WO2011103641A1 - Fabrication d'un stratifié décoratif à l'aide d'encres d'impression durcies aux ultraviolets - Google Patents

Fabrication d'un stratifié décoratif à l'aide d'encres d'impression durcies aux ultraviolets Download PDF

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Publication number
WO2011103641A1
WO2011103641A1 PCT/AU2011/000215 AU2011000215W WO2011103641A1 WO 2011103641 A1 WO2011103641 A1 WO 2011103641A1 AU 2011000215 W AU2011000215 W AU 2011000215W WO 2011103641 A1 WO2011103641 A1 WO 2011103641A1
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WO
WIPO (PCT)
Prior art keywords
coating
substrate
compatible
overlay material
printing inks
Prior art date
Application number
PCT/AU2011/000215
Other languages
English (en)
Inventor
David Elwyn Price
Original Assignee
Depco-Trh Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2010900806A external-priority patent/AU2010900806A0/en
Application filed by Depco-Trh Pty Ltd filed Critical Depco-Trh Pty Ltd
Priority to AU2011220343A priority Critical patent/AU2011220343A1/en
Publication of WO2011103641A1 publication Critical patent/WO2011103641A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/14—Printing or colouring
    • B32B38/145—Printing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/02—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board the layer being formed of fibres, chips, or particles, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/06—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/10—Next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M7/00—After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock
    • B41M7/0081—After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock using electromagnetic radiation or waves, e.g. ultraviolet radiation, electron beams
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • B32B2037/243—Coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/12—Coating on the layer surface on paper layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/28—Multiple coating on one surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/028—Paper layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/75—Printability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/04—Time
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/12—Pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
    • B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
    • B32B2310/0831—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation using UV radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/08—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0012—Mechanical treatment, e.g. roughening, deforming, stretching

