WO2011131846A1 - Composite material, method of producing the same and the use thereof - Google Patents

Composite material, method of producing the same and the use thereof Download PDF

Info

Publication number
WO2011131846A1
WO2011131846A1 PCT/FI2011/050379 FI2011050379W WO2011131846A1 WO 2011131846 A1 WO2011131846 A1 WO 2011131846A1 FI 2011050379 W FI2011050379 W FI 2011050379W WO 2011131846 A1 WO2011131846 A1 WO 2011131846A1
Authority
WO
WIPO (PCT)
Prior art keywords
composite material
layers
paper
functional layer
based material
Prior art date
Application number
PCT/FI2011/050379
Other languages
French (fr)
Inventor
Kasperi Sokka
Original Assignee
Metsäliitto Osuuskunta
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 Metsäliitto Osuuskunta filed Critical Metsäliitto Osuuskunta
Priority to EP11771648A priority Critical patent/EP2560812A1/en
Publication of WO2011131846A1 publication Critical patent/WO2011131846A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/12—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/08—Impregnating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/067—Wood fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/712—Weather resistant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B32B2311/24—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/16—Wood, e.g. woodboard, fibreboard, woodchips
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives

Definitions

  • the present invention relates to a composite material according to the preamble of Claim 1, and a method of producing the composite material according to the preamble of Claim 10, and the use according to Claim 11.
  • coating materials are pre- viously known, for instance in the plywood industry. It has been possible to manufacture coating materials in different ways, for instance from different mixtures. It is also known that coating materials are made from paper materials which are impregnated with plastics.
  • the composite material and the method of producing it and using it, according to the present invention are characterized by what is stated in the independent claims.
  • the present invention is based on a composite material.
  • Ac- cording to the invention in order to provide the composite material with at least one predetermined structural property, the composite material comprises at least one layer of paper- based material and at least one functional layer, which layers are stacked one upon the other in a predetermined order and attached to each other, and the generated composite material is then impregnated with resin.
  • composite material means any combination of materials which is composed of paper-based material and at least one other material.
  • the composite material is in a board-like form, more preferably in the form of a thin " boardlike material, for instance in the form of a web, track, roll, sheet or a similar form.
  • paper-based material means any papery material which is at least partly formed of wood fibres, plant-derived fibres, recycled fibres, recirculated fibres or other suitable fibres ; or different combinations of these. It has been possible to produce the paper-based material by any method which is known per se.
  • the composite material comprises at least two layers of paper-based material .
  • the composite material com- prises more than two layers of paper-based material.
  • one functional layer is arranged between two layers of paper-based material.
  • the composite material comprises at least two functional layers. In another embodiment, the composite material comprises more than two functional layers. In another embodiment, the composite ma- terial comprises one functional layer.
  • more than one functional layer is arranged between two layers of paper-based material.
  • at least two functional lay- ers are placed between layers of paper-based material.
  • the composite material comprises at least two layers of paper-based material and at least two functional layers, and the layers of the pa- per-based material and the functional layers are arranged alternating in such a way that first there is a layer of paper- based material which is underlain by a functional layer.
  • the structural property of the functional layer is chosen from the following group: having a thermal insulation capacity, being a barrier to moisture, being impermeable to air, protecting against fire, being resistant to mechanical stress, being resistant to chemicals, being weather-resistant, and combinations of these.
  • the functional layer is formed of a metal-based material.
  • the metal-based material is aluminium or an. aluminium- based material.
  • the metal-based material can be formed of any metal or combination of metals.
  • the functional layer is formed of a polymer-based material .
  • the polymer-based material can comprise preferably po- lyethene, polypropylene, polyamide, aramid, carbon fibre, resin, cellulose, cellulose ester, cellulose ether, viscous fibre, cuprous fibre, modal fibre or other polymer or plastic, all of which are suitable for the purpose, or different combi- nations of these.
  • the functional layer is formed of a combination of polymer-based material and metal -based material.
  • a polymer-based layer provides the composite material with moisture barrier properties, thermal insulation properties, air impermeability properties, mechanical stress resistance properties, weather- resistance properties, chemical resistance properties or combinations of these.
  • a metal-based layer provides the composite material with fire resistance properties, thermal insulation properties, air impermeability properties, mechanical stress resistance properties, or combinations of. these.
  • the layers of the composite material are attached to each other by means of an adhesive agent.
  • the adhesive agent can be totally or mainly comprised of an adhesive.
  • the adhesive agent can be prepared from any material which is suitable for the purpose and which possesses adhesive properties:
  • the adhesive agent is chosen from the following group: cold-set and thermoplastic adhesive resins, for instance phenol-formaldehyde glue, melamine-formaldehyde glue, urea- formaldehyde glue, polyurethane glue and combinations of these.
  • the adhesive agent can be in the form of an adhesive layer or a filmy adhesive agent.
  • the adhesive agent can be applied or sprayed, or arranged by using extrusion, between the layers.
  • the layers of composite material are attached to each other by means of a laminating process.
  • the composite material is perforated.
  • the perforation can be carried out in order to facilitate further processing. In one embodiment, the perforation is carried out before the composite material is impregnated with resin.
  • the generated composite material is impregnated with resin during the laminating process. In another embodiment, the generated composite material is impregnated with resin in a separate impregnation stage.
  • the resin is chosen from the following group: phenolic resin, melamine resin, melamine-urea resin, urea-formaldehyde resin, epoxy resin, polyester resin and dif- ferent combinations of these.
