DE102004026481A1 - Production of coated substrates with a 3-dimensional structured surface, e.g. furniture parts, involves press-coating with melamine resin-impregnated paper containing synthetic polymer fibres - Google Patents

Abstract

A method for the production of coated substrates with a 3-dimensional structured surface by impregnating paper with a crosslinkable aminoplastic resin (I), applying the impregnated paper to the substrate and forming it 3-dimensionally, in which the base paper used contains 5-90 wt% synthetic polymer fibres based on total fibre content. An independent claim is also included for aminoplastic resin sheet or film containing the above paper impregnated with (I).

Description

The The invention relates to a method for three-dimensional coating of materials.

Usually are used to coat three-dimensionally structured surfaces (3D coating) Thermoplastic films used, e.g. for coating wood-based materials in the furniture industry. These films are made, for example, with the help of membrane presses, as described in DE-A 38 27 497 and DE-A 199 20 577, pressed onto the material. The significant advantage of these thermoplastic films is its elasticity, disadvantageous are the high costs in the production, u.a. caused by the extra Use of adhesives.

Desirable is, the self-adhesive cost-effective Melamine resins, e.g. in the furniture industry used for finishing smooth surfaces, as well for coating three-dimensionally structured surfaces. The Melamine resins are also characterized by high gloss and good printability out. Pure melamine resins are too brittle for this application.

The older German Application Serial No. 10301901.4 discloses self-adhesive for the first time Melamine resin films suitable for the 3D coating of furniture can be used are. These melamine resins consist of a mixture of melamine-formaldehyde condensates, etherified melamine-formaldehyde condensates and acrylate dispersions. A disadvantage of these melamine resin films in comparison to the thermoplastic films are their properties during pressing. The elasticity of melamine resin films or movies is not yet sufficient enough in a standard procedure Coatings without cracking and wrinkles at the compression points to realize.

Of the The invention was therefore based on the object of finding melamine resin films, with the help of the membrane presses of the prior art Press without cracking and wrinkles at the compression points to let.

It was surprising a process found that for the production of partially or Completely coated materials with a three-dimensionally structured surface is particularly suitable in the for three-dimensional coating Aminoplast resin films or films can be used, which by means of a Membrane press with a lower press table, an upper press table, one on one covered with the aminoplast resin film or film and thus to be coated workpiece Lowerable elastic membrane, which with a press table a pressure-tight Chamber forms, with channels for introducing and discharging a fluid acting on the membrane and with a press control to which material is applied wherein the Aminoplastharzfolien or films impregnated with aminoplast resin decor paper containing 5 to 90 wt .-% based on the total fiber content, Contains fibers of synthetic polymers.

Under the term "three-dimensional Deformation "is the partial or complete Coating of bodies, Structures, reliefs, profiles, embossing and the like to understand. These have three-dimensionally structured surfaces, So forms, designs or structures that are in all three Spatial directions extend. The shape changes can be both fluent also be abrupt, such as in sharp-edged structures, like edges, corners, and / or points that have a defined angle describe, consisting of two or more converging Levels results. Furthermore, under "three-dimensional deformation" is also the full coating, or simultaneous / simultaneous coating of fronts and edges, of regular or irregular shaped bodies, profiles and the like.

When Starting material for the fibers of synthetic polymers are advantageously polyamide, Polyimide, polyurethanes, polypropylene, polyethylene, polyacrylonitrile, Polyvinyl alcohol or various polyesters, for example polyethylene terephthalate, Polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, used. Preference is given to the use of fibers made of polyamide, Polyester, polypropylene or polyethylene.

mixtures of fibers of synthetic polymers are also advantageous. For example, a mixture of two of the above synthetic fibers such as e.g. Polyamide, polypropylene, polyethylene and polyester fibers in a weight ratio of from 1:99 to 99: 1 become. Depending on the specification of the decor papers to be obtained can be advantageous Fiber blends selected where more than two types of fibers can be present.

It is also possible to use fibers of copolymers, for example block polymers of polyamide, polyimide, polyurethanes, polypropylene, polyethylene, polyacrylonitrile, polyvinyl alcohol or various polyesters, for example polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate. Copolymers of monomers, such as, for example, propylene, ethylene, (meth) acrylonitrile, vinyl alcohol or esters, for example of vinyl alcohol, may also serve as the basis for making the synthetic fibers.

