WO2001010939A1 - Procede pour produire des plaques presentant une surface decorative - Google Patents

Procede pour produire des plaques presentant une surface decorative Download PDF

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Publication number
WO2001010939A1
WO2001010939A1 PCT/EP2000/007752 EP0007752W WO0110939A1 WO 2001010939 A1 WO2001010939 A1 WO 2001010939A1 EP 0007752 W EP0007752 W EP 0007752W WO 0110939 A1 WO0110939 A1 WO 0110939A1
Authority
WO
WIPO (PCT)
Prior art keywords
resin
acrylate
radiation
impregnated
curable
Prior art date
Application number
PCT/EP2000/007752
Other languages
German (de)
English (en)
Inventor
Erich Beck
Christof JÄCKH
Wolfgang Kranig
Karlheinz Dickerhof
Wolfram Weiss
Original Assignee
Basf Aktiengesellschaft
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Basf Aktiengesellschaft filed Critical Basf Aktiengesellschaft
Priority to AU68366/00A priority Critical patent/AU6836600A/en
Publication of WO2001010939A1 publication Critical patent/WO2001010939A1/fr

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Classifications

    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/18Paper- or board-based structures for surface covering
    • D21H27/22Structures being applied on the surface by special manufacturing processes, e.g. in presses
    • D21H27/24Structures being applied on the surface by special manufacturing processes, e.g. in presses characterised by the surface to be covered being phenolic-resin paper laminates, vulcan fibre or similar cellulosic fibreboards
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00Processes for producing special ornamental bodies
    • B44C5/04Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0469Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D161/00Coating compositions based on condensation polymers of aldehydes or ketones; Coating compositions based on derivatives of such polymers
    • C09D161/20Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen
    • C09D161/26Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds
    • C09D161/28Condensation polymers of aldehydes or ketones with only compounds containing hydrogen attached to nitrogen of aldehydes with heterocyclic compounds with melamine

