阅读说明：本技术 新型涂覆制品及其制备方法和用途 (Novel coated articles, method for their preparation and use ) 是由 M·斯坦纳 D·斯特鲁维 于 2019-08-27 设计创作，主要内容包括：本发明涉及一种包括载体材料和树脂组合物的涂覆制品,其中所述树脂组合物优选为B级树脂组合物。本发明还涉及制备所述涂覆制品的方法,和特别涉及所述涂覆制品用于生产模板的用途。(The present invention relates to a coated article comprising a support material and a resin composition, wherein the resin composition is preferably a B-stage resin composition. The invention also relates to a method for producing said coated article, and in particular to the use of said coated article for producing a template.)

1. A coated article comprising:

a) a support material, preferably paper, and

b) resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin, wherein the resin composition has:

-the molar ratio of phenol to total formaldehyde is at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1:13,

-a molar ratio of melamine to total formaldehyde of at least 1:1, preferably at least 1:2, most preferably at least 1:3, and

-the molar ratio of urea to total formaldehyde is at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1: 4.

2. The coated article of claim 1, wherein the resin composition is a B-stage resin composition.

3. The coated article of claim 1 or 2, wherein the resin composition has:

-the molar ratio of phenol to total formaldehyde is at most 1:30, preferably at most 1:25, most preferably at most 1:20,

-a molar ratio of melamine to total formaldehyde of at most 1:20, preferably at most 1:15, most preferably at most 1:10, and

-the molar ratio of urea to total formaldehyde is at most 1:20, preferably at most 1:15, most preferably at most 1: 10.

4. A coated article according to any of the preceding claims, wherein the resin composition is characterized in that it has a degree of crosslinking of less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80%.

5. The coated article according to any of the preceding claims, wherein the resin composition is characterized by a total residual volatile content of at least 3 wt.%, preferably at least 4 wt.%, more preferably at least 5 wt.%, and most preferably at least 7 wt.%.

6. The coated article of any of the preceding claims, wherein the article comprises more than 50 wt% resin, preferably at least 55 wt% resin, most preferably at least 60 wt% resin, based on the weight of the dry coated article.

7. The coated article according to any of the preceding claims, wherein the resin composition is obtainable by compounding at least the following components:

a) melamine, urea, phenol and formaldehyde; or

b) MF-resins, UF-resins and PF-resins.

8. The coated article of any of the preceding claims, wherein the article has a 7-day COBB value of 300g/m²Or less, preferably 250g/m²Or less, more preferably 200g/m²Or lower.

9. The coated article according to any of the preceding claims, wherein the carrier material comprises a further resin composition and the further resin composition is different from the resin composition of claim 1b), claim 2 or claim 3.

10. The coated article according to any of the preceding claims, wherein the resin composition comprises a base, preferably a metal hydroxide, more preferably an alkali metal hydroxide, most preferably sodium hydroxide or potassium hydroxide.

11. A wood product, in particular a formwork, obtainable by applying a coated article according to any one of claims 1 to 10 to a wood board.

12. A method for preparing a coated article, in particular a formwork for a concrete formwork, comprising the steps of:

a) providing a carrier material, preferably paper,

b) applying onto the support material a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin,

c) the resin composition is subsequently cured to give a resin composition having a degree of crosslinking of less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80%.

13. A method for preparing a coated article, in particular a formwork for a concrete formwork, comprising the steps of:

a) the supply of the paper is carried out,

b) a first resin composition is applied to the paper,

c) applying a second resin composition to the paper, wherein the first resin composition is different from the second resin composition,

d) the first and second resin compositions are subsequently cured to provide a B-staged resin composition.

14. A method for preparing a coated article, in particular a formwork for a concrete formwork, comprising the steps of:

a) the supply of the paper is carried out,

b) a first resin composition is applied to the paper,

c) applying a second resin composition to the paper, wherein the first resin composition is different from the second resin composition,

d) the first and second resin compositions are subsequently cured to give a resin composition having a degree of crosslinking of less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80%.

15. Use of a coated product according to any of the preceding claims 1-10 for the production of wood products.

16. The wood product, in particular a formwork, according to claim 11, wherein said coated product is applied to a wood board by hot pressing.

17. A formwork panel obtainable by applying onto a wood board a coated article comprising a support material, preferably paper, and a resin composition comprising a mixture of melamine-urea-phenol-formaldehyde-co-condensate and/or melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin.

18. A template comprising wood, preferably spruce, birch and/or willow, and a coated carrier material, preferably paper, comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives.

19. A template comprising wood, preferably spruce, birch and/or willow, and a coated carrier material, preferably paper, comprising at least two different resin compositions, wherein each resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives.

20. The template of claim 18 or 19, wherein at least one resin composition has:

-the molar ratio of phenol to total formaldehyde is at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1:13,

-a molar ratio of melamine to total formaldehyde of at least 1:1, preferably at least 1:2, most preferably at least 1:3, and

-the molar ratio of urea to total formaldehyde is at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1: 4.

21. The template of claim 18, 19 or 20, wherein at least one resin composition has:

-the molar ratio of phenol to total formaldehyde is at most 1:30, preferably at most 1:25, most preferably at most 1:20,

-a molar ratio of melamine to total formaldehyde of at most 1:20, preferably at most 1:15, most preferably at most 1:10, and

-the molar ratio of urea to total formaldehyde is at most 1:20, preferably at most 1:15, most preferably at most 1: 10.

22. The template of any one of claims 18-21, wherein at least one resin composition has:

-the molar ratio of phenol to total formaldehyde is from 1:10 to 1:15,

-the molar ratio of melamine to total formaldehyde is from 1:4 to 1:8, and

-the molar ratio of urea to total formaldehyde is from 1:3 to 1: 8.

23. The form of any one of claims 18-22 for use in a concrete form.

Technical Field

The invention relates to a coated article comprising a support material and a resin composition comprising melamine, urea, phenol and formaldehyde. In another aspect, the present invention relates to a coated article comprising a support material and a B-stage resin composition comprising melamine, urea, phenol and formaldehyde. The invention also relates to a method for producing said coated articles and in particular to the use of these coated articles for producing building forms, in particular concrete forms.

Background

The form for a concrete form should meet certain requirements, and particularly after the form is formed, the resulting concrete should have a smooth surface. In this case, the template should also have a smooth-surfaced coating. In addition, it is advantageous that the template coating has good water resistance. Since these products are typically cost-intensive, the template should be reusable.

Phenolic resins, i.e. (PF) -resins are synthetic polymers obtained by the reaction of phenol or substituted phenols with formaldehyde. Phenolic resins are known for use in the preparation of forms for concrete forms because of their good surface properties, which render concrete smooth. This may be associated with its low brittleness.

EP 2749385 a1 describes a plywood impregnated with phenolic resin which can be reused in a concrete mould.

However, due to the toxicity of phenols, there is a continuing need for more environmentally friendly and user friendly preparation of coated articles for use in the production of templates.

