DE102007028531A1 - Manufacturing composite material, useful as construction material e.g. furniture, comprises supplying carrier, applying textile surface structure onto surface of carrier, laminating construction, and optionally applying protective layer - Google Patents

Abstract

Manufacturing a composite material (I) comprises: supplying a carrier; applying a textile surface structure onto at least one surface of the carrier, where the textile surface structure having at least one binder in the B stage state and having at least one functional material; laminating the construction under the action of pressure and heat so that the binder present in the B stage receives its final hardening; and optionally applying at least one further protective layer and drying. Independent claims are included for: (1) a composite material comprising: a carrier, at least one textile surface structure applied onto at least one of the two sides of the carrier, which surface structure comprises at least one finally hardened B-stage binder; at least one functional material applied on the top of the textile surface structure provided with the B-stage binder or introduced into the textile surface structure, and optionally further protective layers applied on the functional material; (2) a semifinished product comprising a carrier and at least one textile surface structure applied onto at least one of the two surfaces of the carrier, which textile surface structure has at least one binder in the B stage; and (3) decorative semifinished products, preferably continuous pressure laminates (CPL) and high pressure laminates (HPL), comprising at least one textile surface structure containing B-stage binders, preferably a non-woven fabric comprising at least one decoration as functional layer as well as optionally further functional materials.

Description

The The invention relates to new composites, in particular as materials in interior design, for cladding, constructions and for the production of furniture and similar products suitable.

Composites increasingly replace traditional building materials as construction materials and have to be adapted for varied application. So on the one hand is a sufficient mechanical stability on the other hand, a good processability and low Weight required. There has been no lack of attempts to existing composites to improve.

So It is already known, wood-based materials made of crushed wood and use of binder, with other materials to combine. For this purpose, the two materials are usually laminated and form a composite material. By selection and combination The materials can thus have the mechanical properties be improved and at the same time a reduction, for example of the Weight, can be achieved.

Out WO 2006/031522 are composite materials based on wood-based materials and non-wovens, which are solidified by means of a "B" stage binder known, for example, the underlying nonwovens US-A-5,837,620 . US-A-6,303,207 and US-A-6,331,339 known. Although the cited documents generally disclose that further additives can be added to the binder or the nonwoven, but details are not given.

It Thus, the task was the already known products in terms their application properties and manufacturing processes optimize.

• a) Zuführen eines Trägers
• b) Aufbringen eines textilen Flächengebildes auf mindestens einer Oberfläche des Trägers, wobei das textile Flächengebilde mindestens einen Binder im B-Stage Zustand aufweist und welches mindestens ein Funktionsmaterial aufweist,
• c) Laminieren des gemäß Schritt b) erhaltenen Aufbaus unter Einwirkung von Druck und Wärme, so dass der im B-stage vorliegenden Binder endverfestigt wird,
• d) ggf. Aufbringen mindestens einer weiteren Schutzschicht und Trocknung.

The present invention is a process for producing a composite material comprising the measures:

• a) feeding a carrier
• b) applying a textile fabric to at least one surface of the carrier, wherein the textile fabric has at least one binder in the B-stage state and which has at least one functional material,
• c) laminating the structure obtained according to step b) under the action of pressure and heat, so that the binder present in the B-stage is finally solidified,
• d) optionally applying at least one further protective layer and drying.

at the carrier used according to step a) it is preferably wood-based materials, papers, cork, cardboard, mineral plates and / or so-called honeycombs. Honeycombs are Components with three-dimensional reinforcement structures, the due to their structure (honeycomb structure) an extraordinary Stability and strength at the same time low Allow weight. Such honeycombs are long gone Time used in many applications, including as internal reinforcement of plate-shaped elements in the construction sector or in furniture.

at The wooden materials are plate-shaped or strand-shaped Wood materials produced by mixing different types of wood particles with natural and / or synthetic binders in the course a Heißverpressung be prepared. The inventively used Wood materials preferably comprise plywood, chipboard, especially chipboard and OSB (Oriented Strand Boards), wood fiber material, in particular porous fibreboard, vapor permeable fibreboard, hard (high-density) wood fiber boards (HDF) and medium-density wood fiber boards (MDF), and Arboform. Arboform is a thermoplastic processable material of lignin and other wood components.

at The papers are preferably papers based on natural, synthetic, mineral or ceramic Fibers or mixtures of these types of fibers.

at The cardboard boxes are preferably based on cardboard of natural and / or synthetic fibers, these being mineral and / or ceramic fibers and mixtures from these fiber types.

at The mineral plates are preferably commercially available Mineral board with cardboard covering on both sides, around gypsum fiber boards, Ceramic fiber boards, cement or lime slabs. The plates can optionally with natural and / or synthetic fibers be reinforced, which also mineral and / or may comprise ceramic fibers. The reinforcing fibers can in the form of filaments, monofilaments or staple fibers.

Next The described materials, the carrier also made Cork or other vegetable materials.

The Basis weight of the carrier contained in the composite depends on the end use and is not subject to any special restriction.

The textile fabrics used according to step b) are all structures, which are made of fibers and from which a textile surface has been produced by means of a surface-forming technique.

