Decorative laminate and method for producing the same

Abstract

The invention relates to a decorative laminate with an abrasion-resistant surface coating for laminate floor boards or the like, which is characterized in that the thermoset resin mass that forms the resin impregnation of the decorative web and the abrasion-resistant surface resin layer that is materially integral with it with a closed surface is formed with a thermosettable synthetic resin and conventional additives and/or adjuvants, the synthetic resin mass as a component containing a mixture integrated into the resin mass or such a compound of at least one wax or wax blend based on a polyalkylene polymer and at least one polyvinyl pyrrolidone, in that the particles of the abrasion-resistant hard material in the surface layer are concentrated essentially only directly bordering the decorative web surface and in the vicinity thereof, and in that the covering density of the particles of abrasive material located in the surface layer in the same—proceeding from a high value directly on the decorative web—toward the outer surface of the surface layer, following a steep negative gradient, drops to a value of zero.

1 . Decorative laminate with abrasion-resistant surface coating for laminate bodies coated or to be coated therewith, especially laminate floor boards or panels based on wood materials, 
 the laminate being formed with at least one layer of an outside fibrous material web and/or paper web (decorative web) on the visible, useful side, provided with a suitable decoration and impregnated with a (partially) thermoset synthetic resin, which web is impregnated and coated with a thermoset or partially thermoset mass finished to be abrasion-resistant based on at least one thermosettable synthetic resin from the group of melamine resins, formaldehyde resins and urea resins, and furthermore a wax based on a thermoplastic polymer, to which mass at least one further additive and/or one further adjuvant has been added,    in the thermoset or partially thermoset resin mass of the decorative web that forms the surface or wear layer on the decorative web, particles of at least one abrasion-resistant hard material,    especially α-aluminum oxide and α-corundum and/or tungsten carbide, being distributed, characterized in that 
 the thermoset or partially thermoset resin mass that forms the resin impregnation of the body of the decorative web and the highly abrasion-resistant surface resin layer with a closed or smooth outer surface, which is applied in a one-step process, and which is integral or materially integral with the web, is formed with at least one of the aforementioned thermosettable synthetic resins and the additives and/or adjuvants that are known in the art and that are conventional for laminate impregnations and coatings,  
 the synthetic resin mass as a component important to improved useful properties and to permanent freedom from cracking of the surface layer containing a mixture integrated into the resin mass or such a compound of at least one wax or wax blend based on a polyethylene, polypropylene and/or polyamide polymer or copolymer and at least one polyvinyl pyrrolidone, and  
 the particles of the abrasion-resistant hard material, especially Al 2 O 3  particles or corundum particles and/or tungsten carbide particles, in the surface layer are located essentially only directly on or directly bordering the decorative web or on its visible side or surface and in the immediate vicinity thereof and are concentrated there, and  
 the distribution or covering density of the particles of abrasive material located in the surface layer of the decorative laminate in the same—proceeding from a high value, especially between 80% and 95%, directly on the decorative web and on its visible side or surface and in the immediate vicinity thereof—toward the outer surface of the surface layer, preferably within a thickness range of the surface resin layer of from 0.05 to 0.15 mm, following a steep negative gradient, drops essentially to a value of zero.  
   
   
   
       2 . Decorative laminate according to  claim 1 , wherein the wax blend in the compound in the (partially) set resin mass is a wax blend based on micronized (thermoplastic) polymers based on ethylene from the Poro Company, Salzburg, Austria, especially one with the commercial designation “PORO 100. ” 
   
   
       3 . Decorative laminate according to  claim 1 , wherein the polyvinyl pyrrolidone of the compound contained in the (partially) set resin mass has a molecular weight in the range of from 25,000 to 750,000, preferably from 100,000 to 500,000.  
   
   
       4 . Decorative laminate according to  claim 1 , wherein the aluminum oxide particles or corundum particles contained in the surface layer of the laminate have a tabular form in significant portions, especially at least 40%, preferably at least 80%, and their average grain size is in the range from 10 to 100 μm, especially from 10 to 50 μm.  
   
