Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C5/00—Processes for producing special ornamental bodies
  • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
  • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
  • B41M3/00—Printing processes to produce particular kinds of printed work, e.g. patterns
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
  • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
  • B41M5/00—Duplicating or marking methods; Sheet materials for use therein
  • B41M5/0041—Digital printing on surfaces other than ordinary paper
  • B41M5/0047—Digital printing on surfaces other than ordinary paper by ink-jet printing
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
  • B44C3/02—Superimposing layers
  • B44C3/025—Superimposing layers to produce ornamental relief structures

Definitions

• the present invention relates to a method for producing a structured wear protection film, a structured wear protection film, the use of a structured wear protection film and a decorative panel with a structured wear protection film.
• Structured surfaces for wear protection are known per se and are used in particular to protect decorative panels.
• EP 2 740 610 A1 , EP 2 730 429 A1 and WO 2018/078043 A1 relate to methods for producing a structured wear protection layer.
• decorative panel is to be understood as meaning wall, ceiling, door or floor panels which have a decoration applied to a carrier plate.
• Decorative panels are used in a variety of ways both in the area of interior design of rooms and for the decorative cladding of buildings, for example in trade fair construction.
• One of the most common areas of application for decorative panels is their use as floor covering, to cover ceilings, walls or doors.
• the decor panels often have a decor and a surface structure that is intended to imitate a natural material.
• wear or cover layers are generally applied above the decorative layer.
• a surface structure imitating a decorative template is introduced into such wear or cover layers, so that the surface of the decorative panel has a Has haptically perceptible structure, which is adapted to its shape and pattern of the applied decor in order to obtain a replica of a natural material that is as true to the original as possible, also with regard to the haptics.
• a disadvantage of such methods can be that in particular the formation of small and locally limited structures, such as pores, is only possible with great difficulty.
• the exact alignment of the embossing tools relative to the decor can cause problems.
• variations in the structure can only be implemented with great effort and, for example, small production series are comparatively uneconomical, since embossing tools have to be manufactured and exchanged for each series.
• embossing tools have to be manufactured and exchanged for each series.
• structured wear protection film is to be understood in the context of the invention as a film that can be applied to panels or other material, has haptically perceptible structures and protects against wear.
• wear protection base film is to be understood in the context of the invention as a film that can be applied to panels or other material, does not have to have any special structuring and can serve as a substrate for applying structures.
• malleable is to be understood as meaning a material which is plastically deformable, that is to say changes its shape through the action of force.
• the material can be liquid or solid, for example.
• digital printing process is to be understood in the context of the invention as a computer-controlled direct printing process.
• the term “hardening” is to be understood as meaning that the malleable material loses its malleability.
• a liquid moldable material can be solidified.
• a plastically deformable solid can be converted into an elastically deformable solid, for example by hardening.
• the material can partially lose its malleability, that is to say lose its malleability at certain points, for example on the surface. It can also be understood to mean that the malleability is only reduced and the material does not become completely non-malleable. It can also be understood as complete hardening.
• An above-described method for producing a wear protection film thus serves in particular for the improved production of structured surfaces for wear protection.
• a wear protection base film provides a substrate on which structuring can take place.
• a moldable, lacquer-containing cover layer By applying a moldable, lacquer-containing cover layer to at least a partial area of the wear protection base film, a structurable layer is provided which is held by the wear protection base film and can therefore be easily shaped and nevertheless can be guided through the process with the wear protection base film.
• the partial structuring of the lacquer-containing top layer with a digital printing process for generating a structure of the lacquer-containing top layer makes it possible to obtain a structuring of the lacquer-containing top layer that is particularly true to detail. Since no embossing tools have to be used in the digital printing process, the wear protection base film as a substrate can provide sufficient stability for the structuring.
• the introduced structure By subsequently hardening the now structured, lacquer-containing top layer, the introduced structure is fixed so that it remains essentially unchanged even when a force is applied.
