WO2014147171A1

WO2014147171A1 - Method for producing a carrier plate equipped with a décor

Info

Publication number: WO2014147171A1
Application number: PCT/EP2014/055588
Authority: WO
Inventors: Oliver Florenske; Sebastian Mittnacht; Michael VIEBAHN
Original assignee: Knauf Gips Kg
Priority date: 2013-03-21
Filing date: 2014-03-20
Publication date: 2014-09-25
Also published as: EP2976222A1; HK1216735A1; RU2015140569A; DE102013102915A1; RU2630765C2

Abstract

The invention relates to a method for producing a carrier plate (1) equipped with a décor as a component of a wall and/or ceiling cover and/or as a component of a dry-construction wall. The carrier plate (1) is equipped with an applied image and/or a graphic pattern as a decorative layer (2). According to the invention, the decorative layer (2) is applied to the carrier plate (1) by an ink jet method by means of a water-based ink or by a powder coating method. Before the decorative layer is applied, the carrier plate is equipped with a priming layer (5, 6) having a specified degree of whiteness. The decorative layer is coated with a transparent cover layer (3, 4) cured by means of UV light.

Description

METHOD FOR PRODUCING A DECORATED CARRIER PLATE

Description:

The invention relates to a method for producing a decorated with a decor carrier plate as part of a wall and / or ceiling panel and / or drywall, after which the carrier plate is equipped with an applied image and / or a graphic pattern as a decorative layer.

The coating of carrier plates and in particular plasterboard for the realization of a decorative layer has been known for some time. Reference is made to the extent generic EP 2 423 403 A2, which deals with a printed plasterboard. At this point, the procedure is such that a multicolored print is applied directly to the cover layer of the plasterboard panel on the visible side. In addition, multi-colored ink is used. The ink is cured by ultraviolet light. In addition, the color print is designed and expands so far that at least partially the flat visible side of the plasterboard is covered.

The above-described direct printing on the cover layer of the plasterboard, d. H. on a component of the plasterboard without prior application of, for example, paper layers, although theoretically feasible, in practice, however, hardly or only with considerable difficulty to realize. This can be attributed to several phenomena that have hitherto prevented a significant deployment in practice.

For reasons of cost, the cover layers are not produced with reproducible quality during the production of the plasterboard, and they differ significantly in their color shade and / or absorption behavior. Such variations are observed not only from top to top, but also over the top of the top layer. As a result of this

For example, the ink applied by the prior art in the ink-jet method is more or less strongly absorbed into the cover layer and at the same time, when viewed on differently colored surfaces, strikes the surface extension of the cover layer. As a consequence of this, hardly reproducible decorative layers can be applied to the plasterboard in question and, if so, with significantly reduced quality.

A further problem to be considered is that the UV curable inks used in the context of EP 2 423 403 A2 have a relatively high calorific value, and consequently a plasterboard which has been suitably equipped does not meet particularly high requirements in terms of the achieved fire protection class.

Although in the context of DE 10 2007 013 135 A1 alternatives to UV-based color systems are described, so u. a. Ink-jet printing processes using water-based ink as printing ink. However, the known teaching relates to a method for producing a carrier plate, which is used primarily for furniture applications and for this reason u. a. a resinated and printable or printed paper layer is used. Derarti- ges is not or hardly suitable because of the inevitable resin content for the fire protection applications described above.

In the context of DE 10 2007 049 784 A1, a building board is described which is printed by means of an inkjet printing process. Water-based inks can be used for inkjet printing. The overall aim is to produce dry walls, ceilings, or cladding with decorative surfaces in a simple way. An additionally applied to the body paper web with the printed

Surface and intermediate adhesive ensures again that the fire protection behavior is problematic.

DE 694 1 1 1 14 T2 deals inter alia with the production of a marked sheet. Also, a body having a sheet attached to building material of the type described. As a result, the interior decoration of a wall plate should be made possible again in a simple manner. Aspects of fire protection are addressed as little as in the rest of the prior art and problematized. This is where the invention starts.