   
       5 . Decorative laminate according to  claim 1 , wherein in the surface layer of the laminate, in addition to the abrasion-resistant hard material particles, there are spheroidal silicate spherules, preferably glass spherules, with diameters in the range of from 30 to 100 μm.  
   
   
       6 . Decorative laminate according to  claim 1 , wherein the (partially) set resin mass that forms the impregnation of the decorative web and its surface layer contains resin modifiers, such an external flexibilizers, preferably sugar, and/or glycols, such as diethylene glycol, and/or internal flexibilizers, such as ε-caprolactam and/or p-toluene sulfonic acid amide, and/or cross-linking regulators, preferably dicyanodiamide, acetoguanamine, and/or benzoguanamine.  
   
   
       7 . Decorative laminate according to  claim 1 , wherein the (partially) set resin mass that forms the impregnation of the decorative web and its surface layer additionally contains at least one natural substance or substance identical to nature from the group of guar seed flour, flour(s) of Jerusalem artichoke, chicory and/or dahlia, locust bean gum flour, cesa gum, guar gum, gum arabic, carrageen, tragacanth gum, agar agar and/or xanthene, but preferably locust bean gum flour and/or xanthene.  
   
   
       8 . Decorative laminate according to  claim 1 , wherein the quantitative portion of the wax or wax blend in the compound contained in the (partially) set resin mass is 0.5 to 2.5% relative respectively to the entire (partially) set resin mass without the abrasion-resistant hard material particles.  
   
   
       9 . Decorative laminate according to  claim 2 , wherein the quantitative portion of the polyvinyl pyrrolidone(s) of the compound contained in the (partially) set resin mass is 1.5 to 12%, preferably 3 to 8%, relative respectively to the entire (partially) set resin mass, but without the abrasion-resistant hard material particles.  
   
   
       10 . Process for producing decorative laminates with an abrasion-resistant surface or wear layer for laminate bodies coated therewith, especially floor boards or panels based on wood materials, the laminate being formed with at least one layer of an outside fibrous material web and/or paper web (decorative web) on the visible, useful side, provided with a suitable decoration and impregnated with a (partially) thermoset synthetic resin, which web is impregnated and surface-coated with a thermoset mass finished to be abrasion-resistant based on at least one thermosettable synthetic resin, to which at least one thermoplastic polymer-based wax and furthermore at least one additive or adjuvant is added, in the (partially) thermoset synthetic resin mass of the decorative web that forms the surface layer of the decorative web, particles of at least one abrasion-resistant hard material, especially α-aluminum oxide and α-corundum and/or tungsten carbide being distributed, according to  claim 1 , wherein 
 a fibrous material web or paper web printed with the respectively intended decoration is impregnated in a one-step process with a mass of a thermosettable resin that contains conventional components as well as further additives and/or adjuvants and abrasion-resistant hard material particles, and is coated with simultaneous formation of a surface or wear resin layer that forms a closed or smooth outer surface, which is materially-integral or integral with the resin impregnation of the decorative web, and within which 
 the particles of the abrasion-resistant hard material, especially Al 2 O 3  particles or corundum particles and/or tungsten carbide particles, settle essentially directly to and into the immediate vicinity of the surface of the decorative web and collect there in a high concentration and  
 the distribution density of the particles of abrasive material located in the surface layer of the decorative layer in the same, proceeding from a high value directly to or on the surface of the decorative web and in the immediate vicinity thereof, toward the outer surface—following a steep negative gradient—drops essentially to a value of zero,  
 for impregnation and coating of the fibrous material web or paper web, a resin mass being used that as a component that is important—for improved production and useful properties and for permanent freedom from cracking of the surface layer of the laminate—contains a mixture integrated into it or such a compound of a micronized wax or such a wax blend based on a polyethylene, polypropylene and/or polyamide polymer or copolymer and with at least one polyvinyl pyrrolidone, and  
 wherein after impregnation and surface coating of the decorative web that takes place simultaneously with it, the conventional (partial) curing of the decorative web or—after appropriate moisture removal—with or without interposition of a supporting web that is to be placed underneath the decorative web—direct application of the coated decorative web impregnated with the described resin mass to a wood material substrate in a board or panel form, preferably to floor boards or panels, takes place.  
   
   
   
       11 . (canceled)