WO2014084787A1 - Procédé de production d'un panneau de bâtiment par impression numérique - Google Patents

Procédé de production d'un panneau de bâtiment par impression numérique Download PDF

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Publication number
WO2014084787A1
WO2014084787A1 PCT/SE2013/051401 SE2013051401W WO2014084787A1 WO 2014084787 A1 WO2014084787 A1 WO 2014084787A1 SE 2013051401 W SE2013051401 W SE 2013051401W WO 2014084787 A1 WO2014084787 A1 WO 2014084787A1
Authority
WO
WIPO (PCT)
Prior art keywords
carrier
primer
salt
print
printing
Prior art date
Application number
PCT/SE2013/051401
Other languages
English (en)
Inventor
Niclas HÅKANSSON
Jan Jacobsson
Melker Ryberg
Rickard Rittinge
Göran ZIEGLER
Marcus Bergelin
Original Assignee
Ceraloc Innovation Ab
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
Application filed by Ceraloc Innovation Ab filed Critical Ceraloc Innovation Ab
Priority to EP13857806.7A priority Critical patent/EP2925529B1/fr
Priority to CN201380061754.1A priority patent/CN104822533B/zh
Priority to KR1020157017046A priority patent/KR102193522B1/ko
Publication of WO2014084787A1 publication Critical patent/WO2014084787A1/fr

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Classifications

    • 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
    • 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
    • B41M5/00—Duplicating or marking methods; Sheet materials for use therein
    • B41M5/0011—Pre-treatment or treatment during printing of the recording material, e.g. heating, irradiating
    • B41M5/0017—Application of ink-fixing material, e.g. mordant, precipitating agent, on the substrate prior to printing, e.g. by ink-jet printing, coating or spraying
    • 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
    • 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
    • B41M5/0064—Digital printing on surfaces other than ordinary paper on plastics, horn, rubber, or other organic polymers
    • 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
    • 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
    • B41M7/0027—After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock using protective coatings or layers by lamination or by fusion of the coatings or layers
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels

Definitions

  • the present invention relates to a method of producing a building panel comprising a core and a printed carrier of a thermoplastic material forming a decor layer.
  • the invention also relates to a method of forming a decorative substrate.
  • thermoplastic core usually comprises a thermoplastic core, a thermoplastic decor layer arranged on the core, a protective layer on the decor layer, and a coating applied on the protective layer.
  • the thermoplastic material is often PVC.
  • the decor layer is printed with a pattern resembling natural stone, wood, ceramics etc.
  • the pattern is often printed by rotogravure printing or direct printing.
  • rotogravure printing or direct printing does not offer the desired flexibility in changing design of the patterns and adapting patterns for different needs of clients. Furthermore, a certain repetition of the pattern cannot be avoided by rotogravure printing or direct printing.
  • digital printing has offered new possibilities to the flooring industry to customize decorative patterns for flooring applications and to print small quantities of decor layers.
  • digital printing is conventionally meant printing by means of non-contact printing, for example using a Drop-on- Demand (DOD) technique.
  • DOD Drop-on- Demand
  • a drop of ink is placed with great accuracy on a paper or wood surface.
  • Examples of DOD techniques are piezoelectric DOD inkjet and thermal DOD inkjet.
  • the piezoelectric material changes shape when a voltage is applied. The change of shape of the piezoelectric material generates a pressure pulse in the fluid, thereby ejecting a droplet of ink from the nozzle.
  • thermal DOD inkjet printer ink drops are ejected by forming an ink vapour bubble by heating the ink.
  • inks may be used for digital printing, such as UV curable inks, solvent based inks and aqueous inks (also called waterborne or water based inks).
  • aqueous inks also called waterborne or water based inks.
  • UV curable inks When printing on a thermoplastic surface such as a layer adapted to from a decor layer of a LVT, printing is facilitated by using UV curable inks or solvent based inks compared to aqueous inks. Printing with an aqueous ink on a thermoplastic surface has proved to be difficult. A drop of an aqueous ink does not stay but tends to bleed on the thermoplastic surface, resulting in a print of low quality. However, due to environmental reasons, it is favourable to replace UV curable inks and solvent based inks.
  • a further object of at least certain embodiments of the present invention is to provide a method for producing a building panel comprising a thermoplastic decor layer including printing with an aqueous pigment ink composition.
  • a further object of at least certain embodiments of the present invention is to provide an improved print with an aqueous pigment ink on a thermoplastic material.
  • a further object of at least certain embodiments of the present invention is to reduce bleeding of an aqueous pigment ink on a thermoplastic material.
  • a further object of at least certain embodiments of the present invention is to provide an improved print with an aqueous pigment ink on a thermoplastic material without negatively affecting the bonding of the printed thermoplastic surface to another layer such as a protective layer arranged on the printed surface.
  • thermoplastic material a carrier comprising a thermoplastic material
  • a primer comprising at least one salt, preferably a metal salt, on a first surface of the carrier,
  • the printed carrier forms a decor layer of the floor panel.
  • the protective layer is arranged on the first surface of the carrier.
  • a second surface of the carrier is facing the core.
  • Aqueous inks may also be called water based or waterborne inks.
  • the building panel may be a floor panel.
  • the floor panel may be of the type usually named luxury Vinyl Tile (LVT) or luxury Vinyl Plank.
  • the core may be formed of a different material than a thermoplastic material, for example a wood- based material such as MDF or HDF.
  • the core according to the first aspect of the invention may comprise a layer comprising a thermoplastic material arranged on a substrate, for example a wood-based substrate such as MDF or HDF.
  • the inventive method it is possible to create advanced designs of the decor layer in a more flexible and less expensive way compared rotogravure printing or direct printing.