The with the B-stage binder to be provided textile fabrics can basically also without binders, in particular chemical binders are used. However, the required Strengths in the further processing of the fabrics To ensure binder can also be introduced and / or known needling methods find use. Besides the possibility a mechanical consolidation, z. B. by calendering or needling, in particular, the hydrodynamic needling is mentioned here. Suitable binders are chemical and / or thermoplastic binders.

Prefers become the textile fabrics to be provided with the B-stage binder but preconsolidated with a chemical binder. The used Binders can be the same or different but from the group of B-stage binders compatible binder systems to be selected. The additional binder content is at most 25% by weight, preferably 10% by weight or fewer; the minimum content is 0.5% by weight, preferably minute 1% by weight.

at The fiber-forming materials are preferably natural fibers and / or fibers of synthesized or natural polymers, ceramic Fibers, mineral fibers or glass fibers, these also in shape of mixtures can be used. As textile surfaces Woven fabrics, scrims, knitted fabrics, knitted fabrics and nonwovens, preferably Nonwovens, understood.

at the textile surfaces of mineral and ceramic fibers these are aluminosilicate, ceramic, dolomite, wollastonite fibers or from fibers of volcanics, preferably basalt, diabase and / or Melaphyr fibers, in particular basalt fibers. Diabase and melaphyre are collectively referred to as paleo-basalts and Diabase is often referred to as greenstone.

The Mineral fiber fleece can be made of filaments, d. H. infinitely long fibers or formed from staple fibers. The average length the staple fibers used in the invention Nonwoven made of mineral fibers is between 5 and 120 mm, preferably 10 to 90 mm. In a further embodiment of the invention The mineral fiber fleece contains a mixture of continuous fibers and staple fibers. The average fiber diameter of the mineral fibers is between 5 and 30 microns, preferably between 8 and 24 microns, more preferably between 8 and 15 μ.

The basis weight of the textile fabric of mineral fibers is between 15 and 500 g / m ² , preferably 40 and 250 g / m ² , which refers to a sheet without binders.

at The textile surfaces of glass fibers are in particular nonwovens prefers. These are made of filaments, d. H. infinitely long fibers or constructed of staple fibers. The average length of the Staple fibers is between 5 and 120 mm, preferably 10 up to 90 mm. In a further embodiment of the invention The glass fiber fleece contains a mixture of continuous fibers and staple fibers.

Of the average diameter of the glass fibers is between 5 and 30 μm, preferably between 8 and 24 μm, more preferably between 10 and 21 microns.

Next The above-mentioned diameters may also be so-called Glass microfibers find use. The preferred average Diameter of the glass microfibers here is between 0.1 and 5 microns. The textile surface forming microfibers can also in mixtures with other fibers, preferably glass fibers. Furthermore is also a layered structure of microfibers and Glass fibers possible.

The Textile fabrics can additionally one Reinforcement made of fibers, threads, or filaments have. Preferred are reinforcing threads Multifilaments or rovings based on glass, polyester, carbon or metal. The reinforcing threads can as such or in the form of a textile fabric, For example, as a fabric, scrim, knit, knitted fabric or nonwoven be used. Preferably, the reinforcements from a parallel group of threads or a clutch.

The weight per unit area of the textile fabric of glass fibers is between 15 and 500 g / m ² , preferably 40 and 250 g / m ² , these details referring to a sheet without a binder.

suitable Glass fibers include those made of A glass, E glass, S glass, C glass, T-glass or R-glass were made.

The textile surface can be prepared by any known method become. For glass webs, these are preferably the dry or wet laid process.

Of the textile surfaces made of fibers of synthetic polymers are nonwovens, in particular so-called spunbonds, ie spunbonded nonwovens which are produced by a disposition of melt-spun filaments. They consist of continuous synthetic fibers made of melt-spinnable polymer materials. Suitable polymer materials are, for example, polyamides, such as. As polyhexamethylene diadipamide, polycaprolactam, aromatic or partially aromatic polyamides ("aramids"), aliphatic polyamides, such as. As nylon, partially aromatic or wholly aromatic polyester, polyphenylene sulfide (PPS), polymers with ether and keto groups, such as. As polyether ketones (PEK) and polyetheretherketone (PEEK), polyolefins, such as. As polyethylene or polypropylene, cellulose or polybenzimidazoles. Besides the above-mentioned synthetic polymers, those polymers which are spun from solution are also suitable.

Prefers the spunbonded nonwovens are made of melt spinnable polyester. Come as a polyester material in principle all known types suitable for fiber production into consideration. Particularly preferred are polyesters which are at least 95 mol% polyethylene terephthalate (PET), especially those made of unmodified PET.

Should the composites of the invention in addition have a flame retardant effect, so it is beneficial if they are were spun from flame-retardant modified polyester. Such flame retardant modified polyesters are known.

The Single titer of polyester filaments in spunbonded between 1 and 16 dtex, preferably 2 to 10 dtex.