In the past, the reduction in free phenol concentration was readily achieved by increasing the molar ratio of formaldehyde to phenol in the phenolic resin. But this generally increases the concentration of free formaldehyde in the resin, thereby increasing the amount of formaldehyde released during processing and curing. This method is also disadvantageous because formaldehyde may be carcinogenic.

To reduce free phenol, WO 2008/141042 a1 teaches the preparation of a conventional phenolic resin in a first step, followed by removal of residual phenol (e.g. by heating under vacuum, azeotropic distillation or membrane evaporation), and subsequent addition of an organic solvent or dibasic ester. As a result, this production process is also based on phenol-rich resins and requires more complex technology and expensive process steps.

In WO 2015/117758 a1, phenolic resins comprising vinasse are disclosed, which results in a reduced proportion of aromatic hydroxy compounds in the resin. Phenol is still one of the main components in such resin compositions.

There is therefore a need for a coated article, in particular for the production of stencils, which overcomes at least one of the above-mentioned disadvantages.

Disclosure of Invention

This problem is solved by providing a coated article comprising a support material, preferably paper, and a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin. In one embodiment, the resin composition has:

-the molar ratio of phenol to total formaldehyde is at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1:13,

-a molar ratio of melamine to total formaldehyde of at least 1:1, preferably at least 1:2, most preferably at least 1:3, and

-the molar ratio of urea to total formaldehyde is at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1: 4.

In a preferred embodiment, the resin composition is a B-stage resin composition. By "coated" articles is meant that each article has at least a portion of the resin composition of the present invention applied thereto.

Unless explicitly stated otherwise, the melamine-urea-phenol-formaldehyde-co-condensate and/or the mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin are often collectively referred to as "(MUPF) -resin".

The term "B-staged" refers to the degree of crosslinking. When referring to a B-stage resin, it is meant that the polymer chains in the composition are only partially crosslinked, i.e., the degree of crosslinking is less than 100% (see A. Brent Strong, Fundamentals of compositions Manufacturing 2nd Ed., Society of Manufacturing Engineers,2008, p.124). In a preferred embodiment, the degree of crosslinking of the B-stage resin composition is less than 95%, more preferably less than 90%, even more preferably less than 80%.

"crosslinking" is understood in the context of the present invention to be a chemical bond that connects polymer chains, preferably by forming a covalent bond. Such bonds may be formed by various types of reactions known in the art, and in particular may be formed by condensation reactions. Crosslinking of the polymer chains may be initiated by chemical additives, ultraviolet light, electron beam, or heat. The terms "crosslinking" and "curing" are used interchangeably.

In the context of the present invention, the term "condensation" or "condensation reaction" refers to the polymerization of monomers or the formation of polymer chains with the formation of at least one by-product such as water, ammonia, alcohol or hydrogen chloride.

As used herein, a "carrier material" is any material that can be coated with a resin composition. The carrier material may typically be selected from paper (especially kraft or sack paper), cardboard, glass fibre, textiles including woven and non-woven fabrics, plastics including rigid foams and foamed plastics, mineral materials such as ceramics or porous concrete, metals such as metal foils, and the like.

As used herein, the term "paper" is defined as a layered material consisting essentially of fibers or textiles, which may be natural or synthetic materials, preferably derived from plants, in particular wood or grass. The paper is preferably kraft paper.

In a preferred embodiment of the invention, the carrier material has a weight per square meter of 20-100gsm, preferably 30-90gsm, most preferably 40-80 gsm. The carrier is preferably kraft paper.

The total weight of the coated article of the invention may be from 80 to 300g/m²Preferably 100-270g/m²More preferably 115-240g/m². Most preferably, the total weight of the coated article is 120-220g/m²。

The resin composition contained in the coated article of the present invention may alternatively be defined as a flowable resin composition. A resin composition is defined as "flowable" if an article coated with the resin composition exhibits flowability, particularly at elevated temperatures and a given preset pressure. Due to the fact thatThe amount of resin that leaks from the coated article by this treatment reflects the "flowability". When the temperature is 160 ℃ and the temperature is 2.0N/mm²Preferred resin compositions of the present invention exhibit a weight loss of at least 1%, more preferably at least 2%, at least 3% or most preferably at least 5% after 2min down-pressing. This flowability can be quantified in a flowability test, as described in example 4 below.

The invention therefore also relates to a coated article comprising a support material, preferably paper, and a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin, wherein the resin composition can be characterized by its flowability. In a preferred embodiment, when the article is at 160 ℃ and 2.0N/mm²The resin composition has a flow of at least 1%, preferably at least 2%, at least 3% or most preferably at least 5% after being subjected to pressure for 2 min.

In another method, the resin composition included in the coated article of the present invention may be defined as a resin composition comprising at least 3 wt% residual volatiles.

Those skilled in the art will know and be able to select appropriate methods and standard tests for determining the level of residual volatiles such as solvents including organic solvents and water. Residual volatiles can be measured, for example, by holding the coated article in an oven at 160 ℃ for 2min and determining the amount of volatiles reflected in the weight loss of the article due to such treatment. The test for determining residual volatiles is given in detail in example 3 below.

In a preferred embodiment of the invention, the total content of residual volatiles in the resin composition is at least 5 wt.%, and most preferably at least 7 wt.%.

The total residual volatile content of the coated article is preferably less than 20 wt.%, more preferably less than 15 wt.%, most preferably less than 10 wt.%. In a most preferred embodiment, the total content of residual volatiles is from 3 to 15 wt.%, in particular from 3 to 10 wt.%.

The invention therefore also relates to a coated article comprising a carrier material, preferably paper, and a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin, wherein the total residual volatile content of the resin composition is at least 2 wt%.

All other embodiments and advantages of the invention described in detail below are likewise directed to any of these three alternative characterizations, alone or in combination. Thus, it is also possible and even preferred that the coated article of the invention is characterized by two or all of the three characterizations as described above.

The present inventors have found that the use of the (MUPF-) resins as defined in the present invention has no critical influence on the quality of the resulting coated articles and the templates produced therefrom. In particular, the coated article of the invention did not show cracking (example 2), which would prevent its use for the manufacture of high quality reusable templates.

The stencils produced with the coated articles of the present invention generally exhibit similar (and in some aspects even better) performance as stencils coated with phenolic resin compositions. This is surprising since melamine-formaldehyde or urea-formaldehyde resin compositions or mixtures thereof are known to have an increased brittleness and thus to be more easily cracked (g.w.becker, d.braun, h.gaussephl, r.gellert, Kunststoff-Handbuch, volume 10, page 47).

In particular, the inventors have found that the coated articles of the invention have a low water permeability (as defined by the COBB value), even significantly lower than the water permeability of the articles coated with the phenolic resin composition (example 2).

Water permeability can be measured by the amount of water absorbed by the surface of the coated article (i.e., the COBB value). The lower the COBB value, the lower the absorption rate. The low water permeability of the form comprising the coated article may preferably be suitable for concrete form applications where a smooth concrete surface is preferred.

