Multilayer composite body

Abstract

The invention relates to a multilayer composite body comprising at least: a cover layer, a decorative layer, a mineral layer, and a barrier layer, wherein a first barrier layer is connected to the at least one mineral layer via at least one connecting layer; the connecting layer has a viscosity of approximately 1,700 to 2,500 mPas, measured using a Brookfield viscometer at 20°C according to DIN ISO 2555: 2018-09; the decorative layer comprises pigments and / or dyes, optionally light stabilizers; the mineral layer has a linear expansion coefficient of approximately 7.5 to 8.5 x 10-6 K-1, measured at 23°C according to ISO 11359-2: 2021-11; at least one support element is provided between the first barrier layer and the second barrier layer; the first barrier layer and the second barrier layer are bonded to the support element without an additional connecting layer; the support element fixed to the first barrier layer and to the second barrier layer has a linear expansion coefficient of approximately 8 to 9 x 10-6 K-1, measured at 23°C according to ISO 11359-2: 2021-11; the at least one mineral layer is situated at a distance to the support element via at least one first barrier layer; and the multilayer composite body has a total thickness of approximately10 to 30 mm, preferably12 to 25 mm, particularly preferably16 to 20 mm.

Description

[0001] REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 / 1 dr.schie

[0002] Multilayer composite body

[0003] The invention relates to a multilayer composite body comprising at least: a top layer, a decorative layer, a mineral layer and a barrier layer according to the preamble of claim 1.

[0004] Such multi-layered composite materials are used, for example, in the furniture industry as furniture fronts or furniture doors.

[0005] Such a multilayer composite body is disclosed, for example, in EP 3074227B1. This multilayer composite body, comprising a first composite panel with a top layer, an intermediate layer, and a bottom layer; a second composite panel with a first layer, a second layer, and a third layer of polymeric materials; and a support element arranged between the first and second composite panels via at least one bonding layer, has proven particularly successful in the furniture industry. This multilayer composite body is constructed such that the first composite panel is classically constructed or manufactured on the front side of the support element, which is made of a wood-based material or wood substitute, in an equivalent manner to the second composite panel, while the second composite panel is arranged on the back side and is usually referred to as the so-called counter-layer.

[0006] In the state of the art, multi-layered composite bodies, in particular furniture panels made of wood-based materials or wood substitute materials, such as MDF panels or HDF panels, are used, the surfaces of which are coated with decorative layers in the form of, for example, polymeric films.

[0007] Here too, the structure of the multi-layered composite bodies is designed such that identical polymeric films, designed as decorative layers, are arranged on the front and back of the support element, which is designed as a furniture panel, as a so-called counter-layer.

[0008] Using such decorative layers, it is possible to depict different optics or...

[0009] Possible structures such as wood grain, stone textures, etc. REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0010] It is at least visually possible to create the impression of, for example, a stone structure, although this lacks the corresponding feel or roughness.

[0011] However, there is a desire to design such multi-layered composite bodies in such a way that they truly correspond to the corresponding structures in terms of appearance and feel.

[0012] German patent DE10340238 B4 discloses a coating process for a substrate made of wood or a wood substitute material. In the first step, a filler compound is applied to the substrate. In the next step, an airtight film containing air and / or air bubbles is laid on top of the filler compound and pressed down. The film, the filler compound (including air bubbles), and the substrate are then compressed, creating a textured surface. Afterward, the film is removed, and the filler compound is allowed to dry. This process is intended to create surface textures, depending on the filler compound used, that closely mimic, for example, natural stone surfaces or concrete.In particular, the surfaces have a natural texture, which is likely due to the use of the airtight film, as air pockets remain in the filler during the pressing process and bursting bubbles create an uneven surface that looks very natural.

[0013] However, particularly in the case of multi-layered composite bodies with mineral coatings, for example also formed as fillers or ceramic or stone surfaces, very complex solutions are required, since the different materials result in different thermal or chemical effects, which require that such mineral coatings be arranged on both the front and the back, as a so-called counter-layer, of the support elements.

[0014] A disadvantage of this state of the art is that it results in very expensive multi-layered composite bodies, requiring an equivalent, symmetrical structure of layers on both the front and back, leading to high costs and complicated processing dependencies. REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0015] Another disadvantage of such multilayer composite bodies from the prior art is that, particularly with mineral coatings or real materials such as stone, concrete or ceramics, there are major challenges in the production of such multilayer composite bodies as well as in their mechanical processing, which on the one hand increase the duration or costs of production and on the other hand require processing techniques that are not yet common in the furniture industry, for example.

[0016] This is where the invention comes in, which has set itself the task of overcoming the disadvantages of the prior art and demonstrating a multi-layered composite body that is easy and cost-effective to manufacture, that is available for use especially in furniture construction with a wide variety of decors and textures, and that can be manufactured without the so-called counter-layer that is otherwise necessary in the prior art.

[0017] According to the invention, this problem is solved by the features of claim 1; further advantageous embodiments are described in the dependent claims.

