Melamine resin, process for its manufacture and its use for the manufacture of coated wood-based materials and laminates

Abstract

A melamine-formaldehyde resin useful for making coated wood-based materials and laminates and having a prolonged pot life comprises (a) melamine-formaldehyde precondensation product wherein the molar ratio of melamine:formaldehyde is 1:1.4 to 1:2.6 (b) 0.1 to 1.0% by weight based on total solids, of an amine of the formula ##STR1## wherein R 1 and R 2 are each identical or different alkyl having 1 to 4 carbon atoms and R 3 is 2-hydroxyethyl, 2-(2-hydroxyethoxy)-ethyl, 3-hydroxy-1-propyl, 3-hydroxy-2-propyl, 2,3-dihydroxypropyl or --CH.sub.2 CH.sub.2 --NR.sup.1 R.sup.2, wherein said amine may be present entirely or partially in the form of its reaction product with the melamine-formaldehyde pre-condensation product.

We claim:  .[.1. Melamine-formaldehyde resin comprising 
     
        product..]. .[.2.  Melamine-formaldehyde resin according to claim 1 containing 0.2 to 1.0% by weight of said amine..]. .[.3. Melamine-formaldehyde resin according to claim 1 characterized in that the molar ratio of melamine:formaldehyde is 1:1.5 to 1:2.3..]. .[.4. Melamine-formaldehyde resin according to claim 1 containing 0.25 to 0.5% by weight of said amine..]. .[.5. Melamine-formaldehyde resin according to claim 1 wherein R 1  and R 2  are both methyl and R 3  is 2-hydroxyethyl or 2,3-dihydroxypropyl..]. .[.6. Melamine-formaldehyde resin according to claim 1 which additionally contains 0.5 to 40% by weight, based on total solids, of a modifying agent based on lower, saturated fatty acid amides..]. .[.7. Melamine-formaldehyde resin according to claim 6 wherein said modifying agent based on lower, saturated fatty acid amides is methylene-bis-formamide of the formula ##STR11## bis-(N-acylaminomethyl) ethers of the formula ##STR12## wherein R is hydrogen or methyl, or a condensation product of ε-caprolactam, formaldehyde and formamide in a molar ratio of 1:a:b, respectively, in which a is a number from 1 to 20, b is a number from 1 to 19, and a and b are so chosen that the quotient a/(b+1) is 0.5 
     
     
        to 1..].  .[.8.  Melamine-formaldehyde resin according to claim 7 wherein a is 1 to 2 and b is 1..]. .[.9. Melamine-formaldehyde resin according to claim 7 containing 2.5 to 25% by weight of the modifying agent based on lower, saturated fatty acid amides..]. .[.10. Melamine-formaldehyde resin according to claim 1 which additionally contains a curing accelerator in an amount sufficient for curing at temperatures above 100° C..]. .[.11. In the process for the manufacture of the melamine-formaldehyde resin as claimed in claim 1 by a condensation reaction of melamine and formaldehyde in the presence of inorganic bases in the pH range of 8.2 to 10.4, wherein the improvement comprises (a) condensing melamine and formaldehyde in a molar ratio of 1:1.4 to 1:2.6 until a dilutability with water of 1:3 to 1:0.8 is obtained, and (b) adding before, during or after 0.1 to 1.0% by weight, based on total solids, of an amine of the formula ##STR13## wherein R 1  and R 2  are each identical or different alkyl with 1 to 4 carbon atoms and R 3  is 2-hydroxyethyl, 2-(2-hydroxyethoxy)-ethyl, 3-hydroxy-1-propyl, 3-hydroxy-2-propyl, 2,3-dihydroxypropyl or   --CH.sub.2 CH.sub.2 --NR.sup.1 R.sup.2     wherein said amine may be present entirely or partially in the form of its reaction product with the melamine-formaldehyde condensation product..].   
     
