DE202009000539U1 - Mineral coated textile surfaces for wood-based materials - Google Patents

Abstract

Composite comprising:
a) at least one wood-based material carrier,
b) at least one textile fabric applied to at least one of the two sides of the wood-based material carrier,
characterized in that the textile fabric has at least one mineral coating and an adhesive layer between the wood material carrier and the textile fabric is present.

Description

The The present invention relates to a composite material consisting from a wood-based base and one using glue applied, provided with a mineral coating, textile Area. The composite material serves as a substitute for conventional wood-based panels in the construction sector with Plasterboard be planked.

So far be under construction / timber frame construction in residential buildings, wohnnahen Object buildings and other buildings Plasterboard or similar mineral plates on the base wood support plates (E. W panels, such as chipboard, OSB, MDF / LDF, plywood, lightweight construction Plates or similar) mounted in a separate operation. The resulting joints, especially in the area of the abutting edges, can subsequently coated with a suitable fine spatula become. The same applies to the attachment points of the gypsum boards on the base wood support (eg screw / nail, etc.)

The Function of the mineral or gypsum boards is on the respective Inside u. a. a base for decorative finishes too create (eg wallpaper, paint) and at the same time certain To meet fire safety requirements.

The Assembly of mineral or gypsum boards on the wooden elements on site on the construction site or in element construction leads to increased Workload and significant additional costs.

It There is therefore the task of providing a composite material, which avoids the disadvantages described above and in cost-effective manner can be produced.

The The present invention provides a remedy and solves this Problem by placing a mineral coated nonwoven on a Laminated wood base is laminated and glued. The assembly and completion of the invention produced Composites can be made simpler and more economical become, since one the finished invention Can assemble composite material in just one operation.

object The present invention is a composite material that is at least a wood-based base and at least one textile Includes fabric, wherein the textile fabric at least on one side of the wood-based base is arranged and has a mineral coating, and the wood-based base material and the textile fabric are connected by means of an adhesive layer.

The Textile fabrics act as a carrier for the mineral coating by means of coating systems is applied to the textile surface. Subsequently the coated textile fabric is laminated onto the wood-base base or glued to this.

The mineral coated textile fabric is by means of a suitable adhesive to the surface of the wood material base support connected. This is first an adhesive layer on the surface applied to the Holzwerkstoffbasisträgers and then the coated textile fabric with the wood-base base, z. B. by means of rollers, pressed or laminated. After drying and possibly required confectioning is the invention Composite for end use ready for use.

Both Components - textile fabric and mineral Coating - reduce the formation and spread of fire. At the same time it becomes a homogeneous, stable and smooth surface provided for further use. Due to the surface quality is a multiple Painting no longer necessary.

• a) mindestens einen Holzwerkstoffträger,
• b) mindestens ein auf mindestens einer der beiden Seiten des Holzwerkstoffträger aufgebrachtes textiles Flächengebilde,

dadurch gekennzeichnet, dass das textile Flächengebilde mindestens eine mineralische Beschichtung aufweist und eine Klebeschicht zwischen Holzwerkstoffträger und dem textilen Flächengebilde vorliegt.The subject matter of the present invention is thus a composite material comprising:

• a) at least one wood-based material carrier,
• b) at least one textile fabric applied to at least one of the two sides of the wood-based material carrier,

characterized in that the textile fabric has at least one mineral coating and an adhesive layer between the wood material carrier and the textile fabric is present.

In a preferred embodiment of the invention the mineral coating and / or the adhesive layer more Functional materials.

at the wood-based base material used according to the invention are preferably wood-based materials, such as plates, wherein these additional wooden material constructions, such as frames, Lattice or three-dimensional reinforcement structures, so-called Honeycombs, which may have the wood materials further strengthen.