The fibers of synthetic polymers advantageously have no branching. The individual fibers have similar lengths to typical natural fibers. Advantageously, the synthetic fibers have a length of 0.5 to 20 mm, in particular from 0.5 to 10 mm, particularly preferably from 2 to 9 mm. The fiber diameter is usually at 5 to 30 microns, preferably 10 to 25 microns. The fibers furthermore have an average surface area of from 1500 to 3500 m ² / g, in particular from 2000 to 2500 m ² / g.

The Preparation of the synthetic fibers is known to the person skilled in the art. Common production methods are For example, the spinning process or the production by flashing process.

The synthetic fibers can in any ratio with the paper pulp of decorative paper, for example birch, Eucalyptus and long fiber pulp, such as pine or spruce, mixed and on all common ones Paper machines are processed. The pulps, for example recovered by the sulfite or the sulfate preparation method. The pulps may optionally bleached by different methods known to those skilled in the art become. The cellulose bevels are selected depending on the application, the advantages and disadvantages of the individual cellulose fibers in the Experts are known. The processing of the fibers into decorative paper is well known. Depending on the type of fiber used and fiber content are minor changes required in papermaking, for example in the fiber blend, Fiber pretreatment, fiber addition, grinding and process control. When drying the decorative paper, the temperature should be advantageous a range of 50 to 150 ° C do not exceed. Temperatures of over 120 ° C can too lead reduced sheet thickness. The generally known decorative paper production can also be used for conventional finishing processes be followed, such as smoothing, gluing, embossing, printing (for example Gravure, flexographic or digital printing), impregnation, deformation and / or Paint.

The decorative papers used according to the invention have a Bendtsen porosity of 300 to 2000 ml / min, in particular 400 to 1200 ml / min, and thus have a very good impregnability. The porosity is adjusted according to the requirements of the impregnation. The wet strength is advantageously 6N to 40N. The hiding power of the decor paper is usually 0 to 100%, in particular 60 to 100%. The decorative paper usually has a basis weight of 40 to 300 g / m ² , in particular from 80 to 200 g / m ² . The color impression moves between white and black, bright colors in numerous nuances are realizable.

The Decor papers can one-sided or bilateral smoothness have one side smoothness preferred is.

The Decorative paper containing 5 to 90% by weight, based on the total fiber content, Contains fibers of synthetic polymers, advantageously contains 95 to 10 wt .-% Cellulose. The cellulose is advantageously chemically unchanged. The Cellulose can basically bleached or unbleached. The use is preferred of bleached cellulose. Eucalyptus can be used to advantage Globulus, nordic birch and long fiber. The decorative paper preferably contains 10 to 60 wt .-%, based on the total fiber content, fibers synthetic polymers and 90 to 40 wt .-% cellulose. Especially contains the decorative paper 10 to 40 wt .-%, based on the total fiber content, Fibers of synthetic polymers and 90 to 60 wt .-% cellulose. Particularly preferably contains the decorative paper 10 to 40 wt .-%, based on the total fiber content, fibers made of polyamide, polyester, polypropylene and / or polyethylene.

The used according to the invention Decorative paper can be next to the cellulose fibers and the synthetic fiber Polymer usual, contain other ingredients known in the art, such as Secondary fibers, fillers or pigments. Control the inorganic or organic pigments et al the opacity generation, Color transfer, printability and thickness increase. Advantageously, white or Color pigments as compounds in the form of oxides, silicates, carbonates, Sulphates or carbon blacks in the recipe.

preferred inorganic pigments used in the decor paper according to the invention as a colorant can serve, are, for example, iron oxides, iron cyanoferrate, sodium aluminum silicates and / or Titanium dioxides. The titanium dioxides are, for example, after the chloride or the sulphate process. Depending on the application, these can modified, for example coated or coated, be. The Modification can be done with different materials, for example with phosphorus, phosphorus pentoxide, aluminum, zirconium, alumina and / or silicon dioxide.

