EP2857221B1 - Panel with super-matt surface - Google Patents

Panel with super-matt surface Download PDF

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Publication number
EP2857221B1
EP2857221B1 EP13187605.4A EP13187605A EP2857221B1 EP 2857221 B1 EP2857221 B1 EP 2857221B1 EP 13187605 A EP13187605 A EP 13187605A EP 2857221 B1 EP2857221 B1 EP 2857221B1
Authority
EP
European Patent Office
Prior art keywords
layer
lacquer
panel
micro
creasing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP13187605.4A
Other languages
German (de)
French (fr)
Other versions
EP2857221A1 (en
Inventor
Thomas Grafenauer
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Flooring Technologies Ltd
Original Assignee
Flooring Technologies Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Flooring Technologies Ltd filed Critical Flooring Technologies Ltd
Priority to EP13187605.4A priority Critical patent/EP2857221B1/en
Priority to TR2018/11685T priority patent/TR201811685T4/en
Priority to PL13187605T priority patent/PL2857221T3/en
Publication of EP2857221A1 publication Critical patent/EP2857221A1/en
Application granted granted Critical
Publication of EP2857221B1 publication Critical patent/EP2857221B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00Processes for producing special ornamental bodies
    • B44C5/04Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0469Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
    • B44C5/0476Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper with abrasion resistant properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/02Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain a matt or rough surface
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/06Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44FSPECIAL DESIGNS OR PICTURES
    • B44F1/00Designs or pictures characterised by special or unusual light effects
    • B44F1/02Designs or pictures characterised by special or unusual light effects produced by reflected light, e.g. matt surfaces, lustrous surfaces
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/08Flooring or floor layers composed of a number of similar elements only of stone or stone-like material, e.g. ceramics, concrete; of glass or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass
    • E04F15/082Flooring or floor layers composed of a number of similar elements only of stone or stone-like material, e.g. ceramics, concrete; of glass or with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass in combination with a lower layer of other material
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00Flooring
    • E04F15/02Flooring or floor layers composed of a number of similar elements
    • E04F15/10Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/102Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of fibrous or chipped materials, e.g. bonded with synthetic resins
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/02Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
    • B05D3/0209Multistage baking
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/06Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
    • B05D3/061Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using U.V.
    • B05D3/065After-treatment
    • B05D3/067Curing or cross-linking the coating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/06Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
    • B05D3/068Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using ionising radiations (gamma, X, electrons)

