EP2947235A1

EP2947235A1 - Finishing element and process for the realization of said finishing element

Info

Publication number: EP2947235A1
Application number: EP15168979.1A
Authority: EP
Inventors: Emilio Menini; Paolo Carpigiani; Mario Russo
Original assignee: Studiograph Print & Service Srl
Current assignee: Studiograph Print & Service Srl
Priority date: 2014-05-23
Filing date: 2015-05-22
Publication date: 2015-11-25

Abstract

The present invention refers to a process for the realization of a finishing element, comprising the following steps:
- coating, at least partially, a block (12) of lightweight material with a printable material (14);
- printing a predetermined image on the printable material (14).

Description

The present invention refers in general to a finishing element and to a process for the realization of said finishing element. More particularly, the present invention refers to a finishing element to be used, for example, in the building sector, in the furniture industry, in the field of advertising and more and to a process for the realization of said finishing element.
As is known, the market offers a variety of typologies of finishing elements used to finish the edges or the corners of walls and / or ceilings made of materials such as plaster or more.
Similarly, there are covering elements made of a vitreous or ceramic material, for example to cover the walls of bathrooms or other areas.
Said finishing and / or covering elements can be colored or decorated to improve their final appearance.
Since said finishing and / or covering elements are made of plaster, ceramic or glass, their weight is heavy, which makes it difficult the displacement and the application on the surfaces of destination thus complicating the fixing operations.
Besides, since said finishing and / or covering elements are often made of heavy and fragile materials, said elements are subject to easy breakage and can cause damage to objects or people coming into contact with these materials in emergency situations.
Moreover, in the production of said elements it is necessary to use components and materials which are often harmful and toxic to the environment and to humans such as the so-called volatile organic compounds (VOCs), according to European standards (Directive 1999/13/EC).
An object of the present invention is to realize a finishing element that is able to overcome the problems of the finishing and / or covering elements of the prior art and to overcome the problems of the relevant known processes used for their realization.
Another object of the invention is to realize a finishing element that is lightweight and easy to use.
Another object of the invention is to provide a process for the realization of a finishing element that is respectful of the environment.
The above objects are all achieved by a process for the realization of a finishing element, comprising the following steps:

coating, at least partially, a block of lightweight material with a printable material;
printing a predetermined image on the printable material.

The presence of the printable material allows to greatly improve the printing performance and to obtain special visual effects that, if necessary, can also deceive the human eye.
Besides, since the volume is almost entirely made of light material, the weight of the finishing element is much lower than that which would be obtained using only the printable material.
Advantageously, the lightweight material used to realize the block may have a density less than 35 kilograms per cubic meter so as to obtain finishing elements that have very reduced total weights.
Even more advantageously, the lightweight material may be polyester foam because this material is easily recyclable, non-flammable and insulating.
Furthermore, the printable material may be a mixture of acrylic resins, silica sands, anti-mold agents, viscosity maintainers, releasing oxides in aqueous dispersion.
In this way, it is possible to obtain a very good adhesion with the block, in particular of polyester foam, ensuring at the same time an optimal printing performance.
Advantageously, after the application of the printable material, an acrylic-based paint may be applied on the printable material so as to improve the color rendering of the printing.
Moreover, the acrylic-based paint may comprise a dispersion of alkali-resistant acrylic resins having a high compatibility with lime-cement-based plasters.
Advantageously, the printing of the predetermined image may be carried out by using a printer of digital technology using ultraviolet or UV rays and the image may be an image of high resolution or a realistic image so that the human eye is not able to distinguish the image reproduced on the printable material from the object represented on the image itself.
Besides, after the step of printing of a predetermined image, the semi-finished product is coated, at least partially, with a paint in order to protect the print.
Advantageously, the paint is based on acrylic resins in aqueous dispersion and waxes, is not flaking and is odorless.
Finally, the process may comprise the step of inserting a stiffening element to obtain a greater resistance of the finishing element, for example a compression element.
More features and details of the present invention will be better understood from the following description, supplied by way of a non-limiting example, as well as from the following drawings, wherein:

Figures 1, 2 and 3 are schematic views of some steps of the process for the realization of a finishing element according to the invention;
Figure 4 is a schematic view of an optional element for the realization of a finishing element according to a variant of the invention;
Figure 5 is an exploded schematic view of some components of a finishing element according to a variant of the invention.