Definitions

  • the invention relates to a process for the production of boards with a decorative surface by impregnating a support with an aqueous mixture of a heat-curable melamine-formaldehyde resin and a radiation-curable resin, painting the impregnated and dried support with a mixture of a radiation-curable coating resin and one heat-curable melamine-formaldehyde resin as well as radiation curing and pressing of the impregnated and provided with a top coat.
  • top coat Provides top coat and then presses the coating system in the heat.
  • phenol-formaldehyde resins as the impregnating agent gave satisfactory adhesion between the impregnated support and the radiation-hardened topcoat layer after the coating system had been pressed, but because of the discoloration that occurred, it was only of limited use for decorative surfaces , If aqueous aminoplast resins are used as the impregnating agent, the adhesion between the impregnated carrier and the top coat layer after the system has been pressed is often inadequate.
  • the object of the present invention was to find a coating system for panels with a decorative surface which does not have the disadvantages of the known coating systems or has them at least to a lesser extent and has a particularly good adhesive strength between the impregnated support and the topcoat layer.
  • a radiation-curable topcoat which, in addition to a resin with polymerizable olefinically unsaturated C-C double bonds, contains a melamine-formaldehyde resin
  • thermosetting melamine-formaldehyde resin (Al) at least one aqueous solution or aqueous dispersion of a thermosetting melamine-formaldehyde resin (Al), preferably with a solid resin content of 40 to 75% by weight, and
  • (a2) at least one water-dilutable and / or water-dispersible radiation-curable acrylate resin (A2), in particular a urethane, polyester and / or polyether acrylate, the solid fraction of resin (A2) being 0.5 to 70 and in particular 5 is up to 40% by weight of the sum of the solid resin contents of (Al) + (A2); and
  • the dried impregnated carrier is coated with a topcoat which contains a mixture (b1) at least one radiation-curable (meth) acrylate resin (B1) containing a plurality of polymerisable olefinically unsaturated CC double bonds, in particular a polyester acrylate and / or urethane acrylate, optionally with the addition of reactive diluents (acrylate monomers), and
  • (b2) at least one heat-curable etherified melamine-formaldehyde resin (B2), the solid fraction of resin (B2) being 5 to 60% by weight of the sum of the solid proportions of (B1) + (B2).
  • mixtures are therefore used both for the impregnation of the backing and for the topcoat layer, which contain both thermosetting melamine-formaldehyde resins and radiation-curable acrylate resins, which leads to particularly strong bonds between the impregnated backing and the topcoat layer.
  • the film or plate-shaped laminates are suitable for pressing onto profile bodies such as furniture parts, where they are characterized by good hardness, scratch and abrasion resistance and a low tendency to yellowing.
  • Suitable supports or resin supports for impregnation are, in particular, absorbent support materials, such as organic and inorganic fibers, webs, fabrics and mats, but preferably paper sheets. Decorative and cover papers that have sufficient wet strength are particularly worth mentioning as suitable paper supports.
  • the resin supports can be impregnated using conventional methods such as in an impregnation process, but the impregnating agent can also be applied using impregnating rollers.
  • the impregnated carrier can be dried by the action of heat radiation and with hot air and z. B. be carried out in conventional horizontal or vertical drying channels. When drying, physical drying takes place, but also further condensation (pre-gelling) of the impregnating resins.
  • the impregnated carrier With infrared heating zones, the impregnated carrier can be heated from the core with little skin formation.
  • the quality and processability of the impregnated or resin-coated carriers depends on correct drying. It is often advantageous to remove the majority of solvents such as water at relatively low temperatures and to heat them to temperatures of 100 to 140 ° C. only at the end of drying. When drying, the resin must not lose its fluidity. At the end of drying, the resin content should generally be about 30 to 50% by weight and the volatile content should be about 2 to 15% by weight and preferably not more than 8% by weight of the weight of the impregnated carrier. For some later uses of the laminate, it is advisable when the impregnated carrier dries, it is already deformed into a prepreg.
  • the process according to the invention is used to impregnate with an aqueous mixture of a heat-curable melamine-formaldehyde resin (AI) with at least one water-dilutable and / or water-dispersible radiation-curable acrylate resin (A2), such as, in particular, a urethane, polyester and / or polyether acrylic resin. latharz.
  • the solids content or dry matter content of resin (A2) is generally 0.5 to 70 and preferably 5 to 40% by weight of the sum of the solids content of the resins (Al) + (A2).
  • the solids content or dry matter content of resin (AI) is thus 30 to 99.5 wt.%, In particular 60 to 95 wt.
  • Suitable heat-curable melamine-formaldehyde resins are the commercially available water-soluble or water-dispersible melamine-formaldehyde impregnating resins, which usually have a molar ratio of melamine to formaldehyde of 1: 1.1 to 1: 2, preferably 1: 1.3 to 1 : 1.8 and can be processed cheaply under the selected drying and pressing conditions.
  • the melamine-formaldehyde resins are admixed with water-thinnable and / or water-dispersible radiation-curable acrylate resins for impregnation.
  • Acrylic resins are known resinous reaction products known per se from (i) (meth) acrylic acid with (ii) at least two hydroxyl-containing polyesters, polyethers, polyurethanes, melamine resins or epoxy resins (which contain at least two functional groups which react with (meth) acrylic acid), and Reaction products of (i) hydroxyalkyl (meth) acrylates with (ii) compounds containing isocyanate groups.
  • acrylate resins are e.g. B.
  • the acrylate resins which are divided into polyester acrylates, polyether acrylates, urethane acrylates, melamine acrylates and epoxy acrylates depending on the preparation and recurring groups in the main molecular chain, are relatively low molecular weight as so-called prepolymers and generally have an average molecular weight of 300 to 10,000 and preferably 400 to 3000 g / mol, determined by gel permeation chromatography (GPC) against a polystyrene standard.
  • the resins generally contain 0.1 to 1.0 and preferably 0.1 to 0.5 mol of polymerizable olefinically unsaturated CC double bonds per 100 g of prepolymer.
