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BR-112022000852-B1 - METHOD FOR MANUFACTURING LAMINATE, LAMINATE, CARRIER AND METHOD FOR MANUFACTURING THE CARRIER

BR112022000852B1BR 112022000852 B1BR112022000852 B1BR 112022000852B1BR-112022000852-B1

Abstract

METHOD FOR MANUFACTURING LAMINATE, LAMINATE, CARRIER AND METHOD FOR MANUFACTURING THE CARRIER. The invention relates to a laminate comprising a panel and a carrier made of a polyester derived from an aliphatic polyol with 2-15 carbon atoms and an aliphatic polycarboxylic acid with 3 to 15 carbon atoms, wherein the polyester has a polymerization extent determined by gravimetry of at least 0.6, in particular at least 0.7, more particularly at least 0.8, in some embodiments at least 0.9, wherein the carrier is present in the panel, wherein the carrier (which does not include the polyester) has a land weight of 5-200 g/m2 and the panel has a thickness of at least 0.2 mm. The invention also relates to a method for manufacturing the laminate, to the carrier used in this document and to the method for manufacturing the carrier. The method according to the invention allows the manufacture of high-quality laminates at high speed.

Inventors

  • WRIDZER JAN WILLEM BAKKER
  • HANS DANIEL KNEPPER

Assignees

  • PLANTICS HOLDING B.V

Dates

Publication Date
20260310
Application Date
20200716
Priority Date
20190802

Claims (15)

  1. 1. A laminate comprising a panel and a carrier containing a polyester derived from an aliphatic polyol with 2-15 carbon atoms and an aliphatic polycarboxylic acid with 3 to 15 carbon atoms, wherein the polyester has a polymerization extent determined by gravimetry of at least 0.6, the carrier being present in the panel, wherein the carrier (not including the polyester) has a land weight of 5-200 g/m2 and the panel has a thickness of at least 0.2 mm, characterized in that the total thickness of the carrier layers, not including the polymer, is less than 40% of the total thickness of the laminate, not including the polymer.
  2. 2. Laminate, according to claim 1, wherein the laminate is characterized by having a single panel provided on one or both faces with a carrier made of polyester.
  3. 3. Laminate, according to claim 1, wherein the laminate is characterized by comprising at least two panels with a carrier having a polyester sandwiched between the two panels, for example, 2-20 panels with a carrier having a polyester sandwiched between the panels, wherein optionally one of the two outer faces of the laminate is provided with a carrier having a polyester sandwich.
  4. 4. Laminate, according to any one of claims 1 to 3, characterized in that the total thickness of the carrier layers excluding the polymer is less than 30% of the total thickness of the laminate excluding the polymer.
  5. 5. Laminate, according to any one of claims 1 to 4, characterized in that the panel, or at least one of the panels, is of a material different from the carrier, or at least one of the carriers.
  6. 6. A laminate, according to any one of claims 1 to 5, characterized in that the polycarboxylic acid comprises at least 30% by weight of citric acid, calculated from the total amount of polyacid, and/or the polyol consists of at least 50% by mole of glycerol.
  7. 7. Method for manufacturing a laminate characterized by comprising a panel and a carrier containing a polyester, as defined in any one of claims 1 to 6, comprising the steps of: - providing a carrier containing a polyester derived from an aliphatic polyol with 2-15 carbon atoms and an aliphatic polycarboxylic acid with 3 to 15 carbon atoms, wherein the polyester has a polymerization extent, which is the ratio of the fraction of functional groups that have reacted to the maximum of those functional groups that can react, of at least 0.10, the carrier (not including the polyester) having a land weight of 5-200 g/m2, - applying said carrier to a panel to form a laminate of the panel and carrier, wherein said panel has a thickness of at least 0.2 mm, and - subjecting said panel and carrier laminate to a curing step, wherein the total thickness of the carrier layers, not including the polymer, is less than 40% of the total thickness of the laminate, not including the polymer.
  8. 8. Polyester-containing carrier suitable for use in the method defined in claim 7, characterized by comprising a carrier material and a polyester derived from an aliphatic polyol with 2-15 carbon atoms and an aliphatic polycarboxylic acid with 3 to 15 carbon atoms or monomer precursors thereof, wherein the polyester has a polymerization extent of at least 0.1, wherein the carrier, not including the polyester, has a land weight of 5-200 g/m2, wherein the total thickness of the carrier layers, not including the polymer, is less than 40% of the total thickness of the laminate, not including the polymer.
  9. 9. Polyester-lined carrier according to claim 8, characterized in that the polyester is present on both sides of the polyester-lined carrier, wherein the carrier comprises 2-70% by weight of the total carrier and polyester.
  10. 10. A carrier made of polyester, according to claim 8, characterized in that the polyester is present on one side of the carrier, while the other side of the carrier is free of polyester.
  11. 11. Method for manufacturing a polyester-containing carrier, as defined in any one of claims 8 to 10, characterized by comprising the steps of contacting a carrier material with a liquid medium comprising a polyester derived from an aliphatic polyol with 2-15 carbon atoms and an aliphatic polycarboxylic acid with 3 to 15 carbon atoms or monomer precursors thereof, to form a polyester-containing carrier or precursors thereof and optionally subjecting the polyester-containing carrier or precursors thereof to a curing step.
  12. 12. Method, according to claim 11, for manufacturing a polyester-containing carrier, characterized in that the carrier material is porous and the liquid medium is impregnated in the carrier material.
  13. 13. Method, according to claim 11 or 12, for manufacturing a polyester carrier, characterized in that the carrier material is flexible, i.e., it can be wound onto a tube with a diameter of 5 cm or less followed by unwinding without suffering damage.
  14. 14. A method, according to any one of claims 11 to 13, for manufacturing a polyester-containing carrier, characterized in that the polyester in the liquid medium applied to the carrier has a conversion range of between 0.1 and 0.6.
  15. 15. A method, according to any one of claims 11 to 14, for manufacturing a polyester-containing carrier, characterized in that the polyester-containing carrier or its precursors are subjected to a curing step to a polymerization extent of between 0.5 and 0.85.

