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WO2025008160A1 - Revêtements de surface décoratifs gaufrés numériquement - Google Patents

Revêtements de surface décoratifs gaufrés numériquement Download PDF

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Publication number
WO2025008160A1
WO2025008160A1 PCT/EP2024/066617 EP2024066617W WO2025008160A1 WO 2025008160 A1 WO2025008160 A1 WO 2025008160A1 EP 2024066617 W EP2024066617 W EP 2024066617W WO 2025008160 A1 WO2025008160 A1 WO 2025008160A1
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WO
WIPO (PCT)
Prior art keywords
resin composition
crosslinkable resin
layer
topcoat
embossing
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.)
Pending
Application number
PCT/EP2024/066617
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English (en)
Inventor
Jean-François BODY
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.)
Tarkett GDL SA
Original Assignee
Tarkett GDL SA
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 Tarkett GDL SA filed Critical Tarkett GDL SA
Publication of WO2025008160A1 publication Critical patent/WO2025008160A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • 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
    • B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
    • B44C3/02—Superimposing layers
    • B44C3/025—Superimposing layers to produce ornamental relief structures
    • 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

Definitions

  • the invention generally relates to the field of finishing materials for constructions, in particular to decorative surface coverings such as, for instance, floorings, wallcoverings or ceiling coverings.
  • Decorative surface coverings such as flooring, wallcovering or ceiling covering, may be of the so-called homogeneous or heterogeneous types.
  • a homogeneous surface covering has essentially the same composition throughout its thickness (except, maybe, for a topcoat and/or a textile backing), whereas a heterogeneous surface covering comprises a stack of layers which differ in their functions and compositions.
  • a typical layer structure of a heterogeneous surface covering comprises a backing layer, one or more core layers, a decor layer, a protective wear layer and a topcoat.
  • the decor layer may be a thin layer of a natural material, e.g., cork or wood, but may also comprise a printed decor, imitating or not a natural material.
  • the surface covering may be given a surface structure by embossing. Mechanical embossing involves pressing an embossing plate or cylinder against the surface covering under high temperature so as to transfer the three-dimensional pattern of the embossing plate or cylinder into the surface covering. In high-quality surface coverings, the embossing is carried out in register with the printed decor.
  • WO 2017/046309 A1 discloses a base panel suitable to be processed into a covering panel, consisting of: (i) a substrate having a top surface, (ii) a resilient layer having a top surface and a bottom surface, the bottom surface being connected to the top surface of the substrate, and (iii) optionally, a contact layer between the bottom surface of the resilient layer and the top surface of the substrate.
  • the covering panel comprises a digitally printed decor on the top surface of the resilient layer of the base panel.
  • the covering panel may further be provided with an embossing pattern, which may be applied in register with the print, so as to accentuate the appearance of the decor.
  • WO2017067978A1 relates to a method for manufacturing embossed decorative substrates, e.g., panels and boards, in particular based on wood fibers such as MDF (Medium Density Fiberboard) or HDF (High Density Fiberboard) substrates on which a decor is formed by digital printing.
  • MDF Medium Density Fiberboard
  • HDF High Density Fiberboard
  • the method comprises the steps of: a) mechanical embossing a substrate so as to form an embossed surface; b) applying a primer on the embossed surface of the substrate; c) drying or curing the primer coated on the embossed surface so as to form a base layer; d) digitally printing a decor onto the base layer using a liquid ink; and e) drying or curing the liquid ink forming the digitally printed decor.
  • US2020346246A1 relates to a method for manufacturing a structure on a surface of a workpiece.
  • the method comprises the following steps: applying a liquid base layer onto the surface of the workpiece; jetting droplets into the not yet solidified base layer, wherein the droplets at least partially penetrate into the base layer; indurating the base layer; and removing the droplets.
  • EP3109056A1 discloses a method for producing a structure on a surface.
  • a liquid layer is applied onto a workpiece.
  • a manipulation medium in the form of droplets is sprayed onto the liquid layer, whereby a displacement of the liquid layer occurs by the droplets so that recesses together forming a structure in the liquid layer are formed therein.
  • this layer is solidified.
  • US2020368777A1 discloses a method for producing a decorative surface on a workpiece.
  • the method comprises: feeding of the workpiece coated with a liquid layer to a digital printing station; application of an agent capable of at least partially absorbing electromagnetic radiation, at least on a partial area of the surface of the liquid layer, or which, in contact with the surface, produces a reaction product which is capable of at least partially absorbing electromagnetic radiation; irradiation of the surface of the liquid layer and of the agent with electromagnetic radiation having a wavelength of less than 300 nm. Irradiation of the surface of the liquid layer causes polymerization of the liquid layer and leads to micro-folding, thereby forming a microstructure.
  • US2020346395A1 discloses a method for producing a decorative surface, wherein a manipulation medium (such as that of EP3109056A1 or the agent of US2020368777A1 ) to the surface is removed therefrom in a mechanical and/or contactless manner.
  • a manipulation medium such as that of EP3109056A1 or the agent of US2020368777A1
  • US2022355335A1 relates to manufacturing areas having different degrees of hardness in a base layer.
