Non-combustible high pressure laminate

Abstract

A high pressure laminate includes a first layer of resin impregnated paper and at least one layer of fiber reinforced veil. Each layer of fiber reinforced veil includes binder and filler. The laminate is characterized by having a caloric value of lower than 3.0 MJ/kg when tested in accordance with ISO 1716. A method for producing this high pressure laminate is also provided.

1 . A high pressure laminate, comprising: 
 a first layer of resin impregnated paper; and    at least one layer of fiber reinforced veil, each layer of fiber reinforced veil being impregnated with a secondary binder and at least one filler;    said high pressure laminate being characterized by having a caloric value of lower than about 3.0 MJ/kg when tested in accordance with ISO 1716.    
   
   
       2 . The laminate of  claim 1  including a second layer of resin impregnated paper, said at least one layer of fiber reinforced veil being sandwiched between said first and second layers of resin impregnated paper.  
   
   
       3 . The laminate of  claim 1 , wherein said secondary binder is a heat curable resin.  
   
   
       4 . The laminate of  claim 3  wherein said secondary binder is selected from a group consisting of melamine-formaldehyde, phenol-formaldehyde, urea-formaldehyde, epoxy resin, unsaturated polyesters, cross-linkable acrylic resin, polyurethane resin, an epichlorohydrin-polyaminopolyamide resin, an epichlorohydrin-polyamine resin, an epichlorohydrin-polyamide resin and mixtures thereof.  
   
   
       5 . The laminate of  claim 3 , wherein said filler is selected from a group consisting of metal hydroxides, metal carbonates, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite, feldspar, mica, nepheline syenite, pyrophyllite, silica, talc, wollastonite, montmorillonite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminum oxide, iron oxide, magnesium hydroxide, glass micro beads and mixtures thereof.  
   
   
       6 . The laminate of  claim 1 , wherein said filler is selected from a group consisting of metal hydroxides, metal carbonates and mixtures thereof.  
   
   
       7 . The laminate of  claim 6 , wherein said mixtures of metal hydroxides to metal carbonates are provided at a ratio of between about 1:0.01 and about 1:100.  
   
   
       8 . The laminate of  claim 1 , wherein said filler is selected from a mixture of calcium carbonate and aluminum hydroxide.  
   
   
       9 . The laminate of  claim 8  wherein said secondary binder is melamine-formaldehyde.  
   
   
       10 . The laminate of  claim 9 , wherein each said layer of fiber reinforced veil following impregnation includes between about 1 and about 95 weight percent reinforcement fibers, about 2 and about 50 weight percent melamine-formaldehyde, between about 1 and about 85 weight percent calcium carbonate and about 1 and about 85 weight percent aluminum hydroxide.  
   
   
       11 . The laminate of  claim 10  wherein each said layer of fiber reinforced veil following impregnation and prior to pressing has a weight per unit area of between about 250 g/m 2  and about 2000 g/m 2  and a density of between about 500 kg/m 3  and about 2000 kg/m 3 .  
   
   
       12 . The laminate of  claim 10 , wherein said reinforcement fibers are glass fibers selected from a group consisting of E-glass, ECR-glass, AR-glass, M-glass, D-glass, C-glass, S-glass, S2-glass and mixtures thereof.  
   
   
       13 . The laminate of  claim 1  wherein said at least one layer of fiber reinforced veil is woven.  
   
   
       14 . The laminate of  claim 1 , wherein said at least one layer of fiber reinforced veil is nonwoven.  
   
   
       15 . The laminate of  claim 1 , including at least two layers of fiber reinforced veil wherein a first layer of said two layers is woven and a second layer of said two layers is nonwoven.  
   
   
       16 . The laminate of  claim 1 , wherein said at least one fiber reinforced veil includes reinforcing fibers selected from a group consisting of glass fibers, basalt fibers, inorganic fibers and mixtures thereof.  
   
   
       17 . The laminate of  claim 1 , wherein said at least one fiber reinforced veil includes chopped glass fibers  
   
   
       18 . The laminate of  claim 17 , wherein said chopped glass fibers include chopped glass strands, chopped glass rovings, individual chopped glass fibers and mixtures thereof.  
   
   
       19 . The laminate of  claim 1 , wherein said first layer of resin impregnated paper is a melamine impregnated decor paper.  
   
   
       20 . The laminate of  claim 1 , further including a radiation cured paint film on an exposed face of said first layer of resin impregnated paper.  
   
   
       21 . The laminate of  claim 1 , further including a thermally cross-linked urethane acrylate paint layer on an exposed face of said first layer of resin impregnated paper.  
   
   
       22 . A fiber reinforced veil comprising a secondary binder and at least one filler; wherein said veil has a caloric value of lower than about 3.0 MJ/kg when tested in accordance with ISO 1716.  
   