In a further embodiment of the invention, the spunbonded nonwoven fabric can also be a meltbond-bonded nonwoven fabric which contains carrier and hot-melt adhesive fibers. The carrier and hot melt adhesive fibers can be derived from any thermoplastic fiber-forming polymers. Such meltbond-solidified spunbonded nonwovens are, for example, in EP-A-0,446,822 and EP-A-0,590,629 described.

Next Continuous filaments (spunbond process) can be the textile surface also from staple fibers or mixtures of staple fibers and continuous filaments be constructed. The individual titers of the staple fibers in the nonwoven amount between 1 and 16 dtex, preferably 2 to 10 dtex. The staple length is 1 to 100 mm, preferably 2 to 50 mm, more preferably 2 to 30 mm. The textile fabric can also be made of fibers different materials be built to special properties to achieve.

The Textile fabrics can additionally one Reinforcement made of fibers, threads, or filaments have. Preferred are reinforcing threads Multifilaments or rovings based on glass, polyester, carbon or metal. The reinforcing threads can as such or in the form of a textile fabric, For example, as a fabric, scrim, knit, knitted fabric or nonwoven be used. Preferably, the reinforcements from a parallel group of threads or a clutch.

The the nonwovens constituting filaments and / or staple fibers can have a virtually round cross-section or have other shapes, such as dumbbell, kidney-shaped, triangular or tri- or multilobal Cross-sections. It is also possible to use hollow fibers and bicomponent or multicomponent fibers. Furthermore, the hot melt adhesive fiber can also be in the form of Use bic or multicomponent fibers.

The the textile fabric forming fibers can be modified by conventional additives, for example by antistatic agents, such as carbon black.

The basis weight of the textile fabric of synthetic polymer fibers is between 10 and 500 g / m ² , preferably 20 and 250 g / m ² .

at The natural fibers are plant fibers derived from fibers of grasses, straw, wood, bamboo, reed and bast, or Fibers of animal origin. Plant fibers is a collective term and stands for seed fibers, such as cotton, kapok or poplar fluff, Bast fibers, such as bamboo fiber, hemp, jute, linen or ramie, hard fibers, like sisal or manila, or fruit fibers, like coconut. For fibers animal origin is wool, animal hair, feathers and silks.

The basis weight of the textile fabric of natural fibers is between 20 and 500 g / m ² , preferably 40 and 250 g / m ² .

at the textile surfaces of fibers of natural Polymers are cellulosic fibers, such as viscose, or plant or animal protein fibers.

at The textile surfaces of cellulose fibers are in particular Nonwovens preferred. These are made of filaments, d. H. infinitely long Fibers and / or composed of staple fibers. The average Length of the staple fibers is between 1 and 25 mm, preferably 2 to 5 mm.

Of the average diameter of the cellulose fibers is between 5 and 50 μm, preferably between 15 and 30 μm.

The textile fabrics used according to step b), which is applied at least on one side of the carrier, has at least one binder in the B-stage state.

B-stage binders are understood to mean binders which are only partially solidified or hardened and can still undergo a final consolidation, for example by thermal aftertreatment. Such B-stage binders are in US-A-5,837,620 . US-A-6,303,207 and US-A-6,331,339 described in detail. The disclosed there B-stage binders are also the subject of the present description. B-stage binders are preferably binders based on furfuryl alcohol-formaldehyde, phenol-formaldehyde, melamine-formaldehyde, urea-formaldehyde and mixtures thereof. Preferably, they are aqueous systems. Other preferred binder systems are formaldehyde-free binders. B-stage binders are characterized by the fact that they can be subjected to a multi-stage hardening, ie after the first hardening or the first hardenings they still have a sufficient binding effect in order to be able to use them for further processing.

Usually become such binders after addition of a catalyst at temperatures hardened by about 350 F in one step.

to Formation of the B-stage are such binders, possibly after addition of a Catalyst hardened. The curing catalyst content is up to 10 wt .-%, preferably 0.25 to 7 wt .-% (based on the total binder content). As a curing catalyst For example, ammonium nitrate, as well as organic, aromatic Acids, e.g. For example, maleic acid and p-toluenesulfonic acid suitable because it allows the B-stage state to reach faster. In addition to ammonium nitrate, maleic acid and p-toluenesulfonic acid all materials are suitable as curing catalyst, which have a comparable acidic function. To reach of the B-stage is the impregnated with the binder textile Fabrics dried under the influence of temperature, without producing a complete cure. The necessary Process parameters depend on the selected binder system.

The lower as well as the upper temperature limit can be selected by selecting Duration or by adding or avoiding larger ones or more acidic curing catalyst or possibly be influenced by the use of stabilizers.

The Application of the B-stage binder, to which in measure b) designated textile fabrics, can with the help of all done with known methods. In addition to spraying, soaking and pressing the binder can also by means of coating or by means Rotation nozzle heads are applied.

One Another preferred method is the application of the B-stage binder by foam application. When the foam application is using a foaming agent in a foam mixer a binder foam generated by suitable coating aggregates on the nonwoven is applied. Again, the order by means of rotary die heads respectively.

at the foam coating of a B-stage capable binder gives it basically with regard to the foaming agent no restrictions. Preferred foaming agents are ammonium stearates or succinic acid esters with 1% -5% by weight i. Tr. be added to the binder. If necessary also be the catalysts already described added. The solids content of the foam is at least 40%, preferably at least 50%.

