DE19942972A1 - Laminated material with flexible decorative and carrier layers for bonding to a carrier material to form a composite has an outer layer of heat activated adhesive - Google Patents

Abstract

A heat activated adhesive layer(3) is applied to the outside face of the carrier layer(5) during pressing to enable the latter to be bonded to a variety of supporting materials. Independent claims are made for: (1) a process for manufacturing the laminate using heat and pressure; and (2) a use of the laminate as a flexible layer on a carrier layer of a composite plate.

Description

The invention relates to a laminate, a process for its manufacture according to the preamble of claim 1 or of claim 7 and its use.

State of the art

Laminates in the form of an HPL (High Pressure Laminate) or of a CPL (Continuous Pressure Laminate) for example, together with a particle board as a carrier board used for the production of a composite panel.

An HPL or CPL laminate regularly consists of one Melamine formaldehyde resin-impregnated decorative film and a or several core papers containing phenol formaldehyde resin are impregnated or other resin-absorbing carrier media. HPL materials are made in single or multi-day presses with or without cooling cycle using pressure and more suitable Temperature. CPL materials are used in continuous presses (CPL systems) using Pressure and suitable temperature. Before the  Application to a carrier plate to generate the Composite panel is the back of the pressed Layer material mostly ground to a possible flat and adhesive-affine surface for the subsequent one Obtain gluing step with the carrier plate. The Gluing to the carrier plate is generally done under Printing and use of a suitable adhesive system (e.g. one Wood glue). However, the gluing process has the disadvantage that in some cases (e.g. when gluing with wood glue) a not completely even adhesive application before Gluing can be achieved, d. H. that at there is a small amount of the adhesive in some places or even complete (which is preferred in the peripheral areas of the Plate materials occurs) is missing or contrary to this the adhesive (glue) forms lumps or of (open-pore) Backing material is soaked up that the adhesive on the Surface no longer available in sufficient quantity for gluing is available. Likewise, when gluing with conventional adhesive systems on the problem of time limited adhesive activity (e.g. open time), being between the time of applying the adhesive system and the merging of the components to be bonded certain time must not be exceeded by a desired minimum liability of the components to each other fall below. Furthermore, can be used as a carrier plate for the Composite plate only one material can be used withstands the pressure without damage while gluing.

Disadvantageous when using the ones described above Adhesive systems sometimes show the emission of volatile components and solvents from the liquid adhesive system and the associated action on people and the environment as well as the problem of cleaning the Containers, lines and machines from adhering Adhesive residues and the disposal of these adhesive residues or  Cleaning solutions and associated burdens on the Environment.

Object and advantages of the invention

The invention has for its object a To provide layer material, which is particularly suitable for Production of a composite panel is suitable and the does not have the aforementioned disadvantages.

According to the invention, this object is achieved by a laminate solved according to claim 1. The invention further relates to Process for the production of this laminate and its Use.

The invention is based on a laminate with a flexible Decorative layer and at least one resin impregnated Carrier material layer, e.g. B. a resin-impregnated Core paper layer. The core idea behind the laminate is now that at least one resin-impregnated carrier material layer an external thermally activated adhesive layer is applied, which at Shows no adhesive properties at room temperature. Through this Measure the laminate can be compared with much lower pressures only by a suitable one Heating to a predetermined temperature to a Laminate surface. Preferably one thermally activated hot-melt film used. For example can the thermal lamination of the laminate in a Direct coating recooling press but also by others suitable methods on a desired carrier medium, e.g. B. a chipboard to create a composite board on one side or on both sides. To at such a Composite panel production, especially compared to one Cold glue cold press can also increase throughput used a multi-day direct coating recooling press  become. Eliminated by the laminate according to the invention in a composite panel production compared to conventional bonding techniques (e.g. cold gluing) Problems such as adhesive inhomogeneities in the form of partially reduced or missing adhesive application, Accumulations of adhesive or sagging into the carrier medium Glue. In contrast to this is the thermo-activated Adhesive layer in closed and uniform thickness the laminate is preferably present in film form, which when arranged on a composite panel also to a contributes to a calmer surface appearance. Furthermore, due to avoiding incorrect glue points a higher one Process reliability achieved and the yield z. B. at the Composite panel production improved. Another advantage is that when using the thermolaminatable Laminate on the use of a sanding unit Generation of an adhesive-affine laminate back as well on the use of units for storing, dosing and can be dispensed with to apply the adhesive.

The thermally activated laminate also needs no protective film on the adhesive side during storage and / or during transportation. Its glue activity only starts at a predetermined temperature. It can be also a variety for different laminates different adhesive films for different Temperature ranges based on non-polar and polar Provide plastics. About the number of used Core paper layers or other resin-absorbing Carrier material layers can also be the final thickness of the laminate.

