NL1006751C2 - Melam-modified amino-formaldehyde resins - Google Patents

Abstract

Amino-formaldehyde resins containing 2-100 mol. % melam and 0-98 mol. % of another amino compound. Amino-formaldehyde resins are claimed which contain 2-100 mol. % melam and 0-98 mol. % of another amino compound. Independent claims are included covering: (a) a process for preparing the claimed amino resins; (b) sheet-like materials consisting of one or more layers of a sheet-like substrate material impregnated with the melam-containing resin followed by hardening of the resin; (c) spray dried powder products made from the claimed amino resins and (d) resins, preparation process and use as described in the description and examples.

Description

- 1 - PN 8486 AMINO FORMALDEHYDE RESINS 5

The invention relates to amino formaldehyde resins, as well as a process for the preparation of these amino formaldehyde resins. The invention also relates to a sheet-shaped product consisting of one or more layers of a sheet-shaped support, which support is impregnated with an amino-formaldehyde resin.

Amino-formaldehyde resins, such as, for example, urea-formaldehyde (UF), melamine-formaldehyde resins (MF) and melamine-urea-formaldehyde resins (MUF) are well known. US-A-5120821 describes a process for the preparation of melamine-formaldehyde resins from melamine which still contains the impurities of the melamine preparation process. These impurities include minor amounts of ammelide, ammeline, ureidomelamine, melem and melam. The described process yields melamine formaldehyde resins containing up to 1.9 mol% melam, as well as the other impurities mentioned above.

Amino-formaldehyde resins are widely used in (decorative) top laminates and as a press powder for making scratch-resistant products such as crockery and electrical products. The amino-formaldehyde resins must therefore exhibit excellent mechanical properties, for example high strength and surface hardness (abrasion resistance and scratch resistance) and a sufficiently high temperature resistance.

A drawback of unmodified and of already known modified amino formaldehyde resins is that the temperature resistance is limited.

1006751 - 2 -

The object of the invention is to provide amino-formaldehyde resins with an improved heat stability.

The amino formaldehyde resin according to the invention is characterized in that the amino compound in the amino formaldehyde resin comprises 2-100 mol% melam and 0-98 mol% of an (other) amino compound.

Very surprisingly, it has now been found that the amino formaldehyde resins of the invention exhibit properties comparable to those of melamine formaldehyde resins. It has also been very surprisingly found that the amino-formaldehyde resins according to the invention can be made into sheet-shaped products which exhibit properties comparable to the properties of sheet-shaped products of melamine-formaldehyde resins. An advantage of the amino resins as well as the sheet-like articles made from the amino resins according to the invention is an improved temperature resistance compared to

Conventional amino-formaldehyde resins (aminoformaldehyde resins not modified with melam) without sacrificing strength and surface hardness.

The invention therefore also relates to a sheet-shaped product consisting of one or more layers of a sheet-shaped support, such as for instance paper, which support is impregnated with an amino-formaldehyde resin according to the invention with customary additives and wherein the resin is cured. The good properties were retained even if the curing takes place at a pressing temperature and / or pressure higher than the usual. This is of economic advantage because the processing to end product can then be realized with shorter pressing times.

The use of melam as a suitable modifier for amino formaldehyde resins has never been recognized in the prior art 1006751-3. For example, in US-A-5120821 it is expressly noted that the presence of melam in melamine formaldehyde resins adversely affects the resin properties. It is therefore all the more surprising that the amino-formaldehyde resins according to the invention, containing 2-100 mol% melam, achieve the good results.

Melam can be easily prepared by condensing melamine in the presence of a catalyst. Melam can be obtained particularly advantageously by condensing melamine with organic acids, for example paratoluene sulfonic acid or its ammonium and / or melamine salts, as a catalyst at a temperature between 280 and 320 ° C. Such a method is described in WO-A-9616948.

From a cost point of view, the amino formaldehyde resin of the invention will generally contain less than 50 mol% melam.

If the melam content in the amino resin according to the invention is less than 100 mol%, a second (other than melam) amino compound is also present in the amino resin. As the second amino compound, the usual amino compounds can be chosen, which result in curable resins with formaldehyde.

Preferably, in addition to melam, one or more of the following amino compounds are selected: urea, urea derivatives, triazines such as, for example, melamine, aceto- and benzoguanamine, and sulfonamides, carbonamides and dicyandiamides.

Preferably, besides melam, as the amino compound urea or melamine is chosen as the main component, most preferably melamine.

Melamine and / or urea are preferably used in more than 50 mol% relative to the total amount of amino compound.