  • the design of the print can be customized and repetition of the pattern can be avoided.
  • an aqueous ink composition can be used also when printing on a carrier of thermoplastic material.
  • the inks drops tend to displace on the surface of the carrier and tend to mix into each other, thus resulting in a print of bad quality and a print being indistinct.
  • the primer is in one embodiment adapted to change the properties of the surface of the carrier such that the surface becomes more suitable for printing with an aqueous pigment ink composition.
  • the primer may for example be adapted to increase the wettability of the surface of the carrier such that the surface of the carrier obtains hydrophilic properties.
  • the primer comprises at least one salt, preferably an inorganic salt, more preferably a metal salt.
  • the salt may be a polyvalent metal salt.
  • the primer preferably forms a layer of uniformly distributed salt crystals on the surface of the carrier.
  • the primer is coalescent and/or film forming.
  • the primer comprising the salt is adapted to crash the ink composition.
  • the salt of the primer precipitates or agglomerates the pigment of the ink composition.
  • the salt reacts with the aqueous ink composition such that the pigment of the ink composition precipitates.
  • By crashing the aqueous pigment ink composition the ink drops are fixed at the position on the carrier where the ink drops are placed by the nozzle.
  • By crashing the aqueous pigment ink composition the ink drops are prevented from being mixed with each other.
  • the primer makes the ink drops stay on the position where the ink drops are applied on the surface of the carrier.
  • the primer prevents the ink drops from accumulating and mixing into large ink drops.
  • the primer prevents the ink drops from moving on the surface of the carrier. Thereby, it is possible to print with an aqueous pigment ink composition on a thermoplastic surface.
  • a print of high quality made by digital printing with an aqueous pigment ink composition can be obtained.
  • a building panel such as a floor panel of LVT type having a print of high quality obtained in an environmentally friendly way.
  • a primer comprising salt does not adversely affect, or at least substantially adversely affect, the bonding of the printed carrier to the protective layer when applying heat and pressure to form the building panel.
  • the primer and the print do not reduce, or at least substantially reduce, the bonding strength between the layers. Thereby, the desired bonding between the carrier and the protective layer is still achieved.
  • the print is not affected, or at least substantially affected, by pressing the layers together for forming a building panel such as a floor panel by applying heat and pressure.
  • the primer has already agglomerated the ink such that the ink drops are fixed on the carrier and not affected by the pressing.
  • the primer may be an aqueous solution comprising said at least one salt.
  • the primer is applied prior to printing the print.
  • the composition of the primer may be adapted to match the composition of the ink.
  • the primer may be applied as a coating layer on the carrier. Alternatively, the primer does not completely cover the surface of the carrier.
  • the primer may be applied to parts of the surface of the carrier. For example, if only a portion of the carrier is to be printed, such as a second print is to be printed on an already printed surface, the primer is only applied to this portion of the carrier.
  • the primer may be applied by means of digital printing. Thereby, application of the primer may be controlled with high accuracy. For example, by applying the primer to only certain areas of the carrier, bleeding of the ink may be controlled in order to obtained a desired effect.
  • the primer may be an aqueous solution comprising said salt.
  • the salt concentration of the primer may be at least 50% of the saturation point of the salt, preferably at least 70% of the saturation point of the salt, more preferably at least 90% of the saturation point of the salt.
  • the primer is a nearly saturated salt dispersion.
  • the primer may be heated to a temperature above room temperature, for example to 40-60°C.
  • the primer applied on the carrier may have a contact angle with water of less than 50°, preferably less than 40°, more preferably less than 35°, such that about 30°. By decreasing the contact angle, spreading of the primer, and thereby the salt of the primer, on the surface of the carrier is improved.
  • the salt is uniformly distributed on the surface such that a uniform base for the ink is formed.
  • the primer may comprise a wetting agent.
  • the wetting agent increases the wettability of the surface of the carrier. Wetting of the surface is thereby facilitated.
  • the wetting agent of the primer results in that the surface of the carrier coated by the primer obtains hydrophilic properties. By increasing the wetting of the surface, the salt crystals are homogenously distributed over the surface of the carrier, which improves the print result.
  • the wetting agent does not adversely affect the bonding of the printed carrier to the protective layer.
  • the wetting agent may be a non-ionic surfactant.
  • the primer may as an example comprise about 0.5-4 % wt of the wetting agent, preferably 1 -4 % wt such as about 2 % wt.
  • the type and amount of wetting agent may be adapted to the surface tension of the carrier.
  • the primer may be applied by means of digital printing. Thereby, application of the primer may be controlled with high accuracy. For example, by applying the primer to only certain areas of the carrier, bleeding of the ink may be controlled in order to obtained a desired effect.
  • the method may further comprise drying the primer applied on the first surface of the carrier prior to printing.
  • printing in a wet primer may also be possible, depending on the primer used.
  • More than one layer of a primer may also be applied to the surface of the carrier.
  • the step of applying the primer may comprise applying a primer, drying the applied primer, applying an additional layer of the primer, and drying the applied primer prior to printing.
  • the salt is applied on the carrier in solid form.
  • the solid salt crystals are uniformly distributed over the surface of the carrier.
  • the solid salt crystals may be attached to the surface of the carrier in several ways.
  • the carrier is heated prior and/or during the salt is applied in solid form.
  • the carrier is electrically charged such that the surface of the carrier attracts the salt particles.
  • a plasticizer is applied to the surface of the carrier.
  • the solid salt particles are applied to the plasticized surface of the carrier.
  • the solid salt particles are mechanically attached to the surface of the carrier.