The wood-based materials are plate-shaped or strand-shaped wooden materials which are produced by mixing the different types of wood particle with natural and / or synthetic binders in the course of a hot pressing. The wood materials used according to the invention preferably comprise barrier or plywood, chipboard material, in particular chipboard and OSB (Oriented Strand Boards), wood fiber material, in particular especially porous wood fiber boards, vapor permeable wood fiber boards, hard (high density) wood fiber boards (HDF) and medium density wood fiber boards (MDF), and arboform. Arboform is a thermoplastically processable material made of lignin and other wood components.

at the textile fabrics used according to the invention These are all structures that are made of fibers and from those by means of a surface-forming technique a textile surface has been produced.

at the fiber-forming materials are preferably fibers of synthetic polymers, ceramic fibers, mineral fibers or glass fibers, these can also be used in the form of mixtures. In the presence of fiber mixtures, these can also be cellulose or natural fibers. Textile surfaces are tissues, Scrims, knitted fabrics, knitted fabrics and nonwovens, preferably nonwovens, understood.

The Textile fabrics can additionally one Reinforcement made of fibers, threads, or filaments have. This is particularly useful when the textile Sheets exposed to high mechanical requirements becomes. Are preferred as reinforcing threads multifilaments or Rovings based on glass, polyester, carbon or metal. The reinforcing threads can as such or in the form of a textile fabric, for example be used as a fabric, scrim, knit, knitted fabric or fleece. Preferably, the reinforcements consist of a parallel Group of threads or a clutch.

at the textile surfaces of mineral and ceramic fibers these are alumosilicate, ceramic, dolomite wollastonite fibers or from fibers of volcanics preferably basalt, diabase and / or Melaphyr fibers, in particular basalt fibers. Diabase and melaphyre are collectively referred to as paleo-basalts and Diabase is often referred to as greenstone.

The Mineral fiber fleece can be made of filaments, d. H. infinitely long fibers or formed from staple fibers. The average length the staple fibers used in the invention Nonwoven made of mineral fibers is between 5 and 120 mm, preferably 8 to 90 mm. In a further embodiment of the invention The mineral fiber fleece contains a mixture of continuous fibers and staple fibers.

Of the average fiber diameter of the mineral fibers is between 5 and 30 μm, preferably between 8 and 24 μm, more preferably between 8 and 16 microns.

The weight per unit area of the textile fabric of mineral fibers is between 15 and 500 g / m ² , preferably 40 and 250 g / m ² , these details referring to a fabric without a mineral coating.

at The textile surfaces of glass fibers are in particular nonwovens prefers. These are made of filaments, d. H. infinitely long fibers or constructed of staple fibers. The average length of the Staple fibers is between 5 and 120 mm, preferably 8 to 90 mm. In a further embodiment of the invention The glass fiber fleece contains a mixture of continuous fibers and staple fibers.

Of the average diameter of the glass fibers is between 5 and 30 μm, preferably between 8 and 24 μm, more preferably between 10 and 21 microns.

Next The above-mentioned diameters can also be so-called Glass microfibers find use. The preferred average Diameter of the glass microfibers here is between 0.1 and 5 microns. The textile surface forming microfibers can also in mixtures with other fibers, preferably glass fibers. Furthermore is also a layered structure of microfibers and Glass fibers possible or the setting of a gradient, in which the content of microfibers, facing away from the wearer Side of the textile fabric, increases.

The weight per unit area of the textile fabric of glass fibers is between 15 and 500 g / m ² , preferably 40 and 250 g / m ² , these details referring to a fabric without a mineral coating.

suitable Glass fibers include those made of A glass, E glass, S glass, C glass, T-glass or R-glass were made.

The textile surface can be prepared by any known method become. For glass webs, this is preferably the dry or wet laid process.