  • the method comprises the steps: applying a mask (e.g., in the form of droplets) on a partial area of the surface of the base layer, the mask at least partially absorbing electromagnetic radiation; and irradiating the base layer and the applied mask with electromagnetic radiation, in particular with UV radiation and/or IR radiation, to set different degrees of hardness of the base layer.
  • the mask and the areas of the base layer with a lower degree of hardness may be removed, e.g., physically and/or chemically, so as to create depressions or holes in the base layer.
  • WO2010070485A2 relates to manufacturing coated panels comprising at least a substrate and a top layer with a motif.
  • the method for manufacturing of the top layer comprises at least two steps, namely, a first step, in which a synthetic material layer is provided on the substrate, and a second, subsequent step, in which a relief is provided on the surface of the synthetic material layer.
  • the relief comprises a pattern of recesses and/or projections, that is at least partially determined by one or more prints.
  • the same printing technique may be applied both for forming the motif and for forming the one or more prints. For instance, a digital printing technique, such as inkjet printing, may be applied.
  • a method for producing a decorative surface covering e.g., a floor covering or a wallcovering.
  • the method comprises forming an embossed layer by the following steps (additional steps not being excluded): applying at least one crosslinkable resin composition in one or more continuous layers on a face of a surface covering substructure comprising one or more core layers, the one or more core layers comprising one or more linoleum layers, the face of the surface covering substructure having a printed (preferably a digitally printed) decorative motif, the crosslinkable resin composition being applied on the printed decorative motif, and generating a three-dimensional surface relief by digitally embossing the crosslinkable resin composition (in situ, i.e., when applied on the substructure), the digitally embossing comprising at least partially curing the crosslinkable resin composition.
  • the digital embossing is preferably executed in register with the printed decorative motif.
  • crosslinkable refers to the capacity of a (liquid or viscous) resin composition containing unpolymerized or partially polymerized reagents to undergo a curing process, including one or more chemical reactions, that forms covalent bonds (in particular, crosslinks) between polymer chains, and thereby transforms the resin composition into a solid (layer) having a three-dimensional polymeric network.
  • Curing can be induced by heat (in the case of thermoset resins), radiation (including electromagnetic radiation, such as e.g., UV light, and particle radiation, in particular, electron radiation), and/or chemical additives (e.g., hardeners). Curing turns a crosslinkable resin composition (layer) into a crosslinked polymer (layer).
  • the expressions “decor” and “decorative” are used herein to indicate that the corresponding item, layer or surface remains visible in the final product when in use as intended and contributes to the outer appearance of the surface covering.
  • the two- dimensional decor is, preferably, at least one-dimensionally patterned, “at least one- dimensionally patterned” meaning that there are colour or shade variations (preferably including plural gradients and/or steps) of the decor along at least one direction, the variation being noticeable to the naked human eye. More preferably, the decor has such variations in two mutually perpendicular directions.
  • the expression “digital embossing” designates a technique to a impart a three- dimensional surface relief to a surface in accordance with digital data, e.g., in the form of a relief file, provided to the digital embossing equipment.
  • digital embossing techniques may be envisaged in the context of the invention.
  • the embossing depth i.e., the (maximum) amplitude of the thickness variations of the layer wherein the surface relief is realized, preferably ranges from 50 pm to 300 pm, more preferably from 50 pm to 200 pm, but greater embossing depths are possible, e.g., from 50 pm to 500 pm or even more.
  • three-dimensional surface relief designates the deviations from a perfectly flat surface imparted by digital embossing. It will be understood that the scale of the three-dimensional surface relief is greater than the scale of the material-intrinsic surface texture (surface roughness and waviness).
  • digital printing means a digitally (computer-) controlled deposition and immobilization of material (e.g., pigment or dye ink, water or solvent based) in pre-defined patterns onto a surface, the pre-defined patterns being derived from digital data, e.g., in the form of an image file, provided to the digital printing equipment.
  • a digitally printed motif or layer is the result of digital printing. Examples of digital printing include inkjet printing or laser printing.
  • Digital 3D printing refers to such a process, wherein the deposited material is solidified to create a three-dimensional pattern, which is raised or lowered with respect to the surface on which is printed.
  • the surface covering substructure may be substantially PVC-free.
  • PVC-free qualifies an entity (e.g., a composition) containing less than 0.01 % by weight of polyvinyl chloride (PVC). More preferably, the decorative surface covering may be PVC-free as a whole.
  • the crosslinkable resin composition may be applied in direct contact with the printed decorative motif, i.e., the decorative surface covering in that case comprises no intermediate layer between the printed decorative motif and the embossed layer formed out of the crosslinkable resin composition, such as e.g., a PVC-based wear layer.
  • the crosslinkable resin composition that is digitally embossed
  • plural crosslinkable resin compositions and/or crosslinked polymer layers, including the crosslinkable resin composition that is digitally embossed are stacked in layers on the printed decorative motif, the first layer of the stack being applied in direct contact with the printed decorative motif, the further layers of the stack being applied on the first layer.
  • the stack of crosslinkable resin compositions and/or crosslinked polymer layers preferably comprises no intermediate alien layer, i.e., no intermediate layer that is formed neither of a crosslinkable resin composition nor of a crosslinked polymer layer.
  • the one or more crosslinkable resin compositions applied on the printed decorative motif contain no foaming agent (blowing agent).