  • the surface of the carrier may be porous in order to facilitate the bonding of the salt particles to the surface of the carrier.
  • the aqueous pigment ink composition may be a heat activated curing ink.
  • a heat activated curing ink cures when being exposed to heat.
  • the binder in the ink composition cures and the ink is thereby fixed to the surface.
  • bleeding of the ink is reduced.
  • the aqueous pigment ink composition may comprise a binder, water and a pigment.
  • the binder may be dispersed in the ink composition.
  • the binder may be a polymer or cellulose.
  • the pigment may be coated with a binder, preferably a polymer.
  • the pigment may be dispersed in the ink composition.
  • the method may further comprise applying heat to the print.
  • the binder of the aqueous ink composition cures.
  • the heat makes the aqueous ink composition dry faster.
  • the carrier may also be heated before and/or during printing on the surface of the carrier.
  • the printing may be made by an inkjet printer, preferably a piezo- electric DOD (Drop on Demand) inkjet printer.
  • DOD Drop on Demand
  • the surface of the carrier may be pre-treated by corona, flaming or plasma.
  • Corona, plasma and flaming treating the surface of the carrier enhances the chemical bonding to the resin matrix in the carrier. Thereby, bonding of the ink to the carrier is improved.
  • Corona, flaming or plasma treatment increases the wettability of the surface of the carrier.
  • Corona, flaming or plasma treatment may be combined with applying a primer after corona, flaming or plasma treatment.
  • the first surface of the carrier may be facing the core. The print is thereby printed at a lower surface of the carrier.
  • the first surface of the carrier may be facing away from the core.
  • the print is thereby printed at an upper surface of the carrier.
  • the method may further comprise printing a second print by means of digital printing on a second surface of the carrier. Consequently, the carrier is provided with a print on both its surfaces. Same pattern or design may be printed on both surfaces of the carrier. Alternatively, the print or design may be different. The first and second print may together form a specific design.
  • the method may further comprise printing a second print by means of digital print on the first print.
  • the first and second print may be the same design or pattern. Alternatively, the first and second print may differ. The first and second print may together form a specific design.
  • the method may further comprise arranging an additional carrier on the first carrier, and printing by means of digital printing a second print on a surface of the second carrier.
  • the method may further comprise applying decorative elements on the carrier.
  • the decorative elements may for example be mineral particles, plastic particles, glass particles, coloured fibres, or mother of pearl, creating a decorative effect.
  • the mineral particles may be Granostar ® or similar.
  • the decorative elements may be solid particles, preferably having a size exceeding 1 pm.
  • the protective layer may comprise a thermoplastic material such as polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PUR), polyethylene terephthalate (PET), polyacrylate, polyvinyl butyral, or a combination thereof.
  • the protective layer may be provided with a coating, preferably a UV curable coating, more preferably a coating comprising acrylate oligomers, methacrylate oligomers, or unsaturated polyester. It is also contemplated that only a coating forming a protective layer is applied on the carrier forming the decor layer.
  • the thermoplastic material of the carrier may be polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PUR), polyethylene terephthalate (PET), polyacrylate, polyvinyl butyral, or a combination thereof.
  • the thermoplastic material of the core may be polyvinyl chloride (PVC) or polypropylene (PP).
  • the thermoplastic core may be a Wood Plastic Composite (WPC).
  • the method may further comprise pressing the core, the carrier having the print thereon and the protective layer with an embossed press plate.
  • the method may further comprise forming a mechanical locking system for horizontal and/or vertical locking of adjacent building panels at at least one edge of the building panel.
  • a building panel such as a floor panel
  • the building panel comprises a core comprising a thermoplastic material, a printed decor layer comprising a thermoplastic material, and a protective layer arranged on the printed decor layer, wherein the decor layer is provided with a primer layer arranged on a surface of the decor layer and a print is arranged on the primer layer, wherein the print comprises an aqueous pigment ink composition and the primer layer comprises salt, preferably a metal salt.
  • the aqueous pigment ink composition may be a heat activated curing ink.
  • the metal salt may be a polyvalent metal salt.
  • a method for forming a decorative substrate comprises providing a carrier comprising a thermoplastic material, applying a primer comprising at least one salt, preferably a metal salt, on a first surface of the carrier, printing, preferably by digital printing, a first print on said first surface of the carrier with an aqueous pigment ink composition, applying a protective layer comprising a thermoplastic material on the first surface of the carrier, pressing the protective layer and the carrier together to form a decorative substrate.
  • An embodiment according to the third aspect of the invention incorporates all the advantages of the first aspect of the invention, which previously has been discussed, whereby the previous discussion is applicable also for the method according to the third aspect.
  • the primer comprising the salt is adapted to crash the ink composition.
  • the salt of the primer precipitates or agglomerates the pigment of the ink composition.
  • the salt reacts with the aqueous ink composition such that the pigment of the ink composition precipitates.
  • By crashing the aqueous pigment ink composition the ink drops are fixed at the position on the carrier where the ink drops are placed by the nozzle.
  • By crashing the aqueous pigment ink composition the ink drops are prevented from being mixed with each other.
  • the primer makes the ink drops stay on the position where the ink drops are applied on the surface of the carrier.
  • the primer prevents the ink drops from accumulating and mixing into large ink drops.
  • the primer prevents the ink drops from moving on the surface of the carrier.
  • a primer comprising salt does not adversely affect, or at least substantially adversely affect, the bonding of the printed carrier to the protective layer when applying heat and pressure to form the building panel.
  • the primer and the print do not reduce, or at least substantially reduce, the bonding strength between the layers. Thereby, the desired bonding between the carrier and the protective layer is still achieved.
