Patent EP-2431173-A1 (EP)
Inventor: ULLRICH GERALD DR
IPC: B32B5/22
Filed: 2010-09-21
Abstract: Laminate comprises: (a) a symmetrically or asymmetrically arranged laminate core made of a matrix comprising organic binder resin, inorganic fillers and inorganic and/or organic fibers; (b) at least one supporting layer applied on at least one of the two surfaces of the laminate core; (c) at least one adhesive layer applied on the surface of the supporting layer facing away from the laminate core; and (d) at least one decorative layer that is applied on the surface of the adhesive layer facing away from the laminate core, where the decorative layer is formed multilayered. Laminate comprises: (a) a symmetrically or asymmetrically arranged laminate core made of a matrix comprising (in wt.%) organic binder resin (17), inorganic fillers (45-85) and inorganic and/or organic fibers (10-25); (b) at least one supporting layer comprising at least one layer, preferably at least two layers made of textile fabric exhibiting an end solidified B-stage binder portion of 5-30 wt.%, based on the total weight of the textile surface with the binder after its conversion into B-stage state, applied on at least one of the two surfaces of the laminate core; (c) at least one adhesive layer comprising at least one layer, preferably at least two layers made of textile fabric exhibiting an end solidified B-stage binder portion of 40-80 wt.%, based on the total weight of the textile surface with the binder after its conversion into B-stage state, applied on the surface of the supporting layer facing away from the laminate core; and (d) at least one decorative layer that is applied on the surface of the adhesive layer facing away from the laminate core, where the decorative layer is formed multilayered. The laminate core is formed multilayered, where the individual core layers after completion of product, are connected inseparably with each other and also with underlying and overlying functional layers. The laminate core exhibits: a density of at least 1.70 g/cm 3>, preferably at least 1.80 g/cm 3>determined according to EN ISO 1183-1:2004; a flexural strength of at least 35 MPa, preferably at least 45 MPa, determined according to EN ISO 178:2003; and a flexural modulus of at least 7 GPa, preferably at least 8.5 GPa, determined according to EN ISO 178:2003. Independent claims are also included for: (1) a laminate precursor comprising (i) a symmetrically or asymmetrically arranged laminate core exhibiting at least two layers, preferably at least three layers made of mineral filled textile fabric, which is solidified with a binder portion (5-20 wt.%, based on the total weight of the fabric with the binder), and is impregnated with a core formulation (60-90 wt.%) comprising (in wt.%) thermally curable natural and/or synthetic resin (1-20, preferably 8-12), inorganic fillers (40-90, preferably 50-75) and diluting water (1-30, preferably 9-18), where the obtained core layers are dried upto a residual water content of upto 8 wt.%, preferably upto 5 wt.% and the resin is converted into a reactive B-stage state, component (b), component (c), and component (d); and (2) producing the laminate, comprising (A) forming or introducing the symmetrically or asymmetrically arranged laminate core, (B) supplying at least one supporting layer, which is applied on at least one of the two surfaces of the laminate core, (C) supplying at least one adhesive layer, which is applied on the surface of the supporting layer facing away from the laminate core, (D) supplying at least one decorative layer, which is applied on the surface of the adhesive layer facing away from the laminate core, and (E) laminating the above layers under the influence of pressure and temperature.