Of the textile surfaces of fibers made of synthetic polymers nonwovens, in particular so-called spunbonds, ie spunbonded nonwovens which are produced by a disposition of melt-spun filaments, are preferred. They consist of continuous synthetic fibers made of melt-spinnable polymer materials. Suitable polymer materials are, for example, polyamides, such as. As polyhexamethylenedipiamide, polycaprolactam, aromatic or partially aromatic polyamides ("aramids"), aliphatic polyamides, such as. Nylon, partially aromatic or wholly aromatic polyesters, polyphenylene sulfide (PPS), Polymers with ether and keto groups, such as. As polyether ketones (PEK) and polyetheretherketone (PEEK), polyolefins, such as. As polyethylene or polypropylene, cellulose or polybenzimidazoles. Besides the above-mentioned synthetic polymers, those polymers which are spun from solution are also suitable.

Prefers the spunbonded nonwovens consist of melt-spinnable polyesters. As a polyester material In principle, all known suitable for fiber production come Types into consideration. Particularly preferred are polyesters which are at least 95 mol% polyethylene terephthalate (PET), especially those made of unmodified PET.

The Single titer of polyester filaments in spunbonded between 1 and 16 dtex, preferably 2 to 10 dtex.

In a further embodiment of the invention, the spunbonded nonwoven fabric can also be a meltbond-bonded nonwoven fabric which contains carrier and hot-melt adhesive fibers. The carrier and hot melt adhesive fibers can be derived from any thermoplastic fiber-forming polymers. Such meltbond-solidified spunbonded nonwovens are, for example, in EP-A-0,446,822 and EP-A-0,590,629 described.

Next Endlosfilament (Spunbondverfahren) can the textile Surfaces also made of staple fibers or mixtures of staple fibers and continuous filaments. The individual titers of the staple fibers in the nonwoven amount to between 1 and 16 dtex, preferably 2 to 10 dtex. The staple length is 1 to 100 mm, preferably 2 to 50 mm, more preferably 2 to 30 mm. The textile fabric can also be constructed of fibers of different materials to To achieve special properties.

The the nonwovens constituting filaments and / or staple fibers can have a virtually round cross-section or have other shapes, such as dumbbell, kidney-shaped, triangular or tri- or multilobal Cross-sections. It is also possible to use hollow fibers and bicomponent or multicomponent fibers. Furthermore, the hot melt adhesive fiber can also be in the form of Use bic or multicomponent fibers.

The the textile fabric forming fibers can be modified by conventional additives, for example by antistatic agents, such as carbon black.

The basis weight of the textile fabric of synthetic polymer fibers is between 10 and 500 g / m ² , preferably 20 and 250 g / m ^2. The textile fabrics can be produced without chemical binders. In order to achieve the required strength for further processing of the fabrics, it is also possible to introduce thermoplastic binder polymers and / or use known needling methods. In addition to the possibility of mechanical consolidation, z. As calendering or needling, especially the hydrodynamic needling should be mentioned here.

Prefers However, the fabrics are with a chemical Binder pre-consolidated. The binders used are preferred from the group of the coating material compatible binder systems. The binder content is at most 30 wt .-%.

The Method for producing mineral-coated textile fabrics, in particular nonwovens, are known per se. It will be suitable Materials on a mostly consolidated textile fabric, preferably a binder-bonded nonwoven, by means of common Applied methods. There are standard coating methods such as z. As foam coating, dipping method, doctoring, etc. are used. After coating, the coated material by means of dried known methods.

The mineral coatings consist of flowable paste-like materials, in addition to water essentially Gypsum, lime, chalk or similar inorganic components such as B. aluminum hydroxide. The components mentioned be, alone or in mixtures, and / or in mixtures used with other inorganic or organic components. When Organic ingredients are typically polymer dispersions as a binder, thickener and dispersing aid used. Such mineral masses are known in principle.

Next These basic materials can be the mineral coating material or the adhesive layer, further functional materials as additives contain. The additives are preferably materials for increasing the fire resistance (flame retardants), materials for dissipation of electrostatic charges, materials for Shielding of electromagnetic radiation, organic or inorganic Pigments, in particular colored pigments.