  • the resulting one or more crosslinked-polymer layers are preferably compact, i.e., unfoamed.
  • the one or more core layers may comprise one or more layers of thermoplastic material, e.g., thermoplastic material based on polyethylene terephthalate (PET), polypropylene (PP), or polyvinyl butyral (PVB).
  • thermoplastic material e.g., thermoplastic material based on polyethylene terephthalate (PET), polypropylene (PP), or polyvinyl butyral (PVB).
  • PET polyethylene terephthalate
  • PP polypropylene
  • PVB polyvinyl butyral
  • the term “linoleum” is used in some countries to designate vinyl flooring or wall covering. In the context of the present document, however, the term “linoleum” does not designate a synthetic-polymer-based (e.g., thermoplastic or thermoset) composition but to linoleum based on oxidized vegetable oil, natural resin and organic filler material.
  • a linoleum layer may be made by calendering a linoleum paste on a fibrous support (e.g., a jute backing, a textile layer like a polyester layer, etc.)
  • the linoleum paste generally comprises organic filler material such as, e.g., ground cork and/or wood flour, optionally a mineral filler material such as, e.g., ground limestone or chalk, and the so-called linoleum cement.
  • Linoleum cement comprises oxidized vegetable oil (e.g., linseed and/or soybean oil), which is blended with a natural resin, such as, e.g., rosin (colophony) and/or copal.
  • the linoleum cement may comprise additives, such as, e.g., a drying oil catalyst.
  • the linoleum cement is a viscous mass obtained by an oxidative curing process.
  • the linoleum paste may also comprise additives such as pigments.
  • each linoleum layer may have its own fibrous support.
  • the linoleum paste may contain aluminium trihydroxide as a flame retardant and/or be produced as disclosed in EP 3 305 979 A1 .
  • the one or more linoleum layers and/or the decorative surface covering may be compliant with ISO standard 24011 :2009.
  • the surface covering substructure may comprise a decor layer including a printing substrate and the decorative motif printed on the printing substrate, the decor layer being assembled with the one or more core layers.
  • the decorative motif may be directly printed on one of the one or more core layers.
  • the digital embossing of the crosslinkable resin composition may comprise digitally printing a pattern (“mask pattern”) of a crosslinking blocking agent and/or a repelling agent onto the crosslinkable resin composition, (at least partially) curing the crosslinkable resin composition with the printed pattern in place, and then removing the crosslinking blocking agent and/or the repelling agent and, possibly, uncured crosslinkable resin composition.
  • a pattern (“mask pattern”) of a crosslinking blocking agent and/or a repelling agent onto the crosslinkable resin composition, (at least partially) curing the crosslinkable resin composition with the printed pattern in place, and then removing the crosslinking blocking agent and/or the repelling agent and, possibly, uncured crosslinkable resin composition.
  • the crosslinking blocking agent may comprise crosslinking inhibitors and/or one or more photoprotective agents, e.g., mineral and/or chemical UV filters.
  • the mask pattern may be a binary mask pattern or comprise gradients or graduations of the areal density of crosslinking blocking agent.
  • the mask pattern may also comprise one or more crosslinking blocking agents in combination with one or more repelling agents. If the mask pattern comprises plural components, e.g., plural crosslinking blocking agents, plural repelling agents, or one or more crosslinking blocking agents in combination with one or more repelling agents, these may be applied via separate printheads, so that the areal densities of the different components may be varied relative to one another within the mask pattern.
  • Mineral UV filters may include UV-blocking pigments, such as, e.g., ultrafine titanium dioxide and/or ultrafine zinc oxide.
  • Chemical UV filters may include (2- hydroxy-4-methoxyphenyl)(phenyl)methanone, 3,3,5-trimethylcyclohexyl 2- hydroxybenzoate, 2-ethylhexyl 2-cyano-3,3-diphenylprop-2-enoate, 2-ethoxyethyl (2E)-3-(4-methoxyphenyl)prop-2-enoate, 3-methylbutyl (2E)-3-(4- methoxyphenyl)prop-2-enoate, etc.
  • crosslinking inhibitors examples include phenol, cresol, phenotiazine, hydroquinone, quinone and/or itaconate.
  • the repelling agent may comprise solid particles, a liquid or a gel, displacing crosslinkable resin composition out of the areas where the repelling agent is applied. Upon (partial) curing, the repelling agent may be removed, leaving depressions in the (partially) crosslinked polymer.
  • the removal of the crosslinking blocking agent and/or repelling agent and, possibly, uncured crosslinkable resin composition may be effected by mechanical action, e.g., by blowing, brushing, and/or aspiration.
  • the removal could, e.g., be carried out using one or more brushes which loosen the pattern of crosslinking blocking agent and/or repelling agent and uncured resin residues by mechanical friction and one or more suction apparatuses. Additionally or alternatively, an air-knife could be used.
  • the digital embossing of the crosslinkable resin composition may comprise additive manufacturing.
  • the additive manufacturing may include digitally printing, in stacked manner, plural patterned layers of the crosslinkable resin composition onto the continuous layer.
  • the crosslinkable resin composition may be a radiation-curable resin composition, e.g., a UV-curable resin composition or an electron-beam-curable resin composition.