  • Acrylate resins used for the aqueous mixtures used for impregnation are water-dilutable and / or water-dispersible acrylate resins. They preferably contain sufficient hydrophilic groups for solubility or dispersibility in water, which can be done by using suitable builders which introduce hydrophilic or potentially hydrophilic groups in the resin synthesis of the acrylate resins. Potentially hydrophilic groups are understood to mean groups which are not themselves hydrophilic (e.g. carboxyl or amino groups), but which can be converted into hydrophilic groups (such as a carboxylate or ammonium group) by subsequent reactions, such as neutralizations or salt formation. Adequate dispersibility can also be achieved with the help of suitable emulsifiers.
  • the acrylate resins prefer urethane acrylate resins, polyester acrylate resins and polyether acrylate resins.
  • the impregnated carrier is dried in a conventional manner, e.g. B. at 80 to 150 ° C for about 10 to about 600 seconds.
  • a mixture of a radiation-curable acrylate resin (B1) with a heat-curable melamine-formaldehyde resin (B2) is likewise used for the production of the topcoat layer, the solids content of the heat-curable melamine-formaldehyde resin being 5 to 60, preferably 10 to 40,% by weight .-%, and the solids content of the resin (Bl) is 40 to 95 wt.%, preferably 60 to 90 wt.%, based in each case on the sum of the solids content of the resins (Bl) + (B2).
  • the resin (B2) used is a thermosetting etherified melamine-formaldehyde resin which is largely compatible with the radiation-curable resin (B1).
  • Ethers of methylolmelamines such as hexamethylolmelamine with water-miscible aliphatic alcohols having 1 to 3 carbon atoms, such as the ethers of methanol with hexamethylolmelamine, are particularly suitable.
  • Suitable resins (B1) for the topcoat are radiation-curable resins or paint resins which contain a plurality of polymerizable olefinically unsaturated CC double bonds. Preferred are weather-resistant and low-yellowing coatings which give acrylic resins which contain only a small amount and preferably no structural units such as aromatics, amines, ethers and / or melamines. Preferred acrylate resins also contain no maleinate structural units.
  • Suitable radiation-curable resins (B1) are especially suitable commercially available aliphatic acrylate resins (see definition above), such as in particular polyester acrylates, urethane acrylates.
  • Polyether acrylates or melamine acrylates are not preferred for the topcoat, but can be used in a mixture with predominant amounts of other acrylate resins, such as with urethane acrylates.
  • Preferred acrylate resins (B1) for the topcoat are liquid to highly viscous. In many cases it is advisable to process them in a mixture with acrylate monomers as reactive thinners for the production of the top coat.
  • Suitable reactive diluents are the mono-, di-, tri- and tetraacrylates of aliphatic polyhydric alcohols, such as propylene glycol diacrylate, hexanediol diacrylate, tripropylene glycol diacrylate, trimethylolpropane triacrylate or pentaerythritol tetraacrylate, which can also be used to adjust the hardness of the topcoat.
  • aliphatic polyhydric alcohols such as propylene glycol diacrylate, hexanediol diacrylate, tripropylene glycol diacrylate, trimethylolpropane triacrylate or pentaerythritol tetraacrylate, which can also be used to adjust the hardness of the topcoat.
  • urethane acrylates (B1) preferred as acrylate resins for the top coat layer are used with particular advantage in combination with water-dilutable or water-dispersible urethane, polyester and / or polyether acrylates as resins (A2) of the mixture for impregnating the carrier.
  • the uncured top coats which can be prepared using conventional techniques, e.g. B. applied by doctor blade, fulling, etc., a layer thickness of 5 to 150 and preferably from 10 to 80 microns.
  • the impregnated supports provided with the top coat can be subjected to curing in a known manner by means of high-energy radiation, such as UV light, electron or gamma rays. Curing by UV radiation, e.g. B. with the help of a high pressure mercury lamp in a conventional coating line.
  • high-energy radiation such as UV light, electron or gamma rays.
  • Curing by UV radiation e.g. B. with the help of a high pressure mercury lamp in a conventional coating line.
  • a conventional photoinitiator see, for example, J. Korsar, Light-Sensitive Systems, J. Wiley, New York 1965
  • the required amount of photoinitiators is generally about 1 to 4% by weight, based on the non-volatile paint components.
  • This amount of photoinitiator can be hardened under an inert gas atmosphere, e.g. B. a hardening under nitrogen, significantly reduce z. B. to 0.1 to 1 wt .-% of the amount of non-volatile paint components.
  • the laminate is pressed in a known manner under the action of pressure and heat, which takes place in a known stationary or continuous pressing device. can. Temperatures of approximately 100 to 200 ° C. and pressures of 20 to 100 kp / cm 2 are usually used.
  • the process according to the invention permits the production of laminates and decorative panels which, with satisfactory pot life of the impregnating resins, give products which have particularly good adhesion between the impregnated support and the topcoat layer and do not tend to yellowing.
  • Green decorative paper (100 g / mz) was immersed in a bath with the respective impregnation resin II to 15 (see below) and then squeezed between two rollers.
  • the respective impregnation resin application was about 80 to 100 g / m 2 .
  • the coating was then cured in a belt line at a belt speed of 8.5 m / minute under a 120 W / cm high-pressure mercury lamp (belt-lamp spacing 15 cm).
  • the paper was then pressed with a further 3 impregnated paper layers over a period of 20 minutes in a press at a pressure of 100 kp / cm 2 , while the press was heated from room temperature to 60 ° C. and then cooled again to room temperature.
  • the laminates obtained were tested to check the adhesion of the topcoat using the cross-cut method (DIN 53151) and then tearing off the scotch tape.
  • the pot life was determined as the shelf life of the formulation within which the impregnating resin remained free-flowing.
  • Impregnation resin II 100 parts Kauramin® impregnating resin 753 (BASF) (comparison) as melamine-formaldehyde resin 0.3 part Kauropal® 930/931 (BASF)
  • Impregnating resin 12 100 parts Kauramin® impregnating resin 753 (BASF) (comparison) as melamine-formaldehyde resin
  • Basonat®-PLR 8878 Basonat®-PLR 8878
  • Kauropal® 930/931 BASF
  • hardener 529 BASF
  • Impregnating resin 13 100 parts Kauramin® impregnating resin 753 (BASF) as melamine-formaldehyde resin 13.8 parts Laromer® LR 8949 (BASF) as aq. Urethane acrylate dispersion 0.3 part Kauropal® 930/931 (BASF) 0.24 part hardener 529 (BASF)
  • Impregnating resin 14 100 parts Kauramin® impregnating resin 753 (BASF) as melamine-formaldehyde resin
  • Impregnating resin 15 100 parts Kauramin® impregnating resin 753 (BASF) as melamine-formaldehyde resin
  • Topcoat Ll 61.4 parts Laromer® LR 8987 (BASF) (comparison) as urethane acrylate 16.9 parts Laromer® HDDA (BASF) as hexanediol diacrylate 8 parts Siloid® 162 (Grace) as matting agent 4.5 parts Genocure® MBF (Rahn )
  • Luwipal® 069 melamine-formaldehyde resin partially etherified with methanol
  • Luwipal® 069 melamine-formaldehyde resin partially etherified with methanol
  • Grade 3 chipped area> 5%, but smaller than about
  • Grade 4 chipped area> 15%, but smaller than about