1006751 - 4 -

The formaldehyde: NH2 molar ratio of the aminoformaldehyde resin according to the invention is usually between 0.1: 1 and 4: 1. A ratio between 0.3: 1 and 3: 1 is preferably used. For the purposes of this application, 5 NH2 is understood to mean all amino groups present in melam and in the other amino compound (s) possibly present in the resin. In view of the lower solubility of melam in formaldehyde (compared to the solubility of, for example, melamine), the molar ratio formaldehyde: NH2 is preferably chosen larger as the content of melam in the amino resin increases.

The amino resin of the invention can in principle be prepared in any manner known for amino formaldehyde resins by heating melam and optionally the second amino compound in a formaldehyde-water mixture to 60-100 ° C and at a pH of 6-12 react. The reaction is usually stopped by cooling the solution when the resin mixture has reached a water dilutability factor of 1-4. The "water dilutability factor" is the amount (g) of water that can be added to a resin solution (g) at 20 ° C before the solution becomes cloudy.

If desired, the resin composition according to the invention may contain other components for a further optimization of the combination of the desired properties. Examples of such components are lactams, polyalcohols, glycol ethers, carbamides and acrylates such as, for example, caprolactam, ethylene glycol or diethylene glycol, butanediol-1,4, sorbitol, glucose, trioxytol, urea and thiourea. These components are generally used in amounts between 1-20% by weight relative to the total amount of amino compounds, preferably 5-10% by weight.

Conventional auxiliaries and fillers can be added to the amino resin according to the invention. In 1006751-5 the catalysts, and optionally stabilizers, surfactants, release agents and pigments, are added.

The resin solution obtained is, if desired after addition of an acid (as a curing catalyst), directly processable for impregnating sheet carriers or, if desired, can be further thickened by evaporation. By means of, for example, spray drying, a dry resin powder can be obtained which is suitable for pressing moldings.

The resin composition according to the invention is very suitable for impregnating a sheet-shaped support, such as, for example, sheets of cellulose fiber (paper). This impregnated paper is then, for example, suitable for use in the top layer of a sheet-shaped product and also for the core. As a type of paper, for example "Kraft paper" (for example 120-500 g / m2) or "Decor paper" (for example 50-200 g / m2) can be used. Kraft paper and decor paper are common designations for types of paper in this work area.

For use as a sheet-like product, one or more sheets of the impregnated support are stacked together. The number of sheet carriers is generally 10 or less, and preferably 5 or less. The thickness of the sheet-shaped article can range from 100 µm to about 3 cm. The sheet shaped article is generally made under conventional conditions, such as, for example, described in US-A-30 3730828.

For use as a powder for (press) shaped bodies, such as for example crockery, the resin composition according to the invention can further contain the usual fillers, for example cellulose derivatives, aluminum trihydrate, clay, lime, gypsum, wood flour, glass flour, wollastonite, shell and core flour. Fiber reinforcement can also be used, preferably cellulose fibers, such as, for example, paper or wood chips, or glass fiber.

The fillers and / or fibers are used in amounts of 80% by weight relative to the solid in the resin. Preferably, 70-25 wt% resin at 30-75 wt% filler and fiber reinforcement is used when used as a press material. When used as a laminate, 20-80% by weight resin is used on 80-20% by weight cellulose or paper.

The invention will be further elucidated by means of the non-limiting examples shown below.

Examples IV and Comparative Experiments AC 15 Melam-modified melamine-formaldehyde resin solutions, a melam-formaldehyde solution and a melamine-formaldehyde solution, were prepared by ag of an x% formalin solution, with 1 N NaOH at a pH between 9.0 and 9.4 and heat together with bg melamine, cg melam and dg water to a temperature of t ° C until a clear solution is obtained.

After the solution became clear, the temperature of t ° C was maintained until the resin solution formed reached a water dilutability of y g / g (turbidity at 20 ° C).

The above data to be obtained for these resin solutions are shown in Table 30-1.

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Example VI and comparative experiment D.

The resin of Example V was used for Example VI; the resin from comparative experiment C was used for experiment D.

Both resins were used to investigate the intrinsic properties of the cured products. Before further processing the resins, they are spray dried to 'dry' powder.

Both resins were compacted as powder in a die at 100 ° C (physical water removed), then the temperature was brought to 140 ° C, the pressure being increased to 10 MPa. These conditions were maintained for 1 hour. Then it was cooled to 40 ° C under a pressure of 10 MPa, after which the mold 15 was opened.

The pure unfilled spray dried and cured resins obtained in this way were then examined. The results are summarized in Table 2. It can be seen from this that the heat resistance of the resin 20 according to the invention improves considerably and the other properties remain almost constant.