The invention is based on the technical problem of further developing such a method for producing a carrier plate equipped with a decor so that the decorative layer can be applied simply, quickly and inexpensively and at the same time increased fire protection requirements are met.

To solve this technical problem, a method according to claim 1 is provided.

According to the invention, the support plate in this context has a decorative layer whose application thickness is dimensioned below 20 g / m ² . In this case, the decorative layer is applied to the carrier plate by an ink-jet method with a water-based ink or by a powder coating method.

In addition, prior to the application of the decorative layer, the carrier plate is provided with the primer layer with a predetermined degree of whiteness. In this way

is a reproducible in terms of optical properties pad for the decorative layer available. As a result, the decorative layer with the required low application weight of less than 20 g / m ² can be applied. Also, the decorative layer, as it were sealing transparent and cured by UV light cover layer can be applied with a low application thickness and protects the same time the decorative layer from mechanical influences, light, etc ..

In this way, overall, the primer layer, the decorative layer of limited application thickness of less than 20 g / m ² and finally the UV-cured transparent transparent cover layer as a coating structure in this order overall ensure that a favorable fire protection behavior is observed for the carrier plate produced according to the invention. In fact, by using the water-based ink to realize the decorative layer and the low application thickness of below 20 g / m ² in conjunction with the primer layer and finally the transparent topcoat on the backing plate as a base, total calorific values for the coating build-up are observed to be significantly lower of 2 MJ / m ² . That is, the coating structure on the carrier plate has the aforementioned calorific values of 2 MJ / m ² and less. Of course, the calorific value of the carrier plate must then be added as a base to this coating structure. In this case, the primer layer and the cover layer each have an application thickness also below 20 g / m ² .

Even if, in addition to the coating composition in question, the calorific value of, for example, a plasterboard is added to the covering layer (made of paper) or to the layer side cardboard required here,

the calorific value of the entire carrier plate produced in this way can be limited to values of less than 4 MJ / m ² . This information is based on a commercial plasterboard with a material thickness of about 10 mm to 25 mm. Mostly you will use a so-called fire retardant plasterboard. As a result, relatively high fire protection requirements can be realized. This can essentially be attributed to the use of the water-based ink in one alternative or the use of the powder coating in the context of the other alternative for producing the decorative layer, wherein in each case the low application thickness due to the specifically selected layer structure is below 20 g / m ² primarily responsible for this.

In fact, a carrier plate produced by the process according to the invention meets the fire protection classes A1 and A2 according to DIN EN 13501 -1, which means that the thus equipped carrier plates can be qualified as a total non-flammable without or with shares of combustible building materials. For example, a calorific value of approx. 20 MJ / kg is observed for a gypsum plasterboard as a carrier plate. This corresponds to a calorific value of about 2.9 MJ / m ² , if one uses a commercial plasterboard with a density of about 0.7 g / cm ³ and a thickness of about 1 cm.

The calorific value of about 2.9 MJ / m ² for the plasterboard, which is based on the area, is then added to approximately 0.5 MJ / m ² for the primer layer and about 0.3 MJ / m ² for the decorative layer with the application thickness below 20 g / m ² . Finally, the transparent cover layer, also having an application thickness of less than 20 g / m ³ , which typically has a calorific value of approximately 0.3 MJ / m ^2, must be taken into account

having. This explains in total the specified calorific value of 4 MJ / m ² , (2.9 MJ / m ² + 0.5 MJ / m ² + 2 x 0.3 MJ / m ² ) which is generally undershot, because the previously For the most part, these values represent maximum values, in particular for the layer structure.

In any case, it is clear that the carrier plates produced by the process according to the invention can be qualified as a total non-flammable in the sense of DIN EN 13 501 -1, but at least as flame retardant. As a result, the support plates meet general fire protection requirements for use indoors and convince at the same time by the simple possibility of the applied decor and its mechanical stability. Here are the main benefits.

The decorative layer is defined as usual only on the visible side of the support plate, ie on that surface side of the support plate, which is typically facing a room. Because the carrier plates in question are used inside buildings as components of a wall and / or ceiling paneling. Alternatively or additionally, the carrier plate produced by the process according to the invention can also be used for realizing a drywall. The production and construction of such a drywall is described by way of example in the utility model DE 20 2012 102 265 U1 of the Applicant.