The flame retardants are inorganic flame retardants, organophosphorus flame retardants, nitrogen based flame retardants or intumescent flame retardants. Halogenated (brominated and chlorinated) flame retardants are also useful, but less preferred because of their risk assessment. Step Example le for such halogenated flame retardants are polybrominated diphenyl ethers, eg. DecaBDE, tetrabromobisphenol A and HBCD (hexabromocyclododecane).

at The nitrogen-based flame retardants are melamines and ureas.

at the organophosphorus flame retardants are typically to aromatic and alkyl esters of phosphoric acid. Prefers are TCEP (trichloroethyl phosphate), TCPP (trischloropropyl phosphate), TDCPP (tris-dichloroisopropyl phosphate), triphenyl phosphate, trioctyl phosphate (tris (2-ethylhexyl) phosphate) used.

at the inorganic flame retardants are typically Hyxroxide, such as aluminum hydroxide and magnesium hydroxide, bristle, such as Zinc borate, ammonium compounds such as ammonium sulfate, red phosphorus, Antimony oxides, such as antimony trioxide and antimony pentoxide or vermiculites.

By Use of means for increasing the electrical conductivity can anti-static and electromagnetic shielding effects be achieved.

at The antistatic agents are usually around Particles which are electrically conductive. Suitable materials are electrically conductive carbons such as carbon black, Graphite and carbon nanotubes (C-nanotubes), conductive Plastics or fibers of metal or metal components.

at the materials for the shielding of electromagnetic radiation they are usually electrically conductive Materials. These can be in the form of particles or fibers be constructed from the aforementioned materials.

at The inorganic or organic pigments are particulate Materials, in particular pigments, also used in paints become.

The Required application amount of the mineral coating directed depending on the desired application and the textile used Fabrics or base fleece. It is a homogeneous and to aim for a non-porous surface.

The Application amount of the mineral coating material is at least 25% by weight, preferably 30-90% by weight, more preferably 40-80% by weight, in each case based on the total weight of the dried coated textile fabric, this preferably a fleece is.

The mineral coating penetrates the textile fabric or the web at least partially. In a particularly preferred Embodiment of the invention is that with the mineral coating provided textile fabrics still rollable, d. H. can be processed or stored in the form of roles.

In a preferred embodiment is the mineral Coating designed so that the textile fabric only on the side facing away from the wooden material carrier, d. H. essentially one-sided, coated. The mineral Although coating penetrates the textile fabric however, at least partially, preferably completely no full area and complete Covering coating, leaving at least some parts of the textile Sheet with the adhesive layer in direct contact stand.

The mineral-coated textile fabrics, in particular the mineral coated textile fleece, is with the help of a Adhesive fixed on the wooden material carrier or laminated and bonded. For this purpose, first by means of known methods suitable adhesive on the surface of the wood material carrier applied. Preferred methods are rolling, spraying or doctor blade method.

suitable Adhesives are materials that both surface to the Wooden material carrier as well as mineral coated textile fabrics a sufficient adhesive effect exhibit. Here are preferably building material adhesive, in particular Tile adhesive, wall adhesive, or similar materials. These usually consist mainly of mortar, Gypsum, cement, sand, and / or chalk components. Furthermore you can these adhesives known additives for controlling the viscosity and the binding behavior.

The Thickness of the adhesive layer thus applied in the invention Composite material is at least 0.5 mm, preferably 1-5 mm, more preferably 1.5-3 mm

In addition to the application of an adhesive on the wood material carrier and adhesive films can be used. In this case, films can be used, which develop their adhesive effect directly during pressing. In addition, the use of hot melt adhesive films is possible. In this case, the adhesion takes place thermoplastically when exposed to heat during compression. When using adhesive films, the thickness of the adhesive layer - compared to the above-mentioned building material adhesives - be chosen significantly lower, with a minimum thickness of 10 microns, preferably 20 microns should not be exceeded. The maximum thickness of the adhesive films can be up to several millimeters. The use of very thick polymer films, so called polymer charts, is possible.

