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EP3568307B1 - Panneau de sol ou mural à surface structurée et décorée - Google Patents

Panneau de sol ou mural à surface structurée et décorée Download PDF

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Publication number
EP3568307B1
EP3568307B1 EP18700163.1A EP18700163A EP3568307B1 EP 3568307 B1 EP3568307 B1 EP 3568307B1 EP 18700163 A EP18700163 A EP 18700163A EP 3568307 B1 EP3568307 B1 EP 3568307B1
Authority
EP
European Patent Office
Prior art keywords
layer
plastic film
radiation
structured
curable
Prior art date
Legal status (The legal status 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 status listed.)
Active
Application number
EP18700163.1A
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German (de)
English (en)
Other versions
EP3568307A1 (fr
Inventor
Hans-Jürgen HANNIG
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Akzenta Paneele and Profile GmbH
Original Assignee
Akzenta Paneele and Profile GmbH
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 Akzenta Paneele and Profile GmbH filed Critical Akzenta Paneele and Profile GmbH
Publication of EP3568307A1 publication Critical patent/EP3568307A1/fr
Application granted granted Critical
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Classifications

    • 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
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/24—Pressing or stamping ornamental designs on surfaces
    • 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
    • B44C5/043—Ornamental plaques, e.g. decorative panels, decorative veneers containing wooden elements
    • 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
    • B44C5/0438—Ornamental plaques, e.g. decorative panels, decorative veneers containing stone elements
    • 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
    • B44C5/0461—Ornamental plaques, e.g. decorative panels, decorative veneers used as wall coverings

Definitions

  • the present invention relates to a decorated and surface-structured wall or floor panel.
  • the present invention also relates to a method for producing a decorated and surface-structured wall or floor panel.
  • the present invention relates to a decorated and surface-structured wall or floor panel based on a directly printed composite carrier.
  • Decorated panels are known per se, the term wall panel also meaning panels that are suitable for covering ceilings or doors. They usually consist of a carrier or core made of a solid material, for example a wooden material, which is provided on at least one side with a decorative layer and a cover layer and optionally with further layers, for example a wear layer arranged between the decorative layer and the cover layer.
  • the decorative layer is usually a printed paper impregnated with a resin or a printed layer applied to the support, for example using a suitable printing ground.
  • EP 2 829 415 A1 discloses a method for producing a decorated wall or floor panel, in which a carrier and then a panel are formed starting from a granular carrier material.
  • a WPC can be used as the carrier material.
  • WO2012/001109 A1 discloses a panel (1) comprising a polymer composite layer (4) and a cover layer laminated to the polymer composite layer (4), the cover layer comprising a polymer film (5).
  • a primer layer, a decorative layer, an intermediate layer, a structured plastic film and a topcoat layer made of a radiation-curable paint are arranged on the panel.
  • EP 2 927 017 A1 discloses a method for covering a substrate comprising the steps of supplying a substrate (1), a curable substance (5) and a substantially airtight transparent film (6), wherein a decorative pattern (3) is applied to at least the substrate (1) or is applied to the film (6), forming a stack of the substrate (1), the substance (5) and the film (6), the substance (5) being arranged between the substrate (1) and the film (6), wherein the film (6), the substance (5) and the substrate (1) are brought into close contact with each other and the substance (5) is cured by irradiation through the transparent film (6) and the substance (5) is coated on the film ( 6) and the substrate (1) is fixed.
  • a composite carrier is a plate made from a suitable plastic with the addition of a filler or solid material.
  • the filler or the solid material can be both organic in nature, such as plant fibers or flour, animal fibers such as animal hair, wood fibers or flour, and inorganic in nature, such as mineral in nature. Examples of this are rock dust, mineral fibers or glass fibers. Synthetic fibers can also be included as a filler.
  • decorated wall or floor panel or “decor panel” in the context of the invention is to be understood in particular as meaning wall, ceiling, door or floor panels which have a decor applied to a carrier plate simulating a decor template.
  • Decorative panels are used in a variety of ways both in the field of interior design of rooms and for decorative cladding of buildings, for example in trade fair construction. The decorative panels often have a decoration that is intended to imitate a natural material.
  • Examples of such imitated natural materials or decor templates are types of wood such as maple, oak, birch, cherry, ash, walnut, chestnut, wenge or exotic woods such as panga-panga, mahogany, bamboo and bubinga.
  • natural materials such as stone surfaces or ceramic surfaces are often imitated.
  • a “decor template” in the sense of the present invention can be understood in particular as such an original natural material or at least a surface of such that is to be imitated or imitated by the decoration.
  • a “carrier” can be understood in particular as a layer serving as a core or as a base layer in a finished panel.
  • the carrier can already give the panel a suitable stability or contribute to it.
  • a carrier material can be understood to mean a material that forms the carrier at least to a major extent.
  • the carrier can consist of the carrier material.
  • the carrier material can have, for example, a plastic-containing matrix material in which a solid material or filler with a particle size of less than or equal to 800 ⁇ m, preferably less than or equal to 600 ⁇ m, is embedded.
  • the matrix material serves in particular to accommodate or embed the solid material in the finished carrier.