Of the Process of foam application allows an extremely flexible process management and allows the realization of a Variety of different product features. In addition to the targeted Adjustment of the penetration depth of the foam into the textile surface Binder entry and porosity can be achieved within wide limits vary. The foam application also offers great advantages in litigation, especially in terms of consistency the solids content during the impregnation or coating the textile surface and the required compatibility requirements of the surface production process to the binder.

The functional material used according to step b) can simultaneously with the B-stage binder, z. B. as a mixture or be applied as individual components, or before or after the binder order. Insofar as the B-Stage Binder is applied by foam application, it is advantageous the functional material with the foam or in the Spread foam or apply the functional material to the still to apply fresh foam.

at the functional material used according to step b) are preferably flame retardants, materials for Discharge of electrostatic charges, materials for shielding of electromagnetic radiation, organic or inorganic pigments, in particular colored pigments, materials containing the abrasion and / or Increase slip resistance or decorative layers. The functional materials are preferably on the side facing away from the carrier arranged the textile fabric and can at least partially pull through the fleece.

In a variant of the method, an additional binder for fixing the Funktionsmateria added to the textile fabric. In this case, preferably the same binder (B-stage binder) as present in the textile fabric is selected. The content of functional material is determined by the subsequent use.

at the flame retardants are inorganic flame retardants, Organophosphorus flame retardant, nitrogen based flame retardant or intumescent flame retardant. Halogenated (brominated and chlorinated) flame retardants are also usable due to However, their risk assessment is less preferred. examples for Such halogenated flame retardants are polybrominated diphenyl ethers, z. DecaBDE, tetrabromobisphenol A and HBCD (hexabromocyclododecane).

at The nitrogen-based flame retardants are melamines and ureas.

at the organophosphorus flame retardants are typically to aromatic and alkyl esters of phosphoric acid. Prefers are TCEP (trichloroethyl phosphate), TCPP (trischloropropyl phosphate), TDCPP (tris-dichloroisopropyl phosphate), triphenyl phosphate, trioctyl phosphate (Tris- (2-ethylhexyl) phosphate) used.

at the inorganic flame retardants are typically hydroxides, such as aluminum hydroxide and magnesium hydroxide, borates, such as Zinc borate, ammonium compounds such as ammonium sulfate, red phosphorus, Antimony oxides, such as antimony trioxide and antimony pentoxide.

By Use of means for increasing the electrical conductivity can anti-static and electromagnetic shielding effects be achieved.

at The antistatic agents are usually around Particles which are electrically conductive. Suitable materials are electrically conductive carbons such as carbon black, Graphite and carbon nanotubes (C-nanotubes), conductive Plastics or fibers of metal or metal components.

at the materials for the shielding of electromagnetic radiation they are usually electrically conductive Materials. These can take the form of films, particles, Fibers or wires, and / or textile fabrics be constructed from the aforementioned materials.

at The inorganic or organic pigments are particulate Materials. In addition to fillers such as CaCO3, talc, gypsum or Silica is the pigment, if this is the valence increase of the composite, in particular pigments, the in colors, to be used.

Next the increase in value also uses such materials which increase the usability. Below is In particular, to understand an anti-slip coating, as well as a Coating that ensures increased abrasion protection. For the anti-slip coating are preferably SiC and / or SiO 2 particles used with a grain size of preferably 2-5 mm. The proportion is 1-40%, preferably 10-30%. To increase the effectiveness of the coating or to reduce the proportion of the coating used, can the surface additionally still be structured.

For the surface finish to improve the Abrasion and hardness comparable materials are used. However, grain sizes of under 1 mm, creating a very hard surface can be.

insofar the functional layer should be an anti-slip coating, it is an advantage if these or the underlying particles completely or at least partially into the textile fabric and / or the B-stage binder incorporated. Especially with anti-slip coating and surface coating to improve the abrasion and hardness, it is advantageous if the particles in such a way on the textile fabric be applied that the particles at least partially from the Stand out surface of the textile fabric. The resulting roughness, especially for Anti-slip coating must meet the relevant national standards and regulations are sufficient.

at The decorative layers are decorative elements. this includes are decorative layers and patterns that understand the value of the composite increase. Examples of such patterns are veneers, cork, foils with wood grains, overlay papers, HPL, CPL (multi-layer laminates) or chips Paper or plastics with different colors, too be referred to as decorative semi-finished products. These decorative semi-finished products can B-stage capable binders and / or one or more textile surfaces, preferably nonwoven or nonwoven layers, contain.

The Applying the functional material used in step b) takes place depending on the nature of the respective Functional material by known techniques. Again, the Order done by means of rotary die heads.

The lamination of the structure obtained in step c) in step c) takes place under the action of pressure and heat, in such a way that the binder present in the B-stage is finally solidified. The lamination can be carried out by means of batch or continuous pressing or by rolling. Depending on the B-stage binder used, the parameters pressure, temperature and dwell time are selected.