Definitions

  • the invention relates to a method for producing a panel, in particular for a floor covering, as well as such a panel.
  • panels which are used in particular as a floor covering. These have a carrier plate which is provided on the top with a decor. The decor is preferably on a finish foil. The finish film is then again applied to the carrier plate, preferably laminated.
  • a finish film in this application is usually a resinated or glued paper. The print may have been applied to the film before or after the resin or glue application.
  • finish foils are used as they have good splitting resistance. Decorative support materials that do not have a cleavage strength are unsuitable for floor applications.
  • a seal is provided which, for example, consists of a paint system comprising one or more clearcoat films. In this case, in particular hardenable paints are used. These are cured by heat radiation techniques, UV radiation or electron beam radiation. Coating layers applied in this way usually lead to a more or less shiny surface.
  • lacquers are used in the prior art which have microparticles of different size and concentration and thus create a rough surface.
  • paints are unsatisfactory in terms of their visual appearance as well as their other property in terms of transparency, abrasion and scratch resistance, haptics, etc.
  • WO 2012/013364 A1 is a method for refining transparent plastic substrates, in particular polymethyl methacrylate (PMMA short), which is also known as Plexiglas described.
  • PMMA short polymethyl methacrylate
  • a so-called nanocomposite is proposed, the SiO x nanoparticles, at least one highly crosslinkable binder and contains at least one reactive diluent, wherein the applied nanocomposite lacquer is cured after application first with extremely short-wave UV light only at the surface and brought to the photochemical microfolding and the remainder of the lacquer is then cured with a second UV lamp with long-wave UV light.
  • the paints used in the prior art for floor panels, which give a matte visual impression are unsatisfactory in terms of their property combinations such as good transparency, high abrasion and scratch resistance, excellent chemical resistance and UV resistance, good workability and pleasant feel.
  • the invention is thus based on the technical object of providing an improved panel, in particular for a floor covering, and a method for the production thereof, which create a matted surface which mats an optimum optical surface impression and at the same time a high abrasion and scratch resistance, a good chemical resistance as well as a pleasant haptic in combination offer.
  • the invention is based on the idea of providing a panel which has a carrier plate on the top side of which a decoration is applied or applied.
  • the panel has a paint system of one or more paint layers.
  • a curable lacquer to irradiate it first with very high energy light, in particular with a wavelength so-called vacuum ultraviolet wavelength range, and thereby at least partially polymerize a very thin surface layer of the lacquer and thereby harden , Due to the high photon energy, the light penetrates only in a layer of about 100 nm thickness and triggers the curing. In this process, shrinkage processes occur in the uppermost lacquer layer, which lead to a so-called photochemical microfolding.
  • the topcoat layer On the surface of the outermost lacquer layer, which is also referred to as the topcoat layer, thus creating a microfill.
  • very short-wave UV light light in the ultraviolet Spectral region
  • a subsequent treatment with electron radiation for complete curing of the paint layers of the paint structure is performed.
  • very short-wave UV light is understood in particular light with wavelengths less than 200 nm. UV light with a wavelength less than 200 nm is also referred to as VUV light or VUV radiation, where VUV is the abbreviation for vacuum ultraviolet.
  • the surface Due to the complete curing of both the top coat layer and other paint layers of the paint structure due to electron beam curing is despite the superficial microstructuring before a completely closed paint layer structure, so that a good protection against pollution, moisture and other liquids.
  • the surface has a low tendency to make fingerprints, which result from a contact with the naked hand, in particular visible in a grazing light observation.
  • fingerprints which result from a contact with the naked hand, in particular visible in a grazing light observation.
  • there are no panels whose surface is greasy.
  • the surface shows little or no tendency for lightening in use. Overall, thus, a panel, especially for a floor covering created, which gives an excellent visual impression and also has very good mechanical properties in terms of chemical resistance, skid resistance and wear.
  • lacquers of the lacquer structure used are preferably all lacquers, which are clear and transparent in volume.
  • the invention provides a method for producing a panel, in particular for a floor covering, comprising the steps of providing a support plate, applying a decor to an upper side of the support plate, covering the decor with a lacquer structure which comprises one or more lacquer layers an outer topcoat layer of the paint system is first partially polymerized with very short-wavelength light, in particular light in the VUV wavelength range, so that a microfolding occurs, and then a complete polymerization and curing of the paint structure by means of electron beam curing is performed.
  • the VUV wavelength range includes UV light with a wavelength less than 200 nm.
  • a panel in particular for a floor covering, which comprises: a support plate which is provided on a top side with a decor, which is covered by a lacquer structure of one or more lacquer layers, wherein the lacquer structure comprises an outer top lacquer layer, which on its Outside has a microfolding.
  • the microfolding is formed by a photochemical reaction.
  • the topcoat layer is structured in addition to the microstructure to form structuring depressions (wood pores, knotholes in wood reproductions, veins in stone replicas, etc.), so that the structuring depressions divide at least one material layer of the topcoat layer, in which the microstructure is or will be trained.
  • a panel is obtained in which the at least one topcoat layer, in addition to the microstructure, has a deep structuring in the form of patterning recesses which divide at least one outer material layer of the topcoat layer in which the microstructure is formed.
  • Such a structuring in contrast to the surface structuring produced by the photochemical folding, is referred to here as deep structuring.
  • the structuring is accordingly called deep structuring.
  • the topcoat layer is applied and cured in such a way that a surface-closed, hardened material layer is formed on an inner side opposite the outside of the topcoat layer.
  • This ensures that a closed outer surface is formed, which has the high scratch resistance and abrasion resistance and moisture protection.
  • the partial polymerization with the very short-wavelength light, in particular the VUV light of an excimer laser, in particular a xenon excimer laser, is carried out so that a height of the micro-microfiltration is of the order of about 100 nm.
  • the micro-folding is created, on the one hand, the good slip resistance and on the other hand provides a very pleasant warm feel of the material.
  • the coating structure has, in addition to the outer topcoat layer, at least one further lacquer layer in the form of a basecoat layer for covering the decoration.
  • This is preferably formed with a corundum-containing paint in an application amount of 60 g / m 2 to 100 g / m 2 .
  • a sufficient hardness and abrasion resistance is achieved.
  • the basecoat layer or an intermediate lacquer layer which is applied between the basecoat layer and the topcoat layer and directly adjoins the topcoat layer is made shiny.
  • the coating structure additionally has at least one further lacquer layer which directly adjoins the top lacquer layer and is formed as a glossy lacquer layer.
  • the structuring depressions are introduced in such a way that parts of a lacquer layer having a glossy surface are uncovered or remain exposed.
  • at least one another lacquer layer is applied in front of the topcoat layer, which immediately adjoins the topcoat layer, and this at least one further lacquer layer is formed with a glossy surface and the outer topcoat layer is patterned in addition to the formation of the microfolding to provide patterning wells, so that at least some the structuring depressions the at least one further glossy lacquer layer partially exposed.
  • the further, glossy lacquer layer may in particular be a base lacquer layer or an intermediate lacquer layer.
  • the at least partially polymerized material layer of the topcoat layer having the microstructure formed when the topcoat layer is irradiated can be patterned in order to create structuring depressions that divide this material layer prior to electron beam curing.
  • the structuring depressions extend only into the residual material of the topcoat layer that has not yet been polymerized by the VUV radiation, glossy areas can be formed from the material of the topcoat layer itself, since then exposed areas of the not yet polymerized material of the topcoat layer during electron beam curing no microfolding occurs.
  • the support plate may be any suitable for a floor covering plate of a suitable material for this purpose.
  • a suitable material for this purpose.
  • particularly preferred are high quality materials with low swelling tendency and low thermal expansion.
  • carrier plates made of mineral material, for example gypsum plasterboard, gypsum fiberboard, cement fiber board, cement particleboard or magnesium oxide plates. It is also possible to use wood composite materials, such as in the form of high-density fiberboard (HDF).
  • HDF high-density fiberboard
  • the decor is applied to the top of the carrier plate in one embodiment by means of a printed finish foil.
  • the finish foil can be based on a white paper, which is printed in color, with any desired colors.
  • the finishing film can also be dyed through in the volume and optionally additionally printed in color.
  • the decor can also be applied by means of a different printed or otherwise graphically designed film.
  • a finish foil which can also be a decorative paper.
  • the application of the finish film is preferably carried out by lamination, wherein a polyvinyl acetate glue (PVAc glue) with hardener or a polyurethane hotmelt, in particular a reactive polyurethane hotmelt, or an epoxide hotmelt is used in the lamination.
  • PVAc glue polyvinyl acetate glue
  • a polyurethane hotmelt in particular a reactive polyurethane hotmelt, or an epoxide hotmelt is used in the lamination.
  • a footfall sound insulation layer is additionally applied to an underside of the support plate, which is also preferably carried out by means of a lamination using a polyvinyl acetate adhesive with hardener, a polyurethane hotmelt or an epoxy hotmelt.
  • a footfall sound insulation for the panels is improved.
  • laying a separate introduction of a footfall sound insulation layer can be saved or improved footfall sound insulation can be achieved by the additional applied to the panel impact sound insulation layer.
  • Fig. 1 schematically a flow diagram of a method 100 for producing a panel for a floor covering is shown.
  • a support plate 110 is provided which may already be provided with groove and spring recesses on the end edges.
  • a decor is applied 120.
  • the decor is applied by means of a finish foil.
  • a finish foil is a foil that consists of a preimpregnated paper.
  • the printed finish film is provided 130, which is made in particular on the basis of a printed decorative paper.
  • any decorative paper and any printing can be selected as long as a lamination to the material of the support plate is possible.
  • the printed decor paper or generally the finish film is laminated onto the upper side of the carrier plate 140. In this case, preference is given to using a reactive polyvinyl acetate glue, a polyurethane hotmelt or an epoxy hotmelt.
  • this carrier plate provided with the decoration is sealed with a paint system 150.
  • a corundum-containing basecoat layer with an application amount of preferably 60 g / m 2 to 100 g / m 2 is applied to the finish film 160. Depending on the nature of the finish film, it may be necessary to apply a primer first.
  • one or more intermediate lacquer layers are applied over the base lacquer layer 170.
  • the corundum-containing intermediate lacquer layers are preferably applied in an application amount of 60 g / m 2 to 100 g / m 2 .
  • Both the base coat layer and the intermediate coat layers, but in particular the uppermost intermediate coat layer, are preferably formed as a glossy layer.
  • a topcoat layer 180 is applied to the outermost layer of the resist structure.
  • a nanocomposite lacquer is first applied in an amount of between 5 g / m 2 and 20 g / m 2 190.
  • the nanocomposite lacquer is preferably an acrylate lacquer which Nanoparticles, preferably SiO x nanoparticles.
  • the diameters of the nanoparticles are preferably below 300 nm.
  • the applied nanocomposite lacquer is then irradiated with very short-wave ultraviolet light, preferably in the vacuum ultraviolet spectral range 200.
  • This partial polymerization of the topcoat layer is carried out, which also leads to a photochemical microfolding.
  • the outermost surface of the topcoat layer is thus structured irregularly. This structuring is referred to as microfolding.
  • an uppermost material layer of the topcoat layer is partially polymerized with a layer thickness of about 100 nm. It thus forms a kind of skin which floats on the not yet polymerized remainder of the topcoat layer.
  • irradiation with electron radiation is carried out in order to cure the topcoat layer and optionally further not yet or not completely polymerized paint layers of the paint system 210.
  • the microstructure formed by the partial polymerization under VUV irradiation remains intact. Due to a high efficiency in the double bond conversion and an additional generation of radicals during irradiation with the VUV light, a particularly high degree of crosslinking is achieved in comparison to conventional UV curing. As a result, a significant increase in the curing of the outer, the micro-forming outer material layer of the topcoat layer is achieved. This is further enhanced by the fact that the subsequent electron beam curing is carried out.
  • a footfall sound insulation layer is preferably applied 220.
  • the footfall sound insulation layer 230 is provided.
  • the footfall sound insulation layer is laminated onto an underside of the support plate 240. This is preferably carried out with a reactive polyvinyl acetate glue or alternatively with a polyurethane hotmelt or an epoxy resin. hotmelt.
  • a thickness and condition of the impact sound insulation layer is selected according to the requirements at the planned installation location of the panels.
  • the cover layer is additionally deep-structured, with a surface-closed, hardened material layer being formed on the inside of the cover slip.
  • the individual process steps shown may be subdivided into a plurality of sub-steps, in particular the application of the base coat layer and the intermediate coat layers.
  • drying and partial curing steps for example by irradiation with soft UV radiation or by thermal polymerization, may also be carried out here.
  • individual process steps can also be performed in different order.
  • a lamination of the impact sound insulation could also be carried out as a final process step.
  • a milling of groove and spring components in the end faces of the panel can be made before a lamination of the impact sound insulation.
  • Fig. 2 schematically a section of a cross section through a finished panel 1 is shown. The individual layers are shown only schematically and not shown to scale relative to each other both in terms of their internal structure and their strength ratios.
  • the panel 1 comprises as a main component a support plate 2. This may, for example, a plate of a mineral material, such as a gypsum composite, so for example, a plasterboard or a gypsum fiber board, act.
  • a footfall sound insulation layer 5 is laminated.
  • the lamination is preferably carried out with a polyvinyl acetate glue which contains a hardener, or a polyurethane hotmelt or an epoxy hotmelt.
  • a top 3 of the support plate 2 a decor is applied.
  • a printed finish film 6, which preferably consists of a paper material, is applied for this purpose.
  • the finish foil 6 is on the top 3 of the Support plate 2 preferably laminated.
  • a reactive Polyvinylacetatleim, a polyurethane hotmelt or an epoxy hotmelt can be used.
  • the paint system 7 comprises in the illustrated embodiment, first, a base coat layer 8, an applied thereon intermediate lacquer layer 9 and an outer topcoat 10.
  • the corundum basecoat 6 is a clearcoat, which is applied so that an application rate of 60 g / m 2 to 100 g / m 2 results.
  • the corundum-containing intermediate coating layer 9 formed thereon preferably has an application amount of 60 g / m 2 to 100 g / m 2 .
  • the intermediate lacquer layer 9 is preferably formed so that an upper side 11 of the intermediate lacquer layer 9 is formed shiny.
  • the lacquer of the intermediate lacquer layer is a clear, transparent lacquer.
  • the topcoat 10 is applied to the top 11 of the intermediate coat 9.
  • the topcoat layer 10 has on an upper side 12 an outer thin material layer 13 with a micro stop 14.
  • the micro-cladding 14 in the outer thin material layer is formed via a partial polymerization of the applied topcoat layer 10 during an irradiation of extremely short-wave UV light in the vacuum ultra-violet wavelength range, ie with light whose wavelength is less than 200 nm.
  • Particularly suitable for this purpose is the radiation of a xenon excimer laser whose radiation has a wavelength of 172 nm.
  • the microfolding is due to shrinkage processes that have occurred in the partial polymerization initiated by the irradiation with the VUV light. Due to a low penetration depth of the VUV radiation or of the VUV light, the outer thin material layer (13) has a material layer thickness 15 of approximately 100 nm.
  • the residual material 16 of the topcoat layer 10 is fully cured by electron beam curing and crosslinked. Due to this exposure to electron radiation, the outer thin material layer 13 of the topcoat layer 10 as well as the basecoat layer 8 and the intermediate lacquer layer 9 are completely cured. Thus, all layers of the paint assembly 7 are completely cured. As a result, a complete sealing of the finish foil 6 or upper side 3 of the carrier plate 2 is achieved.
  • the finished panel 1 now has a matte optical structure and beyond a pleasant feel.
  • the photochemically produced micro-cladding 14 which has been retained during electron-beam curing leads to the panel having a slip resistance according to DIN 51130 of R10.
  • DIN 51130 of R10 a slip resistance according to DIN 51130 of R10.
  • During production there are no panels showing baconiness.
  • the extremely low gloss of the surface of the panel is maintained even when the surface is touched with an unprotected palm.
  • the surface does not tend to visually reproduce fingerprints.
  • a tendency to glare is also absent.
  • the topcoat layer in which the topcoat layer is initially applied areally with approximately constant paint layer thickness, a structured application of the paint layer is possible, so that different paint layer thicknesses of the topcoat layer already exist before carrying out the first curing step.
  • coarser structures for deep structuring can be realized. This can be done for example by applying the topcoat with a structured paint application roller. If a matt-gloss surface structure is to be produced, in which deepened areas resulting from the deep structuring show a gloss effect in structuring depressions such as wood pores or other structures, but the rest of the surface has a matt surface impression, then advantageously at least those directly adjacent to the topcoat layer Intermediate lacquer layer or the base lacquer layer, if no intermediate lacquer layer exists, formed as a glossy lacquer layers.
  • a deep structuring can take place via a structured roller, in that fine structures are pressed into the not yet completely cured topcoat layer.
  • the deep structuring is carried out so that their structures have structure depths which are greater than the structure depths of the microstructuring due to the microstructure.
  • the deep structuring will be done between the VUV curing step and the electron beam curing step. This can be achieved in a simple manner that the micro-layer is not completely closed. In the subsequent electron beam hardening, high-gloss sections thus arise in the deep-structured area. Nevertheless, the overall impression of the surface is dull and only at certain viewing angles is a gloss effect observable in small areas.
  • a device 300 for producing a panel 1 with a matte finish is shown.
  • the device 300 is designed as a production line.
  • a carrier plate 2 is provided.
  • the decor is applied to the upper side 3 of the carrier plate 2.
  • this is designed as a laminating station in which a finish foil 6, preferably a printed decorative paper, is laminated onto the upper side 3 of the carrier plate 2.
  • a finish foil 6, preferably a printed decorative paper is laminated onto the upper side 3 of the carrier plate 2.
  • the base coat is applied in a first painting station 320 with a paint application device 330.
  • the application of the paint can take place in any suitable form, for example via a roller or the like.
  • a first curing device 340 partial polymerization, drying or the like of the base coat layer may be carried out.
  • the intermediate lacquer layer is applied analogously.
  • the second painting station likewise comprises a paint application device 360 and optionally a second curing device 370, for example a UV light source or the like.
  • a topcoat application device 400 comprises a paint application device 410 for applying the topcoat layer and a VUV light source 420, for example a xenon excimer laser, for partially polymerizing the topmost material layer of the topcoat layer and forming the microfill.
  • an electron beam device 430 is provided for subsequent electron beam curing.
  • a footfall sound insulation layer 5 is laminated on the underside of the support plate 2 in a footfall sound insulation laminating station 440. Connecting is usually carried out at a post-processing station 450, a division of the support plate and / or introduced tongue and groove in the support plate or the plate sections, preferably milled. Finally, one or more finished panels 1 are present. It will be apparent to those skilled in the art that only a greatly simplified production facility is described herein and individual intermediate processing and refining stations and steps are not described.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Laminated Bodies (AREA)

Description

Die Erfindung betrifft ein Verfahren zum Herstellen eines Paneels, insbesondere für einen Fußbodenbelag, sowie ein solches Paneel.The invention relates to a method for producing a panel, in particular for a floor covering, as well as such a panel.