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  • Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Organic Chemistry (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention concerne un procédé pour produire des plaques présentant une surface décorative. Ce procédé consiste à (i) imprégner un support, une feuille de papier par exemple, avec un mélange (A) constitué d'une solution aqueuse ou d'une dispersion aqueuse d'une résine de formaldéhyde-mélamine (A1) thermodurcissable et d'une résine acrylate (A2) radiodurcissable, dispersible dans l'eau et/ou diluable dans l'eau, telle qu'un acrylate d'uréthanne, de polyester et/ou de polyéther, (ii) à recouvrir ledit support imprégné et séché avec un vernis de finition constitué d'un mélange (B) contenant une résine acrylate (B1) radiodurcissable, telle qu'un acrylate d'uréthanne, et une résine de formaldéhyde-mélamine (B2) éthérifiée et thermodurcissable, et (iii) à durcir par rayonnement, puis à comprimer ledit support qui est imprégné et pourvu de vernis de finition. Les systèmes de revêtement utilisés présentent, outre leur bonne durée de conservation en pot, lors du traitement, une adhérence particulièrement bonne entre les couches de vernis de finition et les supports imprégnés.
PCT/EP2000/007752 1999-08-10 2000-08-09 Procede pour produire des plaques presentant une surface decorative WO2001010939A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU68366/00A AU6836600A (en) 1999-08-10 2000-08-09 Method for producing plates having a decorative surface