[0018] It has surprisingly been found that a multilayer composite body comprising at least: a top layer, a decorative layer, a mineral layer, and a barrier layer, wherein a first barrier layer is connected to the at least one mineral layer via at least one bonding layer, wherein the bonding layer has a viscosity of approximately 1,700 to 2,500 mPas, measured with a Brookfield viscometer at 20 °C according to DIN ISO 2555:2018-09, wherein the decorative layer contains pigments and / or dyes, optionally a light stabilizer, and wherein the mineral layer has a coefficient of linear expansion of approximately 7.5 to 8.5 x 10⁻⁶. 6 K' 1measured at 23 °C according to ISO 11359-2:2021-11, comprising at least one support element arranged between the first barrier layer and the second barrier layer, wherein the first barrier layer and the second barrier layer are bonded to the support element without an additional bonding layer, and that the support element fixed to the first barrier layer and the second barrier layer has a coefficient of linear expansion of approximately 8 to 9 x 10⁻⁶ 6 K' 1 measured at 23°C according to ISO 11359-2:2021-11, the at least one mineral layer is spaced apart from the support element via at least one first barrier layer, and the multilayer composite body has a total thickness of approximately 10 to 30 mm, preferably 12 to 25 mm. REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0019] This multi-layer composite material, preferably with a thickness of 16 to 20 mm, solves this problem. It can be processed using a mineral filler in a manner typical of the furniture industry, and even with thicker structures, which are particularly necessary for imitating real materials such as stone, concrete, or ceramic, no equivalent mineral coating is required on the reverse side. Thus, the expensive, symmetrical structure known from the prior art, especially the so-called counter-layer, is no longer necessary for the first time. Furthermore, this multi-layer composite material is designed to ensure sufficient adhesion between the different materials. Another advantage of the multi-layer composite material is its cost-optimized layer structure.

[0020] A further advantage of the multi-layered composite material is that it allows for a wide variety of surface finishes and designs. This is because the asymmetrical structure on the front side enables the application of varying weights and larger quantities of mineral filler, which would be problematic as a counter-layer on the back. Another advantage of the multi-layered composite material is its significantly reduced weight. Furthermore, its lower density and lower hardness compared to natural materials like stone, concrete, or ceramic offer more advantages in terms of wear resistance and cost-effective processing.

[0021] Another advantage of the multi-layered composite material is that the top layer is arranged at a distance from at least one decorative layer and at least one mineral layer. This advantageously compensates for any color differences in the mineral layer.

[0022] Furthermore, the multilayer composite body is designed such that the top layer has a thickness of approximately 5 to 50 pm, preferably 10 to 35 pm.

[0023] The decorative layer of the multilayer composite body has a thickness of approximately 0.05 to 0.2 pm, preferably 0.05 to 0.1 pm.

[0024] The mineral layer of the multilayer composite body has a thickness of approximately 0.3 to 3 mm, preferably 0.3 to 2 mm.

[0025] The bonding layer of the multilayer composite body has a thickness of approximately 5 to 45 pm, preferably 5 to 35 pm. REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0026] The barrier layer of the multilayer composite body has a thickness of 50 to 150 pm, preferably 60 to 120 pm.

[0027] The support element of the multilayer composite body has a thickness of approximately 10 to 50 mm, preferably approximately 12 to 30 mm.

[0028] The multi-layered composite body is further designed such that the top layer is applied with an application rate of approximately 10 to 25 g / m². 2 , preferably 12 to 20 g / m² 2 is upset.

[0029] The decorative layer of the multilayer composite body is applied at a rate of approximately 5 to 50 g / m². 2 , preferably 10 to 40 g / m² 2 upset.

[0030] The bonding layer of the multilayer composite body is applied with a quantity of approximately 5 to 30 g / m². 2 on, preferably 10 to 20 g / m² 2 upset.

[0031] The multi-layered composite body is further designed in such a way that the top layer is formed as a lacquer layer, for example as a UV-curable lacquer.

[0032] The decorative layer of the multilayer composite body is designed as a color layer, printing layer, foil, and the like.

[0033] The bonding layer of the multilayer composite body is designed as an adhesion promoter layer, primer layer, and the like.

[0034] A further advantage of the multilayer composite is that the material of the functional layer incorporates an adhesion promoter system, preferably in the form of aqueous dispersions or solutions in organic solvents of binder resins, which are selected in particular from the group consisting of polyurethanes, polyesters, acrylates, methyl methacrylates, epoxy resins, ethylene vinyl acetates, polyvinyl acetates, polyvinylidenes, natural rubber, as well as mixtures of two or more of the aforementioned binder groups. This can be used with or without the addition of crosslinking / activator components, e.g., based on polyisocyanates, amines, or peroxides.

[0035] It is also advantageous if the top surface of the multilayer composite body has a different surface roughness according to DIN EN ISO 25178-2:2023-09.

[0036] Surface roughness, as defined by the invention, is characterized by a sequence of peaks and valleys with varying heights, depths, and spacing on the surfaces. REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0037] Surface roughness is defined as the shorter frequency of the actual surfaces in relation to the valleys.

[0038] DIN EN ISO 25178-2:2023-09 contains a collection of international standards regarding the analysis of surface roughness, in particular two measurement methods: contact measuring method (with probe) and non-contact measuring method (with optical probe).

[0039] This dual approach solves problems that were previously encountered with the profile method, namely the fluctuation of measurement results depending on the measuring side and the scanning device.

[0040] The multi-layered composite body is further designed such that the mineral layer and / or the decorative layer and / or the top layer have a surface roughness S a (mean arithmetic height) of approximately 10 pm to 250 pm, preferably 15 pm to 200 pm, particularly preferably 20 to 150 pm according to DIN EN ISO 25178-2:2023-09. This can be very well characterized by the measured value S a , the so-called mean arithmetic height.