Aus dem Stand der Technik sind Paneele bekannt, welche insbesondere als Fußbodenbelag verwendet werden. Diese weisen eine Trägerplatte auf, die auf der Oberseite mit einem Dekor versehen ist. Das Dekor befindet sich vorzugsweise auf einer Finishfolie. Die Finishfolie ist dann wiederum auf die Trägerplatte aufgebracht, vorzugsweise aufkaschiert. Eine Finishfolie ist in dieser Anwendung üblicherweise eine beharztes oder beleimtes Papier. Der Druck kann vor oder nach dem Harz- bzw. Leimauftrag auf die Folie aufgebracht worden sein. Für Fußbodenanwendungen werden Finishfolien eingesetzt, da sie eine gute Spaltfestigkeit besitzen. Dekorative Trägermaterialien, die keine Spaltfestigkeit besitzen, sind für Fußbodenanwendungen ungeeignet. Zum Schutz gegen Umwelteinflüsse ist eine Versiegelung vorgesehen, die beispielsweise aus einem Lackaufbau aus einer oder mehreren Klarlackschichten besteht. Hierbei kommen insbesondere härtbare Lacke zum Einsatz. Diese werden durch Wärmestrahlungstechniken, UV-Strahlung oder Elektronenstrahlung ausgehärtet. So aufgetragene Lackschichten führen in der Regel zu einer mehr oder weniger glänzenden Oberfläche.From the prior art panels are known which are used in particular as a floor covering. These have a carrier plate which is provided on the top with a decor. The decor is preferably on a finish foil. The finish film is then again applied to the carrier plate, preferably laminated. A finish film in this application is usually a resinated or glued paper. The print may have been applied to the film before or after the resin or glue application. For floor finishes, finish foils are used as they have good splitting resistance. Decorative support materials that do not have a cleavage strength are unsuitable for floor applications. For protection against environmental influences, a seal is provided which, for example, consists of a paint system comprising one or more clearcoat films. In this case, in particular hardenable paints are used. These are cured by heat radiation techniques, UV radiation or electron beam radiation. Coating layers applied in this way usually lead to a more or less shiny surface.

Zwar ist es aus der DE 10 2009 044 802 A1 oder der EP 1 645 339 A1 bekannt, eine oberste Versiegelungsschicht zu strukturieren, jedoch bleibt ein im Wesentlichen glänzender Eindruck der Oberfläche bestehen.Although it is from the DE 10 2009 044 802 A1 or the EP 1 645 339 A1 It is known to structure an uppermost sealing layer, but a substantially glossy impression of the surface remains.

Um einen matten Oberflächeneindruck zu erzeugen, werden im Stand der Technik Lacke eingesetzt, welche Mikropartikel unterschiedlicher Größe und Konzentration aufweisen und so eine raue Oberfläche schaffen. Solche Lacke sind jedoch hinsichtlich ihres optischen Eindrucks als auch ihrer sonstigen Eigenschaft im Hinblick auf Transparenz, Abrasions- und Kratzfestigkeit, Haptik etc. unbefriedigend.In order to produce a matt surface impression, lacquers are used in the prior art which have microparticles of different size and concentration and thus create a rough surface. However, such paints are unsatisfactory in terms of their visual appearance as well as their other property in terms of transparency, abrasion and scratch resistance, haptics, etc.

Aus der WO 2012/013364 A1 ist ein Verfahren zum Veredeln von transparenten Kunststoffsubstraten, insbesondere Polymethylmethacrylat (kurz PMMA), welches auch als Plexiglas bekannt ist, beschrieben. Dort ist ein sogenannter Nanokompositlack vorgeschlagen, der SiOx-Nanopartikel, zumindest ein hochvernetzbares Bindemittel und zumindest einen Reaktivverdünner enthält, wobei der aufgetragene Nanokompositlack nach dem Auftragen zunächst mit extrem kurzwelligem UV-Licht nur an der Oberfläche ausgehärtet und zur photochemischen Mikrofaltung gebracht wird und der Rest des Lacks anschließend mit einer zweiten UV-Lampe mit langwelligerem UV-Licht ausgehärtet wird.From the WO 2012/013364 A1 is a method for refining transparent plastic substrates, in particular polymethyl methacrylate (PMMA short), which is also known as Plexiglas described. There, a so-called nanocomposite is proposed, the SiO x nanoparticles, at least one highly crosslinkable binder and contains at least one reactive diluent, wherein the applied nanocomposite lacquer is cured after application first with extremely short-wave UV light only at the surface and brought to the photochemical microfolding and the remainder of the lacquer is then cured with a second UV lamp with long-wave UV light.

Aus EP 2418019 A1 ist ein Verfahren zur partiellen Mattierung von UV-Lackschichten bekannt, wobei auf ein Trägersubstrat eine UV-Lackschicht aufgetragen wird und diese anschließend mit einem Excimer-Strahler behandelt wird, wobei der Excimer-Strahler innerhalb einer Schablone, die für die Excimer-Strahlung durchlässige und für die Excimer-Strahlung undurchlässige Bereiche aufweist, situiert ist, und die UV-Lackschicht durch die Schablone mit dem Excimer-Strahler partiell belichtet wird.Out EP 2418019 A1 a method for the partial matting of UV lacquer layers is known, wherein on a support substrate, a UV lacquer layer is applied and this is subsequently treated with an excimer radiator, wherein the excimer radiator within a template, the permeable to excimer radiation and for the excimer radiation impermeable areas, is located, and the UV lacquer layer is partially exposed through the template with the excimer radiator.

Aus WO 2012/048747 A1 , F. Bauer et al., Progress in Organic Coatings 69 (2010), 287-293 , und DE 10 2008 024 149 A1 sind Oberflächenbeschichtungen Verfahren bekannt, bei dem eine Lackschicht erst mittels monochromatischer Strahlung im Bereich 172 nm teilweise ausgehärtet wird und die restliche Schicht in einem nächsten Schritt mittels Vakuum UV-Strahlung ausgehärtet wird.Out WO 2012/048747 A1 . F. Bauer et al., Progress in Organic Coatings 69 (2010), 287-293 , and DE 10 2008 024 149 A1 surface coatings are known methods in which a lacquer layer is first partially cured by means of monochromatic radiation in the range 172 nm and the remaining layer is cured in a next step by means of vacuum UV radiation.

Aus DE 10 2011 001 807 A1 ist ein Bodenpaneel und ein Verfahren zu dessen Herstellung bekannt, wobei oberhalb einer Trägerschicht eine zusätzliche Dekorschicht aufgebracht ist.Out DE 10 2011 001 807 A1 is a Bodenpaneel and a method for its production is known, wherein above a carrier layer, an additional decorative layer is applied.

Aus DE 10 2007 019 871 A1 ist ein Verfahren und eine Vorrichtung zur Beschichtung eines plattenförmigen Werkstücks mit einem fließfähigen Medium bekannt mit einer dreidimensionalen Struktur, wobei der Auftrag des fließfähigen Mediums über eine gravierte Auftragswalze dergestalt erfolgt.Out DE 10 2007 019 871 A1 is a method and an apparatus for coating a plate-shaped workpiece with a flowable medium known with a three-dimensional structure, wherein the order of the flowable medium via an engraved applicator roll takes place in such a way.

Die im Stand der Technik für Fußbodenpaneele verwendeten Lacke, welche einen matten optischen Eindruck vermitteln, sind hinsichtlich ihrer Eigenschaftskombinationen wie guter Transparenz, hoher Abrasions- und Kratzfestigkeit, hervorragender Chemikalienresistenz und UV-Resistenz, guter Bearbeitbarkeit und angenehmer Haptik nicht befriedigend.The paints used in the prior art for floor panels, which give a matte visual impression are unsatisfactory in terms of their property combinations such as good transparency, high abrasion and scratch resistance, excellent chemical resistance and UV resistance, good workability and pleasant feel.

Der Erfindung liegt somit die technische Aufgabe zugrunde, ein verbessertes Paneel, insbesondere für einen Fußbodenbelag, und ein Verfahren zu dessen Herstellung zu schaffen, die eine mattierte Oberfläche schaffen, welche einen optimalen matten optischen Oberflächeneindruck und zugleich eine hohe Abrasions- und Kratzfestigkeit, eine gute chemische Widerstandsfähigkeit sowie eine angenehme Haptik in Kombination bieten.The invention is thus based on the technical object of providing an improved panel, in particular for a floor covering, and a method for the production thereof, which create a matted surface which mats an optimum optical surface impression and at the same time a high abrasion and scratch resistance, a good chemical resistance as well as a pleasant haptic in combination offer.

Die Aufgabe wird erfindungsgemäß durch ein Verfahren mit den Merkmalen des Patentanspruchs 1 sowie ein Paneel mit den Merkmalen des Patentanspruchs 4 gelöst. Vorteilhafte Ausgestaltungen der Erfindung ergeben sich aus den Unteransprüchen.The object is achieved by a method having the features of claim 1 and a panel having the features of claim 4. Advantageous embodiments of the invention will become apparent from the dependent claims.

Der Erfindung liegt die Idee zugrunde, ein Paneel zu schaffen, welches eine Trägerplatte aufweist, auf deren Oberseite ein Dekor aufgebracht wird bzw. aufgebracht ist. Zur Versiegelung der Oberseite weist das Paneel einen Lackaufbau aus einer oder mehreren Lackschichten auf. Um die matte Oberflächenoptik zu schaffen, ist vorgesehen, einen aushärtbaren Lack zu verwenden, diesen zunächst mit sehr hoch energetischem Licht, insbesondere mit einer Wellenlänge sogenannten vakuumultravioletten Wellenlängenbereich, zu bestrahlen und eine sehr dünne Oberflächenschicht des Lacks hierdurch zumindest teilweise zu polymerisieren und hierdurch zu härten. Aufgrund der hohen Photonenenergie dringt das Licht nur in eine Schicht von etwa 100 nm Schichtstärke ein und löst das Aushärten aus. Bei diesem Vorgang treten Schrumpfungsprozesse in der obersten Lackschicht auf, die zu einer sogenannten photochemischen Mikrofaltung führen. An der Oberfläche der äußersten Lackschicht, welche auch als Decklackschicht bezeichnet wird, entsteht somit eine Mikrofaltung. Bei der Bestrahlung mit dem sehr kurzwelligen UV-Licht (Licht im ultravioletten Spektralbereich) entsteht somit eine die Mikrofaltung aufweisende Haut, welche auf dem ansonsten noch nicht ausgehärteten übrigen Material der Decklackschicht schwimmt. Um dieses übrige Material der Decklackschicht auszuhärten sowie die vollständige Aushärtung der bereits mit dem sehr kurzwelligen UV-Licht polymerisierten obersten Schicht sowie gegebenenfalls weiterer Lackschichten des Lackaufbaus zu erreichen, wird eine anschließende Behandlung mit Elektronenstrahlung zum vollständigen Aushärten der Lackschichten des Lackaufbaus ausgeführt. Unter sehr kurzwelligem UV-Licht wird insbesondere Licht mit Wellenlängen kleiner 200 nm verstanden. UV-Licht mit einer Wellenlänge kleiner 200 nm wird auch als VUV-Licht oder VUV-Strahlung bezeichnet, wobei VUV die Abkürzung für Vakuum-Ultra-Violett ist.The invention is based on the idea of providing a panel which has a carrier plate on the top side of which a decoration is applied or applied. For sealing the upper side, the panel has a paint system of one or more paint layers. In order to provide the matte surface appearance, it is provided to use a curable lacquer, to irradiate it first with very high energy light, in particular with a wavelength so-called vacuum ultraviolet wavelength range, and thereby at least partially polymerize a very thin surface layer of the lacquer and thereby harden , Due to the high photon energy, the light penetrates only in a layer of about 100 nm thickness and triggers the curing. In this process, shrinkage processes occur in the uppermost lacquer layer, which lead to a so-called photochemical microfolding. On the surface of the outermost lacquer layer, which is also referred to as the topcoat layer, thus creating a microfill. When irradiated with the very short-wave UV light (light in the ultraviolet Spectral region) thus creates a micro-skin having skin, which floats on the otherwise uncured remaining material of the top coat layer. In order to cure this remaining material of the top coat layer and to achieve complete curing of the top layer already polymerized with the very short-wave UV light and optionally further paint layers of the paint structure, a subsequent treatment with electron radiation for complete curing of the paint layers of the paint structure is performed. Under very short-wave UV light is understood in particular light with wavelengths less than 200 nm. UV light with a wavelength less than 200 nm is also referred to as VUV light or VUV radiation, where VUV is the abbreviation for vacuum ultraviolet.