Preferred organic pigments which can serve as colorants in the decor paper used according to the invention are, for example, those from the class of monoazo pigments (eg products derived from acetoacryloylidene derivatives or from β-naphthol derivatives), laked monoazo dyes (eg laked β-oxynaphthoic acid dyes), disazo pigments, condensed disazo pigments, isoindo linderivatives, derivatives of naphthalene or perylenetetracarboxylic acid, anthracinone pigments, thioindigo derivatives, azomethine derivatives, quinacridones, dioxazines, pyrazoloquinazolones, phthalocyanine pigments or laked basic dyes (eg laked triarylmethane dyes).

Of the Total pigment content in the finished base paper is advantageous between 0 and 40 wt .-% based on the total paper, in particular between 5 and 20% by weight. When using pigments 5 to 10% by weight of pigments based on silicates and up to 20% by weight, preferably 0 to 15 wt .-%, titanium dioxides and iron oxides used.

The Wet-strength decorative papers are usually easy to handle reprocess within known standard processes.

Suitable crosslinkable aminoplastic resins are all resins known to the person skilled in the art, in particular melamine-urea-formaldehyde- and melamine-formaldehyde-resin or mixtures thereof. These resins may be partially or completely etherified with alcohols, preferably C ₁ -C ₄ -alcohols, in particular methanol. Preference is given to using etherified and unetherified melamine-urea-formaldehyde and melamine-formaldehyde resins or mixtures thereof, in particular etherified and unetherified melamine-formaldehyde resins.

Especially preferred are resin mixtures, the melamine-formaldehyde condensate (s), etherified melamine-formaldehyde condensate (s) and polymer dispersion (s) contain.

• (i) 5 bis 80 Gew.-%, insbesondere 10 bis 50 Gew.-%, besonders bevorzugt 15 bis 30 eines oder mehrerer Melamin-Formaldehyd-Kondensationsprodukte,
• (ii) 0 bis 80 Gew.-%, insbesondere 0 bis 50 Gew.-%, besonders bevorzugt 0 bis 30 eines oder mehrerer veretherte Melamin-Formaldehyd-Kondensationsprodukte, und
• (iii) 15 bis 95 Gew.-%, insbesondere 20 bis 80 Gew.-%, besonders bevorzugt 30 bis 70 einer oder mehrerer Polymer-Dispersionen

enthalten. Die Mengenangaben der Komponenten (i), (ii) und (iii) ergänzen sich auf 100 Gew.-% und beziehen sich auf die Flüssigharzmischung.In particular, such resin mixtures are suitable, the

• (i) from 5 to 80% by weight, in particular from 10 to 50% by weight, particularly preferably from 15 to 30, of one or more melamine-formaldehyde condensation products,
• (Ii) 0 to 80 wt .-%, in particular 0 to 50 wt .-%, particularly preferably 0 to 30 of one or more etherified melamine-formaldehyde condensation products, and
• (Iii) 15 to 95 wt .-%, in particular 20 to 80 wt .-%, particularly preferably 30 to 70 of one or more polymer dispersions

contain. The quantities of the components (i), (ii) and (iii) are complementary to 100 wt .-% and relate to the liquid resin mixture.

Of the Melamine resin mixture can additional auxiliaries and additives are added, for example 0.1 to 50 wt .-%, preferably 0.2 to 30 wt .-%, in particular 0.5 to 20% by weight of urea, caprolactam, phenyldiglycol, butanediol and / or sucrose based on 100 wt .-% of the mixture (i) to (iii). Furthermore, can she usual Additives such as wetting agents, hardeners and Catalysts.

In addition, the resin mixture may contain one or more of the following components in a total amount of 0 to 5% by weight, based on the resin mixture: anionic surfactants (sodium, potassium and / or ammonium salts of the fatty acid and sulphonic acid; C ₁₂ to C ₁₆ alkyl sulfates, ethoxylated, sulfated and / or sulfonated fatty alcohols, alkylphenols, sulfodicarboxylated esters, polyglycol ether sulfates), nonionic surfactants (ethoxylated fatty alcohols and alkylphenols having 2 to 150 ethylene oxide units per molecule), cationic surfactants (ammonium, phosphonium -, and / or sulfonium compounds having a hydrophobic structural element containing at least one long aliphatic hydrocarbon chain), starch, polyethylene glycol and / or poly (vinyl alcohol).