  • the print is not affected, or at least not substantially affected, by pressing the layers together for forming a building panel by applying heat and pressure.
  • the primer has already agglomerated the ink such that the ink drops are fixed on the carrier and not affected by the pressing.
  • Pressing may be performed by applying heat and pressure. By applying heat pressure, the carrier with the print and the protective layer are bonded together.
  • the decorative substrate may be bonded to a core.
  • the core may, for example, comprise a thermoplastic material, or a wood-based material such as MDF or HDF.
  • the salt may be applied on the carrier in solid form.
  • the primer may be an aqueous solution comprising said salt.
  • the salt concentration of the primer may be at least 50% of the saturation point of the salt, preferably at least 70% of the saturation point of the salt, more preferably at least 90% of the saturation point of the salt.
  • the primer applied on the carrier may have a contact angle of less than 50°, preferably less than 40°, more preferably less than 35°, such that about 30°.
  • the primer may comprise a wetting agent.
  • the primer may as an example comprise 0.5-4 % wt of the wetting agent, preferably 1 -4 % wt such as about 2 % wt.
  • the wetting agent may comprise a non-ionic surfactant.
  • the primer may be applied by means of digital printing.
  • the method may further comprise drying the primer applied on the first surface of the carrier prior to printing.
  • the aqueous pigment ink composition may be a heat activated curing ink.
  • the aqueous pigment ink composition may comprise a binder, water and a pigment.
  • the method may further comprise applying heat to the print.
  • the printing may be made by an inkjet printer, preferably a piezoelectric DOD (Drop on Demand) inkjet printer.
  • an inkjet printer preferably a piezoelectric DOD (Drop on Demand) inkjet printer.
  • the protective layer may comprise a thermoplastic material such as polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PUR), or polyethylene terephthalate (PET), polyacrylate, polyvinyl butyral, or a combination thereof.
  • a thermoplastic material such as polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PUR), or polyethylene terephthalate (PET), polyacrylate, polyvinyl butyral, or a combination thereof.
  • the thermoplastic material of the carrier may be polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PUR), or polyethylene terephthalate (PET), polyacrylate, polyvinyl butyral, or a combination thereof.
  • PVC polyvinyl chloride
  • PP polypropylene
  • PE polyethylene
  • PS polystyrene
  • PUR polyurethane
  • PET polyethylene terephthalate
  • Fig. 1 illustrates a top view of an embodiment of a building panel such as a floor panel.
  • Fig. 2a illustrates a cross-section of an embodiment of a building panel such as a floor panel.
  • Fig. 2b illustrates a cross-section of an embodiment of a building panel such as a floor panel.
  • Fig. 2c illustrates a cross-section of an embodiment of a building panel such as a floor panel.
  • Fig. 2d illustrates a cross-section of an embodiment of a building panel such as a floor panel.
  • Fig. 3a illustrates a side view of a printing line.
  • Fig. 3b illustrates a side view of an alternative printing line.
  • Fig. 3c illustrates a top view of the printing line in fig. 3a.
  • Fig. 4 illustrates bonding of layers for forming a building panel.
  • Fig. 5 illustrates a decorative substrate. Detailed description
  • the floor panel 1 comprises a core 2, a carrier 3 provided with a print forming a decor layer 6, and a protective layer 4.
  • the core 2, the carrier 3 and the protective layer 4 are bonded together to form the floor panel 1 .
  • the floor panel 1 may also be provided with a backing layer (not shown) arranged on the lower surface of the core 2.
  • a coating 5 may be provided on top of the protective layer 4.
  • the core 2 comprises a thermoplastic material.
  • the thermoplastic material may be polyvinyl chloride (PVC) or polypropylene (PP).
  • the core 2 may further comprise fillers, for example calcium carbonate, and additives such as plasticizer, impact modifier, stabilizer, processing aids, pigment, lubricants etc.
  • the core may be a Wood Plastic Composite (WPC) comprising a thermoplastic binder and wood fibres or particles.
  • WPC Wood Plastic Composite
  • the core 2 may also comprise more than one layer.
  • the layers may be of similar or different material.
  • the core 2 may comprise several layers comprising a thermoplastic material, or may comprise at least one layer comprising a thermoplastic material arranged on a substrate of, for example, a wood based material such as MDF or HDF.
  • the carrier 3 comprises a thermoplastic material such as polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PUR), polyethylene terephthalate (PET), polyacrylate, polyvinyl butyral, or a combination thereof.
  • the carrier may further comprise additives such as a plasticizer.
  • the carrier 3 may be in form of a
  • thermoplastic foil or film The thickness of the carrier 3 may be 0.01 -1 mm.
  • the carrier 3 may be transparent, coloured or opaque.
  • the colour of the carrier 3 may form a base colour for the print.
  • the protective layer 4 is arranged on the carrier 3.
  • the protective layer 4 is bonded to the carrier 3.
  • the protective layer 4 may be in form of a thermoplastic foil or film.
  • the protective layer 4 comprises a thermoplastic material such as polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PUR), polyethylene terephthalate (PET), polyacrylate, polyvinyl butyral, or a combination thereof.
  • the protective layer 4 may further comprise additives such as a plasticizer.
  • the thickness of the protective layer 4 may be 0.01 -1 mm. Wear resistant particles such as aluminium oxide particles may be included in the protective layer 4.
  • the protective layer 4 is preferably transparent.
  • a coating 5 may be arranged on the protective layer 4.
  • the coating 5 is preferably a UV curable coating, more preferably a coating comprising an acrylate oligomer, methacrylate oligomer, or unsaturated polyester.
  • the protective layer 4 is formed by the coating applied directly on the printed carrier 3 forming the decor layer 6.