  • the matrix material has a plastic or a plastic mixture.
  • the proportions of matrix material or solid material can be selected. As a result, good adaptability to the desired area of application can become possible. In principle, however, it can be preferred that the proportion of the solid material is greater than or equal to the proportion of the matrix material.
  • plastics which can preferably serve as matrix material include, in particular, thermoplastics, for example polyethylene or polypropylene, or mixtures of the aforementioned plastics.
  • the matrix material comprises polypropylene, for example in the form of LDPE, it being possible for the polypropylene to have a mixture of a homopolymer and a copolymer.
  • a mixture of a homopolymer and a copolymer can enable particularly advantageous properties for the matrix material by being able to be formed into a carrier in a range from ⁇ 180 ° C to ⁇ 200 ° C, so that a particularly effective process control, for example with example line speeds in a range of 6m/min.
  • the matrix material can in principle be free of an adhesion promoter.
  • a copolymer that can be used is one that is made up of, for example, propylene and ethylene as monomer units, it being possible for the density of the copolymer to be greater than or equal to the density of the homopolymer.
  • the use of a homopolymer enables a high melt flow rate to be made possible, in which case the melt flow rate of the homopolymer can in particular be greater than that of the copolymer.
  • This can enable particularly good formability of the carrier during the manufacturing process.
  • the homopolymer can thereby enable particularly good embedding of the solid material.
  • the copolymer on the other hand, can be used in particular for the mechanical strength of the carrier material or the carrier, since a copolymer often has a comparatively high degree of hardness, in particular in relation to the homopolymer.
  • the homopolymer based on the polypropylene, is present in a proportion of ⁇ 10% by weight to ⁇ 40% by weight, for example in a proportion of ⁇ 20% by weight.
  • the copolymer based on the polypropylene in a proportion of ⁇ 60% by weight to ⁇ 90% by weight, for example in a proportion of ⁇ 70% by weight to ⁇ 80% by weight, for example in a proportion of ⁇ 72% by weight to ⁇ 76% by weight, in particular wherein the Polypropylene consists of the homopolymer and the copolymer.
  • the solid that is distributed in the matrix material this has a particle size of less than 800 ⁇ m, preferably less than 600 ⁇ m.
  • the solid can be very finely distributed in the matrix material.
  • the solid can be, for example, a wood-based material such as wood flour, or another material such as a component of the rice plant, such as rice husk, rice stalk and rice husk, cellulose or a mineral material such as rock flour, chalk or other inorganic mineral materials. It can be particularly preferred if the solid is formed from talc, for example consists of it.
  • the solids can be in the form of chips, shavings, flour or grains, i.e. in powder form, without limitation.
  • a so-called WPC carrier can thus be designed, which is known in principle and is widely accepted.
  • a carrier according to the invention can be made by modifying products that are known per se.
  • talc As a solid, it can be advantageous that a high degree of stability can be made possible, particularly in this embodiment.
  • a carrier material can enable improved moisture resistance, in particular with reduced swelling caused by moisture or heat.
  • Talcum is understood to mean, in a manner known per se, a magnesium silicate hydrate which, for example, can have the chemical molecular formula Mg 3 [Si 4 O 10 (OH) 2 ]. It can be advantageous if the specific surface density according to ISO 4352 (BET)) of the talc particles is in a range from ⁇ 4 m 2 /g to ⁇ 8 m 2 /g, for example in a range from ⁇ 5 m 2 /g up to ⁇ 7 m 2 /g.
  • the talc has a bulk density according to DIN 53468 in a range from ⁇ 0.15 g/cm 3 to ⁇ 0.45 g/cm 3 , for example in a range from ⁇ 0.25 g/cm 3 to ⁇ 0.35 g/cm 3 .
  • talc to be present in the form of particles which have a particle size D 50 in a range from ⁇ 3 ⁇ m to ⁇ 6 ⁇ m, preferably in a range from ⁇ 4 ⁇ m to ⁇ 5 ⁇ m, for example 4.5 ⁇ m, and/or or that the talc is in the form of particles having a particle size D 98 in a range from ⁇ 10 ⁇ m to ⁇ 30 ⁇ m, preferably in a range from ⁇ 15 ⁇ m to ⁇ 20 ⁇ m, for example 17 ⁇ m.
  • D 50 or D 98 values which state that 50% (D 50 ) or 98% (D 98 ) of the measured particles are smaller than the specified value.
  • the solid material is at least 50% by weight, for example at least 80% by weight, in particular at least 90% by weight, for example at least 99% by weight.
  • % is present and wherein the solid material, based on the carrier material, is present in an amount, based on the carrier material, of ⁇ 30% by weight to ⁇ 80% by weight, for example from ⁇ 40% by weight to ⁇ 65% by weight. % is present, and wherein the carrier material and the solid material together, based on the carrier material, are present in an amount of ⁇ 90% by weight.
  • the carrier material can consist largely of the solid material and the matrix material. Provision can particularly preferably be made for the matrix material and the solid material to be present together in an amount of ⁇ 97% by weight, for example in an amount of 100% by weight, based on the carrier material, the carrier material thus consisting of the matrix material and the solid material.