  • phenolic resin melamine resin
  • melamine-urea resin melamine-urea resin
  • urea-formaldehyde resin epoxy resin
  • polyester resin dif- ferent combinations of these.
  • the resin is arranged essentially in a hardened, form, after the impregnation.
  • the resin is not in a hardened form after the impregnation, but in the form of a precursor, in which case the resin is hardened while the composite material is used, for instance during production of a coated fibre-based material.
  • the present invention is based on a method of producing any of the composite materials described above.
  • at least one layer of a paper-based material and at least one functional layer are stacked one upon the other in a predetermined order, and the layers are attached to each other to form a composite material, and the obtained composite material is impregnated with resin .
  • the composite material obtained is perfo- rated before impregnation.
  • the layers of the composite material are attached to each other by means of an adhesive agent. In another embodiment, the layers of the composite material are attached to each other by using lamination.
  • At least one or both of the surfaces of the composite material can be surface-finished, for instance by coating or varnishing, or by preparing an adhesive surface on the surface of the composite material, during the impregnation or, alternatively, after the impregnation.
  • the present invention is based on - the use of . any of the composite materials described above.
  • the composite material ' is used together with a fibre-based material, in order to produce the final product .
  • a fibre-based material means a material which is pre- pared from a fibre-based raw material, for instance a material which is prepared from a wood-based and/or plant fibre- based material, preferably board, multilayer board, plywood, veneer or other board-like material.
  • the composite material is used as a coating material, as an intermediate layer material and/or as an adhesive layer material.
  • the composite material is used together with separately prepared laminates, which are known per se, in order to form a combination with the laminate. This combination can be used together with a fibre-based material to form the final product.
  • the composite material is hot-compressed onto the surface of a fibre-based material or between veneers at an elevated pressure and, in one embodiment, at an elevated temperature.
  • the im- pregnated resin is not in a hardened state after the impregnation, the resin is hardened during the hot-compression stage.
  • the composite material is glued in between the layers of veneer.
  • the generated fibre-based final product which comprises composite material
  • the fibre-based final product which comprises composite material, as floor, wall or ceiling material, either as a permanent or as a tern- porary structure, both indoors and outdoors.
  • a versatile composite material which combines many properties is achieved with the present invention.
  • a composite material according to the present invention is a strong but light ma- terial. Desired properties such as thermal insulation capacity, moisture-barrier properties, air permeability, flameproof properties, mechanical stress resistance properties, weather-resistance properties and/or chemical resistance properties can be combined with the composite material according to the present invention.
  • Figure 1 shows a simplified picture of one composite material according to the present invention
  • FIG. 2 shows a simplified picture of another composite " material according to the present invention
  • Figure 3 shows a simplified picture of a third composite material according to the present invention.
  • Figure 4 shows a simplified picture of a fourth composite material according to the present invention.
  • Figure 1 shows a composite material according to the present invention .
  • the composite material according to Figure 1 comprises a paper-based layer 1 which is formed of kraft paper, and a functional layer 3 which is formed of aluminium film.
  • Material layers 1 and 3 are attached to each other by layers of glue, which layers comprise an adhesive which is suitable for the application.
  • the composite material is unperforated and impregnated with melamine resin.
  • the composite material in Figure 2 comprises an initial paper-based layer 1 and a second paper-based layer 2 which are formed of kraft paper, and a functional layer 3 which is formed of aluminium film and which is arranged between them.
  • the material layers 1, 2 and 3 are attached to each other by layers of glue, which comprise an adhesive which is suitable for the " application.
  • the composite material is perforated before impregnation and then impregnated with melamine resin.
  • the composite material in Figure 3 comprises an initial paper-based layer 1 and a second paper-based layer 2 which are formed of kraft paper, and between these layers, a functional layer .4 is arranged which is formed of polyamide and poly- ethylene.
  • the material layers 1, 2 and 4 are attached to each other by laminating.
  • the composite material is perforated before impregnation and then impregnated with melamine resin.
  • the composite material in Figure 4 comprises an initial pa- per-based layer (1) and a second paper-based layer 2 which are formed of kraft paper, and between these layers, an initial functional layer 4 is arranged which is formed of polya- mide and polyethene .
  • Onto one surface of the second paper- based layer 2 is arranged a second functional layer 3 which is formed of aluminium film.
  • the paper-based layers 1 and 2 and the functional layers 3 and 4 are arranged alternating in such a way that first there is a layer of paper- based material which is underlain by a functional layer.
  • the material layers 1, 2, 3 and 4 are attached to each other with an adhesive agent.
  • Example 5 The composite material is perforated before impregnation and then impregnated with phenol -formaldehyde resin.
  • Example 5 The composite material is perforated before impregnation and then impregnated with phenol -formaldehyde resin.
  • the composite materials according to Figures 1-4 are used as coating on a wood-based plywood board.
  • the composite material is arranged onto the surface of the wood-based board by hot- compression. In its function as a coating of the board which is to be produced, the composite material provides the ' board with desired properties and protects the surface . of the board against various stresses.
  • Example 6
  • the composite materials according to Figures 1-4 are used between the veneers of wood-based plywood boards.
  • the composite material is arranged between the veneers and the board which is formed of the veneers is prepared by hot-compressing the veneers together.
  • the composite material provides the board which is to be produced with desired properties.
  • the composite material according to the present invention is suitable to be used as different embodiments in a great variety of applications.