Thus, in a preferred embodiment of the invention, the 7-day COBB value of the coated article is 300g/m²Or less, preferably 250g/m²Or less, more preferably 200g/m²Or lower.

Thus, in a particularly preferred aspect of the invention, the coated article is used for making formwork, in particular formwork for concrete formwork. This is advantageous for environmental protection, since the phenol content of the (MUPF) -resin composition is lower than that of the phenolic resin compositions used for this purpose in the prior art.

Additionally and surprisingly, the (MUPF) -resin compositions used in the present invention have a low free formaldehyde emission, which is even lower than that of the phenolic resin compositions (example 1). This will even further facilitate the production of environmentally friendly wood boards, which are beneficial to health and safety as a whole.

The invention relates to a coated article comprising a support material, preferably paper, and a resin composition comprising a melamine-urea-phenol-formaldehyde co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin. In one embodiment, the resin composition has:

-the molar ratio of phenol to total formaldehyde is at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1:13,

-a molar ratio of melamine to total formaldehyde of at least 1:1, preferably at least 1:2, most preferably at least 1:3, and

-the molar ratio of urea to total formaldehyde is at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1: 4.

The resin composition is preferably B-staged. As outlined above, this means that the resin composition is only partially cured. Alternatively, the resin composition may be characterized by having a flowability of the resin composition of at least 1% and/or a residual volatile content of at least 3 wt%.

As mentioned above, providing the coating material comprising the resin composition of the present invention allows to improve the surface properties of the resulting coated article, which in turn results in high quality wood boards, in particular in formwork, especially for concrete formwork.

In a preferred embodiment, the coated article of the present invention comprises at least 50 wt% of the resin composition, preferably at least 55 wt% of the resin composition, most preferably at least 60 wt% of the resin composition, based on the weight of the dry coated article.

The resin composition of the coated article may be obtained by providing a composition comprising at least: melamine, urea, phenol and formaldehyde. These components condense and at least partially crosslink to form the resin composition.

In one embodiment, a template is provided, obtainable by applying to a wood board a coated article comprising a support material, preferably paper, and a resin composition, wherein the resin composition comprises a mixture of melamine-urea-phenol-formaldehyde-co-condensate and/or melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin.

In another embodiment, a template is provided comprising wood, preferably spruce, birch and/or willow, and a coated carrier material, preferably paper, comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives.

In another embodiment, a template is provided comprising wood, preferably spruce, birch and/or willow, and a coated carrier material, preferably paper, comprising at least two different resin compositions, wherein each of the resin compositions comprises phenol, melamine, urea, formaldehyde and optionally additives.

In another embodiment, a template is provided comprising wood, preferably spruce, birch and/or willow, and a coated carrier material, preferably paper, comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition is a B-stage resin composition.

In another embodiment, a template is provided comprising wood, preferably spruce, birch and/or willow, and a coated carrier material, preferably paper, comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition preferably has a molar ratio of phenol to total formaldehyde of at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1: 13.

In another embodiment, a formwork is provided, comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition preferably has a molar ratio of phenol to total formaldehyde of at most 1:30, more preferably at most 1:25, most preferably at most 1:20, most preferably at most 1: 15.

In another embodiment, a formwork is provided, comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has a molar ratio of phenol to total formaldehyde of preferably at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1:13, and at most 1:30, more preferably at most 1:25, most preferably at most 1:20, most preferably at most 1: 15.

In another embodiment, a template is provided comprising wood, preferably spruce, birch and/or willow, and a coated carrier material, preferably paper, comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has a molar ratio of phenol to total formaldehyde in the range of 1:10 to 1: 15.

In another embodiment, a template is provided comprising wood, preferably spruce, birch and/or willow, and a coated carrier material, preferably paper, comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the molar ratio of melamine to total formaldehyde of the resin composition may preferably be at least 1:1, preferably at least 1:2, most preferably at least 1: 3.

In another embodiment, a formwork is provided, comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition preferably has a molar ratio of melamine to total formaldehyde of at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1: 8.

In another embodiment, a formwork is provided, comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has a molar ratio of melamine to total formaldehyde of preferably at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1:4, and at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1: 8.

In another embodiment, a template is provided comprising wood, preferably spruce, birch and/or willow, and a coated carrier material, preferably paper, comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has a molar ratio of melamine to total formaldehyde of from 1:4 to 1: 8.

In another embodiment, a template is provided comprising wood, preferably spruce, birch and/or willow, and a coated carrier material, preferably paper, comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has a molar ratio of urea to total formaldehyde of at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1: 4.

In another embodiment, a formwork is provided, comprising wood, preferably spruce, birch and/or willow, and a coated carrier material, preferably paper, comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the molar ratio of urea to total formaldehyde of the resin composition is preferably at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1:8, the maximum of the molar ratio of melamine to total formaldehyde.

In another embodiment a formwork is provided comprising wood, preferably spruce, birch and/or willow, and a coated carrier material, preferably paper, comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition preferably has a molar ratio of urea to total formaldehyde of at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1:4, and a molar ratio of urea to total formaldehyde of preferably at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1:8 of the molar ratio of melamine to total formaldehyde.

In another embodiment, a template is provided comprising wood, preferably spruce, birch and/or willow, and a coated carrier material, preferably paper, comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has a molar ratio of urea to total formaldehyde of 1:3 to 1: 8.

In another embodiment, a template is provided comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has the following molar ratios:

the molar ratio of phenol to total formaldehyde is preferably at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1:13, and

the molar ratio of melamine to total formaldehyde is preferably at least 1:1, preferably at least 1:2, most preferably at least 1: 3.

In another embodiment, a template is provided comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has the following molar ratios:

the molar ratio of phenol to total formaldehyde is preferably at most 1:30, more preferably at most 1:25, most preferably at most 1:20, most preferably at most 1:15, and

the molar ratio of melamine to total formaldehyde is preferably at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1: 8.

In another embodiment, a template is provided comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has the following molar ratios:

-the molar ratio of phenol to total formaldehyde is from 1:10 to 1:15,

-the molar ratio of melamine to total formaldehyde is from 1:4 to 1: 8.

In another embodiment, a template is provided comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has the following molar ratios:

the molar ratio of phenol to total formaldehyde is preferably at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1:13, and

the molar ratio of urea to total formaldehyde is preferably at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1: 4.

In another embodiment, a template is provided comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has the following molar ratios:

the molar ratio of phenol to total formaldehyde is preferably at most 1:30, more preferably at most 1:25, most preferably at most 1:20, most preferably at most 1:15, and

the molar ratio of urea to total formaldehyde is preferably at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1:8, of the molar ratio of melamine to total formaldehyde.

In another embodiment, a template is provided comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has the following molar ratios:

-the molar ratio of phenol to total formaldehyde is from 1:10 to 1:15, and

-the molar ratio of urea to total formaldehyde is from 1:3 to 1: 8.

In another embodiment, a template is provided comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has the following molar ratios:

the molar ratio of melamine to total formaldehyde is preferably at least 1:1, preferably at least 1:2, most preferably at least 1:3, and

the molar ratio of urea to total formaldehyde is preferably at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1: 4.