Es zeigt sich, dass eine solche Oberfläche einer so ausgebildeten Decklackschicht erstaunlicherweise im Gegensatz zu anderen Lackoberflächen eine Rutschhemmstufe von R10 gemäß der DIN 51130 aufweist. Dies ist völlig untypisch für Lackoberflächen, die ansonsten keine Rutschhemmung gemäß der obengenannten Norm besitzen. Die so geschaffene mattierte Oberfläche weist ferner eine verbesserte Abrieb- und Kratzfestigkeit auf. Sie bietet eine angenehme Haptik. Die Transparenz und eine Wahrnehmbarkeit des unter dem Lackaufbau befindlichen Dekors sind nicht eingeschränkt.It turns out that surprisingly, unlike other lacquer surfaces, such a surface of a top coat layer formed in this way has an anti-slip step of R10 according to DIN 51130. This is completely atypical for paint surfaces that otherwise have no slip resistance according to the above standard. The matted surface thus created also has improved abrasion and scratch resistance. It offers a pleasant feel. The transparency and perceptibility of the decoration located under the paint structure are not limited.

Aufgrund der vollständigen Aushärtung sowohl der Decklackschicht als auch weiterer Lackschichten des Lackaufbaus aufgrund der Elektronenstrahlaushärtung liegt trotz der oberflächlichen Mikrostrukturierung ein vollständig geschlossener Lackschichtaufbau vor, sodass ein guter Schutz gegen Verschmutzung, Feuchtigkeit und andere Flüssigkeiten besteht. Darüber hinaus weist die Oberfläche eine geringe Neigung auf, um Fingerabdrücke, welche von einer Berührung mit der bloßen Hand herrühren, insbesondere bei einer Streiflichtbetrachtung sichtbar werden zu lassen. Bei der Produktion treten keine Paneele auf, deren Oberfläche eine Speckigkeit aufweist. Ferner zeigt die Oberfläche eine geringe oder keine Neigung zur Aufglänzung in der Nutzung. Insgesamt wird somit ein Paneel, insbesondere für einen Fußbodenbelag, geschaffen, welches einen hervorragenden optischen Eindruck vermittelt und darüber hinaus sehr gute mechanische Eigenschaften hinsichtlich chemischer Beständigkeit, Rutschfestigkeit und Verschleiß aufweist.Due to the complete curing of both the top coat layer and other paint layers of the paint structure due to electron beam curing is despite the superficial microstructuring before a completely closed paint layer structure, so that a good protection against pollution, moisture and other liquids. In addition, the surface has a low tendency to make fingerprints, which result from a contact with the naked hand, in particular visible in a grazing light observation. During production, there are no panels whose surface is greasy. Furthermore, the surface shows little or no tendency for lightening in use. Overall, thus, a panel, especially for a floor covering created, which gives an excellent visual impression and also has very good mechanical properties in terms of chemical resistance, skid resistance and wear.

Darüber hinaus ist eine optimale Transparenz auf das unter dem Lackaufbau befindliche Dekor ohne eine Verfälschung des optischen Eindrucks gegeben.In addition, optimum transparency is given to the decor under the paint structure without any falsification of the visual impression.

Die verwendeten Lacke des Lackaufbaus sind vorzugsweise alles Lacke, welche im Volumen klar und transparent sind.The lacquers of the lacquer structure used are preferably all lacquers, which are clear and transparent in volume.

Insbesondere wird erfindungsgemäß ein Verfahren zum Herstellen eines Paneels, insbesondere für einen Fußbodenbelag, geschaffen, welches die Schritte umfasst: Bereitstellen einer Trägerplatte, Aufbringen eines Dekors auf eine Oberseite der Trägerplatte, Abdecken des Dekors mit einem Lackaufbau, welcher eine oder mehrere Lackschichten umfasst, wobei eine äußere Decklackschicht des Lackaufbaus zunächst mit sehr kurzwelligem Licht, insbesondere Licht im VUV-Wellenlängenbereich, teilpolymerisiert wird, sodass eine Mikrofaltung auftritt, und anschließend eine vollständige Polymerisation und Aushärtung des Lackaufbaus mittels einer Elektronenstrahlhärtung ausgeführt wird. Der VUV-Wellenlängenbereich umfasst UV-Licht mit einer Wellenlänge kleiner 200 nm.In particular, the invention provides a method for producing a panel, in particular for a floor covering, comprising the steps of providing a support plate, applying a decor to an upper side of the support plate, covering the decor with a lacquer structure which comprises one or more lacquer layers an outer topcoat layer of the paint system is first partially polymerized with very short-wavelength light, in particular light in the VUV wavelength range, so that a microfolding occurs, and then a complete polymerization and curing of the paint structure by means of electron beam curing is performed. The VUV wavelength range includes UV light with a wavelength less than 200 nm.

Man erhält somit ein Paneel, insbesondere für einen Fußbodenbelag, welches umfasst: eine Trägerplatte, welche an einer Oberseite mit einem Dekor versehen ist, welches durch einen Lackaufbau aus einer oder mehreren Lackschichten abgedeckt ist, wobei der Lackaufbau eine äußere Decklackschicht umfasst, die an ihrer Außenseite eine Mikrofaltung aufweist. Die Mikrofaltung ist durch eine photochemische Reaktion ausgebildet.One thus obtains a panel, in particular for a floor covering, which comprises: a support plate which is provided on a top side with a decor, which is covered by a lacquer structure of one or more lacquer layers, wherein the lacquer structure comprises an outer top lacquer layer, which on its Outside has a microfolding. The microfolding is formed by a photochemical reaction.

Erfindungsgemäß ist vorgesehen, dass die Decklackschicht zusätzlich zu der Mikrofaltung unter Ausbildung von Strukturierungs-Vertiefungen ( Holzporen, Astlöcher bei Holzreproduktionen, Adern bei Steinnachbildungen usw. ) strukturiert wird, so dass die Strukturierungs-Vertiefungen zumindest eine Materialschicht der Decklackschicht zerteilen, in der die Mikrofaltung ausgebildet ist oder wird. Erfindungsgemäß erhält man ein Paneel, bei dem die mindestens eine Decklackschicht zusätzlich zu der Mikrofaltung eine Tiefenstrukturierung in Form von Strukturierungs-Vertiefungen aufweist, die zumindest eine äußere Materialschicht der Decklackschicht, in der die Mikrofaltung ausgebildet ist, zerteilen. Eine solche Strukturierung wird in Abgrenzung zu der durch die photochemische Faltung erzeugten Oberflächenstrukturierung hier als Tiefenstrukturierung bezeichnet. Das Strukturieren wird entsprechend als Tiefenstrukturieren bezeichnet.According to the invention, the topcoat layer is structured in addition to the microstructure to form structuring depressions (wood pores, knotholes in wood reproductions, veins in stone replicas, etc.), so that the structuring depressions divide at least one material layer of the topcoat layer, in which the microstructure is or will be trained. According to the invention, a panel is obtained in which the at least one topcoat layer, in addition to the microstructure, has a deep structuring in the form of patterning recesses which divide at least one outer material layer of the topcoat layer in which the microstructure is formed. Such a structuring, in contrast to the surface structuring produced by the photochemical folding, is referred to here as deep structuring. The structuring is accordingly called deep structuring.

Die Decklackschicht wird erfindungsgemäß so aufgebracht und ausgehärtet, dass an einer der Außenseite der Decklackschicht gegenüberliegenden Innenseite eine flächig geschlossene, ausgehärtete Materialschicht ausgebildet wird. Hierdurch wird sichergestellt, dass eine geschlossene äußere Oberfläche gebildet wird, welche für die hohe Kratzfestigkeit und Abrasionsbeständigkeit sowie einen Schutz gegen Feuchtigkeit aufweist.
Die Teilpolymerisation mit dem sehr kurzwelligen Licht, insbesondere dem VUV-Licht eines Excimerlasers, insbesondere eines Xenon-Excimerlasers, wird so ausgeführt, dass eine Höhe der Mikrofaltung in der Größenordnung von etwa 100 nm liegt. Hierdurch wird die Mikrofaltung geschaffen, die einerseits die gute Rutschfestigkeit bedingt und andererseits eine sehr angenehme warme Haptik des Materials liefert.
Um einen verbesserten Schutz des Paneels zu schaffen, ist bei einer Ausführungsform vorgesehen, dass der Lackaufbau zusätzlich zu der äußeren Decklackschicht mindestens eine weitere Lackschicht in Form einer Grundlackschicht zum Abdecken des Dekors aufweist. Diese wird vorzugsweise mit einem korundhaltigen Lack in einer Auftragsmenge von 60 g/m2 bis 100 g/m2 ausgebildet. Hierdurch wird eine ausreichende Härte und Abriebfestigkeit erreicht.
Bei einer Weiterbildung der Erfindung wird die Grundlackschicht oder eine Zwischenlackschicht, die zwischen der Grundlackschicht und der Decklackschicht aufgebracht wird und unmittelbar an die Decklackschicht angrenzt, glänzend ausgeführt. Bei einer solchen Ausführungsform weist der Lackaufbau zusätzlich mindestens eine weitere Lackschicht aufweist, die unmittelbar an die Decklackschicht angrenzt und als glänzende Lackschicht ausgebildet ist. Hierdurch lässt sich bei geeignet gewähltem Dekor eine Steinoptik täuschend echt nachbilden.
According to the invention, the topcoat layer is applied and cured in such a way that a surface-closed, hardened material layer is formed on an inner side opposite the outside of the topcoat layer. This ensures that a closed outer surface is formed, which has the high scratch resistance and abrasion resistance and moisture protection.
The partial polymerization with the very short-wavelength light, in particular the VUV light of an excimer laser, in particular a xenon excimer laser, is carried out so that a height of the micro-microfiltration is of the order of about 100 nm. As a result, the micro-folding is created, on the one hand, the good slip resistance and on the other hand provides a very pleasant warm feel of the material.
In order to provide improved protection of the panel, in one embodiment it is provided that the coating structure has, in addition to the outer topcoat layer, at least one further lacquer layer in the form of a basecoat layer for covering the decoration. This is preferably formed with a corundum-containing paint in an application amount of 60 g / m 2 to 100 g / m 2 . As a result, a sufficient hardness and abrasion resistance is achieved.
In one development of the invention, the basecoat layer or an intermediate lacquer layer which is applied between the basecoat layer and the topcoat layer and directly adjoins the topcoat layer, is made shiny. In such an embodiment, the coating structure additionally has at least one further lacquer layer which directly adjoins the top lacquer layer and is formed as a glossy lacquer layer. As a result, a stone look can be imitated deceptively real with suitably selected decor.