Abstract

The present invention relates to a composite material and to a method of producing the composite material. The invention discloses that the composite material, in order to provide it with at least one predetermined structural property, comprises at least two layers of a paper-based material (1, 2), and at least one functional layer (3, 4) is arranged between these two layers (1, 2), in which case the layers (1, 2, 3, 4) are stacked one upon the other in a predetermined order, and attached to each other, and the obtained composite material is then impregnated with resin.

Description

COMPOSITE MATERIAL, METHOD OF PRODUCING THE SAME AND THE USE THEREOF
FIELD OF THE INVENTION
The present invention relates to a composite material according to the preamble of Claim 1, and a method of producing the composite material according to the preamble of Claim 10, and the use according to Claim 11.
BACKGROUND TO THE INVENTION
Different composite materials are already known, and these materials are made by combining at least two different mate- rials. In the production of a composite material, the aim is to maximise the useful properties of the materials and to minimise the weaknesses.
Furthermore, the use of different coating materials is pre- viously known, for instance in the plywood industry. It has been possible to manufacture coating materials in different ways, for instance from different mixtures. It is also known that coating materials are made from paper materials which are impregnated with plastics.
AIM OF THE PRESENT INVENTION
It is an aim of the present invention to provide a novel composite material usable for many purposes by combining differ- ent properties that are consistent with the purposes for which a light composite material structure is used. Another aim of the present . invention is to provide a novel composite material to be used together with fibre-based materials, in order to provide the fibre-based materials with additional SUMMARY OF THE INVENTION The composite material and the method of producing it and using it, according to the present invention, are characterized by what is stated in the independent claims.
The present invention is based on a composite material. Ac- cording to the invention, in order to provide the composite material with at least one predetermined structural property, the composite material comprises at least one layer of paper- based material and at least one functional layer, which layers are stacked one upon the other in a predetermined order and attached to each other, and the generated composite material is then impregnated with resin.
Here, composite material means any combination of materials which is composed of paper-based material and at least one other material. Preferably, the composite material is in a board-like form, more preferably in the form of a thin" boardlike material, for instance in the form of a web, track, roll, sheet or a similar form. Here, paper-based material means any papery material which is at least partly formed of wood fibres, plant-derived fibres, recycled fibres, recirculated fibres or other suitable fibres ; or different combinations of these. It has been possible to produce the paper-based material by any method which is known per se.
In one embodiment of the present invention, the composite material comprises at least two layers of paper-based material . According to another embodiment, the composite material com- prises more than two layers of paper-based material.
In one embodiment of the present invention, one functional layer is arranged between two layers of paper-based material.
In one embodiment of the present invention, the composite material comprises at least two functional layers. In another embodiment, the composite material comprises more than two functional layers. In another embodiment, the composite ma- terial comprises one functional layer.
In one embodiment of the present invention, more than one functional layer is arranged between two layers of paper-based material. In another embodiment, at least two functional lay- ers are placed between layers of paper-based material.
In one embodiment of the present invention, the composite material comprises at least two layers of paper-based material and at least two functional layers, and the layers of the pa- per-based material and the functional layers are arranged alternating in such a way that first there is a layer of paper- based material which is underlain by a functional layer.
In one embodiment of the present invention, the structural property of the functional layer is chosen from the following group: having a thermal insulation capacity, being a barrier to moisture, being impermeable to air, protecting against fire, being resistant to mechanical stress, being resistant to chemicals, being weather-resistant, and combinations of these.
-
In one embodiment of the present invention, the functional layer is formed of a metal-based material. In another embodiment, the metal-based material is aluminium or an. aluminium- based material. Alternatively, the metal-based material can be formed of any metal or combination of metals.