• the wear protection base film and / or the moldable, lacquer-containing top layer has a plastic composition, preferably an acrylate-based plastic composition, in particular a polyurethane-modified acrylate plastic composition.
• the moldable, lacquer-containing top layer has the plastic composition in an as yet uncured form, so that the top layer can be molded, and that the wear protection base film has the plastic composition in an at least partially cured form, so that it can be used as a substrate for the moldable lacquer-containing top layer can serve.
• the structured wear protection film is flexible overall and at the same time has particularly good protective properties, such as stability, scratch resistance, heat resistance, water resistance and the like.
• the plastic composition can contain a dipropylene glycol diacrylate, preferably in an amount of> 0 to ⁇ 15% by weight based on the plastic composition, and a reaction product of pentaerythritol, epichlorohydrin and acrylic acid, preferably in an amount of ⁇ 2 to ⁇ 15% by weight based on the plastic composition.
• the plastic composition can additionally have a catalyst, preferably in an amount of 1 to 10% by weight based on the plastic composition.
• the catalyst can preferably be a tertiary ammonium salt, in particular a tertiary ammonium salt selected from the group consisting of tetrabutlyammonium bromide, methyltrioctylammonium chloride, benzyltriethylammonium chloride, hexadecyltrimethylammonium bromide and mixtures thereof.
• the catalyst can be tetrabutylammonium bromide.
• the plastic composition can additionally have a photoinitiator, preferably in an amount of 0.1 to 2% by weight, based on the plastic composition.
• the photoinitiator can be a phosphine oxide, preferably an aromatic phosphine oxide, in particular phenylbis (2,4,6-trimethylbenzoyl) phosphine oxide.
• the moldable, lacquer-containing cover layer and the wear protection base film both have the same plastic composition.
• the formable, lacquer-containing cover layer and the wear protection base film consist essentially of the same material after the lacquer-containing cover layer has hardened.
• the visual impression of the structured wear protection film is improved, since the wear protection base film and the lacquer-containing top layer also have the same optical properties after curing and thus unwanted light refraction between the two layers can be avoided.
• the wear protection base film and / or the mouldable lacquer-containing top layer has hard materials, preferably in an amount between 5% by weight and 40% by weight, the hard materials preferably having an average grain diameter between 10% and 40% by weight ⁇ m and 250 ⁇ m.
• hard materials is understood to mean materials which have sufficient hardness.
• the hard materials can have a Mohs hardness of at least 8, preferably at least 9.
• suitable hard materials are titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, aluminum oxide (corundum), zirconium oxide, zirconium nitride or mixtures of these.
• the structured wear protection film can be particularly resistant to abrasion.
• Hard materials in the wear protection base film enable abrasion protection over the entire surface of the structured wear protection film.
• Hard materials in the mouldable lacquer-containing top layer enable abrasion protection of the Structure after hardening of the lacquer-containing top layer. As a result, it can be achieved that the structure becomes less blunted by stress.
• the formable lacquer-containing top layer has a thickness of ⁇ 1 ⁇ m to 5 mm, preferably ⁇ m 10 ⁇ m to 200 ⁇ m, in particular bis 50 ⁇ m to 60 ⁇ m. It can be provided that the lacquer-containing top layer is applied in an application amount of ⁇ 50 g / m 2 to ⁇ 100 g / m 2 , preferably ⁇ 60 g / m 2 to ⁇ 80 g / m 2 , for example 70 g / m 2 , is applied.
• the formable lacquer-containing cover layer has a material curable by electromagnetic radiation, in particular a material curable by UV radiation and / or IR radiation
• a material curable by electromagnetic radiation is understood to mean a material in which a chemical reaction can be set in motion by electromagnetic radiation, whereby the material becomes harder.
• this chemical reaction can be a polymerization or a crosslinking reaction.
• the partial structuring of the lacquer-containing top layer is carried out with a digital printing process by spraying on a displacement ink with an inkjet process.