  • the carrier material can consist of at least one polymeric, in particular thermoplastic, material, for example as a plastic mixture, as matrix material, talc and optionally an adhesion promoter.
  • polymeric, in particular thermoplastic, material for example as a plastic mixture, as matrix material, talc and optionally an adhesion promoter.
  • the carrier material can also have a fiber material that, based on the carrier material, in an amount of >0% by weight to ⁇ 20% by weight, in particular from ⁇ 3% by weight to ⁇ 12% by weight, about from ⁇ 5% to ⁇ 10% by weight.
  • the fiber material it can be provided that the fiber material has fibers that are selected from the group consisting of plant, animal, mineral or artificial fibers
  • the carrier material can have between ⁇ 0% by weight and ⁇ 10% by weight of other additives, such as flow aids, thermal stabilizers or UV stabilizers.
  • the carrier material can have, for example, a matrix material containing a plastic, a solid material and a fiber material, the solid material being at least 50% by weight, in particular at least 80% by weight, in particular at least 95% by weight.
  • the matrix material being present in an amount, based on the carrier material, of ⁇ 20% by weight to ⁇ 70% by weight, in particular from ⁇ 30% by weight to ⁇ 55% by weight .-%, in particular from ⁇ 35 wt .-% to ⁇ 45 wt .-%, and wherein the solid material, based on the carrier material, in an amount of ⁇ 30 wt .-% to ⁇ 75 wt .-%, in particular from ⁇ 40% by weight to ⁇ 65% by weight, in particular from ⁇ 45% by weight to ⁇ 60% by weight, and the fiber material, based on the carrier material, is present in an amount of > 0% by weight.
  • Matrix material, the fiber material and the solid material together, based on the carrier material (20), are present in an amount of ⁇ 95% by weight, in particular ⁇ 97% by weight.
  • the fiber material has fibers that have a length in a range of ⁇ 10 ⁇ m, preferably in a range of ⁇ 5 ⁇ m, for example in a range of ⁇ 2 ⁇ m to ⁇ 5 ⁇ m, for example in a range of ⁇ 3 ⁇ m to ⁇ have 4 ⁇ m.
  • fibers of this type can enable high stability, although there can be significant advantages in terms of manufacturability.
  • This configuration is in particular a departure from the solutions of the prior art, in which, insofar as fibers were contained in a material, have a comparatively large length in order to achieve a desired effect. This is because fiber lengths in the millimeter range were mostly used in the prior art.
  • fibers also allow a significant improvement in stability in the above-described range.
  • the fiber material has fibers which have a diameter or a thickness of ⁇ 5 ⁇ m to ⁇ 30 ⁇ m, for example in a range of ⁇ 7 ⁇ m to ⁇ 20 ⁇ m.
  • This configuration can also allow a significant improvement in stability, particularly in the previously defined carrier material with matrix material, solid material and fiber material in the above-described proportions, with processability not being impaired or not significantly impaired by the presence of the fibers.
  • a very high-quality product without production-specific disadvantages can also be made possible in this embodiment.
  • the fiber material has fibers that are selected from the group consisting of vegetable, animal, mineral or synthetic fibers fibers.
  • vegetable fibers include, for example, cellulose fibers, ligneous fibers and fibers made from straw, corn stalks, bamboo, leaves, algae extracts, hemp, cotton or oil palm fibers.
  • animal fiber materials are keratin-based materials such as wool or horsehair.
  • cellulose for example, can be of particular advantage.
  • Mineral fiber materials are examples of mineral wool or glass wool.
  • man-made fibers include, for example, plastic fibers such as fibers made from polyester or also polytetrafluoroethylene (PTFE).
  • PTFE polytetrafluoroethylene
  • the fiber material has plastic fibers, it can be advantageous if the melting point of the plastic fibers is higher than the melting point of the matrix material.
  • This refinement can in turn entail production-specific advantages. This is because, in order to produce a carrier from the predefined carrier material, it can be advantageous to melt the carrier material or the matrix material and to form a carrier under pressure, as is described below. In this embodiment, in such a process it can be prevented that the plastic fibers also melt, which could at least partially eliminate the above-described advantages of the fiber material.
  • exemplary plastic fibers include, for example, polytetrafluoroethylene (PTFE).
  • the edge areas of a panel according to the invention can be structured or profiled in order to provide, in particular, detachable connecting elements.
  • a profiling within the meaning of the invention it can be provided that, by means of suitable material-removing tools, at least one part of the edges of the decorative panel decorative and/or functional profile is introduced.
  • a functional profile is understood to mean, for example, the incorporation of a groove and/or tongue profile in an edge in order to design decorative panels that can be connected to one another via the profiles introduced.
  • Elastic materials are advantageous, particularly in the case of tongue and groove profiles, since they alone can be used to create profiles that are particularly easy to handle and stable. In particular, no further materials are necessary to produce the connecting elements.
  • a decorative background or primer to be provided according to the invention is applied to at least a partial area of the carrier.
  • a primer in particular for printing processes, can first be applied as a decorative background.
  • This primer can be applied, for example, in a thickness of ⁇ 10 ⁇ m to ⁇ 60 ⁇ m.
