 2 ), a pressure between 5 bar and 2000 bar, in particular between 15 bar and 1500 bar. 21. The method according to any one of claims 1 to 20, characterized in that when injecting the decorative layer ( 3 ) or when pressing the same with the carrier ( 2 ) a temperature between 100 ° C and 200 ° C, in particular between 120 ° C and 180 ° C, is set. 22. Composite body ( 1 ) with a carrier ( 2 ) made of at least one thermoplastic or thermoelastic polymer and at least one decorative layer ( 3 ) with an open-pore structure, in particular a wood veneer, characterized by at least one between the carrier ( 2 ) and the decorative layer ( 3 ) arranged film-like layer ( 4 ). 23. Composite body according to claim 22, characterized in that the film-like layer ( 4 ) comprises a film made from at least one polymer. 24. Composite body according to claim 22 or 23, characterized records that the film from at least one thermo plastic or thermoelastic polymer. 25. Composite body according to one of claims 22 to 24, there characterized in that the film is natural polymers contains or consists of such.   26. Composite body according to one of claims 22 to 25, characterized in that the film with the decorative layer ( 3 ) and / or the support ( 2 ) contains cross-linked functional groups containing polymers or consists of such. 27. Composite body according to claim 26, characterized in that that the functional groups oxygen and / or Contain nitrogen. 28. Composite body according to claim 26 or 27, characterized records that the functional groups from the group Hydroxy, carboxy, aldehyde, acetate, carbonate, Ke clay, ester, ether, amine and amide groups selected are. 29. Composite body according to one of claims 22 to 28, there characterized in that the film contains proteins or consists of such. 30. Composite body according to claim 22, characterized in that the film-like layer ( 4 ) has a paper layer. 31. Composite body according to claim 30, characterized in that the paper ply be with at least one polymer is layered and / or impregnated. 32. Composite body according to claim 30 or 31, characterized records that the paper layer with at least one resin is coated and / or impregnated. 33. Composite body according to one of claims 22 to 32, characterized in that the film-like layer ( 4 ) contains fibers. 34. Composite body according to claim 33, characterized in that the film-like layer ( 4 ) contains natural fibers. 35. Composite body according to one of claims 22 to 34, characterized in that on the decorative layer ( 3 ) has a surface structure on the visible side. 36. Composite body according to one of claims 22 to 35, characterized in that the carrier ( 2 ) contains natural polymers or consists of such. 37. Composite body according to one of claims 22 to 36, characterized in that the carrier ( 2 ) consists of natural polymers based on lignin or polymer blends containing them. 38. Composite body according to one of claims 22 to 37, characterized in that the carrier ( 2 ) has reinforcing fibers. 39. Composite body according to one of claims 22 to 38, characterized in that the carrier ( 2 ) has natural reinforcing fibers. 40. Composite body according to claim 38 or 39, characterized records that the reinforcing fibers from the group Hemp, cellulose, flax, sisal, miscanthus, ko Kos, Ramie and wood fibers are selected. 41. Use of a composite body ( 1 ) according to one of claims 22 to 40 for floor coverings, in particular parquet. 42. Use of a composite body ( 1 ) according to one of claims 22 to 40 for wall or ceiling coverings. 43. Use of a composite body ( 1 ) according to one of claims 22 to 40 for interior trim and interior fittings for motor vehicles. 44. Use of a composite body ( 1 ) according to one of claims 22 to 40 for housings, in particular for electrical and / or electronic devices. 45. Use of a composite body ( 1 ) according to one of claims 22 to 40 for furniture and musical instruments.