  • the radiation-curable crosslinkable resin composition may, e.g., comprise urethane (meth)acrylate, epoxy (meth)acrylate, polyester (meth)acrylate, polyether (meth)acrylate, amino (meth)acrylate, silicone (meth)acrylate, polyether urethane (meth)acrylate and/or any mixtures thereof.
  • the crosslinkable resin composition may optionally comprise at least one photoinitiator.
  • the curling effect refers to a phenomenon that causes the lift of one or more of the edges of the decorative surface covering. Without being bound by any theory, this could be the consequence of the shrinkage of the at least one crosslinkable resin composition during curing.
  • the following parameters of the at least one crosslinkable resin composition are preferred:
  • Tg glass transition temperature
  • crosslink density (after curing) which is comprised between 1 and 10 mol/m 3 and more preferably between 2 and 5 mol/m 3 .
  • DMA dynamic mechanical analysis
  • the thickness of the at least one layer of the at least one crosslinkable composition may preferably be comprised between 50 pm and 220 pm and more preferably between 120 pm and 180 pm.
  • the at least one photoinitiator may preferably be selected from the group consisting of a-hydroxyketones, a-aminoketones, benzildimethyl-ketals, acyl phosphines, benzophenone derivatives, thioxanthones and blends of these and more preferably is selected from the group consisting of a-hydroxyketones, benzophenone, acyl phosphines and/or any mixtures thereof and most preferably is selected from the group consisting of hydroxyketones, acyl phosphines and/or any mixtures thereof.
  • the at least partial curing of the crosslinkable resin composition may be effected with UV light.
  • the UV light may be produced with a mercury lamp, a gallium lamp, a UV-LED, and/or an excimer lamp.
  • the at least partial curing of the crosslinkable resin composition may comprise generating a microfolded skin layer in the crosslinkable resin composition by exposing the crosslinkable resin composition to V-lIV (vacuum ultraviolet) light (i.e. , light with a wavelength in the range from 100 nm to 200 nm).
  • V-lIV vacuum ultraviolet
  • the method may further comprise application of a continuous topcoat over the at least partially cured crosslinkable resin composition.
  • the topcoat may comprise a radiation curable crosslinkable composition, e.g., a radiation-curable crosslinkable (pre-)polymer resin.
  • Applying the continuous topcoat may comprise generating a microfolded skin layer in the topcoat by exposing the UV-curable topcoat to V-LIV light and then curing the topcoat in depth. In-depth curing of the topcoat may include irradiation with UV light of longer wavelengths (> 200 nm), capable of penetrating further into the topcoat layer than the V-UV light, which is quickly absorbed in the superficial skin layer (typically not thicker than 200 nm).
  • the topcoat composition preferably comprises (poly)urethane (meth)acrylate.
  • the embossed layer may be fully cured (crosslinked) in a final step of the digital embossing or in a subsequent step.
  • the embossed layer could be fully cured in the same step as the in-depth curing of the topcoat.
  • a particularly preferred embodiment of the inventive method relates to producing a decorative surface covering, e.g., a floor covering or a wallcovering, comprising: applying a crosslinkable resin composition in one or more continuous layers on a face of a surface covering substructure comprising one or more core layers, the one or more core layers comprising or consisting of one or more linoleum layers, the face of the surface covering substructure having a printed decorative motif, the crosslinkable resin composition comprising urethane acrylate.
  • a three-dimensional surface relief may then be generated by digitally embossing the crosslinkable resin composition on the substructure comprising the one or more linoleum layers, the digitally embossing comprising at least partially curing the crosslinkable resin composition.
  • a UV-curable continuous topcoat may be applied over the at least partially cured crosslinkable resin composition.
  • Application of the UV-curable topcoat may comprise generating a microfolded skin layer in the topcoat by exposing the UV- curable topcoat to V-UV light and then curing the topcoat in depth. Complete curing of the crosslinkable resin composition of the digitally embossed layer may be effected in the same step as the in-depth curing of the topcoat.
  • the decorative surface covering may comprise additional layers not specifically mentioned above.
  • it may comprise one or more reinforcing layers, such as, e.g., a fibre veil, a glass veil, a fibre mesh, etc.
  • the decorative surface covering panel may also comprise a backing layer on the rear surface, e.g., a fibre backing, a foam underlay (e.g., a PU foam underlay like in EP 3 228 448) and/or an acoustic foam.
  • Fig. 1 is a schematic illustration of the manufacturing of a decorative surface covering according to a first preferred embodiment of the invention
  • Fig. 2 is a schematic illustration of a variant of the manufacturing process of Fig. 1 ;
  • Fig. 3 is a schematic illustration of the manufacturing of a decorative surface covering according to a further preferred embodiment of the invention.
  • Fig. 1 illustrates a first embodiment of the proposed method for producing a decorative surface covering, e.g., a floor covering.
  • a multilayer surface covering substructure (also: core structure) 10 is provided as a printing substrate in a digital printing stage 12.
  • An industrial digital printer 14 prints a two-dimensional decorative motif onto the surface covering substructure 10.
  • the surface covering substructure 10 may comprise a primer layer or base coat for printing thereon or it may comprise a printable layer that is part of the structural layers.
  • the layer that receives the ink directly thereon may be referred to as the decor-carrying layer 16.
  • the digital printer 14 may comprise printheads that project ink droplets onto the decor-carrying layer 14 in a very precise manner, in terms of position and volume of the droplets.