  • a liquid radiation-curing mixture based on a urethane or a urethane acrylate, optionally with one or more of a photoinitiator, a reactive diluent, a UV stabilizer, a rheological agent such as a thickener, free-radical scavenger, leveling agent, defoamer or preservative, pigment and/or or a dye used.
  • a white primer can be applied.
  • the primer can have polyurethane, for example, be designed as a polyurethane paint, and be provided with white pigments, for example.
  • the decoration or the decorative layer can be produced by a printing process, with both flexographic printing, offset printing or screen printing processes and, in particular, digital printing techniques such as inkjet processes or laser printing processes being suitable.
  • the decorative layer is formed from a radiation-curable ink.
  • a UV-curable ink can be used.
  • the lacquer applied to the decorative layer to form a layer of a radiation-curable lacquer comprises an acrylate, a diacrylate, a methacrylate, a urethane, urethane acrylate or mixtures of these.
  • a paint can contain other components such as, in particular, a photoinitiator, a reactive diluent, a UV stabilizer, a rheological agent such as a thickener, a free-radical scavenger, a leveling agent, an antifoam or a preservative, a pigment and/or a dye.
  • a paint can also contain several and/or different of the aforementioned components.
  • the paint contains a diacrylate in a concentration between ⁇ 20% by weight and ⁇ 60% by weight and a methacrylate in a concentration between ⁇ 1% by weight and ⁇ 20% by weight .-% having.
  • photoinitiator for radiation-curable coatings or compositions used in this invention for example, compounds from the group selected from benzophenones such as benzophenone, 4,4-bis (diethylamino) benzophenone, and 3,3',4,4'-tetramethoxybenzophenone, anthraquinones such as t-butyl anthraquinones and 2-ethyl anthraquinones, thioxanthones such as 2,4-diethylthioxanthone, isopropylthioxanthone and 2,4-dichlorothioxanthone; Acetophenones such as diethoxyacetophenone, 2,2-dimethoxyphenylacetophenone, 2-hydroxy-2-methyl-1-phenylpropan-1-one, benzyl dimethyl ketal, 1-hydroxycyclohexylphenyl ketone, 2-methyl-2-morpholino(4-methylthiophenyl)propan-1-one
  • a photoinitiator can be present in the lacquer composition, for example, in a concentration of between 0.5 and 5% by weight.
  • the structured plastic film consists of a plastic which is selected from the group consisting of polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polycarbonate (PC), polybutane terephthalate (PBT), a polytrimethylene terephthalate ( PTT), a copolymer or a block copolymer of these.
  • PP polypropylene
  • PE polyethylene
  • PET polyethylene terephthalate
  • PC polycarbonate
  • PBT polybutane terephthalate
  • PTT polytrimethylene terephthalate
  • the plastic film preferably has a thickness between >60 ⁇ m and ⁇ 500 ⁇ m, preferably between ⁇ 80 ⁇ m and ⁇ 350 ⁇ m, in particular between ⁇ 100 ⁇ m and ⁇ 300 ⁇ m, such as 120 ⁇ m, 140 ⁇ m, 160 ⁇ m, 180 ⁇ m, 200 ⁇ m, 220 ⁇ m, 240 ⁇ m, 260 ⁇ m or 280 ⁇ m on.
  • a thickness has proven to be particularly suitable with regard to the manageability in the production process of the decorative panel as well as the haptic impression that can be achieved with it.
  • the structured plastic film has an embossing depth of between 60 ⁇ m and 180 ⁇ m.
  • the embossing depth is less than the layer thickness of the plastic film.
  • the thickness of the film in non-embossed areas is to be understood as layer thickness.
  • the embossing depth is between 25% and 65% of the layer thickness of the plastic film.
  • the lacquer applied to the structured plastic layer to form a top lacquer layer has an acrylate, a diacrylate, a methacrylate, a urethane, urethane acrylate or mixtures of these.
  • a paint can contain other components such as, in particular, a photoinitiator, a reactive diluent, a UV stabilizer, a rheological agent such as a thickener, a free-radical scavenger, a leveling agent, an antifoam or a preservative, a pigment and/or a dye.
  • a paint can also contain several and/or different of the aforementioned components.
  • the topcoat layer is formed from a plurality of layers of paint or is formed by multiple application of paint compositions of the same or different composition. It can also be provided that at least one paint layer or paint application has a paint composition which has a hard material such as titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, aluminum oxide (corundum), zirconium oxide or mixtures of these to increase wear resistance of the layer formed.
  • a hard material such as titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, aluminum oxide (corundum), zirconium oxide or mixtures of these to increase wear resistance of the layer formed.
  • a non-structured plastic film is also to be understood as meaning a plastic film that is not fully or only partially structured, which is given additional structuring in the course of the further process.
  • an incompletely cured layer of the radiation-curable paint applied in step d) is one that has already been gelled by suitable measures, such as exposure to low-intensity and/or short-duration electromagnetic radiation, but not yet is fully cured and to that extent still contains radically polymerizable components.
  • the corresponding surface of the carrier is pretreated by means of a corona and/or plasma treatment. In this way, improved adhesion of the primer layer to the surface can be achieved.
