SK286500B6 - Method for producing floor-finish and wall-finish with differential gloss decoration - Google Patents

Abstract

The invention concerns a method for floor-finish and wall-finish with differential gloss decoration effect characterised in that it consists in producing an undercoat (10) and then producing gloss effects by differentiated deposits (20, 22, 24) without total overlap of at least two topcoat type protective layers with different characteristics, in similar or different register, with the undercoat.

Description

The invention relates to an improved method for producing floor and wall coverings in a contrasting matt and glossy finish in combination with other decorations (drawings, plastic patterns, layering) customary for this kind of article.

The invention also relates to products made in this way.

BACKGROUND OF THE INVENTION

New types of floor coverings, especially flexible floor coverings, have been continuously developed to satisfy customers' requirements. The development focuses on the creation of new drawings, layering and plastic patterns (mechanical or chemical roughening) and on their utility properties (wear resistance, toughness).

The search for new external effects generally implies a coherence (continuity) between the drawing, the relief pattern and possibly other optical effects. The aim is to create locally defined effects of different gloss zones.

To create matt and shiny effects, mechanical wrinkling is now most used to create structures with varying degrees of mattness.

Current performance and wear and chemical resistance requirements require top coatings to be of higher quality than conventional products. However, it is precisely at these top layers that, due to their frequent treatment, the dullness created by mechanical wrinkling occurs.

Further developments should respect current coating or surface treatment technologies, especially in large areas. The proposed solutions cannot assume the disposal of existing material or significantly higher prices for new equipment.

WO 99/39042 discloses floor and wall coverings in a contrasting gloss whose at least one layer is provided with wear-resistant grains, for example alumina.

This technique requires the use of resins suitable for crosslinking, for example urethane-based resins, regardless of the presence or absence of said beads.

The method described requires at least a chemical wrinkle step and involves the application of a topcoat on a portion of the plastic surface of the article. The top coat has a different gloss and creates a contrast effect. According to the second recommended solution, one continuous topcoat and one discontinuous topcoat are applied to the plastic surface.

This technique of overlapping the plastic surface, also called kisscoating, requires a very careful procedure.

Inaccurate adjustment of the device may cause differences in product thickness and loss of contact, possibly damaging the plastic surface.

SUMMARY OF THE INVENTION

The invention largely removes the above drawbacks. The proposed method is easy and economical to carry out. By varying the application of different grades or topcoat qualities, it is possible to make a tile with good wear resistance and numerous contrast effects.

According to the invention, the base cladding layer is first carried out by conventional techniques known to those skilled in the art. Glossy effects are then created by differently applying at least two topcoat layers of different properties, without fully covering them and coinciding or not coinciding with the bottom layer decoration.

With these techniques, we get a compact product with different shiny effects in topcoat coatings.

The base layer to which the decoration with different glosses is applied can be smooth or plastic after mechanical or chemical wrinkling and can be flexible or solid.

The base layer decoration can be printed, made by inlaid coating, or other known techniques. The product can be made on commonly used flooring equipment up to a width of 4 m or wider.

The linings may be made of synthetic materials such as PVC and polyolefins, semi-synthetic linoleum materials or laminated materials and wood.

The first protective layer is first applied continuously or discontinuously to the selected base layer, followed by drying.

This is followed by the discontinuous application of a second protective layer whose dullness is different from that of the first layer.

If the first layer is discontinuous, it may be partially covered by the second layer. Partial overlap will be necessary if the first layer is continuous.

The additional gloss shades (for example, the shade between the brightest and matt layers) are made either by further partially overlapping the first and second layers, or by applying one or more additional protective layers.

Each application of the protective layer is followed by drying, which may be carried out by hot air or infrared radiation.

After drying, crosslinking is performed, preferably by UV or electron beam.

The layers of different gloss may be laid in agreement or disagreement with the actual decoration of the tile and / or in agreement or disagreement with the plastic pattern of the article.

The gloss level of protective coatings with different glosses can vary from 5 to 90 (below 60 degrees).

The thickness of the layers thus applied is 3 to 50 µm.

The laying of different protective layers of different gloss can be carried out by one or more of the following techniques (it being understood that the first protective layer can be applied optionally continuously):

- air wiper,

- screen printing,

- heliography,

- flexographic printing,

- cylinder.