Below, a process for the realization of a finishing element according to the invention is described.
With reference to Figure 1, a block 12 is used as raw material.
The block 12 is preferably made of a lightweight material, shaped as desired, and forms the starting base for the process in question.
The shape of a parallelepiped of the block 12 in Figure 1 is representative but it is possible to use blocks having varied forms such as baseboards or friezes of various types.
The block 12 has a thickness included between 10 and 40 millimeters but obviously, it is also possible to operate with different thicknesses that may be lower or higher than the preferred thicknesses.
The block 12 is made of materials having a closed-cell structure, a characteristic that favors the thermal insulation. Obviously, also different materials may be used, even with an open cell structure.
Below, reference is made conveniently, but not in a limitative way, to expanded polystyrene (EPS).
Besides, the expanded polystyrene is preferably produced with special additives which reduce the water absorption of about 40%.
Said characteristic is obtained with both a partial immersion and a total immersion in long periods in respect to the conventional EPS (without additives) so as to make the material compatible for the parts coming into contact with the soil or having humidity problems.
Furthermore, a strong vapor permeability prevents the formation of mold and condensation. Its duration in the time makes the material easily recyclable. Moreover, since said material is devoid of nutrients, it is possible to avoid the growth of bacteria o other microorganisms.
The EPS is a material composed only by carbon atoms and hydrogen atoms.
As visible in Figure 2, a printable material 14 is applied on a face of the block 12 so as to obtain a surface that is more easily printable than the block on which the printable material is applied.
The printable material 14 is a resin but also another suitable material can be used for such purposes.
Preferably, the resin used is a product for both internal and external use and is not toxic. This resin is obtained by mixing acrylic resins, silica sands, anti-mold agents, viscosity maintainers, releasing oxides in aqueous dispersion.
The resin 14 is semifluid before the application so as it is possible to evenly apply a layer of the wished thickness on the entire surface of the block 12. The preferred thickness of the resin application is 3 millimeters.
Preferably, the resin is spread and applied by means of a plastering machine with compressed air at a pressure of 12bar. Besides, the application of the resin is done with two subsequent coats leaving a time of twelve hours between the first coat and the second coat.
With a good coverage and a strong adhesion of the block 12 to the expanded polystyrene it is possible to obtain an optimal structural stability of the semi-finished product obtained in respect to the variations of temperature and humidity. Besides, a good permeability to water vapor and a high index of water repellency are maintained.
Further features of the semi-finished product are not to propagate flames and have a good resistance to the aging.
Tests have been performed on finishing elements produced according to the present invention and an average resistance to bending of 5.00 N/mm² and a resistance to compression of 8.00 N/mm² (Ref. Regulations EN 12004) have been found.
Furthermore, a classification has been done (with reference to European Classification EN 13501-1) regarding the reaction to fire A2, i.e. incombustible materials, and accessory classification s1, i.e. the best as concerns the production of smoke during the combustion, and a further accessory classification d0, i.e. the best as regards dripping during combustion.