  • the floor panel 1 may be provided with a backing layer (not shown) on the lower surface of the core.
  • the backing layer may comprise a
  • thermoplastic material such as polyvinyl chloride (PVC), polyester,
  • polypropylene PP
  • PE polyethylene
  • PS polystyrene
  • PUR polyurethane
  • PET polyethylene terephthalate
  • the carrier 3 is provided with a print 10 giving the carrier its decorative properties.
  • the printed carrier 3 forms a decor layer 6.
  • the print 10 may be a decorative design.
  • the decorative design may be natural designs and patterns such as a wood pattern or stone pattern.
  • the decorative design may also be a fantasy design or pattern or a photograph.
  • the print is applied to a primer layer comprising at least one salt, preferably a metal salt.
  • the salt crystals form a primer layer onto which the pigments of the ink are injected.
  • the salt crystals preferably form a uniform layer.
  • the floor panel 1 is provided with a mechanical locking system for locking the floor panel 1 to adjacent floor panels horizontally and/or vertically.
  • the mechanical locking system comprises at a first edge of the floor panel a tongue groove 16 adapted to receive a tongue 15 of an adjacent floor panel, and a locking strip 12 provided with a locking element 13 adapted to cooperate with a locking groove 14 of an adjacent floor panel and lock the floor panel 1 in a horizontal direction to the adjacent floor panel.
  • the mechanical locking system further comprises at a second edge a locking groove 14 adapted to receive a locking element 13 of an adjacent floor panel, and a tongue 15 adapted cooperate with a tongue groove 16 of an adjacent floor panel and lock the panel 1 in a vertical direction.
  • the mechanical locking system is formed in the core 2 of the floor panel 1.
  • Both long side edges and short side edges of the floor panel 1 may be provided with a mechanical locking system.
  • long side edges of the floor panel 1 may be provided with the mechanical locking system for horizontally and vertically locking
  • the short side edges may be provided with a mechanical locking system for horizontally locking only. It is also contemplated that other locking systems may be used, for example of the type described in WO2007/015669.
  • the carrier 3 is provided with the print 10 on its upper surface facing away from the core 2.
  • the carrier 3 is provided with the print 10 on its lower surface facing the core 2.
  • the protective layer 4 and/or the coating 5 may be excluded.
  • a protective layer 4 is arranged over the carrier 3 forming the decor layer 6 and the coating 5 is excluded.
  • the floor panel 1 comprises a core 2 of the type described above with reference to fig. 1 and fig. 2a and a carrier 3 of the type described above with reference to fig. 1 a. In all other aspects, the floor panel 1 corresponds to the floor panel 1 described with reference to fig. 1 and fig. 2a.
  • the carrier 3 is provided with two prints 10, 1 1 of the above described type.
  • a first print 10 is printed on a first surface of the carrier 3 facing the core 2.
  • a second print 1 1 is printed on a second surface of the carrier 3 facing away from the core 2.
  • the first and the second print 10, 1 1 may be the same pattern or design.
  • the first and second print 10, 1 1 may differ.
  • the first and the second print 10, 1 1 may be similar pattern or design.
  • a protective layer 4 is arranged on the carrier 3.
  • a coating 5 may be applied on top of the protective layer 4.
  • the floor panel 1 in fig. 2c comprises a core 2, carrier 3 and protective layer 4 of the type described above with reference to fig. 1 and fig. 2a. In all other aspect, the floor panel 1 corresponds to the floor panel 1 described with reference to fig. 1 and fig. 2a.
  • an additional carrier 7 is arranged on the carrier 3.
  • a first print 10 is printed on the carrier 3, preferably on an upper surface of the carrier 3 facing away from the core 2.
  • a second print 1 1 is printed on the additional carrier 7, preferably on an upper surface of the additional carrier 7 facing away from the core 2.
  • the first and the second print 10, 1 1 may be the same pattern or design.
  • the first and second print 10, 1 1 may differ.
  • the first and the second print 10, 1 1 may be similar pattern or design.
  • a protective layer 4 is arranged on the additional carrier 7.
  • a coating 5 may be applied on top of the protective layer 4.
  • the additional carrier 7 is of the same type as the carrier 3.
  • the second print 1 1 is printed on a lower surface of the additional carrier 7.
  • the protective layer 4 and/or the coating 5 can be excluded.
  • the additional carrier 7 also has the function of a protective layer.
  • the floor panel 1 corresponds to the floor panel 1 described with reference to fig. 1 and fig. 2a.
  • a carrier 3 in form of a foil or film, for forming the decor layer 6 of the above described type is provided.
  • the carrier comprises a thermoplastic material such as polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PUR), polyethylene terephthalate (PET), polyacrylate, polyvinyl butyral, or a combination thereof.
  • the carrier 3 is arranged on a roll 8.
  • a primer is applied on the first surface of the carrier 3.
  • the primer is applied on the surface of the carrier 3 adapted to form the decor layer 6.
  • the primer is applied on the carrier 3 by an applying device 20.
  • the primer is an aqueous solution a salt, preferably at least one metal salt.
  • the metal salt may be a monovalent metal salt, for example comprising a monovalent ion such as Na + .
  • the metal salt may be a polyvalent metal salt.
  • the polyvalent metal salt comprises divalent ions such as Ca 2+ , Cu 2+ , Ni 2+ , Mg 2+ , Zn 2+ , or Ba 2+ , or trivalent ions such as Al 3+ or Fe 3+ .
  • the metal salt may for example be sodium chloride or calcium chloride.
  • the metal salt crashes the ink composition resulting in precipitation of the pigment of the ink composition.
