Method for manufacturing a laminate, an aminoplast resin catalyst used therein, and a laminate obtained thereby

1 . A method for manufacturing a laminate, comprising at least a carrier material and a cured aminoplast resin, wherein said method at least comprises:

the step of providing a carrier material;

the step of providing a resin mixture, at least comprising said aminoplast resin and capsules comprising a catalyst for curing said resin;

the step of assembling a stack at least comprising said carrier material and said resin mixture;

the step of curing said resin under application of heat and pressure,

wherein the capsules comprise a shell comprising melamine.

2 . The method in accordance with claim 1 , wherein said carrier material is a paper layer,

wherein said paper layer is impregnated with said resin mixture.

3 . The method in accordance with claim 1 , wherein said laminate further comprises a board material and/or one or more further carrier materials.

4 . The method in accordance with claim 1 , wherein said carrier material is a low ash content alpha-cellulose paper.

5 . The method in accordance with claim 1 , wherein said step of curing is performed at a pressure of 20 to 40 bars.

6 . The method in accordance with claim 1 , wherein said step of curing is performed at a temperature of 120° C. to 220° C.

7 . The method in accordance with claim 1 , wherein said step of curing is performed in a press that is provided with a structured mould.

8 . The method in accordance with claim 7 , wherein said structured mould comprises protrusions having a height larger than 0.4 mm.

9 . The method in accordance with claim 1 , wherein said catalyst is heptanoic acid,

wherein the capsules have a core shell ratio between 20-80 and 80-20.

10 . The method in accordance with claim 1 , wherein said catalyst is heptanoic acid,

wherein the capsules have an average diameter as expressed with a d50 particle size as determined by a laser light scattering granulometry technique (ISO EN 13320:2009), of below 40 μm.

11 . The method in accordance with claim 1 , wherein

said carrier material is a paper layer having a dry paper weight of 15 to 35 grams per square meter;

said resin mixture is provided by impregnating said carrier material;

said catalyst being hexanoic, heptanoic or octanoic acid and being present at a rate between 2 and 20 grams per square meter;

wherein said capsules have a core shell ratio between 50-50 to 80-20;

wherein said capsules having an average diameter as expressed with a d50 particle size as determined by a laser light scattering granulometry technique (ISO EN 13320:2009), of below 25 μm;

wherein said stack comprises at least a board material, a decorative paper layer possibly impregnated with thermosetting resin; and said carrier material impregnated with said resin mixture;

said step of curing is carried out in a short cycle press containing a structured press element, at a pressure of 20 bar or above, at a temperature of 185° C. or above.

12 . A method for impregnating a paper, wherein said paper is impregnated with a resin mixture at least comprising an aminoplast resin and capsules comprising a catalyst,

wherein said catalyst is heptanoic acid,

wherein the capsules have an average diameter as expressed with a d50 particle size as determined by a laser light scattering granulometry technique (ISO EN 13320:2009), of below 25 μm;

wherein said capsules are pressure-activatable and release said catalyst upon exerting pressure.

13 . A laminate obtained by the method of claim 1 .

14 . The method in accordance with claim 1 , wherein the catalyst is a pressure activatable catalyst.