Description

[001] The present invention relates to a method for manufacturing a laminate comprising a panel and a polymer layer, wherein the polymer layer is of a specific type of biopolymer. The invention also relates to laminates that can be obtained by the method according to the invention and to intermediate products suitable for use in the laminates and methods according to the invention. [002] Document WO2012/140238 describes a laminate comprising a panel and a polymer layer, wherein the polymer layer is applied over at least part of the panel, the polymer layer comprising a polyester derived from an aliphatic polyalcohol with 2-15 carbon atoms and a polyacid, the layer having a thickness in the range of 10-4000 microns, wherein the aliphatic polyalcohol contains at least 50 mol% glycerol and the polyacid contains at least 30 mol% tricarboxylic acid. The laminate is manufactured by a method in which a panel is given a coating layer of a composition comprising the polyester and the coated panel is held at a temperature of 20 to 200 °C for a period of 5 minutes to 5 days. In the examples, periods of 15 hours, three hours and two hours are used. In commercial operation, the manufacture of laminates occurs at very high speeds. It has been found that the method described above is difficult to perform at the high speeds applied commercially while still obtaining a good product. Another problem with the method described in document no. WO2012/140238 is that the liquid resin can sometimes cause stains on the surface layer, which is undesirable, especially in edge applications. Another issue is that when the method is used to bond the panels together, the adhesion strength is not always sufficient. [003] There is a need in the art for a method for manufacturing laminates using biopolyester described in document no. WO2012/140238, a method that allows the manufacture of high-quality laminates at high speed. [004] The present invention provides such a method. [005] The invention relates to a method for manufacturing a laminate comprising a panel and a polymer layer comprising the steps of [006] - to provide a carrier endowed with a polyester derived from a polyolaliphatic with 2-15 carbon atoms and an aliphatic polycarboxylic acid with 3 to 15 carbon atoms, wherein the polyester has a polymerization extent, which is the ratio of the fraction of functional groups that have reacted to the maximum of those functional groups that can react, of at least 0.10, the carrier having a land weight of 5-200 g/m2, [007] - apply said carrier to a panel, the panel having a thickness of at least 0.2 mm to form a laminate of the panel and the carrier, and [008] - subject the said panel and carrier laminate to a curing step. [009] The invention also relates to a laminate comprising a panel and a carrier provided with a polyester derived from an aliphatic polyol with 2-15 carbon atoms and an aliphatic polycarboxylic acid with 3 to 15 carbon atoms, wherein the polyester has a polymerization extent determined by gravimetry, of at least 0.6, in particular at least 0.7, more particularly at least 0.8, in some embodiments at least 0.9, wherein the carrier is present in the panel, wherein the carrier (which does not include the polyester) has a land weight of 5-200 g/m2 and the panel has a thickness of at least 0.2 mm. [010] The invention also relates to a polyester-containing carrier suitable for use in the method of this invention comprising a carrier material and a polyester derived from an aliphatic polyol with 2-15 carbon atoms and an aliphatic polycarboxylic acid with 3 to 15 carbon atoms or monomer precursors thereof, wherein the polyester has a polymerization extent of at least 0.1, in particular at least 0.20, and at most 0.95, in particular between 0.25 and 0.9, or between 0.5 and 0.85, wherein the carrier, which does not include the polyester, has a land weight of 5-200 g/m2. [011] The invention also relates to a method for manufacturing a polyester-supplied carrier according to the invention, comprising the steps of [012] place a carrier material, preferably in the form of a sheet or other, in contact with a liquid medium comprising a polyester derived from an aliphatic polyol with 2-15 carbon atoms and an aliphatic polycarboxylic acid with 3 to 15 carbon atoms or monomer precursors thereof, to form a carrier endowed with polyester or precursors thereof and optionally subject the carrier endowed with polyester or precursors thereof to a curing step. [013] The present invention is thus characterized by the use of a polyester carrier in the manufacture of the laminate. A key feature of the present invention is that the carrier has a land weight of 5-200 g/m2 (determined in the absence of polyester). The carrier is thus relatively thin and relatively lightweight. This allows the carrier to be, as the name indicates, a carrier for the polyester. On the other hand, the panel has a thickness of at least 0.2 mm, and can be much thicker dependi