From the visible side with the decorative coating to distinguish the back of the support plate, which is the opposite side compared to the visible side. In general, the backing plate is equipped at the back with fasteners to allow their attachment as a cladding or building wall. Of course, one is also

Edge determination of the support plate conceivable and is encompassed by the invention.

The water-based ink used in the invention is composed essentially of at least one water-soluble dye, at least one polyhydric alcohol and water. The polyhydric alcohol is typically one having two to six carbon atoms, such as ethanol, propanol, glycerin, butanediol, hexylene glycol, dipropylene glycol, etc.

The dye is present in the water-based ink at a level of up to 15% by weight. The proportion of the alcohol is regularly up to 50% by weight in the water-based ink. In exceptional cases, it is also possible to use up to 80% by weight of the polyvalent alcohol in question in the ink. The remainder is water. The dye may of course also be a dye mixture.

Overall, it is important to set the viscosity of the ink as low as possible, so that even small structures can be applied by inkjet and defined in the decorative layer. The dynamic viscosity of the ink at room temperature should typically not be greater than 1.5 mPa · s, in particular not even greater than 1.3 mPa · s.

As usual, the ink-jet method works by applying mechanical vibration in the ink or displacement to the ink by means of a piezoelectric device or the like. Alternatively, bubbles may also be generated by heating in the ink in order to utilize the pressure generated thereby. As a consequence of this are from a

Ink jet recording system generates ink droplets and ejected onto the carrier plate.

For this purpose, a recording head or the respective recording head of the ink jet recording system has one or more nozzles. As a result, the ink can leave the nozzle as a very small droplet of ink and be ejected onto the carrier plate in the example case.

The water-based ink defining the decorative layer according to the invention within the scope of a first alternative is applied to the carrier plate with an application thickness below 20 g / m ² . In particular, even an application thickness of less than 10 g / m ^{2 is} sufficient. After the application of the water-based ink to the carrier plate, it has proven useful to dry the thus defined decorative layer or the ink. Only then is the decorative layer equipped with the cover layer. For drying the decorative layer, conventional methods such as a fan heater, an infrared radiator, etc. may be used. In principle, drying with an infrared laser beam is also possible and is encompassed by the invention.

As an alternative to the previously described ink jet method with the water-based ink in the realization of the decorative layer can also be worked so that the carrier plate is equipped with a powder coating as a decorative layer. In this case, the decorative layer is applied to the carrier plate by a powder coating method. In this case, comparable application thicknesses below 20 g / m ² and in particular less than 10 g / m ² can be observed.

Such powder coating methods assume that the carrier plate is first rendered electrically conductive and then coated with a powder coating or powder in general. The powder is the desired colorants in the form of powder in the context of the invention, which are required for realizing the decoration or the decorative layer. For this purpose, the carrier plate must first be subjected to a surface pretreatment. This requires an optional cleaning of the carrier plate. In addition, the powder to be coated must be electrostatically charged. For this purpose, it is possible, for example, to work with the so-called triboelectric charging in paint spray guns so that on the output side of the spray gun an electrically charged powder cloud is produced, which then deposits on the carrier plate. Subsequently, the thus applied powder coating is crosslinked by so-called burn-in. The powder is melted in a dryer and hardens. An additional electrostatic charge of the carrier plate is usually not required here.

In this way, a decorative layer can be easily applied to the carrier plate. In this case, the invention expressly allows a so-called direct printing, ie that the decorative layer directly - without, for example, an additional paper support, an upstream primer, etc. - is applied to the carrier plate to be coated. According to the invention, however, priming is first carried out with the aid of the primer layer with a predetermined degree of whiteness in order to be able to produce reproducible conditions and to keep the application weight of the decorative layer low. Subsequently, the decorative layer is sealed with the transparent cover layer. This transparent cover layer is applied to the decorative layer on its surface side facing away from the carrier plate.

