WO2008017317A1

WO2008017317A1 - A process for producing a decoration material

Info

Publication number: WO2008017317A1
Application number: PCT/EP2006/007852
Authority: WO
Inventors: Stefan Henry Dominique Maria Symkens
Original assignee: Chiyoda Europa Nv
Priority date: 2006-08-08
Filing date: 2006-08-08
Publication date: 2008-02-14

Abstract

A process for producing a decoration material comprising : - printing a pattern by means of at least one printing step, on a material substrate, and applying a continuous resin layer on top of the printed pattern, wherein in the composition of at least one of the uppermost printed pattern a porous material has been incorporated.

Description

A process for producing a decoration material

The invention relates to a process for producing a decoration material comprising: - printing a pattern by means of at least one printing step on a material substrate, and - applying a continuous resin layer on top of the printed pattern.

Such a process is generally known in the art, see e.g. US-A-5 178 928.

Decorative materials having printed patterns resembling grain pattern of natural trees have been extensively utilized as surface materials for furniture, household things, wall materials and floor materials. In order to optimize the appearance of the decoration so as to resemble completely the appearance of natural wood, it is required to use a pattern including gloss zones and matt or satin zones in the printed pattern. This is especially important to fully imitate the grain of wood, which is highly dependent of the nature of the wood and must be completely in register with the remaining part of the wood pattern to be imitated.

In the past a number of solutions has been developed in order to produce decoration materials fulfilling these requirements.

In a first known method an additional printing pattern is applied on top of the final resin layer, which printing pattern is made by means of a printing composition containing porous or matt components, if necessary coloured components, mostly in a resin-like material. This method, generally known as optical embossing, was used on very thin paper (23-40 g/m²) without any resin impregnation. A problem with this method was that it was extremely difficult to maintain the register between the printed pattern and the top printing layer. The thin paper was another problem as they were vulnerable in the handling of the material.

A second method, commonly designated chemical embossing has been described in DE 29 45 217. In this method the printing step is carried out with a printing composition containing a substance which repulses the final resin layer as a result of a difference between the surface tension of the two substances. As a result the resin layer will be repulsed at the locations where this special printing composition has been applied, and in this way it is possible to obtain the desired grain effect. As the printing step is performed before the application of the final resin layer the problems with the register are avoided. However there are restrictions with respect to the gloss/matt effect obtained as it is impossible to have a repulsion over bigger surfaces as the resin cannot be repulsed over important distances. A maximum of 1 to 2 mm is obtainable. This is a substantial reduction of the possibilities for making an optical effect and moreover there will always be a zone where no protective resin layer is present resulting in an insufficient resistance of the material.

A third method has been described in EP 1 500 519. In this process the substrate is first coated with a resin layer and subsequently the printing patterns are applied having the desired pattern and gloss/matt zones. All problems with respect to the register and the limited surface characteristics are avoided by this method. However a chemical an physical durability of the surface can only be guaranteed when very hard and durable printing resins are used. A problem is here that these compositions are difficult to print and consist mostly of two- component systems. Moreover it is not possible to reach the normal printing speed as a longer drying time is required in order to have a fully hardened printed pattern.

It is an object of the invention to provide a process for making decoration material as described above in which the cited problems and disadvantages have been avoided.

This and other advantages are obtained in that in the composition of at least one of the uppermost printed pattern a porous material has been incorporated in a sufficient amount.

In French patent specification 2800317 there is described a printing process in which a pattern of matt and brilliant areas is produced. According to this process the base material is provided with a pattern comprising areas printed with a material containing a matt composition and areas printed with a material containing a brilliant composition. Subsequently the whole surface is coated with a brilliant layer and as a consequence of the migrations of the matting composition the brilliant layer becomes matt in the areas printed with matt composition containing inks.

A problem with this system is, that it is difficult in its use as the inks to be used must be in a fluid state in order to enable the migration of the matting composition. This means that the whole process must be performed at a sufficient high speed, and the drying must be adapted to the time necessary for the migration of the particles. This can take several minutes.

According to the invention however the printing patterns may be completely dried and the porous composition present in some of the printed patterns, absorbs part of the final resin coating thereby providing the matting effect.

The process according to the invention does not require special printing nor drying techniques, but the common printing machines known in the art and top resins normally used for making decoration materials are applicable. The same applies to the substrate materials to be used as well as the printing inks and binders used therein. As a consequence the printing process is very reliable and does not increase the problems with respect to folding, register or other printing aspects.

The decoration material is a very natural reproduction of the original, especially wood structure as a result of the use of pattern with different gloss or brilliancy. This is not restricted to reproduction of wood and stone, but phantasy decorations can also be made having different gloss intensity zones. As the matting composition is an environmental friendly composition and no further changes take place with respect to the printing process, no additional environmental charges are introduced by the process according to the invention. Typical examples of porous components are aluminiumsilicate, calciumcarbonate, siliciumdionyde or mixtures thereof and the like. Furthermore different particle sizes can be used. However also organic components can be used with variable particle size such as cellulose, waxes and the like. Some of these components are already commonly used in the printing inks, e.g. as fillers, however it is the selection of the right amount, particle size in combination with the top resin layer which gives the desired gloss/matt effect. These parameters must be selected in such a way that the resin material on top of the printing pattern can be partly absorbed by the porous particles so as to provide the required matting effect.

Following are some examples of possible compositions of decorative materials according to the invention :

a) preimpregnated paper based decorative foil

1. preimpregnated paper

2. helioprinting with standard printing inks

3. helioprinting with modified porous printing ink registered controlled

4. helioprinting with modified porous printing ink registered controlled 5. melamineformaldehyde waterbased top resin layer

b) thinpaper based decorative foil

1. thinfoil 30 gsm

2. helioprinted basecoat with standard printing inks 3. helioprinting with standard printing inks registered controlled

4. helioprinting with standard printing inks registered controlled

5. helioprinting with modified porous printing ink registered controlled

6. solvent-based polyurethane silicone containing top resin layer

c) dekorpaper based decorative finishfoil

1. 50 gsm dekor paper

2. helioprinting with standard printing inks

3. helioprinting with modified porous printing inks registered controlled 4. paperimpregnation with ureaformaldehyde/acrylic resin

5. melamineformaldehyde waterbased top resin layer

d) preimpregnated based decorative foil 1. preimpregnated paper

2. basecoat with porous modified printing ink

3. helioprinting with non-porous printing ink registered controlled

4. helioprinting with non-porous printing ink registered controlled

5. solvent-based polyester top resin layer

Other combinations and compositions of inks, printing units, types of paper and other foils and top resin types are possible Other printing methods are possible as well.

Claims

1. A process for producing a decoration material comprising:

- printing a pattern by means of at least one printing step, or a material substrate, and

- applying a continuous resin layer on top of the printed pattern, characterised in that in the composition of at least one of the uppermost printed pattern a porous material has been incorporated.

2. A process according to claim 1 , characterised in that the printed pattern is made by printing a number of printing patterns in register with each other, and in that at least one of the printing patterns is containing a porous material.

3. A process according to claim 1 , characterised in that the printed pattern is made by printing a number of printing patterns partly in register with each other and partly in overlap with each other and in that at least one of the uppermost printing pattern is containing a porous material.

4. A process according to claim 1 , characterised in that before applying the non-porous printing pattern the material substrate is uniformly coated with a material containing a porous substance and in that the non-porous printing patterns do not cover completely the coating.

5. A process according to claim 1, characterised in that non-porous printing patterns are applied on a porous substrate and that the non-porous printing patterns do not cover completely the porous substrate.