  • the digital printer 14 may comprise a single-pass industrial printer, which uses several printheads aligned side by side in several rows that cover the entire width of the multilayer surface covering substructure. Each row of printheads may print one or more colours. During the printing process, the surface covering substructure 10 advances in the machine direction under the printheads.
  • the digital printer 14 may be custom-made for the application in accordance with the requirements in terms of capacity and print quality.
  • the digital printer 14 could use thermal printhead technology, wherein a current pulse passing through a heating element vaporizes a tiny quantity of ink in a chamber so as to form a bubble, and this bubble propels an ink droplet through the printhead nozzle onto the printing substrate.
  • the digital printer 14 could also use piezoelectric printheads, wherein a piezoelectric element, on application of a voltage, generates a pressure pulse that drives an ink droplet through the nozzle.
  • the ink is chosen in accordance with the printhead technology, the decor-carrying layer, the subsequent processing steps as well as quality and price constraints.
  • Inks typically comprise one or more colorants, a binder that bonds the colorants to the surface and a carrier liquid.
  • Colorants comprise dyes or pigments or a combination of both.
  • Pigments are solid colorant particles that are suspended or dispersed throughout the carrier liquid.
  • Pigment-based inks may be more light-stable and more fade-resistant than dye-based inks.
  • dye-based inks often comprise organic solvents which may lead to higher VOC emissions than pigment-based inks, especially when water is the carrier liquid of the latter.
  • Carrier liquids may include solvents, oil(s), water and polymeric resins. For certain surface coverings, radiation-curable inks may be considered as particularly advantageous.
  • the digital printer 14 may include a drying or curing stage (not shown in Fig. 1 ), wherein the printed decorative motif 18 is solidified and bonded to the decor-carrying layer 16.
  • Such drying or curing stage could comprise one or more heaters and/or one or more blowers and/or one or more radiation sources, depending on the type of ink used by the digital printer 14. Drying/curing prior to application of the layer of crosslinkable resin composition 20 may be particularly recommended if the ink includes non-reactive solvent(s) or carrier(s), which can no longer be efficiently eliminated or reacted after the printed decorative motif has become sandwiched between its substrate and the layer of crosslinkable resin composition 20.
  • the at least one layer of crosslinkable resin composition 20 is applied on the decor-carrying layer and/or the printed decorative motif 18.
  • the crosslinkable resin composition layer 20 is then subjected to a digitally embossing process during which a three-dimensional surface relief is generated in register with the printed decorative motif 18. It may be worthwhile noting that, before the crosslinkable resin composition layer 20 is applied, one or more further crosslinkable resin compositions and/or crosslinked polymer layers may be applied in direct contact with the decor-carrying layer and/or the printed decorative motif 18.
  • These layers preferably form a stack of crosslinkable resin composition layers and/or crosslinked polymer layers containing no further intermediate layer of a different nature, i.e., no intermediate layer that is formed neither of a crosslinkable resin composition nor of a crosslinked polymer layer.
  • the first layer of the stack is preferably a compatibilizing layer applied in direct contact with the printed decorative motif, the further layers of the stack being applied on the first layer.
  • the composition of the compatibilizing layer is preferably selected so as to guarantee adhesion between the printed decorative motif 18 and the stack of transparent or translucent layers applied thereon.
  • the digital embossing-in-register comprises, as a first step, application of a “mask pattern” by digital printing, in register with the decorative motif, a crosslinking blocking agent 22.
  • the mask pattern is applied by means of digital printer 23.
  • the layer of crosslinkable resin composition 20 carrying the mask pattern is at least partially cured, e.g., by one or more UV lamps 24.
  • the crosslinking blocking agent 22 is selected such that it delays or prevents solidification of the crosslinkable resin composition 20 in the zones covered with the mask pattern.
  • the crosslinking blocking agent may comprise crosslinking inhibitors and/or one or more photoprotective agents, e.g., mineral and/or chemical UV filters.
  • the mask pattern may be a binary mask pattern or comprise gradients or graduations of the areal density of crosslinking blocking agent.
  • the mask pattern may also comprise one or more crosslinking blocking agents in combination with one or more repelling agents.
  • the crosslinking blocking agent 22 may comprise one or more photoprotective agents, e.g., mineral and/or chemical UV filters.
  • Mineral UV filters may include UV-blocking pigments, such as, e.g., ultrafine titanium dioxide and/or ultrafine zinc oxide.
  • Chemical UV filters may include (2-hydroxy-4- methoxyphenyl)(phenyl)methanone, 3,3,5-trimethylcyclohexyl 2-hydroxybenzoate, 2- ethylhexyl 2-cyano-3,3-diphenylprop-2-enoate, 2-ethoxyethyl (2E)-3-(4- methoxyphenyl)prop-2-enoate, 3-methylbutyl (2E)-3-(4-methoxyphenyl)prop-2- enoate, etc.
  • the crosslinking blocking agent may comprise a crosslinking inhibitor, such as, e.g., phenotiazine, hydroquinone and/or itaconate.
  • the expression “mask pattern” does not necessarily mean that the crosslinking blocking agent 22 locally blocks or reduces the irradiance of the crosslinkable resin composition 20.