• the term “spraying on” is understood to mean that a material is applied as an aerosol jet to a substrate in the form of particles and / or drops.
• the term “displacement ink” is understood to mean an ink, for example a liquid, solution or suspension, which when it strikes a moldable material partially displaces it.
• the term “inkjet method” is understood to mean a method in which an ink is applied in a matrix via one or more nozzles.
• the moldable, lacquer-containing cover layer is structured by the impact of the displacement ink.
• the impact of a drop or particle can create depressions such as craters or valleys, at the bottom of which the ink remains. Due to the displacement during the formation of the depression, a wall can also arise around the depression, which represents an elevation.
• the displacement ink consists essentially of an ink composition selected from the group consisting of acrylate-based plastic, polyurethane-modified acrylate plastic, water, organic solvent or mixtures thereof.
• the ink composition comprises an ethoxyethyl acrylate, preferably 2- (2-ethoxyethoxy) ethylene acrylate, preferably in an amount of 20 to 40% by weight, based on the ink composition.
• the ink composition esterifies an ethoxylated polyol with acrylic acid, preferably 1,1,1-trimethylolpropane ethoxylate triacrylate, preferably in an amount of 20 to 40% by weight, based on the ink composition.
• the ink composition has a urethane acrylate, preferably in an amount of 10 to 20% by weight, based on the ink composition.
• the ink composition has pentaerythritol acrylic acid ester, preferably in an amount of ⁇ 5 to 10% by weight, based on the ink composition. It can also be provided that the ink composition has amine-modified acrylic oligomers, in particular reaction products of tripropylene glycol diacrylate with diethylamine, preferably in an amount of von 5 to 10% by weight, based on the ink composition.
• the displacement ink is hardened when the lacquer-containing top layer is hardened and is crosslinked with the lacquer-containing top layer.
• the displacement ink is evaporated when the lacquer-containing top layer is hardened.
• a drop speed, a drop volume and a position of the sprayed displacement ink are varied according to a three-dimensional digital template.
• the drop speed By varying and controlling the drop speed, it can advantageously be achieved that structures with different depths can be produced. In addition, it is achieved that structures with different wall sharpness are generated. It can therefore be varied in particular whether the structure has sharp or blunt edges.
• the drop volume By varying the drop volume, the depth of the structure can also be varied.
• the width of depressions in particular can be varied.
• the position By varying the position, it is possible to set where the depressions and elevations are. As a result, overall control over the structuring is achieved, so that a desired structure can be generated in accordance with a three-dimensional digital template.
• the term “three-dimensional digital template” is understood to mean a template that reproduces a structure in three dimensions, it being possible for the template to be stored, for example, in the form of a CAD model on a digital medium.
• the digital template is generated on the basis of a decoration, the digital template providing complementary depressions and elevations corresponding to the feel of the decoration.
• the curing is carried out with UV radiation with a wavelength in a range from ⁇ 10 nm to 450 nm, preferably from 200 nm to 410 nm.
• the curing is carried out in a first curing step with UV radiation in a range from Supplier 315 nm to 450 nm, preferably 380 nm to 410 nm, and in a second curing step with UV Radiation is carried out in a range from ⁇ 10 nm to ⁇ 250 nm, preferably from ⁇ 170 nm to ⁇ 225 nm.
• the surface is hardened particularly strongly. This also enables a particularly high chemical resistance to be achieved. In addition, it can thereby be achieved that good curing is made possible even without photoinitiators or with only a small amount of photoinitiator. Furthermore, hardening with only a small amount of heat input can thereby be made possible.
• the lacquer-containing top layer is irradiated in the second curing step with UV radiation from a radiation source with a power of 5 to 30 W / cm.
• the volume between the UV radiation source and the lacquer-containing top layer has an inert gas atmosphere.
• an inert gas for example N 2 or a noble gas
• there is essentially no oxygen is exposed to direct UV radiation between the UV radiation source and the top layer containing paint.