In one embodiment of the present invention, the functional layer is formed of a polymer-based material . In another embo- diment, the polymer-based material can comprise preferably po- lyethene, polypropylene, polyamide, aramid, carbon fibre, resin, cellulose, cellulose ester, cellulose ether, viscous fibre, cuprous fibre, modal fibre or other polymer or plastic, all of which are suitable for the purpose, or different combi- nations of these.
In one embodiment of the present invention, the functional layer is formed of a combination of polymer-based material and metal -based material.
In one embodiment of the present invention, a polymer-based layer provides the composite material with moisture barrier properties, thermal insulation properties, air impermeability properties, mechanical stress resistance properties, weather- resistance properties, chemical resistance properties or combinations of these.
In one embodiment of the present invention, a metal-based layer provides the composite material with fire resistance properties, thermal insulation properties, air impermeability properties, mechanical stress resistance properties, or combinations of. these.
In one embodiment of the present invention, the layers of the composite material are attached to each other by means of an adhesive agent. The adhesive agent can be totally or mainly comprised of an adhesive. Alternatively, the adhesive agent can be prepared from any material which is suitable for the purpose and which possesses adhesive properties: In one embo- diment, the adhesive agent is chosen from the following group: cold-set and thermoplastic adhesive resins, for instance phenol-formaldehyde glue, melamine-formaldehyde glue, urea- formaldehyde glue, polyurethane glue and combinations of these. In another embodiment, the adhesive agent can be in the form of an adhesive layer or a filmy adhesive agent. In one embodiment, the adhesive agent can be applied or sprayed, or arranged by using extrusion, between the layers. In one embodiment of the present invention, the layers of composite material are attached to each other by means of a laminating process.
In one embodiment, the composite material is perforated. The perforation can be carried out in order to facilitate further processing. In one embodiment, the perforation is carried out before the composite material is impregnated with resin.
According to one embodiment, the generated composite material is impregnated with resin during the laminating process. In another embodiment, the generated composite material is impregnated with resin in a separate impregnation stage.
In one embodiment, the resin is chosen from the following group: phenolic resin, melamine resin, melamine-urea resin, urea-formaldehyde resin, epoxy resin, polyester resin and dif- ferent combinations of these. Alternatively, it is possible to use any other resin or combination of resins which are suitable for the purpose.
In one embodiment, the resin is arranged essentially in a hardened, form, after the impregnation. In another embodiment, the resin is not in a hardened form after the impregnation, but in the form of a precursor, in which case the resin is hardened while the composite material is used, for instance during production of a coated fibre-based material.
Furthermore, the present invention is based on a method of producing any of the composite materials described above. According to the invention, in order to provide at least one predetermined structural property, at least one layer of a paper-based material and at least one functional layer are stacked one upon the other in a predetermined order, and the layers are attached to each other to form a composite material, and the obtained composite material is impregnated with resin .
In one embodiment, the composite material obtained is perfo- rated before impregnation.
In one" embodiment , the layers of the composite material are attached to each other by means of an adhesive agent. In another embodiment, the layers of the composite material are attached to each other by using lamination.
In' one embodiment, at least one or both of the surfaces of the composite material can be surface-finished, for instance by coating or varnishing, or by preparing an adhesive surface on the surface of the composite material, during the impregnation or, alternatively, after the impregnation.
Furthermore, the present invention is based on - the use of . any of the composite materials described above. According to the present invention, the composite material' is used together with a fibre-based material, in order to produce the final product .
Here, a fibre-based material means a material which is pre- pared from a fibre-based raw material, for instance a material which is prepared from a wood-based and/or plant fibre- based material, preferably board, multilayer board, plywood, veneer or other board-like material.
In one embodiment, the composite material is used as a coating material, as an intermediate layer material and/or as an adhesive layer material. In one embodiment, the composite material is used together with separately prepared laminates, which are known per se, in order to form a combination with the laminate. This combination can be used together with a fibre-based material to form the final product.