Table 2: Properties of unfilled pressed resins

V and C.

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experiment D Resin V Resin C

E-modulus11 (MPa) 8100 7900

Shore hardness 21 70 70

Abrasion Resistance 31 0.19 0.19 (g / 500 rotations) 30 Heat Resistance 41 290 270 (° C)

Refractive index 1.68 1.67 1006751 -ΙΟΙ) DIN 53457 2) DIN 53505 3) ΕΝ 438 §6, the abrasion resistance is expressed in the average weight loss in grams per 500 rotations performed over 1500 rotations 4) EN 438 §8 10 Examples VII-XI and comparative experiments EG The resin solutions I to V and A, B and C were used to impregnate paper that was pressed into laminates. The B time (as given in Table 3) was set with paratoluene sulfonic acid. The 15 B time is the time it takes for the resin solution in a closed tube to become cloudy at 140 ° C. The resin of Examples I to V was used for Examples VII-XI the resin of comparative experiments Ar B and C for experiments E, F and 6.

These resins were used to impregnate paper (120 g / m2 decor paper). The impregnated papers were dried at 100 ° C. After drying, the semi-finished products had a resin content and volatile compound content as shown in Table 3.

The laminates were obtained in the usual manner by pressing 4 layers of impregnated paper. The impregnated paper is pressed at 60 ° C for resins I-IV and A-B and at 50 ° C for resins V and C, after which it is pressurized (5 MPa). It is then heated to a pressing temperature of 140 ° C at a rate of about 5 ° C / min. This temperature was maintained for 10 minutes, after which it was cooled again under pressure to 50 ° C at a cooling rate of about 5 ° C / min.

The laminates obtained in this way were then examined. The results are shown in Table 4. Table 3 gives the press conditions 1 006751-11. Table 4 shows that the cigarette test, which is a measure of, inter alia, heat resistance, gives considerably better results for the laminates according to the invention. The scratch and abrasion resistance 5 remain almost constant.

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1006751 - 14 -

Examples XII-XVI and Comparative Experiments H-L

Example VII resp. comparative experiment E was repeated with the resin solution V resp. C where the pressing temperature and / or pressure were changed. The 5 pressing conditions are shown in Table 5. The results of the scratch and abrasion tests performed on the laminates obtained are shown in Table 6.

Surprisingly, it appears that the resin and abrasion resistance are independent of the pressing temperature and pressure. The results are comparable and the differences between them are within the measurement error margin. The heat resistance is also independent of discharge pressure and / or discharge temperature.

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1006751 - 16 -

Table 6: Scratch and abrasion tests

Scratch test Abrasion resistance g.

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Ex. XIII Resin V 1.5 (± 0.1) 0.27 5 Ex. XIV Resin V 1.4 (± 0.1) 0.32

Ex. XV Resin V 1.5 (± 0.1) 0.28

Ex. XVI Resin V 1.4 (± 0.1) 0.31

Cf. Exp. H Resin C 1.3 (± 0.1) 0.36

Cf. Exp. I Resin C 1.5 (± 0.1) 0.29 10 Eq. Exp. J Resin C 1.6 (± 0.1) 0.31

Cf. Exp. K Resin C 1.4 (± 0.1) 0.30

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Claims (8)

Amino-formaldehyde resin, characterized in that the amino compound in the amino-formaldehyde resin contains 2-100 5 mol% melam and 0-98 mol% of an (other) amino compound. Amino-formaldehyde resin according to claim 1, characterized in that the resin contains less than 50 mol% melam. Amino-formaldehyde resin according to claim 1, characterized in that more than 50 mol% of the other amino compound is melamine (relative to the total amount of amino compound). Amino-formaldehyde resin according to any one of the aforementioned claims, characterized in that the molar ratio of formaldehyde: NH2 is between 0.3: 1 and 3: 1. Process for the preparation of amino formaldehyde resins according to any one of the preceding claims, characterized in that melam and optionally the second amino compound are heated in a formaldehyde-water mixture to 60-100 ° C and reacted at a pH of 6 -12. 6. Sheet-shaped product consisting of one or more layers of a sheet-shaped support, which support is impregnated with a resin according to any one of claims 1-4 or a resin obtainable by the method according to claim 5, usual additives and wherein the resin is cured. 7. Spray dried powder of an amino formaldehyde resin according to any one of claims 1-4 or of an amino formaldehyde resin obtainable by the method according to claim 5. 8. Resin, method or application as substantially included in the description and examples. 1006751