To In detail, the resin components are to be understood as follows: Resin component (i) melamine-formaldehyde condensation products are used. The preparation of the resin component (i) is well known. First, will For example, 1 mole of melamine with 1.4 to 2 moles of formaldehyde at pH from 7 to 9 and condensed at temperatures of 40 to 100 ° C until the appropriate Condensation degree is achieved. Advantageously, the molar ratio of Melamine to formaldehyde at 1: 1.15 to 1: 1.9, preferably 1: 1.4 to 1: 1.6.

In the resin component (ii) melamine-formaldehyde condensation products with C ₁ - to C ₄ alkanols such as methanol, ethanol, propanol and / or butanol butanol or glycols, such as ethylene glycol, diethylene glycol, propylene glycol and / or dipropylene glycol, etherified. Preferred are methanol and ethanol. The preparation of the resin component (ii) is well known. The melamine-formaldehyde condensation product is admixed, for example, with 20 to 30 mol of methanol and etherified at pH values of 1 to 5 and temperatures of 40 to 80 ° C. The condensation conditions depend on the water dilutability desired for the resin, which is at least 1: 6. After condensation, the melamine resins are freed of excess alcohol and formaldehyde by distillation. Any residual formaldehyde present is reacted with the addition of urea at temperatures from room temperature to 90 ° C, preferably 60 to 70 ° C. Advantageously, the molar ratio of melamine to formaldehyde to ether group is 1: 1.2: 1 to 1: 6: 6, preferably 1: 2.5: 2 to 1: 5: 4.5.

As resin component (iii) copolymer dispersions are used, their copolymers preferably contain carboxyl, hydroxy, amide, glycidyl, carbonyl, N-methylol, N-alkoxymethyl, amino and / or hydrazo groups. The above-mentioned functional groups in the copolymer are obtained in a conventional manner by copolymerizing corresponding monomers bearing these functional groups.

The Copolymers contain the above-mentioned functional groups generally in amounts such that they are from 0.1 to 50% by weight, preferably 0.3 to 20, based on the copolymer, of these monomers may contain copolymerized functional groups.

As main monomers of the comonomers with the above-mentioned groups are the customary copolymerizable therewith olefinically unsaturated monomers, for example C ₁ - to C ₁₂ -alkyl esters of acrylic acid and methacrylic acid, preferably C ₁ - to C ₈ -alkyl, such as methyl acrylate, methyl methacrylate, ethyl acrylate, Ethyl methacrylate, propyl acrylate, propyl methacrylate, butyl acrylate, butyl methacrylate, 2-ethylhexyl acrylate, 2-ethylhexyl methacrylate, lauryl acrylate and lauryl methacrylate; Vinyl esters of C ₂ - to C ₄ -carboxylic acids, for example vinyl acetate and vinyl propionate, C ₁ - to C ₄ -dialkyl esters of maleic acid and fumaric acid, vinylaromatics such as styrene, α-methylstyrene, vinyltoluene; Acrylonitrile, methacrylonitrile, acrylamide, methacrylamide and vinyl ethers of 3 to 10 carbon atoms, vinyl halides such as vinyl chloride and vinylidene chloride; multiply olefinically unsaturated compounds such as butadiene and isoprene and mixtures of the abovementioned monomers, provided that they are copolymerisable with one another.

to Preparation of the resin mixture will usually be the pH of the Polymer dispersion adjusted to 7.5 to 10 before adding the other components.

The aminoplast resins thus obtained generally have solids contents from 40 to 70% by weight. The solids content here is the dry residue which is determined by adding 1 g of aqueous resin for two hours Drying cabinet at 120 ° C is dried. The viscosity the aqueous Resins are in the range of 10 to 200 mPas, preferably between 30 and 150 mPas (20 ° C).

To This is already being done in the production of the aminoplast resin films or films decorative paper described, the 5 to 90 wt .-%, based on the total fiber content, Contains fibers of synthetic polymers, with the aminoplast resins impregnated in a conventional manner.