In one embodiment, the composite material is hot-compressed onto the surface of a fibre-based material or between veneers at an elevated pressure and, in one embodiment, at an elevated temperature. According to another embodiment, in which the im- pregnated resin is not in a hardened state after the impregnation, the resin is hardened during the hot-compression stage.
In one embodiment, the composite material is glued in between the layers of veneer.
In one embodiment, the generated fibre-based final product, which comprises composite material, is used as building material, such as thermal insulation material, moisture-barrier material, door material or flame-proof material or as a pro- tective board.
In one embodiment, it is possible to use the fibre-based final product,- which comprises composite material, as floor, wall or ceiling material, either as a permanent or as a tern- porary structure, both indoors and outdoors.
Considerable advantages are achieved with a composite material according to the present invention, compared with the known technology.
A versatile composite material which combines many properties is achieved with the present invention. A composite material according to the present invention is a strong but light ma- terial. Desired properties such as thermal insulation capacity, moisture-barrier properties, air permeability, flameproof properties, mechanical stress resistance properties, weather-resistance properties and/or chemical resistance properties can be combined with the composite material according to the present invention.
LIST OF DRAWINGS
Figure 1 shows a simplified picture of one composite material according to the present invention;
Figure 2 shows a simplified picture of another composite" material according to the present invention;
Figure 3 shows a simplified picture of a third composite material according to the present invention; and
Figure 4 shows a simplified picture of a fourth composite material according to the present invention.
DETAILED DESCRIPTIONS OF EMBODIMENTS OF THE. INVENTION In the following, the present invention is described with the help of detailed examples of applications, and reference to: the accompanying drawings . . Example 1
Figure 1 shows a composite material according to the present invention .
The composite material according to Figure 1 comprises a paper-based layer 1 which is formed of kraft paper, and a functional layer 3 which is formed of aluminium film.
Material layers 1 and 3 are attached to each other by layers of glue, which layers comprise an adhesive which is suitable for the application.
The composite material is unperforated and impregnated with melamine resin.
Example 2
The composite material in Figure 2 comprises an initial paper-based layer 1 and a second paper-based layer 2 which are formed of kraft paper, and a functional layer 3 which is formed of aluminium film and which is arranged between them. The material layers 1, 2 and 3 are attached to each other by layers of glue, which comprise an adhesive which is suitable for the" application.
The composite material is perforated before impregnation and then impregnated with melamine resin.
Example 3
The composite material in Figure 3 comprises an initial paper-based layer 1 and a second paper-based layer 2 which are formed of kraft paper, and between these layers, a functional layer .4 is arranged which is formed of polyamide and poly- ethylene. The material layers 1, 2 and 4 are attached to each other by laminating.
The composite material is perforated before impregnation and then impregnated with melamine resin.
Example 4
The composite material in Figure 4 comprises an initial pa- per-based layer (1) and a second paper-based layer 2 which are formed of kraft paper, and between these layers, an initial functional layer 4 is arranged which is formed of polya- mide and polyethene . Onto one surface of the second paper- based layer 2 is arranged a second functional layer 3 which is formed of aluminium film. Thus, the paper-based layers 1 and 2 and the functional layers 3 and 4 are arranged alternating in such a way that first there is a layer of paper- based material which is underlain by a functional layer. The material layers 1, 2, 3 and 4 are attached to each other with an adhesive agent.
The composite material is perforated before impregnation and then impregnated with phenol -formaldehyde resin. Example 5
The composite materials according to Figures 1-4 are used as coating on a wood-based plywood board. The composite material is arranged onto the surface of the wood-based board by hot- compression. In its function as a coating of the board which is to be produced, the composite material provides the' board with desired properties and protects the surface . of the board against various stresses. Example 6
The composite materials according to Figures 1-4 are used between the veneers of wood-based plywood boards. The composite material is arranged between the veneers and the board which is formed of the veneers is prepared by hot-compressing the veneers together. The composite material provides the board which is to be produced with desired properties. The composite material according to the present invention is suitable to be used as different embodiments in a great variety of applications.
The present invention is not limited to apply only to the ex- amples described above, rather many variations are possible as long as the principle of the invention specified by the claims is not infringed.