Definitions

  • the invention relates to a method for manufacturing a decorative laminate using UV curable inks in the printing process, and to decorative laminate products having printing that comprises UV cured inks.
  • substrates for example particleboard, fibreboard, OSB, plywood, or impregnated kraft core papers
  • substrates for example particleboard, fibreboard, OSB, plywood, or impregnated kraft core papers
  • one or more resin impregnated overlaying papers or resin impregnated non-woven materials on one or both sides of the substrate in a hot press.
  • Textured or smooth press tools or textured papers or composite films provide the desired structure and gloss on the finished laminate.
  • the overlaying materials serve as a carrier for the resinous starting material, pigments, additives, print or any subset of those.
  • the overwhelming majority of decor paper today is printed by the rotogravure method. Mainly due to environmental and safety concerns the printing inks are water based and the pigments rarely include heavy metals.
  • the post printing lacquering process may include application of one or more layers that provide technical attributes to the final surface; for example an abrasive substance such as corundum may be included in a lacquer to provide abrasion resistance.
  • the lacquer may be heat cured, or cured by radiation or electron beam. A hot press is not required for additional curing.
  • inkjet printing using UV cured printing inks such inks also become an option for the printing of woodpanels and or decorative materials used with woodpanels.
  • UV cured inks may be used for inkjet printing onto decor paper, pre- impregnated papers used to produce finish foils, impregnated decor paper, woodpanels or veneered surfaces. Even in the case of UV cured printing inks the print is usually protected from wear.
  • the lacquer is usually cured using heat or radiation.
  • UV cured printing inks it is desirable to be able to use UV cured printing inks in applying a printed design by inkjet printing as this is currently the predominate type of ink supplied with industrial width inkjet printing devices. It is also desirable to be able to use existing hot presses and press tools to cure and apply a texture to the protective surface above the UV printed design.
  • existing hot presses and press tools to cure and apply a texture to the protective surface above the UV printed design.
  • the problem of deiamination caused by the choice of inks already exists in the known laminate manufacturing process and was addressed in international patent publication WO2005/051661 by modifying the ink resin system.
  • UV cured ink and the later application of an amino based resin the risk of deiamination between UV cured inks and amino-based resins is exacerbated.
  • the invention entails the concept of applying a coating after printing of a substrate with UV curable inks, but preferably before final curing of the inks, that is compatible with the UV curable inks and also preferably compatible with amino based resin impregnating any overlay of paper or non-woven material placed above the coating. Such an overlay is optional.
  • the coating is finally curable in a hot press.
  • the invention accordingly provides, in one aspect, a method of manufacturing a decorative laminate, including: applying one or more UV curable printing inks to a substrate; applying over the one or more UV curable printing inks on the substrate a coating that is compatible with the one or more UV curable printing inks; partially curing the compatible coating; and placing the coated substrate in a hot press and completing curing at elevated temperature and pressure.
  • the method of the invention preferably includes providing over the compatible coating an overlay, e.g. of paper or non-woven, before said placement of the coated substrate in a hot press.
  • This overlay may be impregnated with a resin, preferably a resin with which the coating is compatible.
  • the overlay material is preferably applied after being fully impregnated.
  • the resin may be, for example, an amino resin, e.g. a melamine and/or urea resin.
  • the invention provides a decorative laminate, including: a substrate having thereon printing comprising one or more UV cured printing inks; and a coating over the printing on the substrate that is compatible with said one or more UV cured printing inks.
  • the coating is preferably also compatible with amino based resin impregnating any protective overlay, e.g. of paper or non-woven material, subsequently placed above the coating.
  • the decorative laminate may further include a protective overlay, e.g. of paper or non- woven material, over said compatible coating. This overlay may be impregnated with an amino based resin with which the coating is compatible.
  • the decorative laminate of the invention may be the product of final or complete curing in a hot press at elevated temperature and pressure, or may be further coated or lacquered on the first mentioned compatible coating, after pressing in a hot press.
  • the decorative laminate may further include a further coating or lacquering over the coating or the protective overlay material.
  • the substrate may be, without limitation, a paper, non-woven, panel or board or an assembly of papers such as a compact laminate.
  • the surfaces of the substrate may be pretreated or prepared to enhance the quality of the UV ink printing.
  • the pretreatment may be by application of a primer or an Inkjet receiving layer, or by application of a unicolour base paper.
  • the preparation of a panel may also include lamination of a unicolour base paper. It is known that a smooth surface provides a better print image, therefore preparation of the substrate surface may also include calendering or alternative smoothing processes.
  • the UV curable ink(s) may, for example, be based on an acrylic or methacrylic resin, and the coating therefore preferably includes an acrylic or methacrylic based constituent.