In another embodiment, a template is provided comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has the following molar ratios:

the molar ratio of melamine to total formaldehyde is preferably at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1:8, and

the molar ratio of urea to total formaldehyde is preferably at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1:8, of the molar ratio of melamine to total formaldehyde.

In another embodiment, a template is provided comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has the following molar ratios:

-the molar ratio of melamine to total formaldehyde is from 1:4 to 1:8, and

-the molar ratio of urea to total formaldehyde is from 1:3 to 1: 8.

In another embodiment, a template is provided comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has the following molar ratios:

the molar ratio of phenol to total formaldehyde is preferably at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1:13,

the molar ratio of melamine to total formaldehyde is preferably at least 1:1, preferably at least 1:2, most preferably at least 1:3, and

the molar ratio of urea to total formaldehyde is preferably at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1: 4.

In another embodiment, a template is provided comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has the following molar ratios:

the molar ratio of phenol to total formaldehyde is preferably at most 1:30, more preferably at most 1:25, most preferably at most 1:20, most preferably at most 1:15,

the molar ratio of melamine to total formaldehyde is preferably at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1:8, and

the molar ratio of urea to total formaldehyde is preferably at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1:8, of the molar ratio of melamine to total formaldehyde.

In another embodiment, a template is provided comprising wood (preferably spruce, birch and/or willow) and a coated carrier material (preferably paper) comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives, and wherein the resin composition has the following molar ratios:

-the molar ratio of phenol to total formaldehyde is from 1:10 to 1:15,

-the molar ratio of melamine to total formaldehyde is from 1:4 to 1:8, and

-the molar ratio of urea to total formaldehyde is from 1:3 to 1: 8.

As used in the context of the present invention, the term "melamine" is defined as a class of compounds consisting of melamine and optionally substituted melamine. Melamine (2,4, 6-triamino-1, 3, 5-triazine) is a compound having the general formula (C)₃H₆N₆) The heterocyclic aromatic compound of (1). "optionally substituted melamine" refers to substituted, partially substituted or unsubstituted melamine. Examples of substituted or partially substituted melamines are 2,4, 6-trialkylamino-1, 3, 5-triazine, 2,4, 6-trialkenylamino-1, 3, 5-triazine, 2,4, 6-triarylamino-1, 3, 5-triazine, 2, 4-dialkylamino-6-amino-1, 3, 5-triazine or 2, 4-diamino-6-alkenylamino-1, 3, 5-triazine.

As used herein, the term "phenol" is defined as a class of compounds consisting of phenol and optionally substituted phenol. Phenol is of the general molecular formula C₆H₅An OH group, and an aromatic organic compound comprising at least one hydroxyl group (-OH) directly bonded to an aromatic hydrocarbon group. "optionally substituted phenol" refers to substituted, partially substituted or unsubstituted phenol. Suitable substituted or partially substituted phenols are, for example, alkylbenzenesA phenol, an alkenylphenol, an arylphenol or a heteroarylphenol.

"Urea" is defined as a compound of the formula CO (NH)₂)₂And optionally substituted ureas. "optionally substituted urea" refers to substituted, partially substituted or unsubstituted amino groups in urea. The urea may be substituted with alkyl, alkenyl, aryl or heteroaryl groups.

"alkyl" means C1-C10 straight or branched chain alkyl groups such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, n-pentyl, isopentyl, neopentyl, tert-pentyl, n-hexyl, isohexyl, n-heptyl, n-octyl, n-nonyl, n-decyl. Preference is given to C1-C6 alkyl, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, n-pentyl, isopentyl, neopentyl, tert-pentyl, n-hexyl, isohexyl.

"alkenyl" means a straight or branched chain alkenyl group of C2-C8 derived from the above-mentioned "alkyl" group having one or more double bonds, such as ethenyl, 1-propenyl, 2-propenyl, 1-butenyl, 2-butenyl, 3-butenyl, 1, 3-butadienyl, 3-methyl-2-butenyl.

"aryl" refers to a monocyclic aromatic hydrocarbon group (e.g., phenyl) or a polycyclic aromatic hydrocarbon group (e.g., 1-naphthyl, 2-naphthyl, 1-anthryl, 2-anthryl, 9-anthryl, 1-phenanthryl, 2-phenanthryl, 3-phenanthryl, 4-phenanthryl, 9-phenanthryl). Preferably phenyl or naphthyl (e.g. 1-naphthyl, 2-naphthyl).

"heteroaryl" refers to monocyclic aromatic heterocyclic groups and condensed aromatic heterocyclic groups.

The compositions used for coating the support material advantageously have a pH value suitable for the condensation of the components. The composition therefore advantageously comprises a component for adjusting the pH, for example alkali metal hydroxides, alkaline earth metal hydroxides, amines or inorganic or organic ammonium compounds may be applied. In the most preferred embodiment, NaOH or KOH is used to adjust the pH.

In an alternative embodiment, the resin composition included in the coated article may be obtained by compounding at least the following components: melamine-formaldehyde (MF) -resins, urea-formaldehyde (UF) -resins and phenol-formaldehyde (PF) -resins. These components are partially cured. Thus, these components are curable condensates.

"Melamine-formaldehyde" resins (abbreviated as (MF) -resins) are thermosetting resins (i.e., aminoplasts). It is made up by condensation of two monomers of melamine and formaldehyde, the formaldehyde acts as cross-linking agent. Melamine reacts with formaldehyde under alkaline conditions to form a mixture of various melamine-formaldehyde adducts (also known as methylolmelamines).

"Urea-formaldehyde" resins (abbreviated as (UF) -resins) are semi-crystalline thermosetting resins. Urea-formaldehyde resins are formed from urea and formaldehyde, which acts as a crosslinking agent.

"thermoset" (i.e., thermosetting plastic or thermosetting resin) is a polymer that irreversibly hardens after curing.

The composition providing the resin composition may further comprise a modifier such as an acrylate, a diol, a diamide, a sulfonamide, thiourea, a lactam, a sugar, a guanamine (preferably caprolactam, acetoguanidine, benzoguanidine), dicyandiamide or p-toluene-sulfonamide or a mixture thereof. Acrylates are preferred. The modifier may react with a component of the composition (as described above).

In the resin composition included in the coated article, the molar ratio of phenol to total formaldehyde is preferably at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1: 13.

In the resin composition comprised in the coated article, the molar ratio of phenol to total formaldehyde is preferably at most 1:30, more preferably at most 1:25, most preferably at most 1:20, most preferably at most 1: 15.

In the resin composition comprised in the coated article, the molar ratio of phenol to total formaldehyde is preferably at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1:13, and at most 1:30, more preferably at most 1:25, most preferably at most 1:20, most preferably at most 1: 15.

The molar ratio of phenol to total formaldehyde in the resin composition included in the coated article is most preferably in the range of 1:10 to 1: 15.