In addition to the different gloss levels, the coatings can be provided with a colored coating.

The proposed technique allows to create gloss contrasts - mattness in two or more stages of different gloss.

The protective coatings selected contain resins commonly used in the "topcoat" technique, which may or may not be colored, the layers being deposited so that the specific gloss of one layer contrasts with the gloss of the adjacent layer.

In contrast to the techniques called kisscoating, the invention allows to cover both the recesses and the tops of the plastic tiling pattern.

Conventional resins are used in the protective layer to form network structures under UV or electron beam. These are polyurethane, melamine, epoxy, acrylate or modified ion exchange and other resins. Resins capable of crosslinking by heat are also suitable, but their processing is more difficult. The incorporation of matt effect additives into such compositions will not decrease, but may even increase abrasion resistance. A variety of techniques and products are also available for practicing this method.

Overview of the figures in the drawing

BRIEF DESCRIPTION OF THE DRAWINGS The invention will be further elucidated by describing examples of embodiments thereof with reference to the drawing in which FIG. 1 shows the steps of manufacturing a cladding according to the invention on a production line; Fig. 2 is a schematic cross-sectional view of a continuous-coat facing in a first embodiment of the invention; Fig. 3 schematically in cross-section a second embodiment of a flat cladding; Fig. 4 is a cross-sectional view of a patterned article having a continuous coating; schematic cross-section of a parquet flooring product with a discontinuous top layer.

In these figures, the same reference numerals are used for the same basic elements.

DETAILED DESCRIPTION OF THE INVENTION

In the production line shown schematically in FIG. 1, the following steps are performed:

manufacturing the base layer 1 in a known manner;

- first coating 2 with polyurethane resin; this step can be carried out by virtually all commonly used techniques, air squeegee, roller or screen printing, heliography or flexographic printing;

- drying 3; it may be dried with hot air and / or an infrared heating device;

- crosslinking 4; conventional techniques employing ultraviolet radiation or electron current are suitable for this purpose;

a second discontinuous coating 5 with a polyurethane resin by means of heliography or flexographic printing;

drying 6 using the same techniques as in step 3;

crosslinking 7 using the same techniques as in step 4;

- a possible third coating 8 with polyurethane resin.

It should be noted that the reference to polyurethane is illustrative, as other resins and their compounds may also be used, which may form network structures under ultraviolet rays or under electron flow.

In FIG. 2 to 5 is a composite base layer denoted by 10, a first layer which may be continuous or discontinuous and corresponds to the first coating 2 of FIG. 1 is denoted by the reference numeral 20, the reference numeral 22 denoting a second topcoat layer which is necessarily discontinuous and corresponds to the second coating 5 of FIG. 1 and reference numeral 24 denotes a second topcoat corresponding to a possible third coat 8 of FIG. First

The base layers of FIG. 2 and 3, for example, the glass fabric 11 impregnated with foam 12 may comprise a compact layer 13 and a conventional wear layer 14.

In the example shown in FIG. 1 applies a continuous matt polyurethane layer 20, a discontinuous layer of higher gloss 22 and a discontinuous layer of medium gloss.

The example of FIG. 3 differs from the example of FIG. 2 in that the layer 20 is discontinuous and the layers 22 and 24 overlap the gaps in the discontinuous layer 20.

In FIG. 4 is a schematic and cross-sectional view of a plastic article. The foam layer 15 is formed by a so-called foam layer. cushion-floor technique. The wear layer 14 follows its plastic pattern without penetrating into it and is also accomplished by known techniques for depositing plastic-shaped layers.

The first topcoat 20 is applied continuously and also follows the plastic shape of the underlying layers.

Further layers 22 and 24 are applied, for example, only to the peaks (layer 22) and to the peaks and recesses (layer 24). Since the layer 20 is continuous, it is possible, as is evident in the right part of FIG. 4, leaving free space between the layer 24 'and 22' and also in the recess formed by the layer 20.

The parquet sample in FIG. 5 from the example of FIG. 1 differs only in the composition of the base layer 10, which consists of the bottom layer 16, the intermediate layer 17 and the wooden sheet (slat) 18.