  • the compatible coating may be applied before or after partial curing or drying of the UV curable ink(s), though it may be advantageous to apply the coating after such partial curing or drying of the ink(s). Partial curing of the ink(s) and compatible coating may be effected simultaneously.
  • the compatible coating is heat curable, e.g. in a hot press.
  • the coating may be partially cured by UV radiation and finally cured by the application of heat and pressure.
  • the coating preferably includes respective acrylic and amino constituents that are curable to form acrylic and amino based resins.
  • a suitable composition (crystal clear thick liquid) is prepared from an acrylate (with hydroxyl functional group), an amino powder such as melamine or urea (either or both of these are dissolved in the formulation), a source of formaldehyde, for example paraformaldehyde, and a crosslinking catalyst.
  • the coating, and preferably also the overlay are advantageously transparent or at least translucent. After application of the print using UV curable inks and application of the coating, and optionally the provision of an amino-resin impregnated protective overlay, the components may be finally cured in a hot press.
  • the compatible coating is applied before the UV curable printing inks are fully cured. It is sufficient that the compatible coating is partially cured by known means such as heat or radiation sources before final curing in a hot press. Preferably the coating may be partially cured by application of UV light, which would enable the coating to be incorporated into the printing equipment.
  • the UV curable inks are not fully cured before application of the coating and partial curing of the coating also further cures the inks.
  • the compatible coating may also be partially cured after application of a protective overlay which has not been impregnated.
  • a further coating or coatings may be applied to the unimpregnated overlaying material after the unimpregnated overlaying material has been applied to, e.g. embedded into, the first-mentioned coating.
  • the further coating or coatings may be the same as the coating compatible with the UV curable inks, or may be a different coating such as an MF resin coating, however the coatings must be compatible to avoid delamination after the hot press.
  • a further coating or lacquering of the laminate surface takes place after the hot press, optionally with a preceding application of a primer or adhesion promoter.
  • Curing of the coating after the hot press may be by any known method, for example by UV or alternative radiation curing, by heat, by electron beam or any combination of these.
  • the coating may be applied as a single coating or may be applied in several layers.
  • the coating may be applied to the printed substrate as several layers with a partial curing of each layer.
  • the compatible coating is applied to an un-impregnated decor paper printed with UV curable inks.
  • the coated decor paper printed with UV curable inks is used in the manufacture of a laminate using the known dry pressing process.
  • a general description of the dry pressing is where the decor paper has not been previously impregnated, the required resin being forced into the decor paper from either a resin impregnated underlay or overlay or an alternative source of resin such as the kraft papers in high pressure laminate manufacture, or a resin coating applied to the surface of a panel.
  • the one or more UV curable inks and the compatible coating may be on one or both sides of a substrate.
  • the coating may be applied by any appropriate means, for example but not limited to roller coating, spraying, brushing, curtain coating, vacuum coating, slotted die or jetting.
  • the coating and or the overlay or overlaying material may contain additives to provide technical or decorative properties, for example but not limited to pigments, dyes, optical brighteners, UV absorbers, impact absorbers, metallic particles, nano-particles, pearlescent effect additives, laser activated particles, antistatic agents, antimicrobial agents, wetting agents, release agents, catalysts, anti-scratch agents, anti-abrasion agents, dispersants, thickeners, gloss or matte effect additives, ; or additives with self cleaning or stain repellency properties.
  • the coating weight measured in grams per square metre (gsm) may be . in the range 1gsm to 100gsm, preferably between 2gsm to 60gsm, more preferably between 3gsm to 40gsm, most preferably between 5gsm to 30gsm.
  • the protective overlay may be a paper or non-woven material, or overlapping material such as loose fibres of cellulose, plastic or glass.
  • a suitable grammage per square metre (gsm) is in the range 10gsm to 100gsm, preferably between 14gsm and 60gsm, more preferably between 16gsm and 30gsm, most preferably between 18gsm and 25gsm.
  • the protective overlay may itself be printed before or after impregnation and prior to application to the UV curable ink printed substrate and the compatible coating. It is practical that the printing of the overlay provides one or more print sections helpful to provide registered embossing or a 3D effect.
  • the protective overlay may by applied without being impregnated.
  • the substrate may be an unimpregnated d6cor paper and the coated substrate used for dry pressing onto a further substrate.
  • the surface of the laminate may be further coated or lacquered after the hot press.
  • Said application of the UV curable inks may be by any known method, for example but not limited to gravure printing, screen printing, offset printing, flexo printing or digital inkjet printing.
  • Inkjet printing is the preferred method due to the known economic advantage of being able to print small lot sizes.
  • Partial curing of the coating before or after application of the protection overlay or overlaying material may be by heat or radiation.
  • the choice of method for introducing energy into the coating to dry or advance the cure can be freely selected and adapted to the preferred coating material. Ideally the introduction of energy to the coating takes place as soon as possible after the application of the coating to the substrate. It is also practical to apply energy for advancing the cure of the coating after the application of the overlay to the coating.