Bei einer nicht erfindungsgemäßen Ausführungsform werden die Strukturierungs-Vertiefungen so eingebracht, dass Teile einer Lackschicht mit glänzender Oberfläche freigelegt werden oder freigelegt sind bzw. bleiben. Hier für ist bei einer Ausführungsform vorgesehen, dass mindestens eine weitere Lackschicht vor der Decklackschicht aufgebracht wird, die unmittelbar an die Decklackschicht angrenzt, und diese mindestens eine weitere Lackschicht mit einer glänzenden Oberfläche ausgebildet wird und die äußere Decklackschicht zusätzlich zu dem Ausbilden der Mikrofaltung unter Schaffung von Strukturierungs-Vertiefungen strukturiert wird, so dass zumindest einige der Strukturierungs-Vertiefungen die mindestens eine weitere glänzend ausgebildete Lackschicht teilweise freigelegen. Bei der weiteren, glänzend ausgebildeten Lackschicht kann es sich insbesondere um eine Grundlackschicht oder eine Zwischenlackschicht handeln.In one embodiment not according to the invention, the structuring depressions are introduced in such a way that parts of a lacquer layer having a glossy surface are uncovered or remain exposed. Here, in one embodiment, it is provided that at least one another lacquer layer is applied in front of the topcoat layer, which immediately adjoins the topcoat layer, and this at least one further lacquer layer is formed with a glossy surface and the outer topcoat layer is patterned in addition to the formation of the microfolding to provide patterning wells, so that at least some the structuring depressions the at least one further glossy lacquer layer partially exposed. The further, glossy lacquer layer may in particular be a base lacquer layer or an intermediate lacquer layer.

Alternativ oder zusätzlich kann die beim Bestrahlen der Decklackschicht gebildete, die Mikrofaltung aufweisende, zumindest teilpolymerisierte Materialschicht der Decklackschicht strukturiert werden, um diese Materialschicht zerteilende Strukturierungs-Vertiefungen vor der Elektronenstrahlhärtung zu schaffen.As an alternative or in addition, the at least partially polymerized material layer of the topcoat layer having the microstructure formed when the topcoat layer is irradiated can be patterned in order to create structuring depressions that divide this material layer prior to electron beam curing.

Reichen die Strukturierungs-Vertiefungen nur bis in das durch die VUV-Strahlung noch nicht polymerisierte restliche Material der Decklackschicht, können glänzenden Bereiche aus dem Material der Decklackschicht selbst gebildet werden, da in diesen dann freigelegten Bereichen des noch nicht polymerisierten Materials der Decklackschicht bei der Elektronenstrahlhärtung keine Mikrofaltung eintritt.If the structuring depressions extend only into the residual material of the topcoat layer that has not yet been polymerized by the VUV radiation, glossy areas can be formed from the material of the topcoat layer itself, since then exposed areas of the not yet polymerized material of the topcoat layer during electron beam curing no microfolding occurs.

Bei der Trägerplatte kann es sich um jede für einen Fußbodenbelag geeignete Platte aus einem hierfür geeigneten Werkstoff handeln. Besonders bevorzugt werden jedoch hochwertige Werkstoffe mit geringer Quellneigung und geringer Wärmeausdehnung.The support plate may be any suitable for a floor covering plate of a suitable material for this purpose. However, particularly preferred are high quality materials with low swelling tendency and low thermal expansion.

Besonders bevorzugt werden Trägerplatten aus mineralischem Material, beispielsweise Gipskartonplatten, Gipsfaserplatten, Zementfaserplatten, Zementspanplatten oder auch Magnesiumoxydplatten. Möglich ist auch ein Einsatz von Holzverbundwerkstoffen, wie beispielsweise in Form von hochdichten Faserplatten (HDF).Particular preference is given to carrier plates made of mineral material, for example gypsum plasterboard, gypsum fiberboard, cement fiber board, cement particleboard or magnesium oxide plates. It is also possible to use wood composite materials, such as in the form of high-density fiberboard (HDF).

Das Dekor wird auf die Oberseite der Trägerplatte bei einer Ausführungsform mittels einer bedruckten Finishfolie aufgebracht. Die Finishfolie kann als Basis ein weißes Papier besitzen, welches farbig, mit beliebigen Farben bedruckt ist. Ebenso kann die Finishfolie jedoch auch im Volumen durchgefärbt und gegebenenfalls zusätzlich farbig bedruckt sein.The decor is applied to the top of the carrier plate in one embodiment by means of a printed finish foil. The finish foil can be based on a white paper, which is printed in color, with any desired colors. Likewise, however, the finishing film can also be dyed through in the volume and optionally additionally printed in color.

Das Dekor kann auch mittels einer andersartigen bedruckten oder auf andere Weise grafisch ausgestalteten Folie aufgebracht werden. Verallgemeinert wird von einer Finishfolie gesprochen, die auch ein Dekorpapier sein kann.The decor can also be applied by means of a different printed or otherwise graphically designed film. Generalized is spoken of a finish foil, which can also be a decorative paper.

Das Aufbringen der der Finishfolie erfolgt vorzugsweise mittels Aufkaschierens, wobei ein Polyvinylacetat-Leim (PVAc-Leim) mit Härter oder ein Polyurethan-Hotmelt, insbesondere ein reaktiver Polyurethan-Hotmelt, oder ein Epoxid-Hotmelt bei der Kaschierung verwendet wird.The application of the finish film is preferably carried out by lamination, wherein a polyvinyl acetate glue (PVAc glue) with hardener or a polyurethane hotmelt, in particular a reactive polyurethane hotmelt, or an epoxide hotmelt is used in the lamination.

Bei einer bevorzugten Ausführungsform wird auf eine Unterseite der Trägerplatte zusätzlich eine Trittschalldämmungsschicht aufgebracht, welche ebenfalls vorzugsweise mittels einer Kaschierung unter Verwendung eines Polyvinylacetat-Leims mit Härter, einem Polyurethan-Hotmelt oder einem Epoxid-Hotmelt ausgeführt wird. Hierdurch wird eine Trittschalldämmung für die Paneele verbessert. Beim Verlegen kann ein gesondertes Einbringen einer Trittschalldämmungslage eingespart werden oder eine verbesserte Trittschalldämmung durch die zusätzliche an dem Paneel aufgebrachte Trittschalldämmschicht erreicht werden.In a preferred embodiment, a footfall sound insulation layer is additionally applied to an underside of the support plate, which is also preferably carried out by means of a lamination using a polyvinyl acetate adhesive with hardener, a polyurethane hotmelt or an epoxy hotmelt. As a result, a footfall sound insulation for the panels is improved. When laying a separate introduction of a footfall sound insulation layer can be saved or improved footfall sound insulation can be achieved by the additional applied to the panel impact sound insulation layer.

Nachfolgend wird die Erfindung unter Bezugnahme auf eine Zeichnung näher erläutert. Hierbei zeigen:

Fig. 1
ein schematisches Flussdiagramm für ein Verfahren zur Herstellung eines Fußbodenpaneels mit matter Oberflächenoptik;
Fig. 2
eine schematische Schnittdarstellung eines Fußbodenpaneels; und
Fig. 3
eine schematische Darstellung einer Vorrichtung zur Herstellung eines Fußbodenpaneels.
The invention will be explained in more detail with reference to a drawing. Hereby show:
Fig. 1
a schematic flow diagram for a method for producing a floor panel with a matt surface appearance;
Fig. 2
a schematic sectional view of a floor panel; and
Fig. 3
a schematic representation of an apparatus for producing a floor panel.

In Fig. 1 ist schematisch ein Ablaufdiagramm eines Verfahrens 100 zur Herstellung eines Paneels für einen Fußbodenbelag dargestellt. Zunächst wird eine Trägerplatte bereitgestellt 110, welche gegebenenfalls bereits mit Nut und Federeinfräsungen an den Stirnkanten versehen ist.In Fig. 1 schematically a flow diagram of a method 100 for producing a panel for a floor covering is shown. First, a support plate 110 is provided which may already be provided with groove and spring recesses on the end edges.

Auf eine Oberseite der Trägerplatte wird ein Dekor aufgebracht 120. Bei der dargestellten Ausführungsform wird das Dekor mit Hilfe einer Finishfolie aufgebracht. Eine Finishfolie ist eine Folie, die aus einem vorimprägnierten Papier besteht. Hierzu wird beispielsweise die bedruckte Finishfolie bereitgestellt 130, welche insbesondere auf Basis eines bedruckten Dekorpapier hergestellt ist. Hierbei kann jedes beliebige Dekorpapier und jede beliebige Bedruckung gewählt werden, solange ein Aufkaschieren auf das Material der Trägerplatte möglich ist. Das bedruckte Dekorpapier oder allgemein die Finishfolie wird auf die Oberseite der Trägerplatte aufkaschiert 140. Hierbei kommen vorzugsweise ein reaktiver Polyvinylacetat-Leim, ein Polyurethan-Hotmelt oder ein Epoxid-Hotmelt zum Einsatz. Als Schutz der mit dem Dekor versehenen Oberseite der Trägerplatte wird diese mit dem Dekor versehene Trägerplatte mit einem Lackaufbau versiegelt 150. Zunächst wird eine korundhaltige Grundlackschicht mit einer Auftragsmenge von vorzugsweise 60 g/m2 bis 100 g/m2 auf die Finishfolie aufgebracht 160. Je nach Beschaffenheit der Finishfolie kann es notwendig sein, zuvor einen Primer aufzubringen.On a top of the support plate, a decor is applied 120. In the illustrated embodiment, the decor is applied by means of a finish foil. A finish foil is a foil that consists of a preimpregnated paper. For this purpose, for example, the printed finish film is provided 130, which is made in particular on the basis of a printed decorative paper. Here, any decorative paper and any printing can be selected as long as a lamination to the material of the support plate is possible. The printed decor paper or generally the finish film is laminated onto the upper side of the carrier plate 140. In this case, preference is given to using a reactive polyvinyl acetate glue, a polyurethane hotmelt or an epoxy hotmelt. To protect the upper side of the carrier plate provided with the decoration, this carrier plate provided with the decoration is sealed with a paint system 150. First, a corundum-containing basecoat layer with an application amount of preferably 60 g / m 2 to 100 g / m 2 is applied to the finish film 160. Depending on the nature of the finish film, it may be necessary to apply a primer first.