The Adhesive layer can also contain functional materials as additives, in particular those additives which increase the Fire resistance or to improve the electromagnetic shielding to lead. To increase the electromagnetic shielding Also suitable are flat structures that come together with the adhesive layer on the surface of the wooden material carrier apply (eg aluminum foil) or as part of it.

• a) Zuführen eines Holzwerkstoffträgers,
• b) Aufbringen mindestens einer Klebeschicht auf eine der Oberflächen des Holzwerkstoffträgers,
• c) Aufbringen des textilen Flächengebildes auf die gemäß b) gebildete Klebeschicht, wobei das textile Flächengebilde mindestens eine mineralische Beschichtung aufweist,
• d) Laminieren des gemäß Schritt c) erhaltenen Aufbaus unter Einwirkung von Druck und gegebenenfalls Wärme,
• e) Trocknung und Konfektionierung.

In addition to the composite material, a further subject of the present invention is a process for the production of the composite material comprising the measures:

• a) feeding a wooden material carrier,
• b) applying at least one adhesive layer to one of the surfaces of the wood-based material carrier,
• c) applying the textile fabric to the adhesive layer formed according to b), the textile fabric having at least one mineral coating,
• d) laminating the structure obtained according to step c) under the action of pressure and optionally heat,
• e) drying and packaging.

insofar the adhesive layer should contain functional materials as an additive, These can already be mixed with the adhesive before or during or after step b).

Instead of the supply of a prefabricated wooden material carrier The formation of the wood-based material carrier can also be done online.

Becomes the adhesive supplied as a film, so it can be fed separately be, d. H. The adhesive film does not necessarily have to applied the surface of the wood material carrier become.

In a variant of the method, the adhesive layer can also on the with the mineral coating provided textile fabrics be applied.

Next The composite and the manufacturing process is also the use of the composite material according to the invention for the interior design of buildings another subject of the present Invention.

Of the Composite material according to the invention can be under construction / timber frame construction for residential buildings, residential buildings and other buildings as a replacement for conventional Wood plasterboard systems used in interior design.

The product according to the invention constitutes an area for the final decoration available, improved the fire retardant properties, reduces weight and eliminates additional installation costs compared to conventional mineral plates.

The Interface of the individual plate boundaries can, as usual in plasterboard, manually coated with a suitable putty material. The mineral coated textile surface can be dyed and thus can contribute to a final decoration.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - EP 0446822A [0031]
• - EP 0590629 A [0031]

Claims (29)