  • overlay and “overlay material” embrace overlaying paper, non-woven materials and overlapping material such as loose fibres of cellulose, plastic or glass.
  • resins and “coating” have been used as synonyms for monomers, oligomers and polymers.
  • Figures 1 to 5 are exploded not-to-scale diagrams of altemative embodiments of decorative laminate according to preferred practices of the invention, while Figures 6 to 8 are schematic representations of three processes according to respective embodiments of the invention.
  • a high density fibreboard (HDF) woodpanel was printed with UV curable inks.
  • Coating (A) compatible with the inks, was applied to the printed panel and partially cured with UV light.
  • the printed and coated HDF panel was placed in a hot press. The press operated at 180°C platen temperature and at 25 bar pressure and remained under pressure for 25 seconds. The press opened and the assembly was removed.
  • the elements of the resultant assembly are depicted in Figure 1 , in which the woodpanel is depicted at 11 , the UV curable printing at 12, and the compatible coating A at 13. After allowing the laminate to cool down, the surface of the panel was tested for delamination by cross-hatching a section of the printed area. No delamination was evident.
  • Coating (A) here and in subsequent examples was a polymeric coating made from a mixture of hydroxyethylacrylate, paraformaldehyde, melamine and a crosslink catalyst.
  • a high density fibreboard (HDF) woodpanel was printed with UV curable inks.
  • a coating (A) was applied to the printed panel and partially cured with UV light.
  • a melamine formaldehyde (MF) impregnated overlay paper was placed above the coating and the assembly placed in a hot press.
  • the MF impregnated overlay paper had a coating of MF and corundum on the side facing the functional coating A.
  • the hot press operated at 200°C platen temperature and at 35 bar pressure and remained under pressure for 25 seconds.
  • the resultant assembly is depicted schematically in Figure 2, in which the MF impregnated overlay paper is indicated at 14. After allowing the laminate to cool down the surface of the panel was tested for delamination by cross-hatching a section of the printed area. No delamination was evident.
  • a high density fibreboard (HDF) woodpanel was printed with UV curable inks.
  • Coating (A) was applied to the printed panel and partially cured with UV light.
  • a second coating (A2) containing corundum was applied over the first coating followed by placement of an unimpregnated overlay paper onto the second coating.
  • the combination of the first coating, second coating and the unimpregnated overlay paper was partially cured using UV light.
  • a coating of MF resin was applied to the unimpregnated overlay paper and partially dried.
  • the printed and multiple coated HDF panel was placed in a hot press. The press operated at 180°C platen temperature and at 30 bar pressure and remained under pressure for 30 seconds. The press opened and the panel was removed.
  • Figure 3 The resultant assembly is depicted schematically in Figure 3, in which the unimpregnated overlay paper is indicated as 14'. After allowing the laminate to cool down the surface of the panel was tested for delamination by cross-hatching a section of the printed area. No delamination was evident.
  • Figure 4 and 5 depict respective modifications in which the assembly of Figure 3 retrieved from the hot press is provided with an outer lacquering 15a or a further MF resin coating 15b applied over the overlay.
  • a white decor paper 80gsm was impregnated with MF resin and partially cured to so- called b-stage.
  • the impregnated and partially cured decor paper 111 was inkjet printed at 112 with UV curable inks at inkjet printer 24.
  • Coating 113 (A) was applied to the printed paper from an applicator 26 and partially cured with UV light from a UV curing unit 28.
  • the impregnated and printed decor paper was placed on a piece of particleboard and placed in a hot press. The press operated at 180°C platen temperature and at 25 bar pressure and remains under pressure for 25 seconds. The press opened and the panel was removed. After allowing the laminate to cool down the surface of the panel was tested for delamination by cross-hatching a section of the printed area. No delamination was evident.
  • coatings 116 of melamine formaldehyde (MF) resin may be applied to both sides of the assembly downstream of UV curing unit 20.
  • overlaying material 114 may be applied over the coating 113 downstream of the UV curing unit.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Physics & Mathematics (AREA)
  • Health & Medical Sciences (AREA)
  • Electromagnetism (AREA)
  • General Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention porte sur un procédé de fabrication d'un stratifié décoratif, lequel procédé met en œuvre l'application d'une ou plusieurs encres d'impression durcissables aux ultraviolets sur un substrat, l'application sur les encres d'impression durcissables aux ultraviolets sur le substrat d'un revêtement qui est compatible avec les encres, le durcissement partiel du revêtement compatible, la disposition du substrat revêtu dans une presse à chaud et l'achèvement du durcissement à une pression et une température élevées. L'invention porte également sur un stratifié décoratif, qui comprend un substrat (11) ayant sur celui-ci une impression (12) comprenant une ou plusieurs encres d'impression durcies aux ultraviolets, et un revêtement (13) sur l'impression sur le substrat, lequel revêtement est compatible avec les encres d'impression durcies aux ultraviolets.
PCT/AU2011/000215 2010-02-25 2011-02-25 Fabrication d'un stratifié décoratif à l'aide d'encres d'impression durcies aux ultraviolets WO2011103641A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2011220343A AU2011220343A1 (en) 2010-02-25 2011-02-25 Manufacture of a decorative laminate using UV cured printing inks