In nachfolgenden Schritten, von denen hier beispielhaft einer gezeigt ist, werden keine, ein oder mehrere Zwischenlackschichten über der Grundlackschicht 170 aufgebracht. Vorzugweise werden die korundhaltigen Zwischenlack-Schichten in einer Auftragsmenge von 60 g/m2 bis 100 g/m2 aufgetragen. Sowohl die Grundlackschicht als auch die Zwischenlackschichten, insbesondere jedoch die oberste Zwischenlackschicht, werden vorzugsweise als glänzende Schicht ausgebildet.In subsequent steps, one of which is shown here by way of example, none, one or more intermediate lacquer layers are applied over the base lacquer layer 170. The corundum-containing intermediate lacquer layers are preferably applied in an application amount of 60 g / m 2 to 100 g / m 2 . Both the base coat layer and the intermediate coat layers, but in particular the uppermost intermediate coat layer, are preferably formed as a glossy layer.

Als äußerste Schicht des Lackaufbaus wird schließlich eine Decklackschicht aufgebracht 180. Hierfür wird zunächst ein Nanokompositlack in einer Menge zwischen 5 g/m2 und 20 g/m2 aufgetragen 190. Der Nanokompositlack ist vorzugsweise ein Acrylatlack, welcher Nanopartikel, vorzugsweise SiOx-Nanopartikel, umfasst. Die Durchmesser der Nanopartikel liegen vorzugsweise unterhalb von 300 nm.Finally, a topcoat layer 180 is applied to the outermost layer of the resist structure. To this end, a nanocomposite lacquer is first applied in an amount of between 5 g / m 2 and 20 g / m 2 190. The nanocomposite lacquer is preferably an acrylate lacquer which Nanoparticles, preferably SiO x nanoparticles. The diameters of the nanoparticles are preferably below 300 nm.

Der aufgebrachte Nanokompositlack wird anschließend mit sehr kurzwelligem ultraviolettem Licht, vorzugsweise im vakuumultravioletten Spektralbereich, bestrahlt 200. Hierdurch wird eine Teilpolymerisation der Decklackschicht ausgeführt, was zugleich zu einer photochemischen Mikrofaltung führt. Aufgrund von bei der Polymerisation auftretenden Schrumpfungseffekten strukturiert sich somit die äußerste Oberfläche der Decklackschicht unregelmäßig. Diese Strukturierung wird als Mikrofaltung bezeichnet. Während der Bestrahlung mit dem VUV-Licht, welches beispielsweise von einem Xenon-Excimerlaser bereitgestellt wird, wird eine oberste Materialschicht der Decklackschicht mit einer Schichtstärke von etwa 100 nm teilpolymerisiert. Es bildet sich somit eine Art Haut, welche auf dem noch nicht polymerisierten Rest der Decklackschicht schwimmt.The applied nanocomposite lacquer is then irradiated with very short-wave ultraviolet light, preferably in the vacuum ultraviolet spectral range 200. This partial polymerization of the topcoat layer is carried out, which also leads to a photochemical microfolding. As a result of shrinkage effects occurring during the polymerization, the outermost surface of the topcoat layer is thus structured irregularly. This structuring is referred to as microfolding. During the irradiation with the VUV light, which is provided, for example, by a xenon excimer laser, an uppermost material layer of the topcoat layer is partially polymerized with a layer thickness of about 100 nm. It thus forms a kind of skin which floats on the not yet polymerized remainder of the topcoat layer.

Anschließend wird eine Bestrahlung mit Elektronenstrahlung vorgenommen, um die Decklackschicht und gegebenenfalls weitere noch nicht oder nicht vollständig polymerisierte Lackschichten des Lackaufbaus auszuhärten 210. Bei diesem Verfahrensschritt bleibt die durch die Teilpolymerisation unter VUV-Bestrahlung gebildete Mikrofaltung erhalten. Aufgrund einer hohen Effizienz im Doppelbindungsumsatz und eines zusätzlichen Generierens von Radikalen beim Bestrahlen mit dem VUV-Licht wird ein besonders hoher Vernetzungsgrad im Vergleich zu klassischem UV-Härten erreicht. Hierdurch wird eine deutliche Steigerung der Härtung der äußeren, die Mikrofaltung bildenden äußeren Materialschicht der Decklackschicht erreicht. Dieses wird noch weiter dadurch gesteigert, dass die anschließende Elektronenstrahlhärtung ausgeführt wird.Subsequently, irradiation with electron radiation is carried out in order to cure the topcoat layer and optionally further not yet or not completely polymerized paint layers of the paint system 210. In this process step, the microstructure formed by the partial polymerization under VUV irradiation remains intact. Due to a high efficiency in the double bond conversion and an additional generation of radicals during irradiation with the VUV light, a particularly high degree of crosslinking is achieved in comparison to conventional UV curing. As a result, a significant increase in the curing of the outer, the micro-forming outer material layer of the topcoat layer is achieved. This is further enhanced by the fact that the subsequent electron beam curing is carried out.

Nach dem Fertigstellen des Lackaufbaus wird vorzugsweise eine Trittschalldämmschicht aufgebracht 220. Zunächst wird die Trittschalldämmschicht bereitgestellt 230. Die Trittschalldämmschicht wird auf eine Unterseite der Trägerplatte aufkaschiert 240. Dieses erfolgt vorzugsweise mit einem reaktiven Polyvinylacetat-Leim oder alternativ mit einem Polyurethan-Hotmelt oder einem Epoxid-Hotmelt. Eine Stärke und Beschaffenheit der Trittschalldämmschicht wird angepasst an die Erfordernisse am geplanten Verlegeort der Paneele gewählt.After completion of the paint structure, a footfall sound insulation layer is preferably applied 220. First, the footfall sound insulation layer 230 is provided. The footfall sound insulation layer is laminated onto an underside of the support plate 240. This is preferably carried out with a reactive polyvinyl acetate glue or alternatively with a polyurethane hotmelt or an epoxy resin. hotmelt. A thickness and condition of the impact sound insulation layer is selected according to the requirements at the planned installation location of the panels.

Abschließend wird die mit dem Dekor und dem Lackaufbau versehene Trägerplatte nachbearbeitet 250, wobei die Trägerplatte gegebenenfalls zerteilt und/oder Nut und Feder in Stirnkanten eingefräst werden.
Das bisher beschriebene Verfahren stellt lediglich eine exemplarische und schematisch leicht vereinfachte Ausführungsform dar. Im erfindungsgemäßen Verfahren wird zusätzlich die Deckschicht tiefenstrukturiert, wobei eine flächig geschlossene, ausgehärtete Materialschicht an der Innenseite der Deckschciht ausgebildet wird. Die einzelnen dargestellten Verfahrensschritte können in mehrere Unterschritte untergliedert sein, insbesondere das Aufbringen der Grundlackschicht und der Zwischenlackschichten. Hierbei können neben dem Auftragen auch noch Trocknungs- und Teilhärtungsschritte, beispielsweise über eine Bestrahlung mit weicher UV-Strahlung oder über thermische Polymerisation, ausgeführt werden.
Darüber hinaus können einzelne Verfahrensschritte auch in unterschiedlicher Reihenfolge ausgeführt werden. Beispielsweise könnte ein Aufkaschieren der Trittschalldämmung auch als abschließender Verfahrensschritt ausgeführt werden. Ebenso kann ein Einfräsen von Nut und Federbestandteilen in die Stirnflächen des Paneels auch vor einem Aufkaschieren der Trittschalldämmung vorgenommen werden.
In Fig. 2 ist schematisch eine Ausschnitt eines Querschnitts durch ein fertiggestelltes Paneel 1 dargestellt. Die einzelnen Schichten sind nur schematisch dargestellt und sowohl hinsichtlich ihrer inneren Struktur als auch ihrer Stärkenverhältnisse relativ zueinander nicht maßstabsgerecht dargestellt.
Das Paneel 1 umfasst als Hauptbestandteil eine Trägerplatte 2. Bei dieser kann es sich beispielsweise um eine Platte aus einem mineralischen Werkstoff, beispielsweise einem Gipsverbundwerkstoff, also beispielsweise eine Gipskartonplatte oder eine Gipsfaserplatte, handeln. Auch andere mineralische Werkstoffe oder Holzwerkstoffe kommen in Betracht, beispielsweise eine hochverdichtete Faserplatte (HDF). An einer Unterseite 4 der Trägerplatte 2 ist eine Trittschalldämmschicht 5 aufkaschiert. Das Aufkaschieren erfolgt vorzugsweise mit einem Polyvinylacetat-Leim, welcher einen Härter enthält, oder einem Polyurethan-Hotmelt oder einem Epoxid-Hotmelt.
Auf eine Oberseite 3 der Trägerplatte 2 ist ein Dekor aufgebracht. Bei der dargestellten Ausführungsform ist hierfür eine bedruckte Finishfolie 6, welche vorzugsweise aus einem Papiermaterial besteht, aufgebracht. Die Finishfolie 6 ist auf die Oberseite 3 der Trägerplatte 2 vorzugsweise aufkaschiert. Hierzu kann ein reaktiver Polyvinylacetatleim, ein Polyurethan-Hotmelt oder auch ein Epoxid-Hotmelt verwendet werden.
Zum Schutz der Finishfolie 6 und der Oberseite 3 der Trägerplatte 2 ist auf die Finishfolie 6 ein Lackaufbau 7 aufgebracht. Der Lackaufbau 7 umfasst bei der dargestellten Ausführungsform zunächst eine Grundlackschicht 8, eine hierauf aufgebrachte Zwischenlackschicht 9 und eine äußere Decklackschicht 10. Die korundhaltige Grundlackschicht 6 ist ein Klarlack, der so aufgebracht wird, dass sich eine Auftragsmenge von 60 g/m2 bis 100 g/m2 ergibt. Auch die darauf ausgebildete korundhaltige Zwischenlackschicht 9 weist vorzugsweise eine Auftragsmenge von 60 g/m2 bis 100 g/m2 auf. Die Zwischenlackschicht 9 wird vorzugsweise so ausgebildet, dass eine Oberseite 11 der Zwischenlackschicht 9 glänzend ausgebildet ist. Auch der Lack der Zwischenlackschicht ist ein klarer, transparenter Lack.
Die Decklackschicht 10 ist auf die Oberseite 11 der Zwischenlackschicht 9 aufgebracht. Die Decklackschicht 10 weist an einer Oberseite 12 eine äußere dünne Materialschicht 13 mit einer Mikrofaltung 14 auf. Die Mikrofaltung 14 in der äußeren dünnen Materialschicht ist über eine Teilpolymerisation der aufgetragenen Decklackschicht 10 während einer Einstrahlung von extrem kurzwelligen UV-Licht im Vakuum-Ultra-Violetten-Wellenlängenbereich ausgebildet, d.h. mit Licht, dessen Wellenlänge kleiner 200 nm ist. Besonders geeignet ist hierfür die Strahlung eines Xenon-Excimerlasers, dessen Strahlung eine Wellenlänge von 172 nm aufweist. Die Mikrofaltung ist auf Schrumpfungsprozesse zurückzuführen, die bei der durch die Bestrahlung mit dem VUV-Licht ausgelösten Teilpolymerisation aufgetreten sind. Aufgrund einer geringen Eindringtiefe der VUV-Strahlung, bzw. des VUV-Lichts, weist die äußere dünne Materialschicht (13) eine Materialschichtstärke 15 von etwa 100 nm auf.
Finally, the provided with the decor and the paint structure carrier plate is reworked 250, wherein the carrier plate optionally divided and / or groove and tongue are milled into end edges.
The method described so far represents only an exemplary and schematically slightly simplified embodiment. In the method according to the invention, the cover layer is additionally deep-structured, with a surface-closed, hardened material layer being formed on the inside of the cover slip. The individual process steps shown may be subdivided into a plurality of sub-steps, in particular the application of the base coat layer and the intermediate coat layers. In addition to the application, drying and partial curing steps, for example by irradiation with soft UV radiation or by thermal polymerization, may also be carried out here.
In addition, individual process steps can also be performed in different order. For example, a lamination of the impact sound insulation could also be carried out as a final process step. Likewise, a milling of groove and spring components in the end faces of the panel can be made before a lamination of the impact sound insulation.
In Fig. 2 schematically a section of a cross section through a finished panel 1 is shown. The individual layers are shown only schematically and not shown to scale relative to each other both in terms of their internal structure and their strength ratios.
The panel 1 comprises as a main component a support plate 2. This may, for example, a plate of a mineral material, such as a gypsum composite, so for example, a plasterboard or a gypsum fiber board, act. Other mineral materials or wood-based materials are also suitable, for example a high-density fiberboard (HDF). On a bottom 4 of the support plate 2, a footfall sound insulation layer 5 is laminated. The lamination is preferably carried out with a polyvinyl acetate glue which contains a hardener, or a polyurethane hotmelt or an epoxy hotmelt.
On a top 3 of the support plate 2, a decor is applied. In the illustrated embodiment, a printed finish film 6, which preferably consists of a paper material, is applied for this purpose. The finish foil 6 is on the top 3 of the Support plate 2 preferably laminated. For this purpose, a reactive Polyvinylacetatleim, a polyurethane hotmelt or an epoxy hotmelt can be used.
To protect the finish film 6 and the top 3 of the support plate 2, a paint system 7 is applied to the finish film 6. The paint system 7 comprises in the illustrated embodiment, first, a base coat layer 8, an applied thereon intermediate lacquer layer 9 and an outer topcoat 10. The corundum basecoat 6 is a clearcoat, which is applied so that an application rate of 60 g / m 2 to 100 g / m 2 results. Also, the corundum-containing intermediate coating layer 9 formed thereon preferably has an application amount of 60 g / m 2 to 100 g / m 2 . The intermediate lacquer layer 9 is preferably formed so that an upper side 11 of the intermediate lacquer layer 9 is formed shiny. Also, the lacquer of the intermediate lacquer layer is a clear, transparent lacquer.
The topcoat 10 is applied to the top 11 of the intermediate coat 9. The topcoat layer 10 has on an upper side 12 an outer thin material layer 13 with a micro stop 14. The micro-cladding 14 in the outer thin material layer is formed via a partial polymerization of the applied topcoat layer 10 during an irradiation of extremely short-wave UV light in the vacuum ultra-violet wavelength range, ie with light whose wavelength is less than 200 nm. Particularly suitable for this purpose is the radiation of a xenon excimer laser whose radiation has a wavelength of 172 nm. The microfolding is due to shrinkage processes that have occurred in the partial polymerization initiated by the irradiation with the VUV light. Due to a low penetration depth of the VUV radiation or of the VUV light, the outer thin material layer (13) has a material layer thickness 15 of approximately 100 nm.