[0041] This parameter is an extension of the line roughness parameter R. a (arithmetic mean) of the surface. This is the magnitude of the height difference at each point compared to the arithmetic mean of the surface. This parameter is generally used to assess surface roughness.

[0042] Furthermore, the multi-layered composite body is designed such that the mineral layer and / or the decorative layer and / or the top layer has a surface roughness S P c (arithmetic mean of the specific curvature) from about 1.0 1 / mm to

[0043] 401 / mm, preferably 1.51 / mm to 351 / mm, particularly preferably 1.5 to 301 / mm according to DIN EN ISO 25178-2:2023-09. This can be assessed using the characteristic value S. pc , the arithmetic mean of the specific curvature.

[0044] This parameter represents the arithmetic mean of the principal curvature of the peaks on the surface. A small value means that the contact points with other objects have a rounded shape. A larger value means that the contact points with other objects are pointed.

[0045] It is also advantageous that the multilayer composite body has a gloss level of maximum 10, preferably maximum 6, on its surface, measured at a measuring angle of 60°, according to DIN EN ISOREHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0046] 2813:2015 - 02. This makes it possible to offer very different textures with different designs.

[0047] The multilayer composite body is further designed such that, after lightfastness testing according to DIN EN ISO 4892-2:2021-11, Method B, Cycle B2, Blue Scale Level 6 according to EN ISO 105_B02:1999, 4.1.1, it exhibits a gray scale color fastness rating of at least 4, preferably at least 4 to 5 according to DIN EN 20105-A02:1994. This ensures that, when the multilayer composite body is used as intended, for example in the furniture industry, the appearance and feel are maintained over a very long service life.

[0048] In a further advantageous embodiment of the multilayer composite body, it is designed such that the mineral layer and / or the decorative layer and / or the top layer has at least one opening / at least one void. This makes it possible to produce multilayer composite bodies that are both visually and haptically similar to real material surfaces such as stone, concrete, or ceramic.

[0049] Furthermore, the multilayer composite body is advantageously designed such that the mineral layer has a thickness of approximately 0.2 to 3.0 mm, preferably approximately 0.3 to 2.5 mm, and particularly preferably approximately 0.5 to 2 mm. This leads, on the one hand, to an economical and cost-effective production of the multilayer composite body and, on the other hand, to the possibility of producing virtually all optical and haptic properties, while simultaneously maintaining a low weight of the multilayer composite body.

[0050] It is also advantageous that the multilayer composite body contains at least the following components:

[0051] 30 to 90 wt.% inorganic fillers,

[0052] 10 to 30 wt% aqueous polymer dispersion based on acrylate

[0053] 10 to 30 wt. % water

[0054] 1 to 10 wt. % finely divided additives.

[0055] By selecting the components and varying their weighting within the mineral layer, economical and cost-effective production is achievable, while at the same time a wide variety of appearances and textures can be produced. REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0056] Furthermore, it proved advantageous that the mineral layer of the multi-layered composite material has a hardness of approximately 3 to 4 on the Moos scale. This means, among other things, that when using the multi-layered composite material, for example in the furniture industry, processing is less prone to wear and is more cost-effective with existing processing technologies and machinery.

[0057] Furthermore, the multilayer composite body is designed such that at least one barrier layer is a resin-impregnated layer with a paper basis weight of approximately 80 to 120 g / m². 2 .

[0058] For example, at least one barrier layer is designed as a paper layer impregnated with melamine resin with a paper basis weight of approximately 80 to 120 g / m². 2 .

[0059] This advantageous structure enables fast, cost-effective and economical production of the multilayer composite body, as it allows for effective separation between the mineral layer and the support element.

[0060] The multilayer composite body is also designed such that the top layer comprises at least one acrylic polymer and has a transmittance of at least 80% for visible light across its thickness, measured according to ISO 13468-2. This ensures that the appearance and feel, particularly those defined by the mineral layer, are visible and tangible in the finished, multilayer composite body.

[0061] It has also proven advantageous for the multilayer composite body that the ratio of the thickness of the mineral layer to the thickness of the support element is approximately 4 to 40, preferably approximately 5 to 35. This makes it possible to produce multilayer composite bodies in both small and large dimensions (length, width) with an appealing appearance and optimized feel, and which can therefore be manufactured economically and cost-effectively.

[0062] The multilayer composite body is further designed such that the support element is made of wood, wood-based materials, wood substitutes, polymeric materials, metallic materials, ceramic materials, glass, paper, and the like. Due to the different materials of the support element, multilayer REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0063] Composite bodies can be manufactured both economically and cost-effectively and can be adapted to a wide variety of optical and haptic requirements, especially in furniture manufacturing.

[0064] It has also proven advantageous for the multilayer composite body to have at least one profile element arranged on at least one narrow surface. This makes it possible, on the one hand, to conceal or protect the different structures of the multilayer composite body, particularly on the narrow surface, and on the other hand, to achieve a visual or tactile effect.

[0065] The multilayer composite body is further designed such that the profile element and / or the multilayer composite body has at least one chamfer on at least one narrow side. This advantageous design of the profile element and / or the multilayer composite body allows for an additional visual or tactile effect.

[0066] The multilayer composite body will now be described in more detail using exemplary embodiments which do not limit the invention.

[0067] It shows:

[0068] Fig. 1: Perspective view of a multi-layered composite body;

[0069] Fig. 2: Perspective view of another multilayer composite body.