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2010900806A AU2010900806A0 (en) 2010-02-25 Manufacture of a decorative laminate using UV cured printing inks
AU2010900806 2010-02-25

Publications (1)

Publication Number Publication Date
WO2011103641A1 true WO2011103641A1 (fr) 2011-09-01

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AU (1) AU2011220343A1 (fr)
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EP2402154A1 (fr) * 2010-06-29 2012-01-04 Guido Schulte Procédé de fabrication de composants plats et composant plat
US20130286088A1 (en) * 2012-04-30 2013-10-31 Ceraloc Innovation Ab Method for forming a decorative design on an element of a wood-based material
EP2900615A1 (fr) * 2012-09-25 2015-08-05 Falco Technologies BVBA Panneau décoratif multicouche et procédé de fabrication d'un panneau décoratif multicouche
US9199428B2 (en) 2013-03-15 2015-12-01 Biovation, Llc Multi-layer additive texture laminates and methods
US9409382B2 (en) 2012-11-28 2016-08-09 Valinge Innovation Ab Method of producing a building panel
EP3095614A1 (fr) * 2015-05-22 2016-11-23 Agfa Graphics Nv Fabrication de surfaces décoratives par impression à jet d'encre
EP3108970A1 (fr) * 2015-06-25 2016-12-28 Hymmen GmbH Maschinen- und Anlagenbau Procédé de fabrication d'un stratifié décoratif peint
US9605168B2 (en) 2014-01-31 2017-03-28 Ceraloc Innovation Ab Digital print with water-based ink
EP3300916A1 (fr) * 2016-09-30 2018-04-04 Agfa Nv Fabrication de surfaces décoratives
EP3300915A1 (fr) * 2016-09-30 2018-04-04 Agfa Nv Procédés d'impression par jet d'encre pour surfaces décoratives
US9994010B2 (en) 2014-01-24 2018-06-12 Ceraloc Innovation Ab Digital print with water-based ink on panel surfaces
US10017950B2 (en) 2011-08-26 2018-07-10 Ceraloc Innovation Ab Panel coating
EP3418059A3 (fr) * 2017-06-01 2019-04-10 The Boeing Company Procédés et systèmes d'impression à jet d'encre sur un film de peinture co-durcissable
US10328680B2 (en) 2013-10-23 2019-06-25 Ceraloc Innovation Ab Method of forming a decorative wear resistant layer
US10914080B2 (en) 2016-09-23 2021-02-09 Columbia Insurance Company Resilient flooring product and methods of making same
US11186997B2 (en) 2016-03-24 2021-11-30 Valinge Innovation Ab Method for forming a décor on a substrate

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EP0474470B1 (fr) * 1990-09-05 1998-02-04 Wilsonart International, Inc. Produit stratifié à surface d'acrylate d'uréthanne
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WO2007022581A1 (fr) * 2005-08-25 2007-03-01 Depco-Trh Pty Ltd Procédé de fabrication d’un papier ou non-tissé de décoration imprégné