  • the primer layer can be applied, for example, by means of rollers, such as rubber rollers, by means of doctor blades, by means of pouring devices, by means of spraying devices or a combination of the aforementioned devices.
  • Flexographic printing, offset printing or screen printing methods are particularly suitable for applying the decorative layer to the primer layer applied in step b) by means of a direct printing method, as well as digital printing techniques such as inkjet methods or laser printing methods.
  • a layer of a radiation-curable lacquer is applied.
  • This lacquer layer can be applied, for example, by means of rollers, such as rubber rollers, by means of doctor blades, by means of pouring devices, by means of spraying devices or a combination of the aforementioned devices.
  • the applied lacquer layer is partially cured by the action of electromagnetic radiation, such as UV radiation or microwave radiation, with this partial curing taking place with the proviso that the applied layer still has a residual fluidity and is not fully cured.
  • a structured or non-structured plastic film is applied to the still flowable paint bed. This can be done, for example, by means of a calender in a calendering step.
  • the plastic film can be pressed at least partially into the paint bed.
  • the plastic film is applied while avoiding the inclusion of air bubbles between the lacquer layer and the plastic film.
  • the plastic film After the plastic film has been applied to the paint layer, it is cured by the action of suitable electromagnetic radiation, as a result of which the film applied thereto is firmly bonded to the layer structure that has taken place up to that point.
  • the embossing means used in step e3) is an embossing roller, an embossing plate or an embossing die with an embossing depth that is less than the thickness of the plastic film applied in step e1).
  • the embossing means has an embossing depth of between 25% and 65% of the layer thickness of the plastic film.
  • the embossing is preferably carried out under the action of heat.
  • the plastic film is at least superficially heated by means of suitable devices, such as IR radiators. Provision can also be made for the embossing means to be heated by means of suitable devices.
  • suitable devices such as IR radiators.
  • the embossing means can be heated by means of suitable devices.
  • a combination of these possibilities can be provided, in which both the plastic film is preheated by means of, for example, IR radiators and then a structure is embossed into the plastic film with correspondingly heated embossing means.
  • the effect of heat is preferably controlled in such a way that the plastic film is heated to a temperature in the range between 30% and 80%, preferably 40% and 70%, of the melting temperature of the plastic film material. It has been shown that with such a heating rate, a good embossing result can be achieved without significantly negatively affecting the durability of the film.
  • the effect of heat is controlled in such a way that a surface temperature of the film of 130° C. is not exceeded.
  • an embossing varnish is applied to it, which has sufficient flexibility to be embossed in a subsequent embossing step.
  • an embossing lacquer is preferably also a radiation-curable lacquer composition.
  • a structure lacquer is applied which essentially corresponds to the embossing lacquer described above.
  • the structural paint is preferably also a radiation-curable paint or a radiation-curable paint composition.
  • the structure paint applied to a non-structured plastic film is gelled or partially cured, in the case of a radiation-curable paint, for example, by the action of electromagnetic radiation more suitably wavelength and dose.
  • a haptically perceptible structure can then be produced in the textured paint gelled or partially cured in this way by applying a likewise radiation-curable composition.
  • the radiation-curable composition can be applied to the gelled or partially cured structure paint, for example, by means of an ink-jet process.
  • the drop of the radiation-curable composition applied to the partially cured textured paint causes a corresponding deformation of the hitherto smooth textured paint surface due to the mechanical action of the force at the moment of impact.
  • the physicochemical properties of the composition applied by means of an ink jet such as density, viscosity, polarity or surface tension, can be adjusted in such a way that the applied droplets partially displace the partially cured or gelled structure paint.
  • the structure paint has a viscosity in the range of 80 - 500 mPa ⁇ s (at 25°) after partial curing or gelling and the composition applied for structuring has a significantly lower viscosity of 8-30 mPa ⁇ s ( at 25°).
  • the final curing of both the gelled or partially cured structure paint and the structuring composition can then take place in an immediately subsequent curing step, for example by means of UV radiation.
  • the structure-forming droplets applied by means of ink jet do not consist of a radiation-curable composition, but of a composition which, under the conditions of application to the gelled or partially cured structure paint, has a high viscosity and thus a Displacement effect compared to the textured paint. It is preferably a composition or compound with an atypical thermal transition behavior, which assumes a gel-like structure at higher temperatures and exhibits the behavior of a liquid at low temperatures.
  • the structure paint is cured by exposure to radiation.
  • the resulting heating causes the composition to form its gel-like structure, which forms corresponding patterns in the structure paint layer.
  • the surface can be cooled to a temperature below the gelation temperature of the composition, at which point the composition can be removed from the surface using simple mechanical means such as a cloth, brush or vacuum.
  • An example of substances for forming a suitable composition with atypical thermal transition behavior are polyoyamers, e.g. Pluronic F127.
  • This is a triblock copolymer with a hydrophobic poly(propylene oxide) segment (PPO) and two hydrophilic poly(ethylene oxide) (PEO) segments, which connect to the PPO segment on both sides, forming a PEO-PPO-PEO sequence.
  • PPO poly(propylene oxide) segment
  • PEO poly(ethylene oxide)
  • This material gels from a critical micelle concentration (CMC) of 21% by weight at a temperature >10°C. Below this temperature the gel structure dissolves and the composition becomes liquid.