In a particularly advantageous embodiment of the Laminate is between the at least one resin-impregnated carrier material layer and the thermally activated adhesive layer a suction layer,  preferably a sodium kraft paper. This The absorbent layer liner enables that in a safe way Combination z. B. a phenol formaldehyde resin impregnated Core paper (thermoset) with a polyolefinic Adhesive layer (thermoplastic), which otherwise if necessary Could show connection problems. In particular through the Structure of the laminate with an intermediate layer of absorbent paper as well as the thermoplastic and elastic adhesive layer has this in comparison to one conventional laminate has greater flexibility. The increased flexibility of the laminate according to the invention facilitates handling and transportation. The adhesive layer reduces the risk of breakage or sets the possibility material fragmentation. This does not allow only reduce material loss, but can also reduce the risk of injuries from splinters or sharp edges be prevented. Due to the increased flexibility of the Laminate and its reduced tendency to break are therefore laminates on single or multi-day presses Recooling cycle or on CPL or short-cycle systems with suitable devices for cooling the thermo-activatable laminate can be produced and at further processing and use safely manageable Thickness is less than 0.5 mm.

It is particularly preferred to use several core paper layers with a specific weight of approx. 70-400 g / m ² , preferably of 150-160 g / m ² . It is also advantageous to use absorbent paper in the form of a kraft paper with a weight of approx. 30-250 g / m ² , preferably 80 g / m ² . In addition, it is preferred if the hot-melt adhesive layer has a specific weight of approximately 20-150 g / m ² , preferably approximately 45 g / m ² .

In a preferred method of making the Laminates according to the invention are the layers  or several resin-absorbing layers of material, e.g. B. resin impregnated core paper layers, possibly one Absorbent paper layer and the adhesive layer in one step pressed under pressure and heat. This will make the resin e.g. B. in the core paper and the adhesive layer "liquid". At the Cooling of the layer structure begins Recrystallization process of the adhesive film, in which the Connection with the underlying layer takes place. It is important for the later gluing process that the Adhesive layer can be heated several times for gluing, provided a critical temperature is not exceeded. Around remove the layer structure from the press in a simple manner to be able to, it is further proposed that before Press one onto the outside adhesive layer Interface, e.g. B. a Teflon film is arranged.

For easy handling of the individual layers Production of the laminate according to the invention is moreover suggested that first a thermo-activated Adhesive film with an impregnated or non-impregnated Paper layer is connected and then the layers with external adhesive film is placed on top of one another and pressed become.

It is particularly preferred if the temperature during the Pressing is chosen so that the resin in the resin-impregnated carrier material layer and the melt the thermally activated adhesive layer without the temperature mentioned above with regard to the adhesive layer is exceeded. Because that would make them Adhesive properties of the adhesive layer diminished or even get lost. The thermally activated adhesive layer offers further the advantage that with a targeted Reheating one of the laminate according to the invention and a carrier plate manufactured composite plate Components in the sense of recycling recycling back into the  Source products separated and component-specific can be reused or recycled.

The pressing process can advantageously in one or Multi-day high-pressure recooling press, preferably in a multi-day high-pressure press with a cooling cycle.

Alternatively, the pressing process can also be carried out in one continuous, so-called CPL pressing system with sufficient cooling capacity to cool the thermo-activatable laminate can be carried out.

The pressing process can also be carried out using the short cycle method Connection with a suitable device for cooling the thermo-activatable laminate outside the Pressing process are carried out.

For an effective pressing process, two of the same can be used Layer sequences in a mirrored arrangement between z. B. two structuring or smooth structuring agents (e.g. Process press plates) at the same time. To do so avoid that the opposite adhesive layers come together connect with each other, is between the mirrored layers a non-adhesive release medium, e.g. B. one on both sides separating film or plate inserted. The separation medium that in another embodiment also between the Structure generator (e.g. press plate, press belt) and the Adhesive layer can be arranged according to the Remove production easily and completely. In a preferred embodiment of the invention Separation medium reused for further manufacturing processes become.

The laminate according to the invention is particularly suitable preferably as a flexible layer on a carrier plate Use composite panel.  

The particular advantage of the laminate according to the invention lies in the fact that the application (lamination) - like already mentioned above - with comparatively low pressures can be done. This means that such carriers with be provided with a thermally activated laminate can at pressures in a conventional standard press to carry out a bonding step (e.g. a Cold glue) undesirably compressed, possibly deformed and partially destroyed and thus in their strength would be reduced. That is, almost all of them pressure-sensitive carrier materials can be used as a carrier plate for gluing with the laminate according to the invention be used. A honeycomb panel is an example Foam sheet, a lightweight board or the like as Carrier plate called. By combining this pressure sensitive materials with the invention thermolaminatable laminate can thus be a Generate numerous new composite materials.

The ones that can be glued with the thermolaminable laminate Support materials can be made from a wide range of materials to get voted. Wood, metal, Plastic, glass, ceramic, textile and other called inorganic or organic materials.

It is also possible to use the thermo-laminatable laminate through targeted, contactless heating alone - for example by infrared radiation or by feeding of hot air - and the resulting melting of the To fix the adhesive layer on almost any carrier plates, without the action of high pressure and temperature on the carrier or on the top of the thermolaminatable Laminate the carrier is damaged or the decorative Surface of the laminate in its degree of gloss and / or their decorative structure is impaired.  