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* Cited by examiner, † Cited by third party
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EP2402154A1 (fr) * 2010-06-29 2012-01-04 Guido Schulte Procédé de fabrication de composants plats et composant plat
US10017950B2 (en) 2011-08-26 2018-07-10 Ceraloc Innovation Ab Panel coating
US20130286088A1 (en) * 2012-04-30 2013-10-31 Ceraloc Innovation Ab Method for forming a decorative design on an element of a wood-based material
US10369837B2 (en) * 2012-04-30 2019-08-06 Valinge Innovation Ab Method for forming a decorative design on an element of a wood-based material
EP2900615A1 (fr) * 2012-09-25 2015-08-05 Falco Technologies BVBA Panneau décoratif multicouche et procédé de fabrication d'un panneau décoratif multicouche
US9409382B2 (en) 2012-11-28 2016-08-09 Valinge Innovation Ab Method of producing a building panel
US9855718B2 (en) 2013-03-15 2018-01-02 Wilsonart Llc Multi-layer additive texture laminates and methods
US10343368B2 (en) 2013-03-15 2019-07-09 Wilsonart Llc Multi-layer additive texture laminates and methods
US9199428B2 (en) 2013-03-15 2015-12-01 Biovation, Llc Multi-layer additive texture laminates and methods
US11077652B2 (en) 2013-10-23 2021-08-03 Ceraloc Innovation Ab Method of forming a decorative wear resistant layer
US10328680B2 (en) 2013-10-23 2019-06-25 Ceraloc Innovation Ab Method of forming a decorative wear resistant layer
US10899121B2 (en) 2014-01-24 2021-01-26 Ceraloc Innovation Ab Digital print with water-based ink on panel surfaces
US9994010B2 (en) 2014-01-24 2018-06-12 Ceraloc Innovation Ab Digital print with water-based ink on panel surfaces
US9605168B2 (en) 2014-01-31 2017-03-28 Ceraloc Innovation Ab Digital print with water-based ink
US11173722B2 (en) 2014-01-31 2021-11-16 Ceraloc Innovation Ab Digital print with water-based ink
US10737506B2 (en) 2014-01-31 2020-08-11 Ceraloc Innovation Ab Digital print with water-based ink
US10071563B2 (en) 2014-01-31 2018-09-11 Ceraloc Innovation Ab Digital print with water-based ink
CN107635778A (zh) * 2015-05-22 2018-01-26 爱克发印艺公司 通过喷墨制造装饰性表面
US10308056B2 (en) 2015-05-22 2019-06-04 Agfa Nv Manufacturing of decorative surfaces by inkjet
EP3095614A1 (fr) * 2015-05-22 2016-11-23 Agfa Graphics Nv Fabrication de surfaces décoratives par impression à jet d'encre
WO2016188743A1 (fr) * 2015-05-22 2016-12-01 Agfa Graphics Nv Fabrication de surfaces décoratives par jet d'encre
CN107635778B (zh) * 2015-05-22 2020-02-21 爱克发印艺公司 通过喷墨制造装饰性表面的方法以及所得装饰性表面
EP3108970A1 (fr) * 2015-06-25 2016-12-28 Hymmen GmbH Maschinen- und Anlagenbau Procédé de fabrication d'un stratifié décoratif peint
US11186997B2 (en) 2016-03-24 2021-11-30 Valinge Innovation Ab Method for forming a décor on a substrate
US11725397B2 (en) 2016-09-23 2023-08-15 Columbia Insurance Company Resilient flooring product and methods of making same
US11434647B2 (en) 2016-09-23 2022-09-06 Columbia Insurance Company Resilient flooring product and methods of making same
US10914080B2 (en) 2016-09-23 2021-02-09 Columbia Insurance Company Resilient flooring product and methods of making same
EP3300916A1 (fr) * 2016-09-30 2018-04-04 Agfa Nv Fabrication de surfaces décoratives
EP3300915A1 (fr) * 2016-09-30 2018-04-04 Agfa Nv Procédés d'impression par jet d'encre pour surfaces décoratives
US10807397B2 (en) 2016-09-30 2020-10-20 Agfa Nv Inkjet printing methods for decorative surfaces
CN109789718A (zh) * 2016-09-30 2019-05-21 爱克发有限公司 装饰表面的制造
RU2742293C2 (ru) * 2016-09-30 2021-02-04 Агфа Нв Изготовление декоративных поверхностей
US10625494B2 (en) 2016-09-30 2020-04-21 Agfa Nv Manufacturing of decorative surfaces
RU2743731C2 (ru) * 2016-09-30 2021-02-25 Агфа Нв Способы краско-струйной печати для декоративных поверхностей
AU2017336195B2 (en) * 2016-09-30 2022-10-13 Agfa Nv Manufacturing of decorative surfaces
CN109789717A (zh) * 2016-09-30 2019-05-21 爱克发有限公司 用于装饰表面的喷墨印刷方法
WO2018060182A1 (fr) * 2016-09-30 2018-04-05 Agfa Nv Fabrication de surfaces décoratives
WO2018060189A1 (fr) * 2016-09-30 2018-04-05 Agfa Nv Procédés d'impression à jet d'encre pour des surfaces décoratives
US11161334B2 (en) 2017-06-01 2021-11-02 The Boeing Company Methods and systems for inkjet printing on co-curable paint film
EP3418059A3 (fr) * 2017-06-01 2019-04-10 The Boeing Company Procédés et systèmes d'impression à jet d'encre sur un film de peinture co-durcissable
US10682840B2 (en) 2017-06-01 2020-06-16 The Boeing Company Methods and systems for inkjet printing on co-curable paint film

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