[0070] Fig. 1 shows a perspective view of a multilayer composite body 10.

[0071] The multilayer composite body 10 comprises at least: a top layer 1, a decorative layer 2, a mineral layer 3, and a barrier layer 5, 7, wherein a first barrier layer 5 is connected to the at least one mineral layer 3 via at least one bonding layer 4, wherein the bonding layer 4 has a viscosity of approximately 1,700 to 2,500 mPas, measured with a Brookfield viscometer at 20 °C according to DIN ISO 2555:2018-09, wherein the decorative layer 2 comprises pigments and / or dyes, optionally a light stabilizer, wherein the mineral layer 3 REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0072] a coefficient of linear expansion of approximately 7.5 to 8.5 x 10 -6 K -1measured at 23 °C according to ISO 11359-2:2021-11, comprising at least one support element 6 arranged between the first barrier layer 5 and the second barrier layer 7, wherein the first barrier layer 5 and the second barrier layer 7 are bonded to the support element 6 in a material-bonded manner without an additional bonding layer, and wherein the support element 6 fixed to the first barrier layer 5 and the second barrier layer 7 has a coefficient of linear expansion of approximately 8 to 9 x 10 -6 K -1measured at 23°C according to ISO 11359-2:2021-11, the at least one mineral layer 3 is spaced apart from the support element 6 via at least one first barrier layer 5, and the multilayer composite body 10 has a total thickness of about 10 to 30 mm, preferably 12 to 25 mm, particularly preferably 16 to 20 mm. In this embodiment, the multilayer composite body 10 is designed such that it comprises at least: a top layer 1, a decorative layer 2, a mineral layer 3, and a barrier layer 5, 7, wherein a first barrier layer 5 is connected to the at least one mineral layer 3 via at least one bonding layer 4, wherein the bonding layer 4 has a viscosity of approximately 2,000 mPas, measured with a Brookfield viscometer at 20 °C according to DIN ISO 2555:2018-09, wherein the decorative layer 2 optionally contains pigments and / or dyes.has a light-protective agent, with the mineral layer 3 having a coefficient of linear expansion of approximately 8 x 10. -6 K -1 measured at 23 °C according to ISO 11359-2:2021-11, comprising at least one support element 6 arranged between the first barrier layer 5 and the second barrier layer 7, wherein the first barrier layer 5 and the second barrier layer 7 are bonded to the support element 6 in a material-bonded manner without an additional bonding layer, and wherein the support element 6 fixed to the first barrier layer 5 and the second barrier layer 7 has a coefficient of linear expansion of approximately 8.5 x 10 -6 K -1 measured at 23°C according to ISO 11359-2:2021-11, the at least one mineral layer 3 is spaced apart from the support element 6 via at least one first barrier layer 5, and the multilayer composite body 10 has a total thickness of approximately 19 mm.

[0073] Furthermore, the multilayer composite body 10 is designed such that the top layer 1 has a thickness of about 5 to 50 pm, preferably 10 to 35 pm.

[0074] The decorative layer 2 of the multilayer composite body 10 has a thickness of approximately 0.05 to 0.2 pm, preferably 0.05 to 0.1 pm. The mineral layer 3 of the multilayer composite body 10 has a thickness of approximately 0.3 to 3 mm, preferably REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0075] The bonding layer of the multilayer composite body has a thickness of approximately 5 to 45 pm, preferably 5 to 35 pm, 0.3 to 2 mm.

[0076] The barrier layer of the multilayer composite body has a thickness of 50 to 150 pm, preferably 60 to 120 pm.

[0077] The support element 6 of the multilayer composite body 10 has a thickness of approximately 10 to 50 mm, preferably approximately 12 to 30 mm.

[0078] In this embodiment, the multilayer composite body 10 is configured such that the top layer 1 has a thickness of approximately 25 pm. The decorative layer 2 of the multilayer composite body 10 has a thickness of approximately 0.05 pm. The mineral layer 3 of the multilayer composite body 10 has a thickness of approximately 0.8 mm. The bonding layer 4 of the multilayer composite body 10 has a thickness of approximately 25 pm. The barrier layer 5,7 of the multilayer composite body 10 has a thickness of approximately 80 pm. The support element 6 of the multilayer composite body 10 has a thickness of approximately 18 mm.

[0079] The multi-layered composite body is further designed such that the top layer is applied with an application rate of approximately 10 to 25 g / m². 2 , preferably 12 to 20 g / m² 2 is upset.

[0080] The decorative layer of the multilayer composite body is applied at a rate of approximately 5 to 50 g / m². 2, preferably 10 to 40 g / m² 2 The bonding layer of the multilayer composite body is applied with an application rate of approximately 5 to 30 g / m². 2 on, preferably 10 to 20 g / m² 2 upset.

[0081] Furthermore, the multilayer composite body 10 is designed such that the top layer 1 is arranged at a distance from the at least one mineral layer 3 via at least one decorative layer 2.

[0082] Furthermore, the multilayer composite body 10 is designed such that the mineral layer 3 and / or the decorative layer 2 and / or the top layer 1 have a surface roughness S a (mean arithmetic height) of approximately 10 pm to 250 pm, preferably 15 pm to 200 pm, particularly preferably 20 to 150 pm according to DIN EN ISO 25178-2:2023-09. REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0083] The multilayer composite body 10 is further designed such that the mineral layer 3 and / or the decorative layer 2 and / or the top layer 1 have a surface roughness S pc (arithmetic mean of the specific curvature) of about 1.0 1 / mm to 401 / mm, preferably 1.51 / mm to 35 1 / mm, particularly preferably 1.5 to 301 / mm according to DIN EN ISO 25178-2:2023-09.