Claims

1. A composite material which, in order to provide the composite material with at least one predetermined structural property, comprises at least one layer of paper-based material (1, 2) and at least one functional layer (3, 4),
c h a r a c t e r i z e d in that the composite material comprises at least two layers of paper-based material (1, 2), and that between the two layers of paper-based material (1, 2) is arranged at least one functional layer (3, 4), in which case the layers (1, 2, 3, 4) are stacked one upon the other in a predetermined order, and attached to each other, and the obtained composite material is then impregnated with resin.
2. The composite material according to Claim 1,
c h a r a c t e r i z e d in that the composite material comprises at least two functional layers (3, 4).
3. A composite material according to Claim 1 or 2 ,
c h a r a c t e r i z e d in that more than one functional layer (3, 4) is arranged between two layers of paper-based material (1, 2) .
4. A composite material according. to any of Claims 1-3, c h a r a c t e r i z e d in that the composite material comprises at least -two layers of paper-based material . (1 , 2) and at least two functional layers (3, 4),. and that the layers of paper-based material (1, 2) and the functional layers (3, 4) are arranged alternating in such a way- that first there is a layer of paper-based material (1, 2) which is underlain by a functional layer (3,- 4) .
5.A composite material according to any of Claims 1-4,
c h a r a c t e r i z e d in that the structural property of the functional layer (3, 4) is chosen from the following group: thermal insulation capacity, moisture-barrier properties, air permeability, flame-proof properties, mechanical stress resistance properties, chemical resistance properties, weather-resistance properties and/or combinations of these.
6. A composite material according to any of Claims 1-5, c h a r a c t e r i z e d in that the functional layer (3, 4) is formed of a metal -based material.
7. A composite material according to any of Claims 1-6, c h a r a c t e r i z e d in that the functional layer (3, 4) is formed of a polymer-based material.
8. A composite material according to any of Claims 1-7, c h a r a c t e r i z e d in that the layers of the composite material (1, 2, 3, 4) are attached to each other with an adhesive agent.
9. A composite material according to any of Claims 1-8, c h a r a c t e r i z e d in that the composite material is perforated .
10. A method of producing a composite material according to any of Claims 1-8, c h a r a c t e r i z e d in that, in order to obtain at least one predetermined structural property, at least one layer of paper-based material and at least one functional layer are stacked one upon the other in a predetermined order, and the layers are attached to each other to form a composite material, and the generated composite material is impregnated with resin.
11. The use of a composite material according to any of
Claims 1-9 together with a fibre-based material.
PCT/FI2011/050379 2010-04-23 2011-04-26 Composite material, method of producing the same and the use thereof WO2011131846A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP11771648A EP2560812A1 (en) 2010-04-23 2011-04-26 Composite material, method of producing the same and the use thereof