• (i) 5 bis 80 Gew.-%, insbesondere 10 bis 50 Gew.-%, besonders bevorzugt 15 bis 30 eines oder mehrerer Melamin-Formaldehyd-Kondensationsprodukte,
• (ii) 0 bis 80 Gew.-%, insbesondere 0 bis 50 Gew.-%, besonders bevorzugt 0 bis 30 eines oder mehrerer veretherte Melamin-Formaldehyd-Kondensationsprodukte, und
• (iii) 15 bis 95 Gew.-%, insbesondere 20 bis 80 Gew.-%, besonders bevorzugt 30 bis 70 einer oder mehrerer Polymer-Dispersionen

enthält.If for the impregnation aminoplast resins of melamine-formaldehyde condensate (s), optionally etherified melamine-formaldehyde condensates) and polymer dispersion (s) are used, also known in the art absorbent cellulosic fibrous or tissue or decorative paper, such as for example in DE 200 19 180 described advantageous to process flexible Aminoplastharzfolien or films. The flexibility in the use of commercial decorative paper is particularly pronounced when the resin mixture

• (i) from 5 to 80% by weight, in particular from 10 to 50% by weight, particularly preferably from 15 to 30, of one or more melamine-formaldehyde condensation products,
• (Ii) 0 to 80 wt .-%, in particular 0 to 50 wt .-%, particularly preferably 0 to 30 of one or more etherified melamine-formaldehyde condensation products, and
• (Iii) 15 to 95 wt .-%, in particular 20 to 80 wt .-%, particularly preferably 30 to 70 of one or more polymer dispersions

contains.

to impregnation the aminoplast resins come in the form of a 40 to 70 weight percent aqueous solution for the application, usually a hardener is added.

When Harder For example Bronsted acids such as organic sulfonic acids, carboxylic acids and their anhydrides, e.g. Maleic acid, maleic anhydride and formic acid, Ammonium compounds, e.g. Ammonium sulphate, ammonium sulphite, ammonium nitrate, Ethanolammoniumchlorid, Dimethylethanolammoniumsulfit and hardener combinations such as morpholine / p-toluenesulfonic acid into consideration.

The Harder can in amounts of from 0 to 2.5% by weight, based on the aqueous impregnating resin, be added. The skilled worker is aware that the hardener dosage adapted to the respective application requirements can, taking the reactivity the impregnating resin / hardener mixtures e.g. above the measurement of turbidity times and Gelierzeiten can be adjusted accordingly.

The impregnating can additional aids as wetting agents are added. As wetting agents are suitable for Example ethoxylated fatty alcohols or alkylphenol ethoxylates, the in amounts of from 0 to 1% by weight, based on the resin solution can.

The manner in which the impregnating liquors are further processed into melamine resin impregnates and how the coating of the wood-based materials takes place with these impregnates is known to the person skilled in the art. The decorative paper used according to the invention can be processed to the same extent as Decor paper known in the impregnation of aminoplast resins.

The impregnation is usually carried out so that the decorative paper is impregnated with the Aminoplastharzlösung. For example, decorative papers having a basis weight in the range of 60 to 200 g / m ^{2 are} impregnated with 120 to 150 wt .-%, based on the paper weight of the impregnating liquor, at room temperature. The impregnated paper is then dried to a residual moisture content of about 5 to 10 wt .-%. Suitable impregnation are the customary impregnation systems, which bring the desired amount of resin onto and into the papers in what is referred to as the one- or two-stage process. The advantage of the two-stage process is that it is possible to use different amino resins for pre- and post-impregnation, if necessary.

The aminoplast films or films prepared in this way subsequently hot or cold deformed. Advantageously, the films or films at elevated temperatures from, for example, 150 to 210 ° C and / or elevated To press for example, 15 to 30 bar during a pressing time of, for example 10 to 60 s pressed with the material.

Advantageous is used to deform a membrane press, the two reservoirs for two different having tempered fluids provided with working valves, which can be controlled and controlled by the press control. Advantageously the membrane press a conveyor for the Fluids on. Preferably, the membrane press for each fluid own and outlets on.

Thereby, in that the press preferably has two storage containers which have different temperatures Fluids contain over Working valves and a conveyor can alternately pressurize the membrane, can realize a heating-cooling exchange press, with a workpiece first hot and subsequently can be cold pressed without this by a press in another press must be transported, which at the same time the significant advantage that the workpiece in the Press remains fixed, so that the material to be coated is not supersede and the coated workpiece do not bulge or can warp, since it reaches a minimum temperature remains fixed in the membrane press.

Advantageous has each reservoir a compressed air valve and a vent valve on. The contents of the reservoir can depend on the individual process steps are subjected to pressure of variable height. Advantageous are in the storage containers Heating devices or cooling devices for the Fluid arranged at elevated Warmth- or waste heat demand while a pressing process also circulated can be.