  • the crosslinking blocking agent 22 may, additionally, or alternatively, be selected so as to (locally) neutralize or deactivate any photoinitiator contained in the crosslinkable resin composition 20, and/or to block crosslinking sites of the reagents of the crosslinkable resin composition 20, and/or to otherwise (locally) impede the chemical reactions that lead to the formation of a polymeric network.
  • uncured crosslinkable resin composition is removed.
  • the removal may be effected by mechanical action, e.g., by blowing, brushing, and/or aspiration.
  • the removal is carried out using one of more brushes 26 which loosen the mask pattern and uncured resin residues by mechanical friction and one or more suction apparatuses 28.
  • a blower e.g., an air knife
  • the crosslinking blocking agent 22 may be removed together with the uncured crosslinkable resin composition.
  • the removal of matter leaves the layer with depressions and/or holes 30 in its surface, which form the three-dimensional surface relief.
  • the digitally embossed layer may thereafter be coated with a top-coat 32.
  • the topcoat 32 may comprise a radiation curable crosslinkable composition, e.g., a radiation-curable crosslinkable (pre-)polymer resin.
  • the coating may be effected by any suitable technique, e.g., by roller-coating (as illustrated in Fig. 1 ) or printing (e.g., digital printing), etc.
  • the topcoat may comprise a UV-curable topcoat.
  • a matte surface finish may be obtained by generating a microfolded skin layer in the topcoat by first exposing the topcoat to V-lIV light (from V-lIV light source 34) and then curing the topcoat in depth.
  • In-depth curing of the topcoat may include irradiation with UV light of longer wavelengths (> 200 nm), capable of penetrating further into the topcoat layer than the V-LIV light, which is quickly absorbed in the superficial skin layer.
  • the UV light of longer wavelengths may be provided by one or more UV lamps 36.
  • the topcoat 32 is preferably comprised of one or more continuous layers, so as to completely seal off the underlying embossed layer.
  • a repelling agent may be used to form the mask pattern.
  • the composition of the mask pattern is a coating repellent agent, it is selected such that it repels the crosslinkable resin composition and prevents the crosslinkable resin composition from entering (or remaining in) the zones covered with the mask pattern.
  • the crosslinkable resin composition is cured while having the mask pattern applied to it, the volumes occupied by the repelling agent become the depressions and voids in the embossed layer. After curing, the repelling agent is removed by brushing, blowing, aspiration and/or any other suitable process.
  • the crosslinking blocking agent may remain on the surface of the crosslinkable resin composition to emboss.
  • the crosslinking blocking agent may also diffuse into the crosslinkable resin composition onto which it has been applied.
  • the expression “mask pattern” should not be taken to imply that it exclusively consists of areas without crosslinking blocking agent and areas with the same uniform areal density of crosslinking blocking agent (binary mask pattern). While a binary mask pattern is an option, in general, the mask pattern may comprise gradients or graduations of the areal density of crosslinking blocking agent.
  • the mask pattern may also comprise one or more crosslinking blocking agents in combination with one or more repelling agents.
  • the mask pattern comprises plural components, e.g., plural crosslinking blocking agents, plural repelling agents, or one or more crosslinking blocking agents in combination with one or more repelling agents, these may be applied via separate printheads, so that the areal densities of the different components may be varied relative to one another within the mask pattern.
  • the mask pattern conceptually corresponds to the superposition of plural mask pattern channels.
  • FIG. 1 illustrates the production of a continuous decorative surface covering (e.g., sheet flooring)
  • Fig. 2 illustrates a variant of the process adapted to individual surface covering elements, such as, e.g., tiles, planks, panels or the like.
  • steps of the process of Fig. 2 are the same as those of the process of Fig. 1 , the reader may refer to the above description.
  • FIG. 3 illustrates a further embodiment of the proposed method for producing a decorative surface covering, e.g., a floor covering.
  • the process of Fig. 3 differs from that of Fig. 1 essentially in the way the digital embossing is carried out.
  • a multilayer surface covering substructure 10 is provided as a printing substrate in a digital printing stage 12.
  • a digital printer 14 prints a two-dimensional decorative motif onto the surface covering substructure 10.
  • the surface covering substructure 10 may comprise a primer layer for printing thereon or it may comprise a printable layer that is part of the structural layers.
  • the layer that receives the ink directly thereon may be referred to as the decor-carrying layer 16.
  • the digital printer 14 may include a drying or curing stage (not shown), wherein the printed decorative motif 18 is solidified and bonded to the decor-carrying layer 16.
  • Such drying or curing stage could comprise one or more heaters and/or one or more blowers and/or one or more radiation sources, depending on the type of ink used by the digital printer 14.
  • the 3D printing is carried out using digital printers 40a, 40b, 40c.
  • the newly deposited layer(s) of crosslinkable resin composition 21 may be cured or precured in order to prepare these layer(s) for the deposition of further layer(s) of crosslinkable resin composition 21 thereon.
  • (intermediate) curing of the crosslinkable resin composition layers 21 a, 21 b, and 21 c is effected with UV lamps 42a, 42b, and 42c located downstream of printers 40a, 40b and 40c, respectively. It is worthwhile noting that the relief may be built up from two, three or more than three individual crosslinkable resin composition layers.