  • the salt may also be a non-metal salt such as ammonium chloride.
  • the salt concentration of the primer may be at least 50% of the saturation point of the salt, preferably at least 70% of the saturation point of the salt, more preferably at least 90% of the saturation point of the salt.
  • the primer may be a saturated solution, or a nearly saturated solution.
  • the primer may further comprise a wetting agent.
  • the wetting agent increases wettability of the surface of the carrier 3.
  • the wetting agent may be a non-ionic surfactant.
  • the wetting agent may be a silicone surfactant, preferably a non-ionic silicone surfactant.
  • the wetting agent may be a polyether modified siloxanes.
  • the wetting agent may be a polyether modified polysiloxanes.
  • the wetting agent may be a polyether modified polymethyl siloxane.
  • the wetting agent may be a polydimethylsiloxane co-polymer.
  • the primer may comprise 0.5-4 % wt of the wetting agent, preferably 1 -4 % wt such as about 2 % wt of the wetting agent.
  • the contact angle of the primer on the carrier may be of less than 50 °, preferably less than 40°, more preferably less than 35°, such that about 30°
  • the primer is preferably homogenously applied to the surface of the carrier 3 such that a uniform layer of salt crystals is formed on the surface of the carrier 3.
  • the wetting agent facilitates wetting of the surface by the carrier 3.
  • the salt crystals are preferably uniformly distributed over the surface of the carrier.
  • the primer is coalescent and/or film forming.
  • the primer may further comprise a binder.
  • the binder of the primer may differ from the binder of the ink composition.
  • the aqueous primer dispersion is applied by spraying by means of a spraying device 20 in the embodiment shown in fig. 3a.
  • the primer may be applied by digital printing, curtain coating, roller application, blasting, and by mechanical application.
  • the primer may form a layer coating the surface of the carrier 3, or the primer may only partly coat the surface of the carrier 3.
  • the primer After the primer has been applied, the primer is dried in a heating device 30. Heat is applied to the surface of the carrier 3 adapted to form the decor layer 6 such that the applied primer dries. Heat may be applied in form of for instance infrared light (IR), near infrared light (NIR), heated air or a combination thereof.
  • IR infrared light
  • NIR near infrared light
  • heated air or a combination thereof.
  • Evaporation of the water of the primer may be obtained at a quicker pace if the primer is heated before being applied to the surface of the carrier 3.
  • the carrier 3 may also be heated before and/or during the primer is applied in order to make the evaporation of the water of the primer faster.
  • the heating of the carrier 3 may be achieved by arranging the carrier 3 on a heated plate.
  • additional layers of the primer are applied to the surface of the carrier 3.
  • the primer may be dried between each application step.
  • the carrier 3 may be rolled on a roller for storage until printing, or may enter into a printing process.
  • the primer comprises a salt applied on the surface of the carrier in solid form.
  • the salt is applied by means of the applying device 20, preferably a scattering device.
  • the salt is preferably at least one metal salt.
  • the metal salt may be a monovalent metal salt, for example comprising a monovalent ion such as Na + .
  • the metal salt may be a polyvalent metal salt.
  • the polyvalent metal salt comprises divalent ions such as Ca 2+ , Cu 2+ , Ni 2+ , Mg 2+ , Zn 2+ , or Ba 2+ , or trivalent ions such as Al 3+ or Fe 3+ .
  • the metal salt may for example be sodium chloride or calcium chloride. The metal salt crashes the ink composition resulting in precipitation of the pigment of the ink composition.
  • the salt crystals forming the primer are preferably uniformly distributed over the surface of the carrier 3.
  • the salt crystals form preferably a uniform layer on the surface of the carrier 3.
  • the primer comprising the salt in solid form may be bonded to the surface of the carrier 3 in several ways.
  • the carrier 3 is heated before and/or during the primer is applied such that the salt binds to the carrier.
  • the carrier 3 is electrically charged such that the carrier attracts the salt crystals of the primer.
  • a plasticizer is applied on the surface of the carrier 3 such that the salt crystals are bonded to the plasticized surface of the carrier 3.
  • a solvent may be applied to the surface of the carrier 3.
  • the salt crystals are mechanically attached to the surface of the carrier 3, for example by making the surface of the carrier 3 porous.
  • the pre-treatment comprises applying a Corona, flaming or plasma treatment on the first surface of the carrier 3 prior to printing.
  • the Corona, flaming or plasma treatment increases the wettability of the surface.
  • a primer of any of the above described type is applied to the treated surface.
  • the primer is subsequently dried before enter the printing process.
  • the carrier 3 is either rolled on roller or enters into a printing process.
  • the carrier 3 enters into a printing process after the primer has been applied.
  • the carrier 3 enters the printing process after the step of drying the primer.
  • a print 6 by digital printing is printed to the pre-treated surface of the carrier 3 adapted to form the decor layer 6 of the floor panel 1.
  • the printer 40 is preferably an inkjet printer.
  • the printer 40 is a DOD (Drop on Demand) piezo-electric inkjet printer.
  • a thermal DOD inkjet printer may also be used.
  • the print 6 is applied in a contactless manner.
  • the printer 40 comprises at least one inkjet print head 45.
  • the printer 40 comprises several inkjet print heads 45.
  • CMYK colours or spot colours may be used. If CMYK is used as a colour system, at least four inkjet print heads 45 is required, one for every colour. If spot colours are used, one print head 45 is required for each spot colour. The number of spot colours and thereby the number of print heads 45 may vary.
  • the printer 40 shown in figs. 3a and 3b comprises four print heads 45, corresponding to CMYK- colours or four spot colours.
  • a number of print heads 45 are arranged one after in a row extending perpendicular to the conveying direction of the carrier 3 through printer.