  • CMC critical micelle concentration
  • a composition which can be applied by means of an ink-jet process for structuring can preferably contain 40% by weight of Pluronic F127.
  • the structuring of the plastic film takes place in accordance with the decorative image in order to haptically support the realistic appearance of the decorative design.
  • the decorative image has so-called register markings, by means of which the embossing means or the already structured plastic film are aligned with respect to the decorative pattern in order to ensure structuring that is synchronous with the decorative pattern.
  • the side of the plastic film facing the wearer is applied to the not yet or not yet fully cured layer of the layer applied in step d) prior to application Radiation-curable paint subjected to a corona treatment and / or plasma treatment.
  • Radiation-curable paint subjected to a corona treatment and / or plasma treatment.
  • an adhesion primer can be applied to the side of the plastic film facing the carrier plate.
  • a composition containing a swelling agent and/or solvent suitable for the plastic film material is applied as an adhesion primer.
  • a composition can contain, for example, acetone, methyl ethyl ketone, ethyl acetate, isobutyl acetate, tetrahydrofuran, dimethyl sulfoxide, sulfolane, acetonitrile, nitromethane, ⁇ -butyrolactone or mixtures of these.
  • such a composition can contain, for example, between ⁇ 5% by weight and ⁇ 35% by weight isobutyl acetate and between ⁇ 2% by weight and ⁇ 65% by weight methyl ethyl ketone.
  • the process is interrupted after process steps e2) or e2′) or e3) and thus before the top layer is applied in step (f).
  • a storable intermediate product or semi-finished product is obtained, which can be further processed temporally and/or spatially from the previous production process by applying the cover layer, possibly with prior structuring.
  • This enables a method for producing such an intermediate product, which then consists of a carrier, a primer layer, a decorative layer, a layer of a radiation-curable lacquer arranged on the decorative layer, and a plastic film.
  • a topcoat layer of a radiation-curable paint is applied to the layered composite formed after process step e2′) or e3).
  • the topcoat layer is formed by a multiple application of paint compositions of the same or different composition and correspondingly process step f) is carried out repeatedly. It can also be provided that at least one paint layer or paint application has a paint composition which has hard materials such as titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, aluminum oxide (corundum), zirconium oxide or mixtures of these to increase wear resistance of the layer formed.
  • hard materials such as titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, aluminum oxide (corundum), zirconium oxide or mixtures of these to increase wear resistance of the layer formed.
  • step g) the topcoat layer applied in step f) is cured. If step f) is repeated in the manner described above, it can be provided that step g) is also repeated, optionally with the proviso that between the repetition of step f) there is no complete curing of the coating composition applied, but only partial curing or gelling and a final hardening by a correspondingly long and/or intensive exposure to suitable electromagnetic radiation, such as UV radiation or microwave radiation.
  • suitable electromagnetic radiation such as UV radiation or microwave radiation.
  • FIG. 1 12 schematically shows the structure of a wall and/or floor panel 100 that is decorated and has a surface structure according to the invention.
  • the panel has a carrier 110 that is preferably made of a plastic composite material.
  • a primer layer 120 is arranged on a surface of the carrier 110, which can also serve as a printing substrate for the decorative layer 130 arranged above it.
  • the decorative layer 130 can be applied to the primer layer 120 by means of a direct printing method such as flexographic printing, offset printing or screen printing methods, and also in particular by means of digital printing techniques such as inkjet methods or laser printing methods.
  • a layer 140 of a radiation-curable lacquer is in turn arranged on the decorative layer 130, by means of which the structured plastic film 150 arranged on the layer 140 is bonded to the layer composite.
  • a topcoat layer 160 is arranged above the structured plastic film 150 . It can be provided that the top coat layer 160 has hard materials and/or solids and/or fibers to improve the wear resistance. In any case, the top coat layer is designed in such a way that it does not or not completely level the surface structure caused by the structured plastic film, so that this is at least partially haptically perceptible on the surface of the wall or floor panel.
  • FIG. 2 shows schematically an intermediate product 101, as can be obtained within the scope of the method according to the invention.
  • the layers 110, 120, 130 and 140 correspond to those from the 1 known layers.
  • the intermediate product shown has a plastic film 151 that is not structured or not finally structured.
  • the surface of the intermediate product 101 formed by the plastic film can be structured by means of suitable embossing means, in particular under the action of heat.
  • a topcoat layer can then be applied in a further processing step that may be separated in terms of time and/or space.
  • layer 152 represents a structured plastic film. This can either be a pre-structured plastic film or a non-structured plastic film as shown in 2 is shown, which was structured in a possibly temporally and / or spatially separate further processing step by means of suitable embossing means, in particular under the action of heat. A topcoat layer can then be applied in a further processing step that may be separated in terms of time and/or space.