Prefers becomes a fluid as a fluid like water or thermal oil used, which have a high heat capacity, so that the required amounts of heat can be supplied and removed by the fluids alone, without that the press tables themselves would have to be heated or cooled. she can even on their surfaces facing the press room with insulation material be equipped, so over the press tables no heat loss occur. A further advantage is that the reservoir, which via compressed air and bleed valves feature, dependent on from the feasible with the membrane press process steps with Pressure or vacuum can be acted upon, so that a change of liquids accelerated or the pressing pressure at any height or on the workpieces and Aminoplast resin films or films optimized provided can be.

Advantageous has the membrane press as a conveyor for the liquids below the first membrane a second elastic membrane, the above a second frame with the first diaphragm a second pressure-tight Chamber forms, depending on from the individual process steps through inlets or outlets with a working fluid can be acted upon. Is particularly advantageous here the use of air as a working fluid, with at under Internal pressure set second chamber in the first chamber between Pressing table and membrane liquid are forced back into the reservoir can. Such a conveyor for liquids is extremely simple, effective with minimal technical effort and low maintenance.

Advantageous the adhesion mediation takes place during the coating by the aminoplast resin, i.e. it will be advantageous to self-adhesive Aminoplastharzfilme 3D deformation used. For some applications though also the use of non-self-adhesive aminoplast resin films be advantageous, in this case, as adhesion promoters commercially available adhesives or other adhesive carriers used. Furthermore, in some applications, a Nachverklebung be beneficial.

The Coating preferably takes place flat in a single step. Furniture parts, whose mechanical stress is low, are advantageous with a single-layer decorative film coated. Particularly preferred only a single deco film for used the structure to be coated.

As materials are advantageously wood materials into consideration such as wood fibers or Particle boards, MDF or HDF boards.

The aminoplast resin films according to the invention or films are characterized in particular by the fact that Pressing the Aminoplastharzfolien or films on materials with a three-dimensionally structured surface made of different materials such as wood, plastics, fiber composites or, in particular, wood-based materials, e.g. Plywood, fiberboard and especially chipboard surfaces receives the crack resistant, glittering and insensitive to water vapor.

typical Fields of application for the aminoplast resin films of the invention or films are as already described furniture parts such as Kitchen fronts, Panels, picture frames, door frames, doors, table tops, Windowsills, Fronts.

Example:

Preparation of Aminoplast Resin Film:

• A) Production of decorative paper A piece of paper was made from a mixture of eucalyptus (20% by weight), birch (80% by weight), polyamide and Polyester fibers (each 15 wt .-% based on the pulp) in produced by a fourdrinier. To this fiber mixture were added Titanium dioxide (10 wt .-% based on the total fibers) and silicate (5 wt .-% based on the total fibers) was added. The paper had a basis weight of 131 g / m2 and showed porosity Bendsten of 990 ml / min.
• B) Preparation of the Harzsytems Component 1: A mixture from 730 g 40 wt .-% aqueous Formaldehyde and 334 g of water was heated to 30 ° C. The pH of the mixture was 25 wt .-% aqueous Natiumlauge adjusted to about 9.5. Subsequently, the addition of 790 g melamine. The reaction mixture was then heated to 100 ° C, whereby the pH dropped slowly. It was for about 60 min. at a pH stirred from 8.6 to 8.8. As soon as a sample of the reaction mixture had a turbidity temperature of 50 ° C., The reaction mixture was cooled to room temperature. component 2: In a reaction vessel were 8.4 submitted sodium peroxodisulfate and 600 g of water and heated to 80 ° C. Under Maintaining the temperature, feed 1 was added within 1 hour continuously too. Feed 1 was from 387 g of deionized water, Prepared 151.2 g of 2-hydroxyethymethacrylate and 58.8 g of acrylic acid. To Start of feed 1 was feed 2 within a further 45 minutes added. Feed 2 consisted of a solution of 81 g of deionized water and 2.1 g of sodium peroxodisulfate. After completion of feed 1 retained The temperature for one hour and then at 80 ° C inlet 3 within 1.5 hours and feed 4 within 2 hours too. Intake 3 consisted of an aqueous Monomer emulsion from 410 g of deionized water, 4.7 g of a 45 Wt .-% aqueous solution of Dowfax 2A1 corresponding surfactant, 378 g Styrene and 436.8 g of n-butyl acrylate. Feed 4 consisted of a solution 410 g of deionized water and 10.5 g of sodium peroxodisulfate. To Termination of feed 4 was allowed 1 hour at 80 ° C afterreact. One cooled then room temperature, gave 134.4 g of a 25% by weight aqueous solution Sodium hydroxide and filtered over a 200 μm sieve. The solids content of the resulting dispersion was 34.4% by weight. and the pH is 7.1. 90 wt .-% of a solution consisting of component 1 were touching to 10% by weight of a solution from component 2 given. The resin mixture had a viscosity of 70 mPas and a solids content of 56.4 wt .-% on.
• C) impregnation of decor paper with aminoplast resin With the resin mixture was after addition of about 0.5 wt .-% hardener (e.g., hardener 529 liquid BASF AG) the decorative paper is impregnated and dried so that the decorative papers have a solids content in the full impregnation of 120 to 130% and a residual moisture of 6 to 10% possessed.
• D) pressing the aminoplast resin film The obtained aminoplast resin films can with membrane presses, as described in DE-A 199 20 577, be pressed.