Material of the following composition was used in each example:

formula A B C D E F aliphatic polyurethane aqueous base; ^and 100 100 100 - - iOO aliphatic polyurethane acrylate ^b • - 100 100 tripropylene glycol diacrylate ^c • - 40 40 40 anti-foaming agent ^d 0.2 0.2 0.2 - - wetting Reagent ^e 0.2 0.2 0.2 0.2 0.2 0.2 viscosity regulator ^f 0.5 0.3 0.2 - matting agent ⁸ 2 3 2 4 photoinitiator ¹¹ 2 2 2 2 2

These ingredients are sold under the trademarks or brands of the following manufacturers:

a. Neorad R 450 Zeneca b. Ebecryl 249 UCB c. TPGDA UBC d. Byk 022 Byk Chemie e. Byk 346 Byk Chemie Fluorad FC 430 3M f. Coatex Rheo 2000 Coatex g. Acematt + with 100 Degussa h. Irgacure 184 Ciba

Example 1 (flat product according to Fig. 2)

The base layer is made by a technique known to those skilled in the art.

A first layer of PU (recipe C) is continuously applied to the base layer by coating rollers (thickness 10 microns / matt 15). PU (polyurethane) is hot air dried.

A second layer of PU (Formulation A) is then applied by a heliography technique (10 micron thickness / gloss 80). The PU is again dried with hot air.

The third layer of PU (recipe B) is applied by a heliographic roller in accordance with the drawing of the second layer of PU (thickness of 10 microns / gloss 50). Hot air drying.

The third PU layers are then crosslinked under ultraviolet rays (160 W / cm).

Example 2 (flat product according to Fig. 3)

The first PU (Formulation C) is coated with a heliographic roller (10 microns / matt). Hot air drying.

The second PU layer (Formulation A) is applied by heliography technique in accordance with the first PU layer (10 micron thickness / matt 80). Hot air drying.

The third PU (recipe B) is applied by heliography technique coincident with the first and second PU layers (10 micron thickness / matt 50). Hot air drying.

This is followed by crosslinking with ultraviolet rays.

Example 3 (plastic article according to Fig. 4)

The first layer of PU (Formulation F) is applied continuously by a heliographic roller (10 micron thickness / matt 15). The PU is then crosslinked by ultraviolet rays.

The second PU (formulation D) is applied by a heliographic roller (10 micron thickness / gloss 80). UV crosslinking.

The third PU (recipe E) is applied by a heliographic roller coincident with the second PU and coincident with the tread pattern in the plastic sample (10 micron thickness / matt 50). UV crosslinking.

Final UV crosslinking.

Claims (8)

PATENT CLAIMS Method for producing wall and wall cladding with different glossy decorations, characterized in that the glossy effects are produced by differently applying the first layer (20) and the second layer (22, 24), wherein said first layer is applied non-sequentially to the base layer (10). ) and then dried, the second layer (22) and / or (24) intended to partially or completely cover the first layer (20) with a different mattness is applied incoherently without completely covering at least two protective layers of different properties; not conforming to the backsheet decoration and / or plastic sample of the article, the gloss degree of said protective layers having a different gloss is 5 to 90 (below 60 degrees) and the thickness of the layers thus applied is 3 to 50 µm. Method according to claim 1, characterized in that the base layer to which the decoration of the different gloss is applied is smooth or plastic after mechanical or chemical wrinkling and can be flexible or solid. Method according to claim 1 or 2, characterized in that the decoration on the layer under the different protective layers (20, 22, 24) is printed and / or performed by inserting the material (inlaid). Method according to claims 1 to 3, characterized in that the additional shades of shade are carried out either by partially covering the first layer (20) and the second layer (22) or by applying one or more additional protective layers (24). Method according to claims 1 to 4, characterized in that after each protective layer is applied, they are dried by hot air or infrared radiation. Method according to any one of claims 1 to 5, characterized in that said layers are colored. Method according to one of Claims 1 to 6, characterized in that the application of different protective layers of different gloss is carried out in a continuous manner by at least one of the techniques, including air scraper, screen printing, heliography, flexographic printing, paint roller. Method according to claim 7, characterized in that the step of applying the various protective layers is carried out separately from the step of manufacturing the base layer.