Landscapes

  • Laminated Bodies (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Claims (12)

  1. Panneau mural ou de sol décoré et structuré en surface (100) présentant
    - un support (110) à base d'un matériau composite synthétique,
    - une couche de primaire (120) disposée sur une surface du support (110),
    - une couche décorative (130) disposée sur la couche de primaire (120),
    - une couche (140) de laque durcissable par rayonnement disposée sur la couche décorative (130),
    - un film en matière synthétique (150, 152) structuré disposé sur la couche (140) de laque durcissable par rayonnement, ainsi
    - qu'une couche de laque de finition (160) disposée sur le film en matière synthétique structuré, où
    la couche de primaire (120) présente un uréthane et/ou un acrylate d'uréthane durcissable par rayonnement, et où la couche décorative (130) présente au moins une composition d'encre durcissable par rayonnement, et où la laque rapportée sur la couche décorative (130) pour la formation d'une couche (140) de laque durcissable par rayonnement présente un acrylate, un diacrylate, un méthacrylate, un uréthane, un acrylate d'uréthane ou des mélanges de ceux-ci, et où la couche de laque de finition (160) disposée sur le film de matière synthétique structuré est formée par une composition de laque durcissable par rayonnement.
  2. Panneau mural ou de sol décoré ou structuré en surface selon la revendication 1, dans lequel le support (110) présente un matériau matriciel contenant une matière synthétique dans lequel un matériau solide et/ou un matériau fibreux est incorporé.
  3. Panneau mural ou de sol décoré ou structuré en surface selon l'une des revendications précédentes, dans lequel le film en matière synthétique structuré (150) est constitué d'une matière plastique, laquelle est choisie dans le groupe constitué du polypropylène (PP), du polyéthylène (PE), du poly éthylène téréphtalate (PET), du polycarbonate (PC), du polybutylène téréphtalate (PBT), d'un poly triméthylène téréphtalate (PTT), d'un copolymère ou d'un copolymère séquencé de ceux-ci.
  4. Panneau mural ou de sol décoré ou structuré en surface selon l'une des revendications précédentes, dans lequel le film de matière synthétique structuré présente une épaisseur entre > 60 µm et ≤ 500 µm, de préférence entre ≥ 80 µm et ≤ 350 µm, notamment entre ≥ 100 µm et ≤ 300 µm.
  5. Panneau mural ou de sol décoré ou structuré en surface selon l'une des revendications précédentes, dans lequel le film de matière synthétique structuré présente une profondeur de gravure entre 60 µm et 180 µm.
  6. Panneau mural ou de sol décoré ou structuré en surface selon l'une des revendications précédentes, dans lequel la laque rapportée sur la couche de matière synthétique structurée pour la formation d'une couche de laque de finition (160) présente un acrylate, un diacrylate, un méthacrylate, un uréthane, un acrylate d'uréthane ou des mélanges de ceux-ci.
  7. Panneau mural ou de sol décoré ou structuré en surface selon l'une des revendications précédentes, où le panneau présente des systèmes d'ancrage complémentaires sur au moins deux bords opposés, au moyen desquels les panneaux peuvent être assemblés pour former un revêtement mural ou de sol assemblé.
  8. Procédé de fabrication d'un panneau mural ou de sol décoré et structuré en surface (100) présentant les étapes de procédé :
    a) la mise en place d'un support (110) à base d'un matériau composite synthétique ;
    b) le dépôt d'une couche de primaire (120) présentant un uréthane et/ou un acrylate d'uréthane durcissable par rayonnement sur la surface du support mis en place ;
    c) le dépôt d'une couche décorative (130) sur la couche de primaire déposée dans l'étape b) au moyen d'un procédé d'impression directe avec une composition d'encre durcissable par rayonnement ;
    d) le dépôt d'une couche (140) de laque durcissable par rayonnement sur la couche décorative déposée dans l'étape c) ;
    ensuite, soit
    e1) le dépôt d'un film synthétique (151) non structuré sur la couche (140) de laque durcissable par rayonnement déposée dans l'étape d) non durcie ou non encore durcie totalement ;
    e2) le durcissement de la laque durcissable par rayonnement déposée dans l'étape d) au moyen de l'action d'un rayonnement électromagnétique approprié, où le film synthétique (151) déposé dans l'étape e1) est fixé sur la structure en couches restante ;
    e3) la structuration du film synthétique (151) non structuré déposé dans l'étape e1) par un produit de gravure pour la formation d'un film synthétique structuré (152) ;
    soit
    e1') le dépôt d'un film synthétique (150) structuré sur la couche (140) de laque durcissable par rayonnement déposée dans l'étape d) non durcie ou non encore totalement durcie ;
    e2') le durcissement de la couche (140) de laque durcissable par rayonnement déposée dans l'étape d) au moyen de l'action d'un rayonnement électromagnétique approprié, où le film synthétique (150) déposé dans l'étape e1') est fixé sur la structure en couches restante ;
    ensuite
    f) le dépôt d'au moins une couche de finition (160) à base d'une laque durcissable par rayonnement sur le film synthétique structuré ; et
    g) le durcissement de l'au moins une couche de finition (160) déposée dans l'étape f).
  9. Procédé selon la revendication 8, dans lequel on emploie, en tant que système de gravure dans l'étape e3), un rouleau de gravure, une tôle de gravure ou une estampe avec une profondeur de gravure qui est inférieure à l'épaisseur du film synthétique (151) déposé dans l'étape e1).