The Applying at least one further protective layer and drying it according to step d) takes place by means of known pressure, Spray, painting technologies. Again, the order by means of rotary die heads respectively. The drying of the protective layer is dependent of the chosen system.

at the protective layers are usually paints, such as powder coatings, clearcoats or transparent coatings, preferably to scratch-resistant paints, which the functional layer against mechanical Influences or to protect against UV aging.

Next The method described above also includes the composite materials not known as such from the prior art.

• a) einen Träger,
• b) mindestens ein auf mindestens einer der beiden Seiten des Trägers aufgebrachtes textiles Flächengebilde welches mindestens einen Binder im B-stage aufweist,
• c) mindestens ein auf die Oberseite des mit dem B-stage Binder ausgerüsteten textilen Flächengebildes aufgebrachtes oder in das textile Flächengebilde eingebrachtes Funktionsmaterial und
• d) gegebenenfalls weitere auf dem Funktionsmaterial aufgebrachte Schutzschichten.

Another object of the present invention is thus a composite comprising

• a) a carrier,
• b) at least one textile fabric applied to at least one of the two sides of the carrier and having at least one binder in the B-stage,
• c) at least one functional material applied to the upper side of the textile fabric finished with the B-stage binder or introduced into the textile fabric, and
• d) optionally further protective layers applied to the functional material.

By Use of selected textile fabrics are Variations and modifications of the invention Verfabrens possible.

• a) Zuführen eines Trägers
• b) Aufbringen eines textilen Flächengebildes auf mindestens einer Oberfläche des Trägers, wobei das textile Flächengebilde mindestens einen Binder im B-Stage Zustand aufweist, und wobei das textile Flächengebilde, bevor es mit dem B-Stage Binder ausgerüstet wurde, einer Verfestigung unterworfen wurde,
• c) ggf. Aufbringen von mindestens einem Funktionsmaterial,
• d) Laminieren des gemäß Schritt b) oder Schritt c) erhaltenen Aufbaus unter Einwirkung von Druck und Wärme, so dass der im B-stage vorliegenden Binder endverfestigt wird,
• e) ggf. Aufbringen mindestens einer weiteren Schutzschicht und Trocknung.

Another object of the present invention is a method for producing a composite material comprising the measures:

• a) feeding a carrier
• b) applying a textile fabric to at least one surface of the support, wherein the fabric has at least one binder in the B-stage state, and wherein the fabric was subjected to solidification before being equipped with the B-stage binder,
• c) optionally applying at least one functional material,
• d) laminating the structure obtained according to step b) or step c) under the action of pressure and heat, so that the binder present in the B-stage is finally solidified,
• e) optionally applying at least one further protective layer and drying.

The Solidification of the textile fabric designated in measure b) can be done by mechanical force, preferably by Needling and / or calendering and / or pressing, and / or by chemical and / or thermoplastic binders. The used Binders can be the same or different but from the group of B-stage binders compatible binder systems to be selected. The additional binder content, d. H. the proportion of binder attributable to the preconsolidation, is not more than 25 wt .-%, preferably 10 wt .-% or fewer; the minimum content is 0.5% by weight, preferably minute 1% by weight.

Prefers become the textile fabrics to be provided with the B-stage binder preconsolidated with a chemical binder.

The Application of the according to step c) optionally used Functional material is dependent on the nature of the respective functional material by means of known techniques. Also Here, the order or the introduction by means of rotary die heads respectively.

following measures d) and e) - as input described under measures c) and d).

conditioned through the selection of pre-consolidated textile fabrics These composites can be processed more easily become and reduce the effort in the production.

• a) einen Träger und
• b) mindestens ein auf mindestens einer der beiden Seiten des Trägers aufgebrachtes textiles Flächengebilde welches mindestens einen Binder im B-stage aufweist, und wobei das textile Flächengebilde eine zusätzliche Verfestigung aufweist.

A further subject of the present invention is thus a semifinished product comprising:

• a) a carrier and
• b) at least one textile fabric applied to at least one of the two sides of the carrier which has at least one binder in the B-stage, and wherein the textile fabric has an additional solidification.

The additional solidification of the textile fabric designated in measure b) can be effected by mechanical action of forces, preferably by needling and / or calendering and / or pressing, and / or by chemical and / or thermoplastic binders. The additional binders used may be the same or different, but must be selected from the group of B-stage binder compatible binder systems. The additional binder content, ie the binder content attributable to the preconsolidation, is at most 25% by weight, preferably 10% by weight or less; the minimum salary is 0.5 % By weight, preferably min. 1% by weight. The additional solidification of the textile fabric is preferably carried out before the application of the B-stage binder.

Prefers become the textile fabrics to be provided with the B-stage binder preconsolidated with a chemical binder.

By a high degree of prefabrication can be adjustments in production easier or faster and thus more cost-effective will be realized. This flexibility represents a significant one economic advantage.

insofar the above semi-finished products already equipped with the functional material are already the finished composites.

Another The subject of the present invention is thus a semifinished product comprising at least one textile fabric, which at least a binder in the B-stage, and wherein the textile fabric has an additional solidification.