[0084] Furthermore, the multilayer composite body 10 is designed such that the mineral layer 3 and / or the decorative layer 2 and / or the cover layer 1 has at least one opening / at least one void 20.

[0085] In this embodiment, the multilayer composite body 10 is designed such that the mineral layer 3, the decorative layer 2, and the top layer 1 have at least one opening / at least one void 20.

[0086] The opening / void 20 has an irregular geometry.

[0087] The opening / void 20 can have a depth of up to approximately 400 pm.

[0088] Furthermore, the multilayer composite body 10 is designed such that it has a gloss level of maximum 10, preferably maximum 6, on its surface, measured at a measuring angle of 60°, in accordance with DIN EN ISO 2813:2015 - 02.

[0089] In this embodiment, the multilayer composite body 10 is designed such that the multilayer composite body 10 has a gloss level of maximum 8 on its surface, measured at a measuring angle of 60°, according to DIN EN ISO 2813:2015-02.

[0090] Furthermore, the multilayer composite body 10 is designed such that the multilayer composite body 10 has a color fastness rating according to the gray scale of at least 4 (four), preferably at least 4 (four) to 5 (five) according to DIN EN 20105-A02:1994, in accordance with lightfastness according to DIN EN ISO 4892-2:2021- II, method B, cycle B2, blue scale level 6 according to EN ISO 105_B02:1999, 4.1.1.

[0091] In this embodiment, the multilayer composite body 10 is designed such that, according to lightfastness testing according to DIN EN ISO 4892-2:2021-11, Method B, Cycle B2, Blue Scale Level 6 according to EN ISO 105_B02:1999, 4.1.1, it exhibits a gray scale color fastness rating of at least 4.5 according to DIN EN 20105-A02:1994. REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Mark: 25.018 dr.schie

[0092] The multilayer composite body 10 is further configured such that the mineral layer 3 has a thickness of approximately 0.2 to 3.0 mm, preferably approximately 0.3 to 2.5 mm, and particularly preferably approximately 0.5 to 2 mm. In this embodiment, the multilayer composite body 10 is configured such that the mineral layer 3 has a thickness of approximately 0.8 mm.

[0093] Furthermore, the multilayer composite body 10 is designed such that the mineral layer 3 has at least the following components:

[0094] 30 to 90 wt.% inorganic fillers,

[0095] 10 to 30 wt% aqueous polymer dispersion based on acrylate

[0096] 10 to 30 wt. % water

[0097] 1 to 10 wt. % finely divided additives.

[0098] Furthermore, the multilayer composite body 10 is designed such that the mineral layer 3 has a hardness of approximately 3 to 4 according to the Moos scale. In this embodiment, the multilayer composite body 10 is designed such that the mineral layer 3 has a hardness of approximately 3.5 according to the Moos scale.

[0099] In a further advantageous embodiment, the multilayer composite body 10 is designed such that the at least one barrier layer 5,7 is a resin-impregnated layer with a paper basis weight of approximately 80 to 120 g / m². 2 .

[0100] In this embodiment, the multilayer composite body 10 is designed such that the at least one barrier layer 5,7 is a layer impregnated with phenolic resin, with a paper basis weight of approximately 100 g / m². 2 .

[0101] The multilayer composite body 10 is further designed such that the top layer 1 comprises at least one acrylic polymer and has a transmittance of at least 80% over its thickness for visible light as measured according to ISO 13468-2.

[0102] In this embodiment, the multilayer composite body 10 is designed such that the top layer 1 comprises at least one acrylic polymer and has a transmittance of approximately 85% for visible light across its thickness, measured according to ISO 13468-2. REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0103] Furthermore, the multilayer composite body 10 is designed such that the ratio of the thickness of the mineral layer 3 to the thickness of the support element 6 is approximately 4 to 40, preferably approximately 5 to 35.

[0104] In this embodiment, the multilayer composite body 10 is designed such that the ratio of the thickness of the mineral layer 3 to the thickness of the support element 6 is approximately 22.5.

[0105] The multilayer composite body 10 is further configured such that the support element 6 is made of wood, wood-based materials, wood substitutes, polymeric materials, metallic materials, ceramic materials, glass, paper, and the like. In this embodiment, the multilayer composite body 10 is configured such that the support element 6 is made of wood-based materials.

[0106] Furthermore, the multilayer composite body 10 is designed such that at least one profile element 8 is arranged on at least one narrow surface 11 of the multilayer composite body 10.

[0107] In this embodiment, the multi-layered composite body 10 is designed such that a profile element 8 is arranged on the left narrow surface 11 and on the rear narrow surface 11.

[0108] Furthermore, the multilayer composite body 10 is designed such that the profile element 8 and / or the multilayer composite body 10 has at least one chamfer 12 on at least one narrow side 9,11.

[0109] In this embodiment, the multilayer composite body 10 is designed such that the profile element 8 has a chamfer 12 on two of its narrow sides 9.

[0110] Furthermore, the multilayer composite body 10 is designed such that the chamfer 12 on the two narrow sides 9 of the profile element 8 is formed at an angle of approximately 45°.

[0111] Fig. 2 shows a perspective view of another multilayer composite body 10.