The use of the thermolaminatable laminate is by no means limited to planar substrates. So lets z. B. the laminate due to its already mentioned increased flexibility and reduced tendency to break as well advantageous on non-planar substrates, such as. B. Apply pipes, columns and other round shaped bodies.

The use of the laminate is also important with regard to its Bondability is not limited to solid supports. So in a special form of use of the thermolaminatable Laminate also with liquid, heated plastic masses be brought into contact in such a way that after cooling of the plastic a flat composite batten or another molded composite element is formed.

Such composite elements are conventional Laminates cannot be produced.

The product technology data of a Laminated chipboard composite board are in any case with comparable to a conventionally produced composite panel. Some parameters, such as B. peel strength, d. H. the Exceed the adhesion of the laminate on the chipboard even the values of a conventional laminate chipboard Verbund clearly. The heat resistance of a composite system according to the invention can be selected by Adhesive layer can be adjusted.

Finally, the laminate according to the invention can be found in Do It Yourself (DIY) - and hobby area by the user himself and individually z. B. by means of an iron or other suitable device on a wooden substrate or the like can be applied.  

drawings

An embodiment of the invention is in the drawing shown and mentioning further advantages and Details explained in more detail.

The figure shows a sectional view of two mirror-symmetrical arranged layer sequences of a laminate Pressing process between two press plates.

Description of the embodiment

In the figure, a section of two mirror-symmetrically arranged laminates 1 between two press plates 2 are shown in cross-section during a pressing process. Each laminate 1 consists of a thermally activated hot-melt film 3 , a subsequent, for. B. 80 g / m ² heavy sodium kraft paper 4 , several phenol formaldehyde resin-impregnated core papers 5 and finally a z. B. Melamine formaldehyde resin impregnated decorative film 6 . So that the superimposed hot-melt film layers 3 do not stick together during the pressing process, there is a separating layer 7 between them .

During the pressing process, the resin melts in the decorative film 6 , in the core paper 5 and the hot-melt film. This connects the decorative film with the core paper and the core paper on one side with the sodium kraft paper. On the other hand, the hot-melt film forms an intimate connection with the sodium kraft paper. The temperature is reduced during the pressing process even under pressure, which causes the melted layers to solidify. After removing the press plates 2 and the reusable separating layer 7 , two thermo-activatable laminates are available after one work step, which can be combined with a large number of carrier materials by reheating, which results in the hot-melt film melting.

Reference list

1

Laminate

2nd

Pressed sheet

3rd

Hot melt film

4th

Soda kraft paper

5

Core paper

6

Decorative film

7

Release film

Claims (15)

1. Laminate with a flexible decorative layer and at least one synthetic resin-impregnated substrate layer, e.g. B. a resin-impregnated core paper layer, characterized in that on the at least one carrier material layer ( 5 ) an external thermally activated adhesive layer ( 3 ) is applied. 2. Laminate according to claim 1, characterized in that that the adhesive layer is a thermally activated hot-melt film is. 3. Laminate according to claim 1, characterized in that a absorbent layer ( 4 ) is arranged between the at least one carrier material layer ( 5 ) and the thermally activated adhesive layer ( 3 ). 4. Laminate according to one of the preceding claims, characterized in that one or more core paper layers ( 5 ) have a specific weight of about 70-400 g / m ² . 5. Laminate according to one of the preceding claims, characterized in that the absorbent layer ( 4 ) comprises a sodium kraft paper or a parchment paper or another suitable absorbent special paper with a specific weight of approx. 30-250 g / m ² . 6. Laminate according to one of the preceding claims, characterized in that the thermally activated adhesive layer ( 3 ) has a specific weight of approximately 20-150 g / m ² . 7. Process for producing a laminate according to a of claims 1 to 6, characterized in that the Layers pressed in one step under pressure and heat become. 8. The method according to claim 6, characterized in that before pressing on the outside adhesive layer Interface, e.g. B. Teflon film is arranged. 9. The method in particular according to claim 6 or 7, characterized characterized in that first a thermally activated Adhesive film with an impregnated or non-impregnated Paper layer is connected and then the layers with external adhesive film is placed on top of one another and pressed become. 10. The method according to any one of claims 7 to 9, characterized in that the temperature during the pressing process is selected so that the synthetic resin in the synthetic resin-impregnated carrier material layer ( 5 ) and the thermally activated adhesive layer ( 3 ) melt. 11. The method according to any one of claims 7 to 10, characterized characterized in that the pressing process in one or Multi-day high-pressure recooling press, preferably one Multi-day high-pressure press with cooling cycle. 12. The method according to any one of claims 7 to 10, characterized characterized in that the pressing process in one CPL (Continuous Pressure Laminate) pressing device. 13. The method according to any one of claims 7 to 10, characterized characterized in that the pressing process in one Short cycle press in connection with a cooling of the  Laminate by a suitable cooling device outside the press is done. 14. Use of the laminate according to one of the Claims 1 to 6 as a flexible layer on a carrier plate a composite panel. 15. Use of the laminate according to one of the Claims 1 to 6 as a flexible layer on a carrier plate a composite plate, the carrier plate from a pressure sensitive material such as B. a honeycomb panel, a foam board, a lightweight board or the like exists.