Claims (12)

Method for 3D coating of materials with aminoplast resin films or films by means of a membrane press with a lower press table, an upper press table, an elastic membrane which can be lowered onto a workpiece coated with aminoplast resin films or films and which is to be coated with a press table, forming a pressure-tight chamber, with channels for the inlet and outlet of a fluid acting on the membrane and with a press control, characterized in that the Aminoplastharzfolien or films containing Aminoplas resin impregnated decor paper containing 5 to 90 wt .-% based on the total fiber content, fibers of synthetic polymers , Method for 3D coating of materials with aminoplast resin films or films using a membrane press with a lower press table, an upper press table, one coated on and covered with aminoplast resin films or films workpiece to be coated lowerable elastic membrane which forms a pressure-tight chamber with a press table and with channels for receiving and discharging a diaphragm fluid and with a press control, wherein the press has two reservoirs for two different tempered fluids, which are provided with working valves , which can be controlled by the press control and the membrane press has a conveying device for the fluids, characterized in that the Aminoplastharzfolien or films containing Aminoplastharz impregnated decor paper containing 5 to 90 wt .-% based on the total fiber content, fibers of synthetic Contains polymers. Method according to claim 1 or 2, characterized that as synthetic polymers polyamide, polyimide, polyurethanes, Polypropylene, polyethylene, polyester, polyacrylonitrile and / or polyvinyl alcohol be used. Process according to claims 1 to 3, characterized that the fibers of synthetic polymers have a length of 0.5 to 20 mm. Process according to claims 1 to 4, characterized that the fibers of synthetic polymers have a diameter of 5 to 30 μm exhibit. Process according to claims 1 to 5, characterized that cellulose is used as the basis of the decorative paper. Process according to claims 1 to 6, characterized that the decorative paper 10 to 60 wt .-% fibers of synthetic Polymers and 40 to 90 wt .-% cellulose contains. Process according to claims 1 to 7, characterized that used as aminoplastic resin melamine-formaldehyde resins become. Process according to claims 1 to 8, characterized as aminoplastic resin, a resin mixture of melamine-formaldehyde condensation product (s) and polymer dispersions). Process according to claims 1 to 8, characterized as aminoplastic resin, a resin mixture of melamine-formaldehyde condensation product (s), etherified melamine-formaldehyde condensation product (s) and polymer dispersions) is used. Process according to claims 1 to 10, characterized that wood, chipboard, MDF or HDF boards are used as materials become. Method for 3D coating of materials with Aminoplast resin films or films by means of a membrane press with a lower press table, a upper press table, one on an aminoplast resin film or films overlaid and thus to be coated workpiece lowerable elastic Membrane, which forms a pressure-tight chamber with a press table, with channels for introducing and discharging a fluid acting on the membrane and with a press control, characterized in that the Production of aminoplast resin films or films containing absorbent cellulose Fibrous fabrics with aminoplast resins containing melamine-formaldehyde condensate (s), etherified melamine-formaldehyde condensates) and polymer dispersions) become.