  10. Procédé selon l'une des revendications 8 ou 9, dans lequel l'étape e3) a lieu sous l'influence de chaleur et l'action de la chaleur est commandée de telle manière que le film synthétique (151) est chauffé jusqu'à une température dans la plage entre 30 % et 80 %, de préférence entre 40 % et 70 %, de la température de fusion du matériau du film synthétique.
  11. Procédé selon l'une des revendications 8 à 10, dans lequel la face du film synthétique (150, 151) orientée vers le support est soumise à un traitement Corona et/ou un traitement par plasma avant le dépôt sur la couche (140) de laque durcissable par rayonnement déposée dans l'étape d) non durcie ou non encore totalement durcie, et/ou un primaire d'adhérence est déposé sur la face du film synthétique (150, 151) orientée vers la plaque support.
  12. Procédé selon la revendication 11, dans lequel on dépose en tant que primaire d'adhérence un agent gélifiant et/ou une composition présentant des solvants, appropriés pour le matériau du film synthétique.
EP18700163.1A 2017-01-11 2018-01-10 Panneau de sol ou mural à surface structurée et décorée Active EP3568307B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP17151000.1A EP3348418A1 (fr) 2017-01-11 2017-01-11 Panneau de sol ou mural à surface structurée et décorée
PCT/EP2018/050580 WO2018130580A1 (fr) 2017-01-11 2018-01-10 Panneau mural ou panneau de sol décoratif à surface structurée

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EP3568307A1 EP3568307A1 (fr) 2019-11-20
EP3568307B1 true EP3568307B1 (fr) 2022-06-15

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US (2) US10967671B2 (fr)
EP (2) EP3348418A1 (fr)
ES (1) ES2924867T3 (fr)
PL (1) PL3568307T3 (fr)
PT (1) PT3568307T (fr)
WO (1) WO2018130580A1 (fr)

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Publication number Priority date Publication date Assignee Title
EP3326835A1 (fr) 2016-11-25 2018-05-30 Akzenta Paneele + Profile GmbH Substrat pour un panneau de sol ou de mur décoré
EP3348418A1 (fr) * 2017-01-11 2018-07-18 Akzenta Paneele + Profile GmbH Panneau de sol ou mural à surface structurée et décorée
EP3835079B1 (fr) * 2019-12-12 2023-07-26 Akzenta Paneele + Profile GmbH Film de protection contre l'usure structuré par impression numérique à degré de brillance réglable
CN114945476A (zh) * 2020-01-13 2022-08-26 地板技术有限公司 用于提供设有个性化的装饰的层压嵌板的方法和设备
ES2911383T3 (es) * 2020-01-15 2022-05-19 Flooring Technologies Ltd Procedimiento para la facilitación de paneles de laminado dotados de elementos decorativos individualizados
CN112497375B (zh) * 2020-11-26 2022-05-17 浙江升华云峰新材股份有限公司 一种数字化木纹3d数码喷印装饰板及其生产工艺
EP4400649A1 (fr) * 2023-01-12 2024-07-17 Unilin, BV Panneau décoratif et feuille décorative
EP4650187A1 (fr) * 2024-05-16 2025-11-19 Akzenta Paneele + Profile GmbH Panneau mural ou de sol décoré

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US2927017A (en) * 1957-09-11 1960-03-01 Orrin F Marvin Recovery of metal values from complex ores
CA2804100C (fr) * 2010-06-30 2019-10-08 Spanolux N.V.- Div. Balterio Panneau comprenant une couche composite polymere et procede de fabrication dudit panneau
DE202011107844U1 (de) * 2011-11-15 2013-02-18 Surface Technologies Gmbh & Co. Kg Paneel mit Kantenbrechung
DE102012022461B4 (de) * 2012-11-15 2017-07-13 SÜDDEKOR GmbH Abriebfestes dekoratives Beschichtungsmaterial, Verfahren zu dessen Herstellung und Verwendung des abriebfesten dekorativen Beschichtungsmaterials
EP2829415A1 (fr) 2013-07-22 2015-01-28 Akzenta Paneele + Profile GmbH Procédé de fabrication d'un panneau mural et de sol décoré
PL2927017T5 (pl) * 2014-04-04 2022-06-20 Flooring Industries Limited, Sarl Sposób pokrywania substratu
EP3348418A1 (fr) * 2017-01-11 2018-07-18 Akzenta Paneele + Profile GmbH Panneau de sol ou mural à surface structurée et décorée
ES2843536T3 (es) 2017-01-13 2021-07-19 Akzenta Paneele Profile Gmbh Panel de pared o de suelo con superficie estructurada y decorada, a base de placa de fibrocemento

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Publication number Publication date
WO2018130580A1 (fr) 2018-07-19
PT3568307T (pt) 2022-08-18
EP3348418A1 (fr) 2018-07-18
ES2924867T3 (es) 2022-10-11
US20190366757A1 (en) 2019-12-05
EP3568307A1 (fr) 2019-11-20
PL3568307T3 (pl) 2022-10-10
US10967671B2 (en) 2021-04-06
US11691453B2 (en) 2023-07-04
US20210187996A1 (en) 2021-06-24

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