• a) einen Träger und
• b) mindestens ein auf mindestens einer der beiden Seiten des Trägers aufgebrachtes textiles Flächengebilde, welches mindestens einen Binder im B-stage aufweist, und wobei das textile Flächengebilde eine zusätzliche Verfestigung aufweist,
• c) mindestens ein auf die Oberseite des mit dem B-stage Binder ausgerüsteten textilen Flächengebildes aufgebrachtes oder in das textile Flächengebilde eingebrachtes Funktionsmaterial und
• d) gegebenenfalls weitere auf dem Funktionsmaterial aufgebrachte Schutzschichten.

Another object of the present invention is thus a composite comprising

• a) a carrier and
• b) at least one textile fabric applied to at least one of the two sides of the backing and having at least one binder in the B-stage, and wherein the textile fabric has an additional strengthening,
• c) at least one functional material applied to the upper side of the textile fabric finished with the B-stage binder or introduced into the textile fabric, and
• d) optionally further protective layers applied to the functional material.

The additional strengthening of the one designated in measure b) textile fabric is already described above. The same applies to the carrier, the B-Stage Binder, the functional material and the protective layers.

Further the invention also includes decorative semi-finished products, in particular CPL and HPL, the at least one B-stage binder containing fabric, preferably a nonwoven which has at least one functional layer comprising.

CPL and HPL typically consist of several, mostly 2-50 Lay Kraft paper with a melamine, MUF or phenol B-stage Binder are soaked. Insofar as these CPL and / or HPL at least one B-stage binder containing nonwoven may a significant reduction in the number of kraft paper layers up towards a complete replacement of the paper layers.

The Use of a nonwoven having a B-stage binder reduced the number of kraft paper layers around at least one layer, preferably however, by at least 50% of kraft paper layers with otherwise identical Properties of the laminate. The reduction of the amount of binder-impregnated Kraft paper allows an improvement of the fire class, which can be up to Classification "non-combustible" can range.

Another The invention thus decorative semi-finished products, in particular CPL and / or HPL containing at least one B-stage binder textile fabrics, preferably a nonwoven, have, wherein the textile fabric also be pre-consolidated can. This can lead to a further reduction in kraft paper layers to lead.

Preferably have the inventive CPL and / or HPL between 1 and 25 layers of a fleece with B-stage binder on. additionally For example, the CPL according to the invention and / or HPL still several layers of kraft paper containing a melamine, MUF or phenol B-stage binders are saturated.

The Production of decorative semi-finished by lamination below Action of pressure and heat in such a way that the binder present in the B-stage is partially or finally solidified. The lamination may be by dis-continuous or continuous Pressing or by rolling done. Depending on the used B-stage Binder, the parameters pressure, temperature and dwell time are selected.

When Carrier, fabric, B-stage binder, Functional material and protective layer are the aforementioned materials suitable. The in the context of the method according to the invention disclosed preferred embodiments also apply to the composite according to the invention.

The The above-mentioned functional material can be in the form of both independent layer facing away from the wearer Side of the textile fabric applied in B-stage or even completely or partially the textile fabric penetrate. These embodiments are for Functional materials such as flame retardants, materials for discharge of electrostatic charges, shielding materials Electromagnetic radiation, organic or inorganic pigments, especially colored pigments or decorative layers suitable.

In a preferred embodiment, the functional material forms a discrete layer in the invention Composite according to the invention. This embodiment is particularly suitable for functional materials which increase the abrasion and / or skid resistance and / or enhance valence through the surface optics. In particular, when the functional material is to provide anti-skid equipment or increased abrasion resistance, it is advantageous if the underlying particles at least partially protrude from the fabric provided with the B-stage binder.

The Functional material is located in the carrier and / or on the side facing away from the carrier of the textile fabric.

Of the Composite material according to the invention allows a direct processability for the following applications, because the composite material is the necessary equipment with functional material already contains.

In a variant, the application of an equipped textile fabric according to step b) also take place during the preparation of the carrier. In other words, instead of the finished carrier in step a) the carrier is first formed in step a). The compression the carrier formed takes place together with the equipped one textile fabrics, wherein the textile fabric in the press or

drying device for the carrier is introduced accordingly. The production of the carrier-fleece composite can be continuous or discontinuously.

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - WO 2006/031522 [0004]
• US 5837620 A [0004, 0044]
• - US 6303207 A [0004, 0044]
• US 6331339 A [0004, 0044]
• - EP 0446822A [0032]
• - EP 0590629 A [0032]

Claims (72)