[0112] The multilayer composite body 10 comprises at least: a top layer 1, a decorative layer 2, a mineral layer 3, and a barrier layer 5, 7, wherein REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0113] The first barrier layer 5 is connected to the at least one mineral layer 3 via at least one bonding layer 4, wherein the bonding layer 4 has a viscosity of approximately 1,700 to 2,500 mPas, measured with a Brookfield viscometer at 20 °C according to DIN ISO 2555:2018-09, wherein the decorative layer 2 comprises pigments and / or dyes and optionally light stabilizers, and wherein the mineral layer 3 has a coefficient of linear expansion of approximately 7.5 to 8.5 x 10 -6 K -1measured at 23 °C according to ISO 11359-2:2021-11, comprising at least one support element 6 arranged between the first barrier layer 5 and the second barrier layer 7, wherein the first barrier layer 5 and the second barrier layer 7 are bonded to the support element 6 in a material-bonded manner without an additional bonding layer, and wherein the support element 6 fixed to the first barrier layer 5 and the second barrier layer 7 has a coefficient of linear expansion of approximately 8 to 9 x 10⁻⁶ 6 K' 1measured at 23°C according to ISO 11359-2:2021-11, the at least one mineral layer 3 is spaced apart from the support element 6 via at least one first barrier layer 5, and the multilayer composite body 10 has a total thickness of about 10 to 30 mm, preferably 12 to 25 mm, particularly preferably 16 to 20 mm. In this embodiment, the multilayer composite body 10 is designed as follows: it comprises at least: a top layer 1, a decorative layer 2, a mineral layer 3, and a barrier layer 5, 7, wherein a first barrier layer 5 is connected to the at least one mineral layer 3 via at least one bonding layer 4, wherein the bonding layer 4 has a viscosity of approximately 1,900 mPas, measured with a Brookfield viscometer at 20 °C according to DIN ISO 2555:2018-09, and wherein the decorative layer 2 optionally contains pigments and / or dyes.has a light-protective agent, with the mineral layer 3 having a coefficient of linear expansion of approximately 7.8 x 10. -6 K -1 measured at 23 °C according to ISO 11359-2:2021-11, comprising at least one support element 6 arranged between the first barrier layer 5 and the second barrier layer 7, wherein the first barrier layer 5 and the second barrier layer 7 are bonded to the support element 6 without an additional bonding layer, and wherein the support element 6 fixed to the first barrier layer 5 and the second barrier layer 7 has a coefficient of linear expansion of approximately 8 x 10' 6 K' 1 measured at 23°C according to ISO 11359-2:2021-11, the at least one mineral layer 3 is spaced apart from the support element 6 via at least one first barrier layer 5, and the multilayer composite body 10 has a total thickness of approximately 19 mm. REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0114] Furthermore, the multilayer composite body 10 is designed such that the top layer 1 has a thickness of about 5 to 50 pm, preferably 10 to 35 pm.

[0115] The decorative layer 2 of the multilayer composite body 10 has a thickness of about 0.05 to 0.2 pm, preferably 0.05 to 0.1 pm. The mineral layer 3 of the multilayer composite body 10 has a thickness of about 0.3 to 3 mm, preferably 0.3 to 2 mm. The bonding layer of the multilayer composite body has a thickness of about 5 to 45 pm, preferably 5 to 35 pm.

[0116] The barrier layer of the multilayer composite body has a thickness of 50 to 150 pm, preferably 60 to 120 pm.

[0117] The support element 6 of the multilayer composite body 10 has a thickness of approximately 10 to 50 mm, preferably approximately 12 to 30 mm.

[0118] In this embodiment, the multilayer composite body 10 is designed such that the top layer 1 has a thickness of approximately 20 pm.

[0119] The decorative layer 2 of the multilayer composite body 10 has a thickness of approximately 0.08 pm. The mineral layer 3 of the multilayer composite body 10 has a thickness of approximately 1.0 mm. The bonding layer 4 of the multilayer composite body 10 has a thickness of approximately 30 pm. The barrier layer 5,7 of the multilayer composite body 10 has a thickness of approximately 100 pm. The support element 6 of the multilayer composite body 10 has a thickness of approximately 20 mm.

[0120] The multi-layered composite body is further designed such that the top layer is applied with an application rate of approximately 10 to 25 g / m². 2 , preferably 12 to 20 g / m² 2 is upset.

[0121] The decorative layer of the multilayer composite body is applied at a rate of approximately 5 to 50 g / m². 2 , preferably 10 to 40 g / m² 2 upset.

[0122] The bonding layer of the multilayer composite body is applied with a quantity of approximately 5 to 30 g / m². 2 on, preferably 10 to 20 g / m² 2 upset.

[0123] Furthermore, the multilayer composite body 10 is designed such that the top layer 1 is spaced apart from the at least one mineral layer 3 via at least one decorative layer 2. REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0124] Furthermore, the multilayer composite body 10 is designed such that the mineral layer 3 and / or the decorative layer 2 and / or the top layer 1 have a surface roughness S a(mean arithmetic height) of approximately 10 pm to 250 pm, preferably 15 pm to 200 pm, particularly preferably 20 to 150 pm according to DIN EN ISO 25178-2:2023-09. In this embodiment, the multilayer composite body 10 is designed such that the mineral layer 3 and / or the decorative layer 2 and / or the top layer 1 have a surface roughness S a (mean arithmetic height) of approximately 100 pm according to DIN EN ISO 25178-2:2023-09.