Composite comprising: a) at least one wood-based material carrier, b) at least one textile fabric applied to at least one of the two sides of the wood-based material carrier, characterized in that the textile fabric has at least one mineral coating and an adhesive layer is present between the wood-material carrier and the textile fabric. Composite material according to claim 1, characterized in that the mineral coating and / or the adhesive layer contains further functional materials. Composite material according to claim 1, characterized in that it is in the wood material base carrier to wooden materials, preferably plates, is, these additional Wood material constructions, such as frames, grids or three-dimensional May have reinforcing structures. Composite material according to claim 1, characterized in that it is in the wood material base carrier around plate-shaped or strand-shaped wooden materials, by Mix of different wood particle shapes with natural and / or synthetic binder produced in the course of a hot pressing become, act. Composite material according to claim 4, characterized in that it is the wood material around Barrier or plywood, wood chipboard, in particular chipboard and OSB (Oriented Strand Boards), wood fiber material, in particular porous wood fiber boards, diffusion-open wood fiber boards, hard (high-density) fibreboard (HDF) and medium density fibreboard (MDF), and a thermoplastically processable material Lignin and other wood components. Composite material according to claim 1, characterized in that as a textile fabric a woven fabric, scrim, knitted fabric, knitted fabric and / or non-woven, preferably a fleece, is. Composite material according to claim 1, characterized in that as a textile fabric from fibers of synthesized polymers, ceramic fibers, mineral fibers or glass fibers, which are also mixtures of the above comprising said fibers. Composite material according to claim 7, characterized in that as a textile fabric additionally contains cellulose or natural fibers. Composite material according to claim 1, characterized in that as a textile fabric is formed from mineral and / or ceramic fibers, preferably from alumosilicate, ceramic, dolomite wollastonite fibers or from Fibers of volcanics, preferably basalt, diabase and / or melaphyre fibers, in particular basalt fibers. Composite material according to claim 1, characterized in that as a textile fabric a mineral fiber fleece, preferably a fleece in which the average Length of the mineral fibers is between 5 and 120 mm. Composite material according to claim 10, characterized in that the average fiber diameter the mineral fibers between 5 and 30 microns, preferably between 8 and 24 μm, more preferably between 8 and 16 μm, is. Composite material according to claim 10, characterized in that the weight per unit area of the textile fabric of mineral fibers is between 15 and 500 g / m ² , preferably 40 and 250 g / m ² , these figures referring to a fabric without a mineral coating. Composite material according to claim 1, characterized in that as a textile fabric is a fiberglass mat, preferably a nonwoven in which the average Length of the glass fibers is between 5 and 120 mm. Composite material according to claim 13, characterized in that the average diameter the glass fibers between 5 and 30 microns, preferably between 8 and 24 μm, more preferably between 10 and 21 μm, is. Composite material according to claim 13, characterized in that the average diameter the glass fibers is between 0.1 and 5 microns. Composite material according to claim 13, characterized in that the glass fiber fleece multi-layered is constructed and the different layers have different glass fiber diameters, defined in claim 14 or claims 14 and 15. Composite material according to claim 1, characterized in that the textile fabric comprises glass fibers, preferably a glass fiber fleece, and the weight per unit area is between 15 and 500 g / m ² , preferably 40 and 250 g / m ² , these details referring to a fabric without refer to mineral coating. Composite material according to claim 1, since characterized in that the fabric comprises fibers of synthetic polymers. Composite material according to claim 18, characterized in that the textile fabric a nonwoven, in particular a spunbonded nonwoven, is. Composite material according to claim 19, characterized in that the fleece is a staple fiber fleece is, whose staple fibers have a length of 1 to 100 mm, preferably 2 to 50 mm, more preferably 2 to 30 mm. Composite material according to claim 1, characterized in that the textile fabric is constructed from fibers of synthetic polymers and the basis weight is preferably between 10 and 500 g / m ² , in particular between 20 and 250 g / m ² . Composite material according to claim 1, characterized in that the mineral coating gypsum, Lime, chalk and / or aluminum hydroxide. Composite material according to claim 1, characterized in that the order quantity of the mineral Coating at least 25% by weight, preferably 30-90% by weight, particularly preferably 40-80% by weight, in each case based on the Total weight of the dried coated textile fabric, is, this is preferably a nonwoven. Composite material according to claim 1, characterized in that the mineral coating the Textile fabrics at least partially penetrates. Composite material according to claim 1, characterized in that the mineral coating only on the side facing away from the wood material carrier of the textile Sheet is applied. Composite material according to claim 25, characterized in that the mineral coating the textile fabrics at least partially, preferably complete, penetrates, but not complete flat and completely covering coating forms, so that at least parts of the textile fabric are in direct contact with the adhesive layer. Composite material according to claim 1, characterized in that the adhesive layer building material adhesive, in particular tile adhesive or wall adhesive comprises, preferably Mortar, gypsum, cement, sand, and / or chalk components contain. Composite material according to claim 1 or 27, characterized in that the adhesive layer has a thickness of at least 0.5 mm, preferably 1-5 mm, more preferably 1.5-3 mm. Composite material according to claim 1, characterized in that the adhesive layer is a film, preferably a hot melt adhesive film.