  • one or more further crosslinkable resin compositions and/or crosslinked polymer layers may be applied in direct contact with the decor-carrying layer and/or the printed decorative motif 18. These layers may form a stack of crosslinkable resin composition layers and/or crosslinked polymer layers containing no further intermediate layer of a different nature, i.e. , no intermediate layer that is formed neither of a crosslinkable resin composition nor of a crosslinked polymer layer. After application of each layer, there may be a curing step before the next layer is applied.
  • the first layer of the stack is preferably applied in direct contact with the printed decorative motif, the further layers of the stack being applied on the first layer.
  • the digitally embossed layer may thereafter be coated with a top-coat 32.
  • the topcoat 32 may comprise a radiation curable crosslinkable composition, e.g., a radiation-curable crosslinkable (pre-)polymer resin, preferably a (poly)urethane acrylate.
  • the coating may be effected by any suitable technique, e.g., by roller-coating (as illustrated in Fig. 3) or printing (e.g., digital printing), etc.
  • the topcoat may comprise a UV-curable topcoat.
  • a matte surface finish may be obtained by generating a microfolded skin layer in the topcoat by first exposing the topcoat to V-lIV light (from V-UV light source 34) and then curing the topcoat in depth.
  • In-depth curing of the topcoat may include irradiation with UV light of longer wavelengths (> 200 nm), capable of penetrating further into the topcoat layer than the V-UV light, which is quickly absorbed in the superficial skin layer.
  • the UV light of longer wavelengths may be provided by one or more UV lamps 36.
  • the topcoat is preferably comprised of one or more continuous layers, so as to completely seal off the underlying embossed layer.
  • the embossing processes of the embodiments of the invention are preferably carried out in register with the decorative motif 18. This may be achieved by providing a relief file representing the three-dimensional surface structure to be imparted and an image file representing the decorative motif, both files corresponding to the same section (defined area) of the decorative surface covering.
  • the embossing equipment and/or the digital printer of the decorative motif are adjusted in such a way that the intended spatial relationship between the three-dimensional surface structure and the decorative motif is achieved.
  • the digital printing and the digital embossing takes place on individual elements, such as, e.g., tile blanks or panel blanks or the like (as shown in Fig. 2), the individual elements may be detected (optically or otherwise) when they arrive at the printing stage and/or the embossing stage, so that the printed decorative motif and the embossing can be precisely aligned with each individual element.
  • misalignments may be monitored and corrected dynamically.
  • registration marks can be applied on the printing substrate when the two- dimensional decorative motif 18 is printed. These registration marks can then be used in the production stages downstream, in particular in the digital embossing stage.
  • the digital embossing stage could comprise one or more optical sensors (e.g., digital cameras), arranged in known spatial relationship to one or more of the digital printers of the embossing stage, for detecting the position and, optionally, the velocity, of the two-dimensional decorative motif at a certain time.
  • the position (and velocity) information provided by the one or more optical sensors may be used by a controller of the embossing stage to adjust the position of the embossed motif to the position of the two-dimensional decorative motif. It may be worthwhile noting that the dynamic monitoring and correction of misalignments using registration marks may be useful when the substrate is a continuous web (in contrast to individual elements).
  • the decorative surface covering being produced is preferably PVC-free.
  • the one or more core layers 10a, 10b of the surface covering substructure 10 comprise or consist of one or more linoleum layers. At least one of the linoleum layers may be made by calendering linoleum paste on a fibrous support 38 (e.g., jute backing, textile layer, polyester layer etc.)
  • the fibrous support 38 may carry one or more layers of linoleum paste.
  • the linoleum paste preferably contains a flame retardant, such as, e.g., aluminium trihydroxide.
  • the layer that serves as the decorcarrying layer 16 may be comprised of white linoleum (linoleum to which white pigment, e.g., TiO2 has been added to confer it a light colour), suitable for serving as a printing substrate.
  • white linoleum lainoleum to which white pigment, e.g., TiO2 has been added to confer it a light colour
  • the crosslinkable resin composition may, e.g., comprise UV curable urethane (meth)acrylate, UV curable polyurethane (meth)acrylate, epoxy (meth)acrylate, polyester (meth)acrylate, polyether (meth)acrylate amino (meth)acrylate, silicone (meth)acrylate, and/or polyether urethane acrylate.
  • the topcoat may have the same or a different composition as the crosslinkable resin composition.
  • the topcoat comprises (poly)urethane acrylate.

Landscapes

  • Laminated Bodies (AREA)

Abstract

Un procédé de production d'un revêtement de surface décoratif, par exemple un revêtement de sol ou un revêtement mural, est proposé. Le procédé consiste à former une couche gaufrée par les étapes suivantes consistant à : appliquer une composition de résine réticulable en une couche continue (20) sur une face d'une sous-structure de revêtement de surface (10) comprenant une ou plusieurs couches centrales (10a, 10b), la ou les couches centrales comprenant une ou plusieurs couches de linoléum, la face de la sous-structure de revêtement de surface comportant un motif décoratif imprimé (18), la composition de résine réticulable étant appliquée sur le motif décoratif imprimé, et générer un relief de surface tridimensionnel (30) par gaufrage numérique de la composition de résine réticulable, le gaufrage numérique consistant à durcir au moins partiellement la composition de résine réticulable. Le gaufrage numérique est de préférence exécuté en correspondance avec le motif décoratif imprimé.