  • Print heads arranged in the same row includes ink having the same colour.
  • the width of the row of print heads preferably corresponds to the width of the carrier 3 on which the print 6 is to be applied.
  • a first, second, third and fourth row 41 , 42, 43, 44 of print heads are arranged one after each other in the conveying direction D of the carrier.
  • a first colour is applied by the print heads in the first row 41
  • a second colour is applied by the print heads in the second row 42
  • a third colour is applied by the print heads in the third row 43
  • a fourth colour is applied by the print heads in the fourth row 44.
  • a printer 40 comprising a print head having different channels may be used.
  • one print head may print one colour or several colours.
  • more than one colour can be printed by an individual print head provided with different channels.
  • One channel is provided for each colour. Consequently, only one row of print heads may be provided in the printer.
  • the ink that is applied by means of the above described inkjet printer 40 is an aqueous pigment ink composition.
  • the ink composition comprises pigments giving the ink its specific colour.
  • the aqueous ink composition is a heat activated curing ink.
  • the ink composition may comprise a binder, water and pigment.
  • the binder may for example be a polymer or cellulose.
  • the binder may be dispersed in the ink composition.
  • the pigment is coated by a binder, preferably a polymer.
  • the polymer may carry carboxyl groups.
  • the polymer may be styrene, acrylic or methacrylic polymer or copolymer, or unsaturated monomers, polyesters, vinyl polymers or copolymers, aromatic and aliphatic polyurethanes, or alkyd resins.
  • the decorative design that is to be printed on the carrier 3 adapted to form the decor layer 6 may be both natural designs and patterns such as a wood pattern or stone pattern.
  • the decorative design may also be a fantasy design or pattern.
  • the inkjet printer 40 prints a print 10 in form of a decorative design on the primer applied on the surface of the carrier 3 adapted to form the decor layer 6.
  • a heating device 50 may be arranged after the digital printer 40, as seen in the conveying direction D of the carrier.
  • the heating device 50 may include infrared (IR) heating, near infrared (NIR) heating, heated air or a combination thereof.
  • the carrier 3 may be rolled on a roller 8 in order to be stored when the print 6 has dried. It is also contemplated that the printing takes place inline.
  • the carrier 3 is printed on one surface only. In an alternative embodiment, the carrier 3 is printed on both surfaces. In that embodiment, a primer as described above is applied to the first surface of the carrier 3, the first surface is printed, a primer as described above is applied to the second surface of the carrier 3, and the second surface is printed. As an alternative, pre-treatment of both surfaces of the carrier 3 takes place before printing on both surfaces of the carrier 3.
  • the carrier 3 for forming the decor layer 6 may be cut or punched into a size corresponding to a size of a floor panel 1 .
  • a film or foil adapted to form the protective layer 4 may be cut or punched into a size corresponding to a size of a floor panel 1
  • the protective layer 4 comprises a thermoplastic material such as such as polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PUR), polyethylene terephthalate (PET), polyacrylate, polyvinyl butyral, or a combination thereof.
  • Core material adapted to form the core 2 may be also cut or punched into a size corresponding to a size of a floor panel 1 .
  • the core may comprise polyvinyl chloride (PVC) or polypropylene (PP) or be a WPC.
  • the decor layer and/or the protective layer are provided on rollers to be bonded together in a continuous process.
  • the printed carrier 3 is arranged on a core 2 comprising at least a layer of thermoplastic material to form a decor layer 6.
  • the print 10 may be facing the core 2 or may be facing away from the core 2. If more than one carrier 3, 7 are provided, the carriers 3, 7 are arranged on top of each other to form the decor layer 6.
  • a protective layer 4 is arranged on the printed carrier 3 forming the decor layer 6.
  • the core 2, the printed carrier 3 adapted to form the decor layer 6, and the protective layer 4 are pressed together to form a floor panel 1 .
  • An embossed press plate may be used to form an embossed surface of the floor panel 1 .
  • Heat and pressure may be used to press the layers together.
  • the temperature may be 120-200 °C.
  • the pressure may be 5-10 bar.
  • the carrier 3 provided with the print is bonded to the protective layer 4.
  • the print is located between the carrier 3 and the protective layer 4 being bonded together.
  • the carrier 3 is also bonded to the core 2.
  • the coating 5 may comprise an acrylate oligomer, methacrylate oligomer, or unsaturated polyester.
  • the floor panel 1 may be further divided into floor panels or
  • a mechanical locking system of the above described type may be formed at at least one edge of the floor panel.
  • the printed carrier 3 is bonded to the protective layer 4 by pressing them together to form a decorative substrate 9. Heat and pressure may be used to press the layers together.
  • the print is located between the carrier 3 and the protective 4 being bonded together.
  • the decorative substrate 9 may be bonded by pressing to a core of any type in a subsequent step, or simultaneously as bonding the printed carrier 3 to the protective layer 4.
  • the core may comprise a thermoplastic material, or at least a layer comprising a thermoplastic material, or may be a wood-based material.
  • the decorative substrate 9 comprising the printed carrier and the protective layer may be stored on, for example, a roller, and later be adhered to a core.
  • the core may comprise other materials than a thermoplastic material.
  • the decorative substrate forms a printed, thermoplastic laminate.
  • a panel as described above may not only be a floor panel, but may also be a building panel such as ceiling panel, a wall panel, a furniture component etc.
  • printing and primer application steps may be performed in an inline process or in an offline process.
  • the printing may be performed by rotogravure printing, screen printing etc. as alternative to digital printing.
  • drying of the primer may be excluded, depending on the properties of the primer.
  • a layer may be arranged between the carrier forming the decor layer and the core.