In the resin composition included in the coated article, the molar ratio of melamine to total formaldehyde may preferably be at least 1:1, preferably at least 1:2, most preferably at least 1: 3.

In the resin composition comprised in the coated article, the molar ratio of melamine to total formaldehyde is preferably at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1: 8.

In the resin composition comprised in the coated article, the molar ratio of melamine to total formaldehyde is preferably at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1:4, and at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1: 8.

The molar ratio of melamine to total formaldehyde in the resin composition included in the coated article is most preferably in the range of 1:4 to 1: 8.

In a preferred embodiment of the invention, the resin composition of the coated article has a molar ratio of urea to total formaldehyde of at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1: 4.

In the resin composition comprised in the coated article, the molar ratio of urea to total formaldehyde is preferably at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1:8 of the molar ratio of melamine to total formaldehyde.

In the resin composition comprised in the coated article, the molar ratio of urea to total formaldehyde is preferably at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1:4, and at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1:8, of the molar ratio of melamine to total formaldehyde.

The molar ratio of urea to total formaldehyde in the resin composition included in the coated article is most preferably from 1:3 to 1: 8.

In the most preferred embodiment of the present invention, the resin composition included in the coated article has the following molar ratio:

the molar ratio of phenol to total formaldehyde is preferably at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1:13,

the molar ratio of melamine to total formaldehyde is preferably at least 1:1, preferably at least 1:2, most preferably at least 1:3, and

the molar ratio of urea to total formaldehyde is preferably at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1: 4.

In the most preferred embodiment of the present invention, the resin composition included in the coated article has the following molar ratio: a molar ratio of phenol to total formaldehyde of at least 1:13, a molar ratio of melamine to total formaldehyde of at least 1:3, and a molar ratio of urea to total formaldehyde of at least 1: 4.

In the most preferred embodiment of the present invention, the resin composition included in the coated article has the following molar ratio:

the molar ratio of phenol to total formaldehyde is preferably at most 1-30, more preferably at most 1:25, most preferably at most 1:20, most preferably at most 1:15,

the molar ratio of melamine to total formaldehyde is preferably at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1:8, and

the molar ratio of urea to total formaldehyde is preferably at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1:8, of the molar ratio of melamine to total formaldehyde.

In the most preferred embodiment of the present invention, the resin composition included in the coated article has the following molar ratio:

-the molar ratio of phenol to total formaldehyde is from 1:10 to 1:15,

-the molar ratio of melamine to total formaldehyde is from 1:4 to 1:8, and

-urea to total formaldehyde molar ratio from 1:3 to 1: 8.

Thus, in a preferred embodiment of the present invention, there is provided a coated article comprising a support material, preferably paper, and a resin composition, wherein the resin composition comprises a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin, wherein the resin composition has:

-the molar ratio of phenol to total formaldehyde is at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1:13,

-a molar ratio of melamine to total formaldehyde of at least 1:1, preferably at least 1:2, most preferably at least 1:3, and

-the molar ratio of urea to total formaldehyde is at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1: 4.

In another preferred embodiment of the present invention, there is provided a coated article comprising a support material, preferably paper, and a resin composition, wherein the resin composition comprises a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin, wherein the resin composition has:

-the molar ratio of phenol to total formaldehyde is at most 1 to 30, more preferably at most 1:25, most preferably at most 1:20, most preferably at most 1:15,

-a molar ratio of melamine to total formaldehyde of at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1:8, and

-the molar ratio of urea to total formaldehyde is at most 1:20, more preferably at most 1:15, most preferably at most 1:10, most preferably at most 1:8, of the maximum molar ratio of melamine to total formaldehyde.

In a more preferred embodiment of the present invention, there is provided a coated article comprising a support material, preferably paper, and a resin composition, wherein the resin composition comprises a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin, wherein the resin composition has:

-the molar ratio of phenol to total formaldehyde is from 1:10 to 1:15,

-the molar ratio of melamine to total formaldehyde is from 1:4 to 1:8, and

-the molar ratio of urea to total formaldehyde is from 1:3 to 1: 8.

In another aspect of the invention, there is provided a template obtainable by applying the above-defined coated article onto a wood board.

The resin composition included in the coated article of the present invention optionally includes additives. Preferred additives are selected from the group consisting of inorganic or organic fillers, dyes, pigments, thickeners, lubricants, defoamers, dispersants, leveling agents, photosensitizers, flame retardants, brighteners, polymerization inhibitors, mold release agents and thixotropic agents. These additives may be used alone or in combination as required.

The additive may also be selected from waxes, oils, fats, fatty acids, alkanes, alkenes and derivatives and mixtures thereof. Preferred additives are selected from the group consisting of silicone oils, paraffin waxes, stearin, stearic acid, ketene dimer (AKD), Alkenyl Succinic Anhydride (ASA), tall oil fatty acids, petroleum pitch, asphalt, and mixtures thereof.

Specific additives present in the first resin composition include paraffin wax, ketene dimer (AKD), petroleum pitch, asphalt, or mixtures thereof. Most preferred is AKD.

In one embodiment of the invention, an alcohol is added to the resin composition to increase the shelf life of the resin composition and/or coated article and/or to increase the permeability of the resin composition to the carrier material. The term "alcohol" as defined in the context of the present invention includes aromatic alcohols and alkyl alcohols, mono-, di-, tri-and polyhydric alcohols and oligomeric or polymeric alcohols. In a preferred embodiment, an alkyl alcohol such as methanol, ethanol or phenoxyethanol is used, preferably phenoxyethanol.

The coated article of the present invention may be produced by a process comprising the steps of:

a) providing a carrier material, and forming a support material,

b) applying to the carrier material a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin,

c) optionally curing the resin composition.

Alternatively, the coated article of the present invention may be produced by a process comprising the steps of:

a) providing a carrier material, and forming a support material,

b) applying to the carrier material a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin,

c) optionally curing the resin composition.

Subsequently, a resin composition is obtained wherein the degree of crosslinking is less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80%.

In another embodiment of the present invention, the coated article of the present invention may be produced by a process comprising the steps of:

a) providing a carrier material, and forming a support material,

b) applying to the carrier material a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin,

c) optionally curing the resin composition.

A resin composition is then obtained wherein the total residual volatile content of the coated article is at least 3 wt%, preferably at least 4 wt%, more preferably at least 5 wt%, and most preferably at least 7 wt%.

The application of the resin composition to the support material may preferably be carried out by at least partially impregnating the support material in the resin composition. In a preferred embodiment, the application of the resin composition to the carrier material is carried out by immersing the carrier material in a bath comprising such a resin composition. In another embodiment, the resin composition is added dropwise to the support material. In another embodiment, the resin composition is sprayed onto the support material.

The support material can be coated with the resin composition on one or both sides, preferably on both sides.

The resin composition advantageously penetrates at least partially into the support material. Thus, the coated support material is preferably at least partially saturated with the resin composition. Optionally, the resin composition may be reapplied. The administration is preferably repeated at least once. Thus, in a preferred aspect of the invention, the process for producing the coated article is at least a two-step process.