• drying can be carried out with particularly short wavelengths. It can be achieved that the UV radiation is absorbed comparatively less. In addition, it can be achieved that the UV radiation does not cause any reactions in the air, such as the reaction to ozone. In addition, undesired surface reactions can be avoided, so that a particularly stable surface is created.
• the hardening begins less than 5 s, preferably less than 2 s, in particular less than 0.5 s, after structuring.
• the moldable, lacquer-containing cover layer is pre-cured prior to structuring.
• the viscosity of the paint-containing top layer can be adapted.
• the structuring can be generated in a particularly true-to-detail manner.
• This can also be understood to mean that hardening is set in motion shortly before structuring, so that during structuring the structures formed achieve a hardness that is sufficient to avoid subsequent deliquescence before final hardening.
• the structuring can be applied directly in synchronism with a decoration.
• the structuring can be aligned directly with the digital printing process in such a way that the structuring is generated synchronously with the decor.
• a “carrier” can in particular be understood to mean a layer serving as a core or as a base layer in a finished panel, which can in particular have a natural material such as a wood material, a fiber material or a material comprising a plastic.
• the carrier can add suitable stability to a panel or contribute to it.
• Wood-based materials within the meaning of the invention are, in addition to solid wood materials, also materials such as, for example, cross-laminated timber, glued laminated timber, rod plywood, veneer plywood, laminated veneer lumber, veneer strips and flexible plywood.
• wood-based materials for the purposes of the invention also include chipboard materials such as chipboard, extruded boards, coarse chipboard (Oriented Structural Board, OSB) and chipboard wood as well as wood fiber materials such as wood fiber insulation boards (HFD), medium-hard and hard fiber boards (MB, HFH), and in particular medium-density Fibreboard (MDF) and to understand high density fibreboard (HDF).
• chipboard materials such as chipboard, extruded boards, coarse chipboard (Oriented Structural Board, OSB) and chipboard wood as well as wood fiber materials such as wood fiber insulation boards (HFD), medium-hard and hard fiber boards (MB, HFH), and in particular medium-density Fibreboard (MDF) and to understand high density fibreboard (HDF).
• Modern wood-based materials such as wood-polymer materials (Wood Plastic Composite, WPC), sandwich panels made of a light core material such as foam, rigid foam or paper honeycomb and a layer of wood applied to it, as well as wood-based chipboard bonded mineral, e.g. with cement, form wood-based materials within the meaning of the invention.
• WPC Wood Plastic Composite
• sandwich panels made of a light core material such as foam, rigid foam or paper honeycomb and a layer of wood applied to it, as well as wood-based chipboard bonded mineral, e.g. with cement, form wood-based materials within the meaning of the invention.
• Cork also represents a wood material in the sense of the invention.
• Plastics that can be used in the production of corresponding panels or the carrier are, for example, thermoplastics such as polyvinyl chloride, polyolefins (e.g. polyethylene (PE), polypropylene (PP), polyamides (PA), polyurethanes (PU), polystyrene (PS)) , Acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polyetheretherketone (PEEK) or mixtures or co-polymers of these.
• the plastics can contain conventional fillers, for example calcium carbonate (chalk) Aluminum oxide, silica gel, quartz powder, wood flour, gypsum, etc. They can also be colored in a known manner.
• the carrier can in particular be a web-like carrier or a plate-shaped carrier.
• a “web-like carrier” can be understood to mean a carrier which, for example in its manufacturing process, has a web-like length and thus a length that is significantly greater than its thickness or width and the length of which can be greater than 15 meters, for example.
• a “plate-shaped carrier” can furthermore be understood in the context of the present invention as a carrier which is formed from the web-like carrier by separation and is in the form of a plate. Furthermore, the plate-shaped carrier can already predetermine the shape and / or size of the panel to be produced. However, the plate-shaped carrier can also be provided as a large plate.