The semi-finished product has a low impact on the ambient in compliance with the directive 2004/42/EC of European Parliament as concerns the limits of emission of volatile organic compounds (VOC).
After the resin of the printable material 14 has been allowed to dry, the resin is treated with one or more coats of base paint, preferably a transparent acrylic gel varnish.
Preferably, a dispersion of alkali-resistant acrylic resins is used which have a high compatibility with lime-cement-based plasters.
The application of the base varnish acts as a binder and allows to better consolidate the subsequent printing on the resin.
Obviously, it is possible to directly print on the printable material 14, without applying the base varnish.
After applying the base varnish, the process continues with a printing 16 of an image or graphics through suitable printing means, preferably UV printers of digital technology including a drying with ultraviolet rays so as to obtain a very high quality in the images and graphics, personalized by request, as visible in Figure 3 which represents schematically the image of a wooden table.
The use of said technology of digital UV printing allows to obtain realistic images deceiving the human eye to the effect that the human eye mistakes the image for a surface made of the represented material.
Thus, it is possible to print an image of a wooden table to the effect that the human eye is confused and perceives to be in front of a real wooden table.
Another example is obtained by using an image of a rusty steel plate through which it is possible to obtain a finishing element which is equivalent, at the sight, to the rusty steel plate from which the image has been obtained.
Preferably, the UV printing colors used in the process according to the invention are printing heads with technology of 12 nanoliters, i.e. the millionth part of a liter.
Preferably, dyestuffs are used without VOC (Volatile Organic Compounds) according to European standards (Directive 1999/13/EC). Besides, all the inks used are preferably in compliance with RoHS, do not include heavy metals, poisonous substances or corrosive substances. This peculiarity allows to obtain a product having a low level of CO₂ emissions. In this way, unlike the processes used in the prior art, it is possible to obtain a process which is respectful to ambient and man.
Below, a step of final varnishing is described during which a layer of varnish is applied on the print of the preceding step. Said varnish may also be applied on all the remaining part of the materials of the semi-finished product. After the printing, the materials are thus finished with polishing varnishes or opaque varnishes or glazed varnishes according to the preferences and the final result to be obtained. The varnishes used are preferably acrylic varnishes.
Preferably, a wax-finishing showing an effect "pearl" is used on the base of acrylic resins in aqueous dispersion and waxes, said finishing being anti-exfoliation and odorless.
This process of final varnishing provides a finishing that ensures a high endurance in the outside, protects and capsules the prints in the rest of the finishing element. In this way, an only body is formed which has one or more layers of varnish.
Thus, it is possible to obtain a longer endurance in the sun and a greater resistance to atmospheric agents and aging.
In this way, the chromatic efficiency of the print can be maintained for years, also for tens of years.
Obviously, said step of final varnishing may be avoided or substituted by an equivalent step.
Hence, a finishing element according to the invention comprises in a non-limiting embodiment:

a block of expanded polyester;
a layer of resin;
a base varnish:
a digital UV print;
a final varnishing.

According to a variant of the invention, it is possible to realize also a finishing element comprising a lightweight generic block, having preferably a density lower than 35 kg/m³ (kilograms per cubic meter) and a layer of printable material on which an image is printed.
According to a variant of the invention, the process may comprise a step of inserting a stiffening element 18, as visible in Figures 4 and 5, by interposing the same between the block 12 and the layer of printable material 14.
Preferably, said stiffening element is a net made of a material which is more rigid than the block to which the stiffening element is coupled.
A preferable form for the net is made of a fiber glass of 160 grams per square meter, ladderproof and alkali resistant, which allows to make the finishing element still more resistant, stable in its applications and harder to scratch so that it is possible to obtain a greater resistance to shocks and compressions.
The process for the realization of a finishing element as described above allows to obtain a finishing element having characteristics which are much better and higher than the characteristics of the finishing elements known.
The finishing element consists especially of a block made of a lighter material than the materials used according to the prior art so that the finishing material becomes lighter and more manoeuvrable on the whole for the montage and the application on walls, ceilings and more.
The process according to the invention allows to realize also components of furniture such as parts of wardrobes or more, which maintain the outer appearance of an element made entirely or partially of the material represented in the printed image, the weight being clearly lower and the endurance being greater over the time.
An example of said application may be a wardrobe door, normally made of wood on the whole or at least coated on its outer portion, for example by framing the element so that this element is visible to whoever is using the wardrobe in question.
If a wardrobe door is produced with an element according to the invention on which an image has been printed to represent the outer appearance of the wood used in the known wardrobe door, it is possible to obtain a door that maintains the wished appearance and is, at the same time, lighter than the known door and more stable over the time. Other examples of application may be support planes of tables, chairs and more.
The used digital UV printing process allows to obtain also edges for the finishing element according to the invention because the print has a shade which is visible as the finishing element is moved away from the edge.
The use of blocks of expanded material such as EPS allows to form a slightly irregular surface by using a hot wire cut. In this way, it is possible to obtain a rough surface to the touch.
The subsequent application of the resin allows to follow the roughness of the used material so as to maintain a roughness which can not be mass-reproduced owing to the peculiarity of the process. In this way, each block coated with resin shows a unique appearance.
When the print is applied, the result is excellent and is not affected by the superficial roughness thanks to the technology of digital UV print. The product obtained by printing and varnished in the subsequent final varnishing step is still rough so that by the touch, the product gives a sensation of matter reminding the simulated material, i.e. the material represented in the printed image.
Said unevenness, when desired, allows to obtain unique pieces, i.e. a product of a high quality, for example the quality of a hand-manufactured article but with a level of productiveness that is typical of the industrial production.
The process according to the invention allows to obtain, when desired, a simulation to the sight and touch of heavy materials, in products weighing much less, also of one or more orders of greatness.
Below, there are listed the results of laboratory tests performed on finishing elements according to the invention on the base of tests of endurance to light through exposure to radiation of a xenon lamp, in XENON TESTS, performed in compliance with the following rules: UNI EN ISO 4892-2:2009 of 24/09/2009, UNI EN ISO 105-B08:2009 of 03/12/2009, UNI EN 20105-A02:1996 of 30/06/1996.
The tests were performed in 600 hours, with cycles of 102 minutes of irradiation, alternated to 18 minutes of water spraying and irradiation.
The visual evaluation, the evaluation of color solidity according to blue/grey scale and the evaluation of color variations, the evaluation of endurance to light after 600 hours of accelerated aging in XENON TESTS, with xenon lamp, have produced the following data:

in the blue-scale ranging from degree 1 of minimum solidity to light to degree 8 of maximum solidity to light, all the tests have produced a degree >7;
in the grey-scale ranging from degree 1 of minimum solidity of color to degree 5 of maximum solidity of color, all the tests have produced degree 5;
concerning the values of relative ΔE cielab, with reference to the grey-scale, the tests have produced the values 0.0 ± 0.2.

Finally, variants may be provided which are to be considered as included in the scope of protection of the invention as defined by the following claims.

Claims

Process for the realization of a finishing element, comprising the following steps:
- coating, at least partially, a block (12) of lightweight material with a printable material (14);

- printing a predetermined image on the printable material (14).
Process according to the preceding claim, wherein the lightweight material used to realize the block (12) has a density less than 35 kilograms per cubic meter.
Process according to one of the preceding claims, wherein the lightweight material is polyester foam.
Process according to the preceding claim, wherein the printable material (14) is a mixture of acrylic resins, silica sands, anti-mold agents, viscosity maintainers, releasing oxides in aqueous dispersion.
Process according to one of the preceding claims, wherein after the application of the printable material (14), an acrylic-based paint is applied on the printable material (14).
Process according to the preceding claim, wherein the acrylic-based paint comprises a dispersion of alkali-resistant acrylic resins having a high compatibility with lime-cement-based plasters.
Process according to one of the preceding claims, wherein the printing of the predetermined image is carried out by using a printer of digital technology using ultraviolet or UV rays and the image is a high resolution or realistic image.
Process according to one of the preceding claims, wherein after the step of printing of a predetermined image, the semi-finished product is coated, at least partially, with a paint.
Process according to the preceding claim, wherein the paint is based on acrylic resins in aqueous dispersion and waxes, is not flaking and is odorless.
Process according to one of the preceding claims, wherein the step of inserting a stiffening element (18) is comprised.