If the process for producing the coated article of the present invention is a two-step process, the resin composition applied in the first coating step (hereinafter also referred to as "first resin composition") may be the same as or different from the resin composition applied in the second step (hereinafter also referred to as "second resin composition").

Preferably, the first and second resin compositions are different. Preferably they differ only by the additive. In a most preferred embodiment, the first resin composition contains no or at least less additives than the second resin composition. The first resin composition may be used to fill the core of the carrier material. The first composition preferably contains no or only small amounts of additives. Additives are generally required in the second resin composition at least partially covering the top of the carrier material. Thus, the two-step coating process allows for the reduction of additives in the first resin composition without loss of quality due to the presence of additives in the second resin composition. In this way, the production cost can be reduced while maintaining high quality.

Thus, in a preferred embodiment, the carrier material is immersed in a bath comprising a first resin composition and in a second step is immersed in a second resin composition. The second application step may be carried out immediately after the first application step, i.e. without a drying step. This "wet-wet" mode of application is preferred. But intermediate drying steps may also be performed. This may be, for example, drying to a solvent content of 15% at room temperature. Drying can be carried out, for example, with infrared light or at elevated temperature.

In another preferred aspect of the present invention, there is provided a method for producing a coated article, in particular a formwork for a concrete formwork, comprising the steps of:

a) providing a support material, preferably paper

b) Applying a first resin composition to a support material,

c) applying a second resin composition to the support material,

d) optionally partially curing the first and second resin compositions.

This method forms a coated article comprising the B-stage resin composition.

This process is preferably a wet-wet process. The resulting coated article may then be applied to a wood board. After being attached to the wood board, for example, by hot pressing, the resin composition of the coated article is completely cured.

In one embodiment of the present invention, it is preferred that the coated article is further coated with a resin (e.g., a binder resin) on only one side. Such adhesive coatings may be used to bond the coated article to a wood board.

"adhesive" in the sense of the present invention means any viscous substance and refers to molecular forces present in the contact area between two different objects, which act to bring them into permanent contact or bonding. The adhesive may include a variety of component materials such as elastomers, resins or tackifiers, fillers, plasticizers and softeners, antioxidants, curing agents, chelating agents, biocides.

In another aspect, the present invention relates to a coated article for attachment to wood products to provide a coated wood product, preferably a form for a concrete form.

According to the present invention, the term "wood product" generally refers to any product formed from a material comprising a wood base. Most preferred are wood based veneers and wood based panels. Wood based panels include wood, plywood, particle board, fiber board, Oriented Strand Board (OSB), plywood, Laminated Veneer Lumber (LVL), laminated lath lumber (PSL), Oriented Strand Lumber (OSL), three-ply board, and the like.

The wood based panel is preferably selected from: wood, plywood, particle board, sandwich board, fibre board, Oriented Strand Board (OSB), plywood, veneer laminated lumber (LVL), lath laminated lumber (PSL), oriented strand laminated lumber (OSL), three-layer board, preferably plywood or sandwich board, in particular spruce, birch or willow plywood.

The coated wood products or wood based panels can be applied in the wood processing industry, in particular for the production of concrete formworks.

Detailed Description

The coated articles of the present invention are described by the following descriptive data and examples, which should not be construed as limiting the scope of protection.

Examples

Example 1: the resin compositions and coated articles of the present invention were prepared and compared for free formaldehyde emission to coated articles comprising a phenolic resin composition

1.1 target

The objective was to evaluate and compare the formaldehyde emission of the coated articles of the present invention comprising resin composition a with the coated articles comprising the phenolic resin composition (composition B).

1.2 test setup

Resin compositions a and B were prepared and used to prepare coated articles.

Composition a is a resin composition comprising a mixture of melamine-formaldehyde, urea-formaldehyde and phenol-formaldehyde. Such a resin composition is described, for example, in US 2005/0136276.

Reference composition B is a standard phenolic resin known in the art, with a ratio of phenol to formaldehyde of 1: 1.5.

Preparation of test matrix:

by impregnating different weights (40 g/m) with resin compositions A or B²、60g/m²Or 80g/m²) The paper of (3) is prepared as a coated article. The coating step is carried out by dipping the paper in a bath.

A coated article comprising composition a or B was prepared by immersing paper in a resin bath and then wet paper in a second resin bath. The coated articles of the invention comprise only composition a, whereas the reference coated articles comprise only phenolic resin (composition B). After the resin composition is applied, the paper is dried.

Free formaldehyde emission test:

free formaldehyde emission test the free formaldehyde emission test was conducted to determine the amount of free formaldehyde emitted relative to a film comprising resin composition a or B of the blank starting material, based on VDA 275.

As a blank, a PET bottle containing only water was part of the measurement.

1.3 results

Table 1 gives the results of the free formaldehyde emission test:

table 1: free formaldehyde emission test results

This test shows that the coated article comprising composition a (according to the invention) has a lower free formaldehyde emission than the coated article comprising composition B (comparative).

Example 2: testing of surface Properties of the coated articles of the invention

2.1 target

The aim was to evaluate and compare three different types of coated articles, coated with resin composition a (invention) or with a known phenolic resin (composition B as described above).

2.2 test setup

The following tests were conducted to determine and show the surface properties of the coated articles of the present invention.

The coated article was prepared as described in example 1. In order to evaluate the surface properties of wood products formed by laminating different wood bases with the coated product according to the invention, the coated product was laminated to the wood base by hot pressing.

The following sections list the pressing conditions and further specifications of the wood base:

cracking test:

to determine the risk of cracking of the coated articles of the invention, the three-ply boards were laminated under different test conditions, notched with a suitable template and dried under fixed test conditions.

After cooling, the cracking (number of cracks, length of cracks) was evaluated.

COBB testing:

the water permeability of the article surface is determined by the amount of water absorbed (i.e., the COBB value) by the test sample surface.

The coated article was pressed on both sides of a three-ply board and cut into a square of 12.5X12.5 cm. After three weeks of storage of the samples in the air conditioned room, the COBB values were determined as follows:

the initial weight of the sample was measured and recorded, and then the sample was stressed in a COBB instrument. The measuring cylinder of the instrument is filled with deionized water. After 7 days, the samples were dried, weighed and the final weight recorded. The COBB value was calculated from the difference between the initial weight and the final weight.

2.3 test results

Cracking test:

the cracking test results are given in table 2 below:

table 2: results of cracking test

Hot pressing: 130 ℃ and 1.8N/mm²

As shown in table 2, the test results show that: the coated article of the invention (composition a) showed comparable results to the prior art phenolic resin composition (composition B). Regardless of the wood product, pressing time or paper weight used in the test, a satisfactory crack index was obtained in all cases.

COBB testing:

the results of the COBB test are shown in table 4 below:

table 4: results of the COBB test

Hot pressing: 130 ℃ and 1.8N/mm²

Evaluation of the COBB test results clearly shows that the water permeability of the articles according to the invention comprising composition a (according to the invention) gives excellent results compared to the articles comprising composition B (reference).