Method for producing a composite material comprising the measures: a) feeding one carrier b) applying a textile fabric on at least one surface of the carrier, wherein the textile fabric at least one binder in the B-stage Has state and which has at least one functional material, c) Laminating the structure obtained according to step b) under the action of pressure and heat, leaving the B-stage final binder is solidified, d) optionally application at least one further protective layer and drying. Process according to claim 1, characterized characterized in that in step a) the carrier is not supplied is only formed. A method according to claim 1 or 2, characterized in that it is in the carrier Wood materials, papers, cork, cardboard, mineral boards and / or honeycombs. A method according to claim 3, characterized characterized in that the wood-based materials are plate-shaped or strand-shaped wooden materials. A method according to claim 4, characterized characterized in that the wood-based materials are plywood, Plywood, chipboard, preferably chipboard and OSB (Oriented Strand Boards), wood fiber material, preferably porous wood fiber boards, vapor-permeable wood fiber boards, hard (high-density) wood fiber boards (HDF) and medium density fiberboard (MDF), and Arboform acts. A method according to claim 3, characterized characterized in that the papers and cardboard to Materials based on natural, synthetic, mineral or ceramic fibers or mixtures of these types of fibers is. A method according to claim 3, characterized characterized in that the mineral plates are plates with double-sided cardboard covering, in particular gypsum fiber boards, Ceramic fiberboard, cement or lime plates, if necessary reinforced with natural and / or synthetic fibers may be, these also mineral and / or ceramic Fibers may include. Method according to one of the claims 1 to 7, characterized in that the textile fabric a woven fabric, scrim, knitted fabric, knitted fabric and / or nonwoven fabric. Method according to one of the claims 1 to 8, characterized in that the textile fabric in addition a reinforcement of fibers, threads, or filaments. A method according to claim 9, characterized characterized in that the reinforcing threads multifilaments or rovings based on glass, polyester, carbon or metal are and preferably in turn in the form of a textile fabric or as a parallel group of threads. A method according to claim 10, characterized characterized in that the reinforcing threads in The form of a woven, laid, knitted, knitted or nonwoven fabric be used. Method according to one of the claims 1 to 11, characterized in that the textile fabric made of natural fibers and / or fibers of synthesized or natural Polymers, ceramic fibers, mineral fibers or glass fibers, these can also be used in the form of mixtures formed becomes. Method according to one of the claims 1 to 11, characterized in that the textile fabric a mineral fiber fleece made of filaments and / or staple fibers. A method according to claim 13, characterized characterized in that the average length of the Staple fibers between 5 and 120 mm. A method according to claim 13 or 14, characterized in that the average fiber diameter the mineral fibers is between 5 and 30 microns. Method according to one of the claims 1 to 11, characterized in that the textile fabric a glass fiber fleece of filaments and / or staple fibers. A method according to claim 16, characterized characterized in that the average length of the staple fibers between 5 and 120 mm. A method according to claim 16 or 17, characterized in that the average diameter the glass fibers is between 5 and 30 microns. A method according to claim 16, characterized characterized in that the glass fiber fleece comprises glass microfibers, their average diameter between 0.1 and 5 microns is. A method according to any one of claims 16 to 19, characterized in that the glass fiber fleece has a basis weight of 15 to 500 g / m ² , which refers to a sheet without binders. Method according to one of the claims 16 to 20, characterized in that the glass fiber fleece means Dry or wet laying process was prepared. Method according to one of the claims 1 to 11, characterized in that the textile fabric Having fibers of synthetic polymers. A method according to claim 22, characterized in that the textile fabric is a fleece, in particular a spunbonded web. A method according to claim 23, characterized characterized in that the spunbonded fabric additionally comprises staple fibers, preferably with a single titer between 1 and 16 dtex and / or a staple length between 1 to 100 mm. A method according to claim 22, characterized characterized in that the nonwoven fibers of polyamides, polycaprolactam, aromatic or partially aromatic polyamides ("aramids"), aliphatic Polyamides, partially aromatic or wholly aromatic polyesters, polyphenylene sulfide (PPS), polymers with ether and keto groups, polyolefins, cellulose or polybenzimidazoles. Method according to one of the claims 1 to 11, characterized in that the textile fabric Natural fibers. Method according to one of the claims 1 to 11, characterized in that the textile fabric Having cellulose fibers, preferably in the form of staple fibers with an average length between 1 and 25 mm. Process according to claim 1, characterized characterized in that the B-stage binder still has a final consolidation, For example, by thermal treatment, experienced. A method according to claim 28, characterized characterized in that the B-stage binder as a foam, preferably by means of rotary die heads, is applied, optionally containing the functional material. A method according to claim 28, characterized in that the binder is a binder based on furfuryl alcohol-formaldehyde, Phenol-formaldehyde, melamine-formaldehyde, urea-formaldehyde and whose mixtures are. Process according to claim 1, characterized characterized in that the functional material is flame retardant, Materials for dissipation of electrostatic charges, materials for the shielding of electromagnetic radiation, organic or inorganic pigments, in particular colored pigments, materials, which increase the abrasion and / or slip resistance, or Decorative layers is. A method according to claim 31, characterized characterized in that the flame retardant is an inorganic Flame retardant, organophosphorus flame retardant, nitrogen based flame retardant or intumescent flame retardant is. A method according to claim 31, characterized characterized in that it is in the antistatic agents and the Materials for shielding electromagnetic radiation Particles which are electrically conductive acts. A method according to claim 31, characterized characterized in that it is the inorganic or organic Pigments around particulate materials, preferably CaCO3, talc, gypsum or silica. A method according to claim 31, characterized characterized in that the functional material is an anti-slip