Das Restmaterial 16 der Decklackschicht 10 ist durch Elektronenstrahlhärtung vollständig ausgehärtet und vernetzt. Aufgrund dieser Beaufschlagung mit Elektronenstrahlung sind auch die äußere dünne Materialschicht 13 der Decklackschicht 10 sowie die Grundlackschicht 8 und die Zwischenlackschicht 9 vollständig ausgehärtet. Somit sind sämtliche Schichten des Lackaufbaus 7 vollständig ausgehärtet. Hierdurch ist eine vollständige Versiegelung der Finishfolie 6 bzw. Oberseite 3 der Trägerplatte 2 erreicht.The residual material 16 of the topcoat layer 10 is fully cured by electron beam curing and crosslinked. Due to this exposure to electron radiation, the outer thin material layer 13 of the topcoat layer 10 as well as the basecoat layer 8 and the intermediate lacquer layer 9 are completely cured. Thus, all layers of the paint assembly 7 are completely cured. As a result, a complete sealing of the finish foil 6 or upper side 3 of the carrier plate 2 is achieved.

Das fertiggestellte Paneel 1 weist nun eine matte optische Struktur auf und darüber hinaus eine angenehme Haptik. Die beim Elektronenstrahlhärten erhalten gebliebene photochemisch hergestellte Mikrofaltung 14 führt darüber hinaus dazu, dass das Paneel eine Rutschfestigkeit nach DIN 51130 von R10 aufweist. Bei der Produktion treten keine Paneele auf, die eine Speckigkeit zeigen. Der extrem niedrige Glanzgrad der Oberfläche des Paneels bleibt auch bei einer Berührung der Oberfläche mit einer ungeschützten Handfläche erhalten. Die Oberfläche neigt nicht dazu, Fingerabdrücke optisch wiederzugeben. Eine Neigung zum Aufglänzen, ist ebenfalls nicht vorhanden.
Abweichend von der in Fig. 2 beschriebenen Ausführungsform, bei der die Decklackschicht flächig zunächst mit annähernd konstanter Lackschichtstärke aufgetragen ist, ist auch eine strukturierte Aufbringung der Lackschicht möglich, sodass unterschiedliche Lackschichtstärken der Decklackschicht bereits vor dem Ausführen des ersten Aushärtungsschritts vorliegen. Hierbei lassen sich gröbere Strukturen für eine Tiefenstrukturierung realisieren. Diese kann beispielsweise über ein Aufbringen des Decklacks mit einer strukturierten Lackauftragwalze erfolgen.
Soll eine Matt-Glanz-Oberflächenstruktur erzeugt werden, bei der aufgrund der Tiefenstrukturierung entstandene vertiefte Bereiche in Strukturierungs-Vertiefungen wie Holzporen oder anderen Strukturen einen Glanzeffekt zeigen, die restliche Oberfläche jedoch einen matten Oberflächeneindruck aufweist, so sind vorteilhafterweise zumindest die unmittelbar an die Decklackschicht angrenzende Zwischenlackschicht oder die Grundlackschicht, wenn keine Zwischenlackschicht existiert, als glänzende Lackschichten ausgebildet.
The finished panel 1 now has a matte optical structure and beyond a pleasant feel. In addition, the photochemically produced micro-cladding 14 which has been retained during electron-beam curing leads to the panel having a slip resistance according to DIN 51130 of R10. During production, there are no panels showing baconiness. The extremely low gloss of the surface of the panel is maintained even when the surface is touched with an unprotected palm. The surface does not tend to visually reproduce fingerprints. A tendency to glare is also absent.
Notwithstanding the in Fig. 2 described embodiment, in which the topcoat layer is initially applied areally with approximately constant paint layer thickness, a structured application of the paint layer is possible, so that different paint layer thicknesses of the topcoat layer already exist before carrying out the first curing step. Here, coarser structures for deep structuring can be realized. This can be done for example by applying the topcoat with a structured paint application roller.
If a matt-gloss surface structure is to be produced, in which deepened areas resulting from the deep structuring show a gloss effect in structuring depressions such as wood pores or other structures, but the rest of the surface has a matt surface impression, then advantageously at least those directly adjacent to the topcoat layer Intermediate lacquer layer or the base lacquer layer, if no intermediate lacquer layer exists, formed as a glossy lacquer layers.