With the aid of the transparent cover layer, it is of course also possible to specify a possible gloss level, a mattness level etc. of the support plate coated in this way. The transparent topcoat is a UV-curable topcoat. This topcoat can be applied by conventional methods, for example by inkjet printing or as a powder coating. Just as well, the transparent topcoat in question can be sprayed on, applied by rollers etc.

The subsequent UV curing of the topcoat of the topcoat, the paint is crosslinked and has the thus realized coating on the required mechanical and light resistance, which is required in the applications described for the cladding of walls, ceilings or for the realization of drywall walls in the interior area. Such UV-curable transparent topcoats are typically applied to the decorative layer with a coating thickness of less than 20 g / m ² . Examples of such topcoats are those based on polyester, polyethylene terephthalate, polyamide or polypropylene.

The layer structure described so far from the decorative layer and the transparent topcoat for sealing can generally and directly be applied to any carrier plate. Even a direct coating without previous priming or applying a paper support is possible. As well the abandonment of a topcoat. In order to be able to master the different suction behavior and the varying coloring of a cover layer in, for example, plasterboard in the introduction, the invention recommends an ink or powder application which corresponds to the surface finish

the cover layer in the example case or the support plate generally takes into account. For this purpose, it is within the scope of the invention to detect the surface finish, in particular with regard to coloring and absorbency for the ink or the powder before coating. Depending on the surface texture determined in this way, the coating process is then correspondingly controlled and modified during the application of the primer layer first and then the decorative layer. This may be such that the application of primer or primer for the primer layer and / or ink for the decorative layer in particularly absorbent areas of the carrier plate is increased accordingly. In addition, the color composition of the ink over the surface of the support plate can be changed so that color deviations of the support plate or the Grundierschicht are compensated as a background. In fact, the background or the color of the substrate (primer layer) in conjunction with the applied decorative layer contributes to the overall color impression of the coating, in the simplest case by making the decorative layer and the color of the substrate an additive color mixture. Using this model, the color composition of the decorative coating can be modified depending on the intensity of the color of the substrate or the support plate so that the result, ie the additive color mixture of the substrate (primer layer) and the decorative layer, leads to a consistent color impression. Since such measures can be applied practically only for unique or are particularly complex, the invention works with the primer, which is applied to the support plate before applying the decorative layer. This primer or primer layer provides a background

defined absorbency and consistently the same color available, so that the above-described adjustments of the decorative layer to the support plate are usually unnecessary or the decorative layer is applied in the ideal case to a predominantly identically laid substrate.

In the case of the primer in question, as a rule aqueous acrylic primers are used, which can be applied, for example, by rolling, by spraying, etc. Even a putty application is possible to compensate for any surface inaccuracies, damage or roughness of the support plate. Mostly, the primer or the so-called primer has a defined color, with a regular white shade is observed. As a result, the subsequently applied decorative coating can be applied to a substrate with defined properties with regard to the absorption behavior as well as the background color, so that the image or graphic pattern realized on the carrier plate is available in reproducible quality.

In principle, such primers can also be applied to the decorative layer before the clear topcoat is applied, before the transparent topcoat is applied, as (transparent) visible-side sealing of the decorative layer. In any case, the primer layer has on the visible side of the carrier plate, on which the decorative layer is applied, over a predetermined degree of whiteness. In addition, the primer layer can be applied as a powder coating or roller coating. In principle, it is even possible and is encompassed by the invention that the primer layer is designed as a separate paper web or laminate layer applied to the carrier plate.

Inn result is a method for producing a decorated with a decor carrier plate as part of a wall and / or ceiling panel and / or a drywall described, in which the decorative coating can be realized particularly simple and inexpensive. In addition, special fire protection requirements are met, the support plate produced is designed at least flame retardant.

In the single figure, a carrier plate produced by the process according to the invention is shown by way of example in a sectional view.