Coating and / or a coating that increased one Abrasion has. A method according to claim 35, characterized in that the anti-slip coating SiC and / or SiO2 Having particles, preferably with a grain size from 2 to 5 mm. A method according to claim 35, characterized characterized in that the coating has an elevated Abrasion, SiC and / or SiO 2 particles has their Grain size is less than 1 mm. A method according to claim 31, characterized characterized in that the decorative layers are veneers, Sheets with wood grains, overlay papers, cork, HPL (high pressure laminates), CPL (continous pressure laminates) or paper chips and / or plastics. A method according to claim 38, characterized in that it is the HPL and CPL decorative semi-finished products, the at least one B-stage binder-containing textile fabric, preferably a non-woven, which at least one functional layer. Method according to one of the claims 1 to 39, characterized in that the lamination in step c) by dis-continuous or continuous pressing or done by rolling. Method according to one of the claims 1 to 40, characterized in that according to step d) a protective layer by means of printing, spraying, painting technologies, preferably by means of rotary die heads, applied becomes. Method for producing a semifinished product comprising the measures a) feeding a carrier b) Applying a textile fabric to at least a surface of the carrier, wherein the textile Fabric at least one binder in B-stage condition and wherein the fabric before it equipped with the B-stage binder, a solidification was subjected c) laminating the according to step b) structure obtained under the action of pressure and heat, so that the binder present in the B-stage is finally solidified. A method according to claim 42, characterized characterized in that in or after measure b) at least a functional material is applied. A method according to claim 42, characterized characterized in that after measure c) at least one protective layer applied and dried. Composite comprising: a) a carrier, b) at least one on at least one of the two sides of the carrier Applied textile fabric which at least has a binder in the B-stage, c) at least one of the Top of the textile finished with the B-stage binder Sheet applied or introduced into the fabric Functional material and d) optionally further applied to the functional material Protective layers. Composite material according to claim 45, characterized in that the textile fabric has an additional solidification. Composite material according to claim 45 or 46, characterized in that the carrier in is defined in claims 2 to 7. Composite material according to claim 45 or 46, characterized in that the textile fabric is defined in claims 8 to 27. Composite material according to claim 45 or 46, characterized in that the B-stage binder in the Claims 28 to 30 is defined. Composite material according to claim 45 or 46, characterized in that the functional material flame retardant, Materials for dissipation of electrostatic charge, materials for the shielding of electromagnetic radiation, organic or inorganic pigments, or decorative layers. Composite material according to claim 50, characterized in that the functional material in the claims 31 to 39 is further defined. Composite material according to claim 45 or 46, characterized in that the functional material in Form of an independent layer on the carrier opposite side of the textile fabric in B-stage applied in whole or in part, the textile fabric penetrates. Comprising semis a) a carrier and b) at least one on at least one of the two sides the carrier applied textile fabric which has at least one binder in the B-stage, and wherein the Textile fabrics an additional consolidation having. Semifinished product according to claim 53, characterized characterized in that the carrier in the claims 2 to 7 is defined. Semifinished product according to claim 53, characterized characterized in that the textile fabric in the claims 8 to 27 is defined. Semifinished product according to claim 53, characterized characterized in that the B-stage binder in the claims 28 to 30 is defined. Semi-finished products according to claim 53, characterized characterized in that the additional solidification means thermoplastic and / or chemical binder, preferably chemical Binder, takes place. Semi-finished products according to claim 53, characterized characterized in that the additional solidification means physical needling methods, in particular by hydrodynamic Needling, and / or pressure, preferably by calender or pressing done. Semi-finished products comprising at least one textile fabric, which has at least one binder in the B-stage, and wherein the Textile fabrics an additional consolidation having. Semifinished product according to claim 59, characterized characterized in that the textile fabric in the claims 8 to 27 is defined. Semifinished product according to claim 59, characterized characterized in that the B-stage binder in the claims 28 to 30 is defined. Semi-finished products according to claim 59, characterized characterized in that the additional solidification means thermoplastic and / or chemical binder, preferably chemical Binder, takes place. Semi-finished products according to claim 59, characterized characterized in that the additional solidification means physical needling methods, in particular by hydrodynamic Needling, and / or pressure, preferably by calender or pressing done. Decorative semi-finished products, in particular CPL and HPL, the at least a textile sheet containing B-stage binder, preferably a non-woven, which at least one decor as a functional layer, as well optionally further functional materials comprising. Decorative semi-finished products according to claim 64, characterized in that the textile fabric, preferably a nonwoven, having an additional solidification. Decorative semi-finished products according to claim 64 or 65, characterized in that it has at least one Carrier has. Decorative semi-finished products according to claim 64 or 65, characterized in that this between 1 and 25 Have layers of a textile fabric. Decorative semi-finished products according to claim 64 or 65, characterized in that these additionally several Lay Kraft paper with a melamine, MUF or phenol B-stage Binder impregnated are. Decorative semi-finished products according to claim 64 or 65, characterized in that at least one functional layer a decorative layer is. Use of the composite according to Claims 45 to 52 as a construction material, in particular in furniture, wall, ceiling and floor coverings. Containing furniture, wall, ceiling and floor coverings a composite according to the claims 45 to 52. Use of the semi-finished products defined in the claims 53 to 63 for the production of decorative semi-finished products according to the Claims 64 to 69 or for the production of composite materials according to claims 45 to 52.