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FI20105442A FI20105442A (en) 2010-04-23 2010-04-23 Composite material, process for its preparation and its use
FI20105442 2010-04-23

Publications (1)

Publication Number Publication Date
WO2011131846A1 true WO2011131846A1 (en) 2011-10-27

Family

ID=42133283

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/FI2011/050379 WO2011131846A1 (en) 2010-04-23 2011-04-26 Composite material, method of producing the same and the use thereof

Country Status (3)

Country Link
EP (1) EP2560812A1 (en)
FI (1) FI20105442A (en)
WO (1) WO2011131846A1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014096555A1 (en) 2012-12-21 2014-06-26 Metsäliitto Osuuskunta Method of preventing delamination of flame retarding structures

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1079047A (en) * 1964-08-28 1967-08-09 Formica Int Improvements in or relating to laminated plastic sheets
US4126725A (en) * 1975-10-31 1978-11-21 Hopeman Brothers, Inc. High pressure laminates
JPH04191040A (en) * 1990-11-27 1992-07-09 Sumitomo Bakelite Co Ltd Thermosetting resin decorative laminated sheet
JPH10337799A (en) * 1997-04-08 1998-12-22 Hitachi Kizai Kk Decorative laminated sheet and decorative panel using the same
EP1468818A1 (en) * 2003-04-14 2004-10-20 Thermopal GmbH Laminated plate

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1079047A (en) * 1964-08-28 1967-08-09 Formica Int Improvements in or relating to laminated plastic sheets
US4126725A (en) * 1975-10-31 1978-11-21 Hopeman Brothers, Inc. High pressure laminates
JPH04191040A (en) * 1990-11-27 1992-07-09 Sumitomo Bakelite Co Ltd Thermosetting resin decorative laminated sheet
JPH10337799A (en) * 1997-04-08 1998-12-22 Hitachi Kizai Kk Decorative laminated sheet and decorative panel using the same
EP1468818A1 (en) * 2003-04-14 2004-10-20 Thermopal GmbH Laminated plate

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014096555A1 (en) 2012-12-21 2014-06-26 Metsäliitto Osuuskunta Method of preventing delamination of flame retarding structures

Also Published As

Publication number Publication date
FI20105442A (en) 2011-10-24
FI20105442A0 (en) 2010-04-23
EP2560812A1 (en) 2013-02-27

Similar Documents

Publication Publication Date Title
US10259199B2 (en) Polymer reinforced composite plywood and laminates
JP5027995B2 (en) Method for producing decorative fiber-reinforced laminate, decorative fiber-reinforced laminate, and decorative fiber-reinforced laminate panel
EP2536895B1 (en) Method for manufacturing composite panel
US10307994B2 (en) Composite board composed of wood material
US8865317B2 (en) Decorative laminate and method for manufacturing same
CA2720236C (en) Manufacturing process for a laminated structure
US11014330B2 (en) Veneer panel with thin thermally conductive layer
US10828874B2 (en) Composite board composed of wood material with a middle layer made of plywood
RU2475506C2 (en) Impregnation with hybrid resins
FI3544778T3 (en) Coated multi-ply wood panel and method of producing a core board
GB201018205D0 (en) Improvements to laminated boards and mouldings
WO2016049056A1 (en) Polymer reinforced composite plywood and laminates
CA2278048A1 (en) Ligneous finishing material
EP2560812A1 (en) Composite material, method of producing the same and the use thereof
FI120085B (en) A moisture barrier coating material and methods for making it and a coated sheet product
CICEKLER et al. Resin impregnation of decor papers and comparison of physical properties
EP2635436B1 (en) Composite product and method of producing the same
KR101261623B1 (en) Panel assembly having paper tube wound with corrugated paper strip and method thereof
EP4289617A1 (en) A multi-layered core board, a door, and a method for manufacturing a multi-layered core
CA3207310A1 (en) Panel and method for producing panels
US9957137B2 (en) Elevator car
RU2520340C1 (en) Paper laminate (versions)
JP2004034512A (en) Decorative sheet and its manufacturing method
RU2516543C1 (en) Paper laminate (versions)
RU2520534C1 (en) Paper laminate (versions)

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 11771648

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

WWE Wipo information: entry into national phase

Ref document number: 2011771648

Country of ref document: EP