In the single figure can be seen in section a support plate 1, which is equipped with a decor. This decor is defined by a decorative layer 2, which in principle can be applied directly to the support plate 1. In addition, the decorative layer 2 is regularly sealed with a transparent cover layer 3 in order to protect the decorative layer 2 from mechanical influences, light, etc. In the exemplary embodiment, an optional primer 4, which is applied to the decorative layer 2 before the topcoat or the transparent topcoat 3 is applied and in order to improve its adhesion, can be seen between the decorative layer 2 and the transparent cover layer 3. It is understood that the primer 4 in this case optically transparent - as the cover layer 3 - is formed.

The decorative layer 2 can be applied directly to the carrier plate 1. In the context of the embodiment and according to the invention, however, first a filler layer or putty primer 5 is applied and then a primer or a primer 6, which is equipped with a defined and predetermined degree of whiteness. On the thus realized primer or primer layer 5, 6 is then the

Decorative layer 2 applied. The primer layer 5, 6 as well as cover layer 3 or 3, 4 has an application thickness of less than 20 g / m ² . For the realization of the decorative layer 2, two basic procedures are available within the scope of the invention. First of all, it is possible to apply the decorative layer 2 by means of an ink jet method and resort to a water-based ink, as already described in the introduction. Alternatively or additionally, however, it is also possible to work with a powder coating in order to realize the decorative layer 2. In both cases, the order is made with an application thickness of less than 20 g / m ² .

The entire layer structure or coating structure is found exclusively on a visible side 1 a of the support plate. 1 In contrast, a back 1 b of the support plate 1, for example, acts as a base for fixing fasteners, with the aid of the support plate 1 is mounted in front of a wall, below a ceiling, etc. as a wall and / or ceiling panel. Alternatively, the support plate 1 can also be fixed to a framework of a drywall to be realized with their help. This is not shown in detail.

The carrier plate 1 as such may consist of materials suitable at this point. Here, materials such as gypsum fiber boards, gypsum plasterboard, gypsum boards with Vliesarmierung, wood-based panels, mineral wool panels, etc. have proven to be particularly favorable.

Claims

claims:

1 . Method for producing a decorative panel (1) provided as part of a wall and / or ceiling paneling and / or a drywall, after which the carrier plate (1) with an applied image and / or a graphic pattern as a decorative layer (2) with an application thickness is provided below 20 g / m ² , after which further the carrier plate (1) before applying the decorative layer (2) with a primer layer (5, 6) is provided with a predetermined degree of whiteness, and then the decorative layer (2) with a transparent and coated by UV light-cured cover layer (3) on its the carrier plate (1) facing away from the surface side, wherein

- The decorative layer (2) on the support plate (1) by an ink jet method with a water-based ink or by a powder coating method is applied.

2. The method according to claim 1, characterized in that the water-based ink is composed of at least one water-soluble dye, at least one polyhydric alcohol and water.

3. The method according to claim 2, characterized in that the dye occupies a proportion of up to 15 wt .-% and the alcohol occupies a proportion of up to 50 wt .-% in the ink.

4. The method according to any one of claims 1 to 3, characterized in that the water-based ink with an application thickness below 10 g / m ^{2 is} applied to the carrier plate (1).

5. The method according to any one of claims 1 to 4, characterized in that the carrier plate (1) is dried with the applied water-based ink and only then with the cover layer (3) is equipped.

6. The method according to any one of claims 1 to 5, wherein a transparent layer (3) is applied in ink and / or powder form and / or as a spray and / or roller application and cured by means of UV light.

7. The method according to any one of claims 1 to 6, characterized in that the primer layer (5, 6) as a separate laminate coating,

Powder coating, roller coating, spray coating, etc. is formed.

8. The method according to any one of claims 1 to 7, characterized in that the cover layer 3; 3, 4 and / or the primer layer (5, 6) with a

Application thickness of less than 20 g / m ^{2 are} applied.

9. Method according to one of claims 1 to 8, characterized in that the coating structure comprising the primer layer (5, 6), the decorative layer (2) and the final decorative layer (3; 3, 4) has a calorific value of less than 2 MJ / cm ² .

10. The method according to any one of claims 1 to 9, characterized in that the carrier plate (1) with the applied coating structure of the

Primer layer (5, 6), the decorative layer (3; 3, 4) has a calorific value of less than 4 MJ / m ² .