Alternativ oder zusätzlich kann eine Tiefenstrukturierung über eine strukturierte Walze erfolgen, indem in die noch nicht fertig ausgehärtete Decklackschicht feine Strukturen eingepresst werden.
In jedem Fall wird die Tiefenstrukturierung so ausgeführt, dass deren Strukturen Strukturtiefen aufweisen, die größer als die Strukturtiefen der Mikrostrukturierung aufgrund der Mikrofaltung sind.
Vorzugsweise wird die Tiefenstrukturierung zwischen dem VUV-Aushärtungsschritt und dem Elektronenstrahlaushärtungsschritt vorgenommen werden. Hierdurch kann auf einfache Weise erreicht werden, dass die Mikrofaltungsschicht nicht vollständig geschlossen ist. Bei der anschließenden Elektronenstrahlhärtung entstehen somit in dem tiefenstrukturierten Bereich hochglänzende Abschnitte. Dennoch ist der Gesamteindruck der Oberfläche matt und lediglich unter bestimmten Betrachtungswinkeln ist in kleinen Bereichen ein Glanzeffekt beobachtbar. Hierdurch können bei entsprechend gewähltem grafischem Druckdekor Steinoberflächen täuschend echt nachgebildet werden.
In Fig. 3 ist schematisch eine Vorrichtung 300 zum Herstellen eines Paneels 1 mit einer matten Oberflächenveredlung gezeigt. Die Vorrichtung 300 ist als Produktionsstraße ausgebildet. Zunächst wird eine Trägerplatte 2 bereitgestellt. In einer Dekorstation 310 wird das Dekor auf die Oberseite 3 der Trägerplatte 2 aufgebracht. In der dargestellten Ausführungsform ist diese als Kaschierstation ausgebildet, in der eine Finishfolie 6, vorzugsweise ein bedrucktes Dekorpapier, auf die Oberseite 3 der Trägerplatte 2 aufkaschiert wird. Alternativ ist es möglich, die Trägerplatte 2 an ihrer Oberseite unmittelbar zu bedrucken. Anschließend wird in einer ersten Lackierstation 320 mit einer Lackaufbringungsvorrichtung 330 der Grundlack aufgebracht. Das Aufbringen des Lacks kann in jeder geeigneten Form, beispielsweise über eine Walze oder Ähnliches, erfolgen. Optional kann in einer ersten Härtungsvorrichtung 340 eine Teilpolymerisation, Trocknung oder Ähnliches der Grundlackschicht ausgeführt werden. In einer zweiten Lackierstation 350 wird analog die Zwischenlackschicht aufgebracht. Die zweite Lackierstation umfasst ebenfalls eine Lackaufbringungsvorrichtung 360 sowie optional eine zweite Aushärtungsvorrichtung 370, beispielsweise eine UV-Lichtquelle oder Ähnliches.
Eine Decklackaufbringungsvorrichtung 400 umfasst eine Lackaufbringungsvorrichtung 410 zum Aufbringen der Decklackschicht sowie eine VUV-Lichtquelle 420, beispielsweise einen Xenon-Excimerlaser, zum Teilpolymerisieren der obersten Materialschicht der Decklackschicht und Ausbildung der Mikrofaltung. Für das anschließende Elektronenstrahlhärten ist eine Elektronenstrahlvorrichtung 430 vorgesehen.
Nach dem Elektronenstrahlhärten wird bei der dargestellten Ausführungsform in einer Trittschalldämmungskaschierstation 440 eine Trittschalldämmschicht 5 auf die Unterseite der Trägerplatte 2 aufkaschiert. Anschließen wird in der Regel an einer Nachbearbeitungsstation 450 ein Zerteilen der Trägerplatte vorgenommen und/oder Nut und Feder in den Trägerplatte oder die Plattenabschnitte eingebracht, vorzugsweise eingefräst. Abschließend liegen ein oder mehrere fertige Paneele 1 vor.
Es ergibt sich für den Fachmann, dass hier lediglich eine stark vereinfachte Produktionseinrichtung beschrieben ist und einzelne Zwischenbearbeitungs- und Veredelungsstationen und -schritte nicht beschrieben sind.
Alternatively or additionally, a deep structuring can take place via a structured roller, in that fine structures are pressed into the not yet completely cured topcoat layer.
In any case, the deep structuring is carried out so that their structures have structure depths which are greater than the structure depths of the microstructuring due to the microstructure.
Preferably, the deep structuring will be done between the VUV curing step and the electron beam curing step. This can be achieved in a simple manner that the micro-layer is not completely closed. In the subsequent electron beam hardening, high-gloss sections thus arise in the deep-structured area. Nevertheless, the overall impression of the surface is dull and only at certain viewing angles is a gloss effect observable in small areas. As a result, stone surfaces can be imitated deceptively real with appropriately selected graphic print decor.
In Fig. 3 schematically a device 300 for producing a panel 1 with a matte finish is shown. The device 300 is designed as a production line. First, a carrier plate 2 is provided. In a decorative station 310, the decor is applied to the upper side 3 of the carrier plate 2. In the illustrated embodiment, this is designed as a laminating station in which a finish foil 6, preferably a printed decorative paper, is laminated onto the upper side 3 of the carrier plate 2. Alternatively, it is possible to directly print on the carrier plate 2 on its upper side. Subsequently, the base coat is applied in a first painting station 320 with a paint application device 330. The application of the paint can take place in any suitable form, for example via a roller or the like. Optionally, in a first curing device 340, partial polymerization, drying or the like of the base coat layer may be carried out. In a second painting station 350, the intermediate lacquer layer is applied analogously. The second painting station likewise comprises a paint application device 360 and optionally a second curing device 370, for example a UV light source or the like.
A topcoat application device 400 comprises a paint application device 410 for applying the topcoat layer and a VUV light source 420, for example a xenon excimer laser, for partially polymerizing the topmost material layer of the topcoat layer and forming the microfill. For subsequent electron beam curing, an electron beam device 430 is provided.
After the electron beam hardening, in the illustrated embodiment, a footfall sound insulation layer 5 is laminated on the underside of the support plate 2 in a footfall sound insulation laminating station 440. Connecting is usually carried out at a post-processing station 450, a division of the support plate and / or introduced tongue and groove in the support plate or the plate sections, preferably milled. Finally, one or more finished panels 1 are present.
It will be apparent to those skilled in the art that only a greatly simplified production facility is described herein and individual intermediate processing and refining stations and steps are not described.

BezugszeichenlisteLIST OF REFERENCE NUMBERS

11
Paneelpaneling
22
Trägerplattesupport plate
33
Oberseite (der Trägerplatte)Top side (the carrier plate)
44
Unterseite (der Trägerplatte)Bottom (the carrier plate)
55
Trittschalldämmschichtimpact sound insulation
66
Finishfoliefinish foil
77
Lackaufbaupaint system
88th
GrundlackschichtBase coat layer
99
ZwischenlackschichtIntermediate coat layer
1010
DecklackschichtTopcoat
1111
Oberseite (der Zwischenlackschicht 9)Top (the intermediate lacquer layer 9)
1212
Oberseite (der Decklackschicht)Top side (the topcoat layer)
1313
Materialschichtmaterial layer
1414
Mikrofaltungmicro fold
1515
Materialstärkematerial thickness
1616
Restmaterial (der Decklackschicht)Residual material (the topcoat layer)
100100
Verfahren zur Herstellung eines PaneelsProcess for the production of a panel
110110
Bereitstellen einer TrägerplatteProviding a carrier plate
120120
Aufbringen eines Dekors auf die TrägerplatteApplying a decoration on the carrier plate
130130
Bereitstellen einer bedruckten FinishfolieProviding a printed finish foil
140140
Aufkaschieren der FinishfolieLaminate the finish foil
150150
Aufbringen eines LackaufbausApplying a paint structure
160160
Aufbringen einer GrundlackschichtApplying a base coat layer
170170
Aufbringen einer ZwischenlackschichtApplying an intermediate lacquer layer
180180
Ausbilden der DecklackschichtForming the topcoat layer
190190
Auftragen eines NanokompositlacksApplying a nanocomposite paint
200200
Bestrahlung mit VUV-LichtIrradiation with VUV light
210210
Elektronenstrahlhärtungelectron beam
220220
Aufbringen einer TrittschalldämmschichtApplying a footfall sound insulation layer
230230
Bereitstellen einer TrittschalldämmschichtProviding a footfall sound insulation layer
240240
Aufkaschieren derLaminate the
250250
Nachbearbeiten (Zerteilen und/oder Einfräsen von Nut und Feder)Reworking (cutting and / or milling in tongue and groove)
300300
Vorrichtung zum Herstellen eines Paneels (Produktionsstraße)Device for producing a panel (production line)
310310
Dekoreinrichtungdecorative furnishings
320320
erste Lackierstationfirst painting station
330330
LackaufbringungsvorrichtungPaint applicator
340340
Aushärtungsvorrichtungcuring apparatus
350350
zweite Lackierstationsecond painting station
360360
LackaufbringungsvorrichtungPaint applicator
370370
Aushärtungsvorrichtungcuring apparatus
400400
DecklackschichtaufbringungsvorrichtungTopcoat application device
410410
LackaufbringungsvorrichtungPaint applicator
420420
VUV-LichtquelleVUV light source
430430
Elektronenstrahlvorrichtungelectron beam device
440440
TrittschalldämmungskaschiervorrichtungTrittschalldämmungskaschiervorrichtung
450450
Nachbearbeitungsstationpost-processing station

Claims (9)

  1. Method for producing a panel (1) for a floorcovering, comprising the steps:
    providing a core board (2),
    applying a decoration to an upper side (3) of the core board (2),
    covering the decoration with a lacquer structure (7) which comprises one or more lacquer layers,
    an outer top lacquer layer (10) of the lacquer structure (7) initially being irradiated with short-wave UV light and in this way at least partially polymerised, so that micro-creasing (14) occurs,
    characterized in that
    complete polymerisation of the lacquer structure (7) is then carried out by means of electron-beam curing, and
    in that the top layer is additionally depth-structured, forming structuring depressions, so that the structuring depressions divide at least an outer material layer (13) of the top lacquer layer (10), in which the micro-creasing (14) is formed,
    wherein the top lacquer layer (10) is applied and cured in such a way that an extensively closed, cured material layer is formed on an inner side of the top lacquer layer (10), located opposite the outer side.
  2. Method according to Patent Claim 1, characterized in that, before the irradiation with the short-wave UV light to form the micro-creasing (14), the top lacquer layer (10) is depth-structured.
  3. Method according to Patent Claim 1, characterized in that the at least partially polymerised outer material layer (13) of the top lacquer layer (10) formed during the irradiation of the top lacquer layer (10) and having the micro-creasing (14) is depth-structured, in order to create structuring depressions dividing this outer material layer (13) before the electron-beam curing.
  4. Panel (1), in particular for a floorcovering, comprising
    a core board (2),
    which is provided with a decoration on an upper side (3),
    which is covered by a lacquer structure (7) of one or more lacquer layers,
    the lacquer structure (7) comprising an outer top lacquer layer (10) which has micro-creasing (14) on its outer side,
    characterized in that
    in addition to the micro-creasing (14), the top lacquer layer (10) has depth structuring in the form of structuring depressions, which divide at least one outer material layer (13) of the top lacquer layer (10) in which the micro-creasing (14) is formed,
    wherein the top lacquer layer (10) has an extensively closed material layer on an inner side located opposite the outer side.
  5. Panel (1) according to Claim 4, characterized in that a height of the micro-creasing (14) is of the order of magnitude of 100 nm.
  6. Panel (1) according to either of Claims 4 and 5, characterized in that the lacquer structure (7) additionally has at least one further lacquer layer (8, 9), which adjoins the top lacquer layer (10) directly and is formed as a glossy lacquer layer.
  7. Panel (1) according to one of Claims 4 to 6, characterized in that the decoration is formed by means of a finishing foil (6) laminated onto an upper side (3) of the core board (2), and/or a footstep damping layer (5) is laminated onto an underside (4) of the core board (2).
  8. Panel (1) according to one of Claims 4 to 7, characterized in that at least the top lacquer layer (10), preferably all the lacquer layers, of the lacquer structure (7) are cured completely by means of electron-beam curing.
  9. Panel (1) according to one of Claims 4 to 8, characterized in that the lacquer layers (8, 9, 10) of the lacquer structure (7) are respectively clear in the volume when completely cured.
EP13187605.4A 2013-10-07 2013-10-07 Panel with super-matt surface Not-in-force EP2857221B1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP13187605.4A EP2857221B1 (en) 2013-10-07 2013-10-07 Panel with super-matt surface
TR2018/11685T TR201811685T4 (en) 2013-10-07 2013-10-07 Panel with super matt surface.
PL13187605T PL2857221T3 (en) 2013-10-07 2013-10-07 Panel with super-matt surface

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP13187605.4A EP2857221B1 (en) 2013-10-07 2013-10-07 Panel with super-matt surface

Publications (2)

Publication Number Publication Date
EP2857221A1 EP2857221A1 (en) 2015-04-08
EP2857221B1 true EP2857221B1 (en) 2018-05-16

Family

ID=49304783

Family Applications (1)

Application Number Title Priority Date Filing Date
EP13187605.4A Not-in-force EP2857221B1 (en) 2013-10-07 2013-10-07 Panel with super-matt surface

Country Status (3)

Country Link
EP (1) EP2857221B1 (en)
PL (1) PL2857221T3 (en)
TR (1) TR201811685T4 (en)

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US11504955B2 (en) 2016-08-19 2022-11-22 Wilsonart Llc Decorative laminate with matte finish and method of manufacture
US11077639B2 (en) 2016-08-19 2021-08-03 Wilsonart Llc Surfacing materials and method of manufacture
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Also Published As

Publication number Publication date
TR201811685T4 (en) 2018-09-21
PL2857221T3 (en) 2018-12-31
EP2857221A1 (en) 2015-04-08

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