   
       23 . The fiber reinforced veil of  claim 22 , wherein said secondary binder is selected from the group consisting of melamine-formaldehyde, phenol-formaldehyde, urea-formaldehyde, epoxy resin, unsaturated polyesters, cross-linkable acrylic resin, polyurethane resin, an epichlorohydrin-polyaminopolyamide resin, an epichlorohydrin-polyamine resin, an epichlorohydrin-polyamide resin and mixtures thereof.  
   
   
       24 . The fiber reinforced veil of  claim 22 , further comprising a binder selected from the group consisting of polyvinyl alcohol, (partially hydrolyzed) polyvinyl acetate, acrylic polymers and copolymers, crosslinkable acrylic polymers and copolymers, polymerizable polyfunctional N-methylol compounds, notably N-methylol ureas such as dimethylol urea and N-methylol melamine type resins, melamine formaldehyde, phenol formaldehyde, furfuryl formaldehyde, resorcinol formaldehyde, styrene butadiene copolymer latices, cationic polyamideepichlorohydrin, aminoresins, epoxyresins, polystyrene emulsion binder, polycarboxylic acid based binders, other latices and/or acrylic polymers or copolymers like acrylamide, ethylene vinyl acetate/vinyl chloride, alkyl acrylate polymer,styrene-butadiene rubber, acrylonitrile polymer, polyurethane resins, polyvinyl chloride, polyvinylidene chloride, copolymers of vinylidene chloride with other monomers, polyvinyl acetate, polyvinyl pyrrolidone, polyester resins, acrylate emulsion resin, and styrene acrylate.  
   
   
       25 . The fiber reinforced veil of  claim 22 , wherein said filler is selected from a group consisting of metal hydroxides, metal carbonates, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite, feldspar, mica, nepheline syenite, pyrophyllite, silica, talc, wollastonite, montmorillonite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminum oxide, iron oxide, magnesium hydroxide, glass micro beads and mixtures thereof.  
   
   
       26 . The fiber reinforced veil of  claim 22 , wherein said fiber reinforced veil includes reinforcing fibers selected from a group consisting of glass fibers, basalt fibers, inorganic fibers and mixtures thereof.  
   
   
       27 . A method of making a high pressure laminate, comprising: 
 pressing a first layer of resin impregnated paper and at least one layer of fiber reinforced veil together at a pressure and temperature sufficient to laminate said paper and said at least one layer of veil together; and    impregnating said paper and said fiber reinforcing veil with a secondary binder and at least one filler to provide a caloric value of lower than 3.0 MJ/kg when said laminate is tested in accordance with ISO 1716.    
   
   
       28 . The method of  claim 27  wherein said step of pressing said paper and said veil together further includes pressing said paper and said veil together at a pressure of between about 525 N/N/m 2  and about 15,750 N/m 2  and simultaneously heating said paper and said veil at a temperature of between about 120 degrees C. and about 220 degrees C.  
   
   
       29 . The method of  claim 27  including selecting said secondary binder from a group consisting of melamine-formaldehyde, phenol-formaldehyde, urea-formaldehyde, epoxy resin, unsaturated polyesters, cross-linkable acrylic resin, polyurethane resin, an epichlorohydrin-polyaminopolyamide resin, an epichlorohydrin-polyamine resin, an epichlorohydrin-polyamide resin and mixtures thereof.  
   
   
       30 . The method of  claim 29 , including selecting said filler from a group consisting of metal hydroxides, metal carbonates, titanium dioxide, calcined clay, barium sulfate, magnesium sulfate, aluminum sulfate, zinc oxide, kaolin clay, chlorite, diatomite, feldspar, mica, nepheline syenite, pyrophyllite, silica, talc, wollastonite, montmorillonite, hectorite, saponite, calcium carbonate, magnesium carbonate, aluminum oxide, iron oxide, magnesium hydroxide, glass micro beads and mixtures thereof.  
   
   
       31 . The method of  claim 29 , including selecting said filler from a group consisting of metal hydroxides, metal carbonates and mixtures thereof.  
   
   
       32 . The method of  claim 29 , including selecting said filler from a mixture of calcium carbonate and aluminum hydroxide.  
   
   
       33 . The method of  claim 27 , including selecting said filler from a group consisting of metal hydroxides, metal carbonates and mixtures thereof.  
   
   
       34 . The method of  claim 27 , including selecting said filler from a mixture of calcium carbonate and aluminum hydroxide.  
   
   
       35 . The method of  claim 27 , further including forming said first layer of resin impregnated paper from melamine impregnated decor paper.  
   
   
       36 . The method of  claim 27 , further including painting an exposed face of said first layer of resin impregnated paper with radiation cured paint.  
   
   
       37 . The method of  claim 27  further including painting an exposed face of said first layer of resin impregnated paper with a thermally crosslinked urethane acrylate paint.