  • a layer having a uniform colour may be arranged between the carrier and the core.
  • a white, PVC foil for LVT was printed directly on by means of a digital printer with a water based ink. The print was dried in 60°C during 10 min. The printed foil was bonded to a transparent protective foil of PVC for LVT in a hot/cold-pressing step at 185°C for 70 seconds at approximately 6 bar pressure, followed by cooling down to 25°C at approximately 5 bar pressure. The bonding between the printed PVC foil and the protective foil was good.
  • the resulting print is of poor quality due to the difference in surface tension between the ink and the LVT-foil.
  • the ink drops have agglomerated to large ink drops.
  • the ink drops have started to bleed into each other.
  • a white, PVC foil for LVT was treated with a primer comprising
  • the foil was dried before further steps.
  • the contact angle of the primer on the PVC foil was measured to about 90°.
  • the foil treated with the primer was printed by means of a digital printer with a water based ink .
  • the print was dried in 60°C during 10 min.
  • the printed foil was bonded to a transparent protective foil of PVC for LVT in a hot/cold-pressing step at 185°C for 70 seconds at approximately 6 bar pressure, followed by cooling down to 25°C at approximately 5 bar pressure. The bonding between the printed PVC foil and the protective foil was good.
  • a white, PVC foil for LVT was treated with a primer comprising
  • the foil treated with the primer was printed by means of a digital printer with a water based ink. The print was dried in 60°C during 10 min. The printed foil was bonded to a transparent protective foil of PVC for LVT in a hot/cold- pressing step at 185°C for 70 seconds at approximately 6 bar pressure, followed by cooling down to 25°C at approximately 5 bar pressure. The bonding between the printed PVC foil and the protective foil was good.
  • the primer was evenly applied over the surface on the LVT-foil.
  • the printed image was not fixated evenly due to insufficient concentration of NaCI in the primer.
  • a white, PVC foil for LVT was treated with a primer comprising
  • the foil treated with the primer was printed by means of a digital printer with a water based ink. The print was dried in 60°C during 10 min. The printed foil was bonded to a transparent protective foil of PVC for LVT in a hot/cold- pressing step at 185°C for 70 seconds at approximately 6 bar pressure, followed by cooling down to 25°C at approximately 5 bar pressure. The bonding between the printed PVC foil and the protective foil was good.
  • the primer is evenly applied over the surface on the LVT-foil.
  • the printed image is fixated evenly over the surface of the foil and a print result with good colour strength and resolution is achieved.
  • the amount of wetting agent applied in the above examples is adapted to the foil used, and to the surface tension of the foil, in the examples, and may be different when using a different substrate and/or different wetting agent.
  • the amount of salt applied in the above examples is adapted to the ink used in the examples, and may be different when using a different ink and/or different type of salt.

Landscapes

  • Floor Finish (AREA)
  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Inks, Pencil-Leads, Or Crayons (AREA)
  • Laminated Bodies (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Finishing Walls (AREA)

Abstract

La présente invention concerne un procédé de production d'un panneau (1) de bâtiment tel qu'un panneau de sol, comportant les étapes consistant à mettre en place un support (3) comportant un matériau thermoplastique, à appliquer un apprêt comportant au moins un sel, de préférence un sel métallique, sur une première surface du support (3), à imprimer par impression numérique un premier motif (10) sur ladite première surface du support (3) avec une composition d'encre à pigment aqueux, à appliquer une couche protectrice (4) sur le support (3) et à appliquer le support (3) sur une âme (2) comportant un matériau thermoplastique, et à presser ensemble, en appliquant de la chaleur et une pression, la couche protectrice (4), le support (3) et l'âme (2) pour former un panneau (1) de bâtiment. La présente invention concerne également un procédé de formation d'un substrat décoratif.
PCT/SE2013/051401 2012-11-28 2013-11-27 Procédé de production d'un panneau de bâtiment par impression numérique WO2014084787A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP13857806.7A EP2925529B1 (fr) 2012-11-28 2013-11-27 Procédé de production d'un panneau de bâtiment par impression numérique
CN201380061754.1A CN104822533B (zh) 2012-11-28 2013-11-27 利用数码印刷制造建筑镶板的方法
KR1020157017046A KR102193522B1 (ko) 2012-11-28 2013-11-27 디지털 프린팅을 이용하여 빌딩 패널을 생산하는 방법

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US201261730699P 2012-11-28 2012-11-28
US61/730,699 2012-11-28
SE1251350-3 2012-11-28
SE1251350 2012-11-28

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KR (1) KR102193522B1 (fr)
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EP4032923A1 (fr) 2021-01-22 2022-07-27 Flooring Industries Limited, SARL Composition de résine thermodurcissable pour panneau stratifié, procédé de fabrication d'un panneau avec une composition de résine thermodurcissable et panneau stratifié comprenant une résine thermodurcissable
EP4043228A1 (fr) 2021-02-10 2022-08-17 Flooring Industries Limited, SARL Substrat imprimé de formulation d'encre et procédé de formulation d'encre
EP4091829A1 (fr) 2021-05-18 2022-11-23 Flooring Industries Limited, SARL Procédé de fabrication de papier imprimable par jet d'encre pour une utilisation en tant que papier décoratif
EP4124461A1 (fr) 2021-07-28 2023-02-01 Flooring Industries Limited, SARL Procédé de fabrication d'une feuille décorative pour un panneau décoratif
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WO2023170528A1 (fr) 2022-03-07 2023-09-14 Flooring Industries Limited, Sarl Procédé de fabrication d'un panneau, panneau, feuille et procédé de fabrication d'une feuille
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