Example 3 residual volatiles testing of coated articles of the invention

Determination of residual volatiles

3.1 target

The residual volatiles of the coated article were determined under fixed drying conditions. The basic test method can be described in DIN EN ISO 287.

3.2 test setup

The coated article was cut to 20x25 cm. Immediately after sample preparation, the weight was determined with a precision balance (maximum tolerance of 0.05%). The initial weight was recorded.

The prepared sample was placed in a ventilated drying oven at 170. + -. 2 ℃ for 2 minutes. After cooling to room temperature, the dry weight was determined.

3.3 evaluation

The volatile content was determined as follows:

volatiles content (%) — (initial weight-final weight) x 100/initial weight.

The average was determined and recorded as residual volatile content.

Example 4 flowability testing of resin compositions in coated articles of the invention

Fluidity test

4.1 target

To quantify the fluidity after drying, the coated article was pressed under a flow press at a predetermined temperature for a predetermined time.

4.2 test setup

The coated article was cut into cube samples of 10x10 cm. After sample preparation, the initial weight was determined. The prepared samples were placed between two squeeze plates (15x15cm) under standard flow extrusion at room temperature (25 ℃). The sample was set at 2.0N/mm²And extruded at 160 ℃ for two minutes, and the resulting weight (final weight) thereof was measured after extrusion.

4.3 evaluation

Flowability can be measured by measuring the percent weight change before and after extrusion and is calculated as follows: flow (%) — (initial weight-final weight) x 100/initial weight.

Preferred embodiments

Embodiment 1:

a coated article comprising:

a) a support material, preferably paper, and

b) resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin, wherein the resin composition is a B-stage resin composition.

Embodiment 2:

a coated article comprising:

a) a support material, preferably paper, and

b) resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin, wherein the resin composition is characterized in that it has a degree of crosslinking of less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80%.

Embodiment 3:

a coated article comprising:

a) a support material, preferably paper, and

b) resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin, wherein the resin composition is characterized by a total residual volatile content of at least 3 wt%, preferably at least 4 wt%, more preferably 5 wt%, most preferably at least 7 wt%.

Embodiment 4:

the coated article of embodiments 1 or 2, wherein the resin composition is characterized by a total residual volatile content of at least 3 weight percent, preferably at least 4 weight percent, more preferably 5 weight percent, and most preferably at least 7 weight percent.

Embodiment 5:

the coated article of embodiments 1 or 3 wherein the resin composition is characterized by a degree of crosslinking of less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80%.

Embodiment 6:

the coated article of any of the preceding embodiments, wherein the coated article has a total residual volatile content of less than 20 wt.%, preferably less than 15 wt.%, more preferably less than 10 wt.%, most preferably from 3 to 15 wt.%, and particularly from 3 to 10 wt.%.

Embodiment 7:

the coated article of any of the preceding embodiments, wherein when at 160 ℃ and 2,0N/mm²After 2min of down-pressing, the resin composition has a flow of at least 1%, preferably at least 2%, at least 3% or most preferably at least 5%.

Embodiment 8:

the coated article of any of the preceding embodiments, wherein the article comprises greater than 50 wt% resin, preferably at least 55 wt% resin, most preferably at least 60 wt% resin, based on the weight of the dry coated article.

Embodiment 9:

the coated article of any of the preceding embodiments, wherein the resin composition is obtainable by compounding at least the following components:

a) melamine, urea, phenol and formaldehyde; or

b) Melamine-formaldehyde (MF) -resins, urea-formaldehyde (UF) -resins and phenol-formaldehyde (PF) -resins.

Embodiment 10:

the coated article of any of the preceding embodiments, wherein the article has a 7-day COBB value of 300g/m²Or less, preferably 250g/m²Or less, more preferably 200g/m²Or lower.

Embodiment 11:

the coated article of any of the preceding embodiments, wherein the resin composition has a molar ratio of phenol to total formaldehyde of at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1: 13.

Embodiment 12:

the coated article of any of the preceding embodiments, wherein the resin composition has a molar ratio of melamine to total formaldehyde of at least 1:1, preferably at least 1:2, most preferably at least 1: 3.

Embodiment 13:

the coated article of any of the preceding embodiments, wherein the resin composition has a molar ratio of urea to total formaldehyde of at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1: 4.

Embodiment 14:

the coated article of any of the preceding embodiments, wherein less than 40 wt.%, more preferably less than 35 wt.%, even more preferably less than 30 wt.% and most preferably less than 20 wt.% of the coating composition penetrates the material to be coated.

Embodiment 15:

the coated article of any of the preceding embodiments, wherein the support material comprises a further resin composition, and the further resin composition is different from the resin composition of embodiment 1 b).

Embodiment 16:

the coated article of any of the preceding embodiments, wherein the total weight of the article is at least 80 to 300g/m²Preferably at least 100 to 270g/m²More preferably at least 115 to 240g/m²Most preferably 120-220g/m²。

Embodiment 17:

the coated article of any of the preceding embodiments, wherein the resin composition comprises additional condensation ingredients selected from the group consisting of: diols, diamides, sulfonamides, thioureas, lactams, sugars, guanamines, preferably caprolactam, acetoguanamine, benzoguanamine, dicyandiamide or p-toluene-sulfonamide.

Embodiment 18:

the coated article of any of the preceding embodiments, wherein the resin composition comprises a base, preferably a metal hydroxide, more preferably an alkali metal hydroxide, most preferably sodium hydroxide or potassium hydroxide.

Embodiment 19:

the coated article of any of the preceding embodiments, wherein the weight per square meter of the support material is from 20 to 100g/m²Preferably 30 to 90g/m²Most preferably 40 to 80g/m²。

Embodiment 20:

the coated article of any of the preceding embodiments, wherein the article is further coated with a resin, such as an adhesive resin.

Embodiment 21:

a wood product obtainable from the coated article of any of the preceding embodiments 1-20.

Embodiment 22:

the wood product of embodiment 21, wherein said wood product is selected from the group consisting of wood based panels or wood based veneers, more preferably wood based panels.

Embodiment 23:

the wood product of any one of the preceding embodiments 21 or 22, wherein the wood-based panel is selected from the group consisting of wood, plywood, particle board, sandwich panel, fiberboard, Oriented Strand Board (OSB), plywood, Laminated Veneer Lumber (LVL), laminated plank lumber (PSL), Oriented Strand Lumber (OSL), three-layer board, preferably plywood or a sandwich panel, in particular spruce, birch, or willow plywood.

Embodiment 24:

a method for preparing a coated article, in particular a formwork for a concrete formwork, comprising the steps of:

a) providing a carrier material, and forming a support material,

b) applying to the carrier material a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin,

c) optionally followed by curing the resin composition to provide a B-staged resin composition.

Embodiment 25:

a method for preparing a coated article, in particular a formwork for a concrete formwork, comprising the steps of:

a) providing a carrier material, and forming a support material,

b) applying to the carrier material a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin,

c) optionally followed by curing the resin composition to obtain a resin composition wherein the degree of crosslinking is less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80%.