[0125] The multilayer composite body 10 is further designed such that the mineral layer 3 and / or the decorative layer 2 and / or the top layer 1 have a surface roughness S pc(arithmetic mean of the specific curvature) of approximately 1.0 1 / mm to 401 / mm, preferably 1.51 / mm to 35 1 / mm, particularly preferably 1.5 to 301 / mm according to DIN EN ISO 25178-2:2023-09. In this embodiment, the multilayer composite body 10 is designed such that the mineral layer 3 and / or the decorative layer 2 and / or the top layer 1 have a surface roughness S pc (arithmetic mean of the specific curvature) of approximately 151 / mm according to DIN EN ISO 25178-2:2023-09.

[0126] Furthermore, the multilayer composite body 10 is designed such that it has a gloss level of maximum 10, preferably maximum 6, on its surface, measured at a measuring angle of 60°, in accordance with DIN EN ISO 2813:2015 - 02.

[0127] In this embodiment, the multilayer composite body 10 is designed such that the multilayer composite body 10 has a gloss level of maximum 5 on its surface, measured at a measuring angle of 60°, in accordance with DIN EN ISO 2813:2015-02.

[0128] Furthermore, the multilayer composite body 10 is designed such that the multilayer composite body 10 has a color fastness rating according to the gray scale of at least 4 (four), preferably at least 4 (four) to 5 (five) according to DIN EN 20105-A02:1994, in accordance with lightfastness according to DIN EN ISO 4892-2:2021- II, method B, cycle B2, blue scale level 6 according to EN ISO 105_B02:1999, 4.1.1.

[0129] In this embodiment, the multilayer composite body 10 is designed such that it meets the lightfastness requirements of DIN EN ISO 4892-2:2021-11, Method B, Cycle B2, Blue Scale Level 6. ENREHAU Industries SE & Co. KG Rehau, March 26, 2025. Int. Mark: 25.018 dr.schie

[0130] ISO 105_B02:1999, 4.1.1. has a grey scale colour fastness rating of at least 4.3 according to DIN EN 20105-A02:1994.

[0131] The multilayer composite body 10 is further configured such that the mineral layer 3 has a thickness of approximately 0.2 to 3.0 mm, preferably approximately 0.3 to 2.5 mm, and particularly preferably approximately 0.5 to 2 mm. In this embodiment, the multilayer composite body 10 is configured such that the mineral layer 3 has a thickness of approximately 1 mm.

[0132] Furthermore, the multilayer composite body 10 is designed such that the mineral layer 3 has at least the following components:

[0133] 30 to 90 wt.% inorganic fillers,

[0134] 10 to 30 wt% aqueous polymer dispersion based on acrylate

[0135] 10 to 30 wt. % water

[0136] 1 to 10 wt. % finely divided additives.

[0137] Furthermore, the multilayer composite body 10 is designed such that the mineral layer 3 has a hardness of approximately 3 to 4 according to the Moos scale. In this embodiment, the multilayer composite body 10 is designed such that the mineral layer 3 has a hardness of approximately 3.1 according to the Moos scale.

[0138] In a further advantageous embodiment, the multilayer composite body 10 is designed such that the at least one barrier layer 5,7 is a resin-impregnated layer with a paper basis weight of approximately 80 to 120 g / m². 2 In this embodiment, the multilayer composite body 10 is designed such that the at least one barrier layer 5,7 is a layer impregnated with melamine resin, with a paper basis weight of approximately 110 g / m². 2 .

[0139] The multilayer composite body 10 is further designed such that the top layer 1 comprises at least one acrylic polymer and has a transmittance of at least 80% over its thickness for visible light as measured according to ISO 13468-2.

[0140] In this embodiment, the multilayer composite body 10 is designed such that the top layer 1 comprises at least one acrylic polymer and is designed over its thickness for REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie

[0141] Visible light has a transmittance of approximately 90% as measured according to ISO 13468-2.

[0142] Furthermore, the multilayer composite body 10 is designed such that the ratio of the thickness of the mineral layer 3 to the thickness of the support element 6 is approximately 4 to 40, preferably approximately 5 to 35. In this embodiment, the multilayer composite body 10 is designed such that the ratio of the thickness of the mineral layer 3 to the thickness of the support element 6 is approximately 18.

[0143] The multilayer composite body 10 is further configured such that the support element 6 is made of wood, wood-based materials, wood substitutes, polymeric materials, metallic materials, ceramic materials, glass, paper, and the like. In this embodiment, the multilayer composite body 10 is configured such that the support element 6 is made of wood substitutes.

[0144] Furthermore, the multilayer composite body 10 is designed such that at least one profile element 8 is arranged on at least one narrow surface 11 of the multilayer composite body 10. In this embodiment, the multilayer composite body 10 is designed such that a profile element 8 is arranged on the left narrow surface 11.

[0145] Furthermore, the multilayer composite body 10 is designed such that the profile element 8 and / or the multilayer composite body 10 has at least one chamfer 12 on at least one narrow side 9, 11. In this embodiment, the multilayer composite body 10 is designed such that the profile element 8 has a chamfer 12 on each of two of its narrow sides 9. The narrow side 11 of the multilayer composite body 10 also has a chamfer 12.

[0146] Furthermore, the multilayer composite body 10 is designed such that the chamfer 12 is formed at an angle of approximately 45° on the two narrow sides 9 of the profile element 8 and on the narrow side 11 of the multilayer composite body 10.