PCT/EP2024/066617 2023-07-03 2024-06-14 Revêtements de surface décoratifs gaufrés numériquement Pending WO2025008160A1 (fr)

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LULU504655 2023-07-03
LU504655A LU504655B1 (en) 2023-07-03 2023-07-03 Decorative surface coverings digitally embossed

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WO2025008160A1 true WO2025008160A1 (fr) 2025-01-09

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WO2010070485A2 (fr) 2008-12-19 2010-06-24 Flooring Industries Limited, Sarl Procédés de fabrication de panneaux et panneau ainsi obtenu
US20150354132A1 (en) * 2013-01-17 2015-12-10 Armstrong World Industries, Inc Curing methods and products produced therefrom
EP3109056A1 (fr) 2015-06-25 2016-12-28 Hymmen GmbH Maschinen- und Anlagenbau Procede et dispositif de fabrication d'une structure sur une surface
WO2017046309A1 (fr) 2015-09-17 2017-03-23 Beaulieu International Group Nv Panneaux de revêtement personnalisés par impression numérique de panneaux de base
WO2017067978A1 (fr) 2015-10-19 2017-04-27 Tarkett Gdl S.A. Procédé de fabrication de substrats en relief imprimés numériquement
EP3228448A1 (fr) 2016-04-05 2017-10-11 Tarkett GDL Revêtement de recouvrement de surface
EP2723561B1 (fr) * 2011-06-24 2017-12-06 Armstrong DLW GmbH Structure en nappe imprimée sur une base de linoléum
EP3305979A1 (fr) 2016-10-10 2018-04-11 Tarkett GDL Composition de linoléum et son procédé de production
EP2889135B1 (fr) * 2013-12-31 2018-10-17 Armstrong World Industries, Inc. Plancher de linoléum
EP3415316A1 (fr) * 2017-06-13 2018-12-19 Hymmen GmbH Maschinen- und Anlagenbau Procédé et dispositif de fabrication d'une surface structurée
US20200346395A1 (en) 2019-05-03 2020-11-05 Hymmen GmbH Maschinen- und Anlagenbau Method and device for producing a decorative surface
WO2022106466A2 (fr) * 2020-11-23 2022-05-27 Tarkett Gdl Gaufrage numérique de revêtements de surface décoratifs
WO2022171859A1 (fr) * 2021-02-12 2022-08-18 I4F Licensing Nv Panneau décoratif et revêtement de panneau décoratif
US20220355335A1 (en) 2020-09-28 2022-11-10 Hymmen GmbH Maschinen- und Anlagenbau Method and device for manufacturing a base layer having different degrees of hardness and workpiece having different degrees of hardness

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2371074A (en) * 1942-09-26 1945-03-06 Armstrong Cork Co Method of manufacturing linoleum compositions
WO2010070485A2 (fr) 2008-12-19 2010-06-24 Flooring Industries Limited, Sarl Procédés de fabrication de panneaux et panneau ainsi obtenu
EP2723561B1 (fr) * 2011-06-24 2017-12-06 Armstrong DLW GmbH Structure en nappe imprimée sur une base de linoléum
US20150354132A1 (en) * 2013-01-17 2015-12-10 Armstrong World Industries, Inc Curing methods and products produced therefrom
EP2889135B1 (fr) * 2013-12-31 2018-10-17 Armstrong World Industries, Inc. Plancher de linoléum
EP3109056A1 (fr) 2015-06-25 2016-12-28 Hymmen GmbH Maschinen- und Anlagenbau Procede et dispositif de fabrication d'une structure sur une surface
WO2017046309A1 (fr) 2015-09-17 2017-03-23 Beaulieu International Group Nv Panneaux de revêtement personnalisés par impression numérique de panneaux de base
WO2017067978A1 (fr) 2015-10-19 2017-04-27 Tarkett Gdl S.A. Procédé de fabrication de substrats en relief imprimés numériquement
EP3228448A1 (fr) 2016-04-05 2017-10-11 Tarkett GDL Revêtement de recouvrement de surface
EP3305979A1 (fr) 2016-10-10 2018-04-11 Tarkett GDL Composition de linoléum et son procédé de production
EP3415316A1 (fr) * 2017-06-13 2018-12-19 Hymmen GmbH Maschinen- und Anlagenbau Procédé et dispositif de fabrication d'une surface structurée
US20200368777A1 (en) 2017-06-13 2020-11-26 Hymmen Gmbh Maschinen-Und Anlagenbau Method for producing a structured surface
US20200346395A1 (en) 2019-05-03 2020-11-05 Hymmen GmbH Maschinen- und Anlagenbau Method and device for producing a decorative surface
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US20220355335A1 (en) 2020-09-28 2022-11-10 Hymmen GmbH Maschinen- und Anlagenbau Method and device for manufacturing a base layer having different degrees of hardness and workpiece having different degrees of hardness
WO2022106466A2 (fr) * 2020-11-23 2022-05-27 Tarkett Gdl Gaufrage numérique de revêtements de surface décoratifs
WO2022171859A1 (fr) * 2021-02-12 2022-08-18 I4F Licensing Nv Panneau décoratif et revêtement de panneau décoratif

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