Embodiment 26:

a method for preparing a coated article, in particular a formwork for a concrete formwork, comprising the steps of:

a) providing a carrier material, and forming a support material,

b) applying to the carrier material a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin,

c) optionally followed by curing the resin composition to obtain a resin composition,

wherein the total residual volatile content of the coated article is at least 3 wt%, preferably at least 4 wt%, more preferably at least 5 wt%, and most preferably at least 7 wt%.

Embodiment 27:

the method of making a coated article of any of the preceding embodiments 24-26, comprising the steps of:

a) the supply of the paper is carried out,

b) applying a first resin composition to the paper,

c) applying a second resin composition to the paper,

d) optionally followed by curing the first and second resin compositions to obtain the first and second resin compositions of the B-stage.

Embodiment 28:

the method of making any of the preceding embodiments 24, 25 or 27, wherein the total content of residual volatiles in the coated article is at least 3 wt%, preferably at least 5 wt%, and most preferably at least 7 wt%.

Embodiment 29:

use of the coated article of any of the preceding embodiments 1-20 to make a wood product of any of the preceding embodiments 21-23.

Embodiment 30:

use of the coated article of any of the preceding embodiments 1-20 to prepare a form for a concrete form.

Very preferred embodiments

1. A coated article comprising:

a) a support material, preferably paper, and

b) resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin, wherein the resin composition has:

-the molar ratio of phenol to total formaldehyde is at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1:13,

-a molar ratio of melamine to total formaldehyde of at least 1:1, preferably at least 1:2, most preferably at least 1:3, and

-the molar ratio of urea to total formaldehyde is at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1: 4.

2. The coated article of embodiment 1, wherein the resin composition is a B-stage resin composition.

3. The coated article of embodiment 1 or 2, wherein the resin composition has:

-the molar ratio of phenol to total formaldehyde is at most 1:30, preferably at most 1:25, most preferably at most 1:20,

-a molar ratio of melamine to total formaldehyde of at most 1:20, preferably at most 1:15, most preferably at most 1:10, and

-the molar ratio of urea to total formaldehyde is at most 1:20, preferably at most 1:15, most preferably at most 1: 10.

4. The coated article of any of the preceding embodiments, wherein the resin composition is characterized by a degree of crosslinking of less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80%.

5. The coated article of any of the preceding embodiments, wherein the resin composition is characterized by a total residual volatile content of at least 3 weight percent, preferably at least 4 weight percent, more preferably at least 5 weight percent, and most preferably at least 7 weight percent.

6. The coated article of any of the preceding embodiments, wherein the article comprises greater than 50 wt% resin, preferably at least 55 wt% resin, most preferably at least 60 wt% resin, based on the weight of the dry coated article.

7. The coated article of any of the preceding embodiments, wherein the resin composition is obtainable by compounding at least the following components:

a) melamine, urea, phenol and formaldehyde; or

b) MF-resins, UF-resins and PF-resins.

8. The coated article of any of the preceding embodiments, wherein the article has a 7-day COBB value of 300g/m²Or less, preferably 250g/m²Or less, more preferably 200g/m²Or lower.

9. The coated article of any of the preceding embodiments, wherein the support material comprises a further resin composition, and the further resin composition is different from the resin composition of embodiments 1b), 2 or 3.

10. The coated article of any of the preceding embodiments, wherein the resin composition comprises a base, preferably a metal hydroxide, more preferably an alkali metal hydroxide, most preferably sodium hydroxide or potassium hydroxide.

11. A wood product, in particular a formwork, obtainable by applying a coated article according to any of embodiments 1 to 10 to a wood board.

12. A method for preparing a coated article, in particular a formwork for a concrete formwork, comprising the steps of:

a) providing a carrier material, preferably paper,

b) applying onto the support material a resin composition comprising a melamine-urea-phenol-formaldehyde-co-condensate and/or a mixture of melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin,

c) the resin composition is subsequently cured to give a resin composition having a degree of crosslinking of less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80%.

13. A method for preparing a coated article, in particular a formwork for a concrete formwork, comprising the steps of:

a) the supply of the paper is carried out,

b) a first resin composition is applied to the paper,

c) applying a second resin composition to the paper, wherein the first resin composition is different from the second resin composition,

a) the first and second resin compositions are subsequently cured to provide a B-staged resin composition.

14. A method for preparing a coated article, in particular a formwork for a concrete formwork, comprising the steps of:

a) the supply of the paper is carried out,

b) a first resin composition is applied to the paper,

c) applying a second resin composition to the paper, wherein the first resin composition is different from the second resin composition,

d) the first and second resin compositions are subsequently cured to give a resin composition having a degree of crosslinking of less than 100%, preferably less than 95%, more preferably less than 90%, most preferably less than 80%.

15. Use of the coated article of any of the preceding embodiments 1-10 to make a wood product.

16. The wood product of embodiment 11, particularly a formwork, wherein said coated product is applied to a wood board by hot pressing.

17. A formwork panel obtainable by applying onto a wood board a coated article comprising a support material, preferably paper, and a resin composition comprising a mixture of melamine-urea-phenol-formaldehyde-co-condensate and/or melamine-formaldehyde (MF) -resin, urea-formaldehyde (UF) -resin and phenol-formaldehyde (PF) -resin.

18. A template comprising wood, preferably spruce, birch and/or willow, and a coated carrier material, preferably paper, comprising at least one resin composition, wherein the resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives.

19. A template comprising wood, preferably spruce, birch and/or willow, and a coated carrier material, preferably paper, comprising at least two different resin compositions, wherein each resin composition comprises phenol, melamine, urea, formaldehyde and optionally additives.

20. The template of embodiment 18 or 19, wherein at least one resin composition has:

-the molar ratio of phenol to total formaldehyde is at least 1:5, preferably at least 1:8, more preferably at least 1:10, most preferably at least 1:13,

-a molar ratio of melamine to total formaldehyde of at least 1:1, preferably at least 1:2, most preferably at least 1:3, and

-the molar ratio of urea to total formaldehyde is at least 1:1, preferably at least 1:2, more preferably at least 1:3, most preferably at least 1: 4.

21. The template of embodiment 18, 19 or 20, wherein at least one resin composition has:

-the molar ratio of phenol to total formaldehyde is at most 1:30, preferably at most 1:25, most preferably at most 1:20,

-a molar ratio of melamine to total formaldehyde of at most 1:20, preferably at most 1:15, most preferably at most 1:10, and

-the molar ratio of urea to total formaldehyde is at most 1:20, preferably at most 1:15, most preferably at most 1: 10.

22. The template of any one of embodiments 18-21, wherein at least one resin composition has:

-the molar ratio of phenol to total formaldehyde is from 1:10 to 1:15,

-the molar ratio of melamine to total formaldehyde is from 1:4 to 1:8, and

-the molar ratio of urea to total formaldehyde is from 1:3 to 1: 8.

23. The form of any one of embodiments 18-22 for a concrete form.