[0147] Patent claims

Claims

REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 / 1 dr.schie Patent claims 1. Multilayer composite body (10) comprising at least: a top layer (1), a decorative layer (2), a mineral layer (3), and a barrier layer (5, 7), wherein a first barrier layer (5) is connected to the at least one mineral layer (3) via at least one bonding layer (4), wherein the bonding layer (4) has a viscosity of about 1,700 to 2,500 mPas, measured with a Brookfield viscometer at 20 °C according to DIN ISO 2555:2018-09, wherein the decorative layer (2) comprises pigments and / or dyes and optionally a light stabilizer, wherein the mineral layer (3) has a coefficient of linear expansion of about 7.5 to 8.5 x 10 -6 K -1measured at 23 °C according to ISO 11359-2:2021-11, comprising at least one support element (6) arranged between the first barrier layer (5) and the second barrier layer (7), wherein the first barrier layer (5) and the second barrier layer (7) are bonded to the support element (6) without an additional bonding layer, and wherein the support element (6) fixed to the first barrier layer (5) and the second barrier layer (7) has a coefficient of linear expansion of approximately 8 to 9 x 10 -6 K -1 measured at 23°C according to ISO 11359-2:2021-11, the at least one mineral layer (3) is spaced apart from the support element (6) via at least one first barrier layer (5), and the multilayer composite body (10) has a total thickness of about 10 to 30 mm, preferably 12 to 25 mm, particularly preferably 16 to 20 mm.

2. Multilayer composite body (10) according to claim 1, characterized in that the top layer (1) is arranged spaced apart from the at least one mineral layer (3) over at least one decorative layer (2).

3. Multilayer composite body (10) according to one of the preceding claims, characterized in that the mineral layer (3) and / or the decorative layer (2) and / or the top layer (1) has a surface roughness S a (mean arithmetic height) of approximately 10 pm to 250 pm, preferably 15 pm to 200 pm, particularly preferably 20 to 150 pm according to DIN EN ISO 25178-2:2023-09. REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie 4. Multilayer composite body (10) according to one of the preceding claims, characterized in that the mineral layer (3) and / or the decorative layer (2) and / or the top layer (1) has a surface roughness S pc(arithmetic mean of the specific curvature) from approximately 1.01 / mm to 401 / mm, preferably 1.51 / mm to 351 / mm, particularly preferably 1.5 to 301 / mm according to DIN EN ISO 25178-2:2023-09.

5. Multilayer composite body (10) according to one of the preceding claims, characterized in that the mineral layer (3) and / or the decorative layer (2) and / or the top layer (1) has at least one opening / at least one void (20).

6. Multilayer composite body (10) according to one of the preceding claims, characterized in that the multilayer composite body (10) has a gloss level of at most 10, preferably at most 6, on its surface, measured at a measuring angle of 60°, in accordance with DIN EN ISO 2813:2015 - 02.

7. Multilayer composite body (10) according to one of the preceding claims, characterized in that the multilayer composite body (10) has a color fastness rating according to the gray scale of at least 4 (four), preferably at least 4 (four) to 5 (five) according to DIN EN 20105-A02: 1994, according to lightfastness testing in accordance with DIN EN ISO 4892-2:2021-11, Method B, Cycle B2, Blue Scale Level 6 according to EN ISO 105_B02:1999, 4.1.

1.

8. Multilayer composite body (10) according to one of the preceding claims, characterized in that the mineral layer (3) has a thickness of about 0.2 to 3.0 mm, preferably about 0.3 to 2.5 mm, particularly preferably about 0.5 to 2 mm.

9. Multilayer composite body (10) according to one of the preceding claims, characterized in that the mineral layer (3) comprises at least the following components: • 30 to 90 wt.% inorganic fillers, • 10 to 30 wt% aqueous polymer dispersion based on acrylate • 10 to 30 wt. % water • 1 to 10 wt. % fine aggregates. REHAU Industries SE & Co. KG Rehau, March 26, 2025 Int. Ref: 25.018 dr.schie 10. Multilayer composite body (10) according to one of the preceding claims, characterized in that the mineral layer (3) has a hardness according to the Moos scale of about 3 to 4.

11. Multilayer composite body (10) according to one of the preceding claims, characterized in that the at least one barrier layer (5, 7) is a resin-impregnated layer with a paper basis weight of about 80 to 120 g / m² 2 .

12. Multilayer composite body (10) according to one of the preceding claims, characterized in that the top layer (1) comprises at least one acrylic polymer and has a transmittance of at least 80% over its thickness for visible light as measured according to ISO 13468-2.

13. Multilayer composite body (10) according to one of the preceding claims, characterized in that the ratio of the thickness of the mineral layer (3) to the thickness of the support element (6) is approximately 4 to 40, preferably approximately 5 to 35.

14. Multilayer composite body (10) according to one of the preceding claims, characterized in that the support element (6) is formed from wood, wood-based materials, wood substitutes, polymeric materials, metallic materials, ceramic materials, glass, paper and the like.

15. Multilayer composite body (10) according to one of the preceding claims, characterized in that at least one profile element (8) is arranged on at least one narrow surface (11) of the multilayer composite body (10).

16. Multilayer composite body (10) according to one of the preceding claims, characterized in that the profile element (8) and / or the multilayer composite body (10) has at least one chamfer (12) on at least one narrow side (9, 11).

Images