     
        .[.12.  Process according to claim 11 wherein said amine is added prior to the condensation reaction and replaces the inorganic base which is omitted..]. .[.13. In the manufacture of resin coated wood-based materials and laminates, the improvement comprises the resin being the 
     
     
        melamine-formaldehyde resin according to claim 1..]. .Iadd.14. Melamine-formaldehyde resin comprising (a) melamine-formaldehyde precondensation product wherein the molar ratio of melamine:formaldehyde is 1:1.4 to 1:2.6 and (b) 0.1 to 1.0% by weight, based on total solids, of an amine of the formula ##STR14## wherein R 3  is 2-hydroxyethyl or 2,3-dihydroxypropyl, wherein said amine may be present entirely or partially in the form of its reaction product with the melamine-formaldehyde precondensation product and (c) 0.5 to 40% by weight, based on total solids, of a modifying agent selected from lower, saturated fatty acid amides, methylene-bis-formamide of the formula ##STR15## bis-(N-acylaminomethyl ethers of the formula ##STR16## and mixtures thereof, wherein R is hydrogen, methyl or a condensation product of ε-caprolactam, formaldehyde and formamide in a molar ratio of 1:a:b, respectively, in which a is a number from 1 to 20, b is a number from 1 to 19, and a and b are so chosen that the quotient a/(b+1) 
     
     
        is 0.5 to 1. .Iaddend. .Iadd.15.  Melamine-formaldehyde resin according to claim 14 containing 0.2 to 1.0% by weight of said amine. .Iaddend. .Iadd.16. Melamine-formaldehyde resin according to claim 14 characterized in that the molar ratio of melamine:formaldehyde is 1:1.5 to 1:2.3. .Iaddend. .Iadd.17. Melamine-formaldehyde resin according to claim 14 containing 0.25 to 0.5% by weight of said amine. .Iaddend. .Iadd.18. Melamine-formaldehyde resin according to claim 14 wherein R 3  is 2-hydroxyethyl. .Iaddend. .Iadd.19. Melamine-formaldehyde resin according to claim 14 wherein a is 1 to 2 and b is 1. .Iaddend. .Iadd.20. Melamine-formaldehyde resin according to claim 14 containing 2.5 to 25% by weight of the modifying agent of component (c). .Iaddend. .Iadd.21. Melamine-formaldehyde resin according to claim 14 which additionally contains a curing accelerator in an amount sufficient for curing at temperatures above 100° C. .Iaddend. .Iadd.22. In the process for the manufacture of the melamine-formaldehyde resin as claimed in claim 14 by a condensation reaction of melamine and formaldehyde in the presence of inorganic bases in the pH range of 8.2 to 10.4, wherein the improvement comprises (a) condensing melamine and formaldehyde in a molar ratio of 1:1.4 to 1:2.6 until a dilutability with water of 1:3 to 1:0.8 is obtained, and (b) adding before, during or after 0.1 to 1.0% by weight, based on total solids, of an amine of the formula ##STR17## wherein R 3  is 2-hydroxyethyl or 2,3-dihydroxypropyl wherein said amine may be present entirely or partially in the form of its reaction product with the melamine-formaldehyde condensation product and (c) adding before, during or after 0.5 to 40% by weight, based on total solids, of a modifying agent selected from lower, saturated fatty acid amides, methylene-bis-formamide of the formula ##STR18## bis-(N-acylaminomethyl) ethers of the formula ##STR19## and mixtures thereof, wherein R is hydrogen, methyl, or a condensation product of ε-caprolactam, formaldehyde and formamide in a molar ratio of 1:a:b, respectively, in which a is a number from 1 to 20, b is a number from 1 to 19, and a and b are so chosen that the quotient a/(b+1) 
     
     
        is 0.5 to 1. .Iaddend. .Iadd.23.  Process according to claim 22 wherein said amine is added prior to the condensation reaction and replaces the inorganic base which is omitted. .Iaddend. .Iadd.24. In the manufacture of resin coated wood-based materials and laminates, the improvement comprises the resin being the melamine-formaldehyde resin according to claim 14. .Iaddend.