Patent DE-102011122595-A1 (DE)
Title: Composite material useful e.g. for furnitures, comprises e.g. carrier material, binder solidified textile underlay layer, overlay layer with additives increasing abrasion resistance of overlay layer surface, and optionally further layer
Inventor: GLEICH KLAUS FRIEDRICH
IPC: B32B21/08
Filed: 2011-12-30
Abstract: Composite material comprises (i) at least one carrier material, (ii) at least one textile underlay layer, which is solidified using binder, (iii) optionally at least one decorative layer, which is applied on the surface of the textile underlay layer, facing away from the carrier material, (iv) at least one overlay layer, which is applied on the surface of textile underlay layer, facing away from the carrier material, or on the optionally present decorative layer, comprising additives that increase the abrasion resistance of overlay layer surface, and (v) optionally at least one further layer. Composite material comprises (i) at least one carrier material, (ii) at least one textile underlay layer, which is solidified using binder, (iii) optionally at least one decorative layer, which is applied on the surface of the textile underlay layer, facing away from the carrier material, (iv) at least one overlay layer, which is applied on the surface of the textile underlay layer, facing away from the carrier material, or on the optionally present decorative layer, comprising additives that increase the abrasion resistance of overlay layer surface, and (v) optionally at least one further layer. The application amount of the additive in the overlay layer is 20-70 g/m 2>. The textile underlay layer is prepared by (a) equipping a binder solidified textile sheet material, which is completely impregnated with 35-65 wt.%, preferably 35-60 wt.% (based on the total weight of the textile sheet material and binder) (a) completely cured binder based on urea-formaldehyde, with at least one (b) B-stage binder based on urea-formaldehyde and/or melamine-formaldehyde, where the B-stage binder exhibits a binder portion of 30-65 wt.%, preferably 15-45 wt.%, based on the total weight of the fabric underlay layer and all binders, where the textile sheet material exhibits a surface weight of 15-200 g/m 2> without binder, and (b) reacting the B-stage binder in B-stage state. The composite material is prepared by pressing the carrier material, the textile underlay layer, in which the B-stage binder is present in B-stage state, the optionally present decorative layer, the textile overlay layer, and the optionally present further layer under complete curing of the B-stage binder. Independent claims are also included for: (1) preparing the composite material, comprising (Aa) providing the carrier material, (Bb) providing at least one textile underlay layer and applying it on the carrier material provided in step (Aa), (Cc) optionally providing the decorative layer and optionally applying it on the underlay layer provided in step (Bb), (Dd) providing and applying the overlay layer on the underlay layer provided in step (Bb) or on the decorative layer provided in step (Cc), (Ee) optionally applying the further layers, and (Ff) pressing all the layers; (2) composite material present as semifinished product comprising the textile underlay layer containing at least one textile sheet material, which is solidified by binder, and at least one high pressure laminate or continuous pressure laminate exhibiting an overlay layer, which is present on the side facing away from the textile sheet material, and comprises (d) 30-65 wt.% (based on the total weight of the textile underlay layer and all binders) at least one layer of a binder based on melamine-formaldehyde, which is not completely cured, and exhibits a residual moisture content of less than 1%, where the weight ratio of completely cured binder and the B-stage binder is 1:1-5:1, and the layer is applied on the surface facing away from the carrier material or on both surfaces of the textile underlay layer; and (3) an underlay for preparing the composite material, which fulfills the requirements of EN13329 Class 34 (tested using small ball) preferably exhibits an impact resistance of 24 N, comprising the binder solidified textile sheet material, where the B-stage binder is present in the B-stage state so that the binder is not completely cured and the binder exhibits a residual moisture content of 4%.