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE19937759.6 1999-08-10
DE1999137759 DE19937759A1 (de) 1999-08-10 1999-08-10 Verfahren zur Herstellung von Platten mit dekorativer Oberfläche

Publications (1)

Publication Number Publication Date
WO2001010939A1 true WO2001010939A1 (fr) 2001-02-15

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2000/007752 WO2001010939A1 (fr) 1999-08-10 2000-08-09 Procede pour produire des plaques presentant une surface decorative

Country Status (3)

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AU (1) AU6836600A (fr)
DE (1) DE19937759A1 (fr)
WO (1) WO2001010939A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1239077A1 (fr) * 2001-03-08 2002-09-11 Technocell Dekor GmbH & Co. KG Materiau à base de papier facilement imprimable
US20190077138A1 (en) * 2016-08-19 2019-03-14 Wilsonart Llc Surfacing materials and method of manufacture

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10301901A1 (de) * 2003-01-17 2004-07-29 Basf Ag Verwendung von Melaminharzfolien und/oder -filmen zur Beschichtung von dreidimensional strukturierten Oberflächen und/oder Formkörpern
DE102004034528A1 (de) * 2004-07-15 2006-02-16 Basf Ag Verwendung von Metaminharzfolien und/oder -filmen zur 3D-Beschichtung

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3975572A (en) * 1975-12-22 1976-08-17 Formica Corporation Thin, tough, stable, mar-resistant laminate
DE2947597B1 (de) * 1979-11-26 1980-11-06 Basf Farben & Fasern Verfahren zum Herstellen von Filmen oder UEberzuegen
DE3418282A1 (de) * 1984-05-17 1985-11-21 Hoechst Ag, 6230 Frankfurt Dekorative platte mit verbesserten oberflaecheneigenschaften
EP0763387A1 (fr) * 1995-09-18 1997-03-19 Werzalit Ag + Co. Procédé pour fabriquer une feuille de protection pour un objet profilé
US5714269A (en) * 1992-11-24 1998-02-03 Casco Nobel Ab Film composite

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3975572A (en) * 1975-12-22 1976-08-17 Formica Corporation Thin, tough, stable, mar-resistant laminate
DE2947597B1 (de) * 1979-11-26 1980-11-06 Basf Farben & Fasern Verfahren zum Herstellen von Filmen oder UEberzuegen
DE3418282A1 (de) * 1984-05-17 1985-11-21 Hoechst Ag, 6230 Frankfurt Dekorative platte mit verbesserten oberflaecheneigenschaften
US5714269A (en) * 1992-11-24 1998-02-03 Casco Nobel Ab Film composite
EP0763387A1 (fr) * 1995-09-18 1997-03-19 Werzalit Ag + Co. Procédé pour fabriquer une feuille de protection pour un objet profilé

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1239077A1 (fr) * 2001-03-08 2002-09-11 Technocell Dekor GmbH & Co. KG Materiau à base de papier facilement imprimable
US20190077138A1 (en) * 2016-08-19 2019-03-14 Wilsonart Llc Surfacing materials and method of manufacture
US10933608B2 (en) * 2016-08-19 2021-03-02 Wilsonart Llc Surfacing materials and method of manufacture

Also Published As

Publication number Publication date
DE19937759A1 (de) 2001-02-15
AU6836600A (en) 2001-03-05

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