• the invention is a carrier whose dimensions exceed the dimensions of the final decorative panels by a multiple and which is divided into a corresponding plurality of decorative panels in the course of the manufacturing process, for example by sawing, laser or water jet cutting.
• the large plate can correspond to the web-shaped carrier.
• a decoration can for example be applied to the carrier, for example by a printing process.
• a suitable printing substrate can also be provided on the carrier.
• the decoration is applied in such a way that, for example, an already printed fiber layer, such as a paper layer, or an already printed film, such as for example made of polyethylene, polypropylene or polyvinyl chloride, is applied to the carrier .
• fiber materials is understood to mean materials such as paper and nonwovens based on vegetable, animal, mineral or artificial fibers, as well as cardboard.
• fiber materials made from vegetable fibers in addition to paper and nonwovens made from cellulose fibers, panels made from biomass such as straw, corn stalks, bamboo, leaves, algae extracts, hemp, cotton or oil palm fibers.
• animal fiber materials are keratin-based materials such as wool or horsehair.
• mineral fiber materials are mineral wool or glass wool.
• the decoration can also be provided with a lacquer-containing layer, which is located between the wear protection base film and the decoration after the wear protection base film has been applied.
• the invention also proposes a structured wear protection film.
• a structured wear protection film is provided, produced according to the method according to the invention, comprising a wear protection base film with a lacquer-containing top layer applied and fixed to at least a portion of the wear protection base foil, the lacquer-containing top layer having structures produced by the digital printing process.
• a wear protection film it can be achieved that a material to be protected is protected from wear.
• the film can already be applied to a material to be protected or it can be present individually.
• the film for example in contrast to an exclusively directly applied wear protection layer, can be applied flexibly to a material to be protected. As a result, such a film can advantageously also be produced independently of the material to be protected.
• the invention also proposes the use of a structured wear protection film according to the invention.
• a structured wear protection film is provided to protect a decorative panel, the decorative panel having a carrier and a decoration on at least a partial area of the carrier and the structured wear protection film being applied to the decoration, the structuring of the lacquer-containing film when the structured wear protection film is applied Cover layer is at least partially aligned synchronously with the decor.
• This means that the structured wear protection film is only applied to a decorative panel after production.
• the at least partially synchronous alignment of the structuring of the wear protection film with respect to the decoration can be implemented, for example, with alignment marks.
• the use according to the invention advantageously means that the production of protected decorative panels has greater flexibility.
• the structured wear protection film according to the invention also prevents the panel from being deformed due to possible shrinkage during the hardening of wear protection layers directly on the panel.
• the invention also proposes a decorative panel with a structured wear protection film.
• a decorative panel with a structured wear protection film having a carrier, with a decoration applied to at least a partial area and a structured wear protection film according to the invention applied to the decoration, and the structures of the structured wear protection film being synchronous with the decoration at least in partial areas.
• a suitable printing substrate can also be provided between the carrier and the decoration.
• the decoration can also be provided with a lacquer-containing layer, which is located between the wear protection film and the decoration.
• the decorative panel is well protected against wear and at the same time has a particularly detailed structuring, the haptic perception of which corresponds to the visual perception of a decor, so that a particularly high-quality overall impression is created.

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Priority Applications (7)

Applications Claiming Priority (1)

Publications (2)

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• 2018
  • 2018-10-02 PL PL18198350T patent/PL3632700T3/pl unknown
  • 2018-10-02 EP EP18198350.3A patent/EP3632700B1/de active Active
• 2019
  • 2019-06-18 WO PCT/EP2019/066017 patent/WO2020069779A1/de active Application Filing
  • 2019-06-18 RU RU2021106702A patent/RU2769650C1/ru active
  • 2019-06-18 CA CA3109340A patent/CA3109340C/en active Active
  • 2019-06-18 US US16/959,751 patent/US11014399B2/en active Active
  • 2019-06-18 CN CN201980009420.7A patent/CN111629908B/zh active Active

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