Embossed and Hot-Melt Laminated Multilayer Composite Film

Abstract

A multi-layered composite film is provided that includes immediately consecutive and mutually bonded layers A-B-C: A: on the visible side, a polymer layer comprising 1 to 100% by weight of extrudable thermoplastic polyurethane-containing polymer and/or ionomer; B: a tie layer comprising one or more modified plastics for the tie; C: on the substrate side, a decorative layer;
wherein the layered composite is coextruded from the layers A and B and hot-melt laminated with the decorative substrate layer at a temperature above the fusion temperature of the layered composite, while simultaneously pattern(s) is/are plastically embossed on the visible side of the multi-layered composite film. The multi-layered composite films may be used as a floor covering, wall panelling or furniture film. A method for manufacturing the multi-layered composite films is also provided.

Claims

1. A multi-layered composite film, comprising at least the following immediately consecutive and mutually bonded layers A-B-C: A: on the visible side, a polymer layer comprising 1 to 100% by weight of extrudable thermoplastic polyurethane-containing polymer and/or ionomer; B: a tie layer comprising one or more modified plastics for the tie; C: on the substrate side, a decorative layer; characterised in that the layered composite is coextruded from the layers A and B and hot-melt laminated with the decorative substrate layer at a temperature above the fusion temperature of the layered composite, while simultaneously one or more patterns is/are plastically embossed on the visible side of the multi-layered composite film in the same step.

2. The multi-layered composite film according to claim 1, characterised in that the embossing depth index I.sub.P is at least 6.0 once the multi-layered composite film has cooled to room temperature, and the embossing depth index I.sub.P is dimensionless and defined as follows (all values being in micrometres):
I.sub.P=R.sub.Z(visible side)×1000/(R.sub.Z(substrate side)×thickness(A-B-C)).

3. The multi-layered composite film according to claim 1, characterised in that the decorative layer comprises paper, plastic film or a combination of paper and plastic film which is printed on.

4. The multi-layered composite film according to claim 3, characterised in that the decorative layer C comprises a primer.

5. The multi-layered composite film according to claim 1, characterised in that the profile or pattern embossed on is synchronised with the decorative pattern.

6. The multi-layered composite film according to claim 1, characterised in that it contains no PVC or melamine resin.

7. The multi-layered composite film according to claim 1, characterised in that the polymer of the polymer layer A is selected from thermoplastic polyurethane or Surlyn® ionomer, or mixtures of the same.

8. The multi-layered composite film according to claim 1, wherein the modified plastic(s) for the tie comprise(s) one or more polymer(s) modified with maleic anhydride, alkylated maleic anhydride and/or carboxylic acid, in particular one or more copolymer(s) or grafted (co)polymers of monomers which support carboxylic acid functionality, in particular maleic anhydride and/or alkylated maleic anhydride with polypropylene, polyethylene, ethylene-vinyl acetate (EVA), ethylene-butyl acrylate (EBA), ethylene-acrylic acid (EAA), ethylene-methacrylic acid (EMAA), maleic acetate (MAH) and/or polyacrylate rubber (ACM).

9. The multi-layered composite film according to claim 1, characterised in that the decorative layer C contains an extrudable thermoplastic polymer selected from the group consisting of polyethylenes, polypropylenes and polybutylenes, polystyrene, polyamide, polyester and mixtures of the same.

10. The multi-layered composite film according to claim 1, characterised in that the polymer layer A exhibits a thickness in the range of 1 to 500 μm, preferably 5 to 200 μm; and/or the tie layer B exhibits a thickness in the range of 1 to 100 μm, preferably 5 to 20 μm, in particular 6 to 10 μm; and/or the substrate layer C exhibits a thickness of 1 to 500 μm, preferably 10 to 150 μm.

11. The multi-layered composite film according to claim 1, characterised in that it comprises at least the consecutive and mutually bonded layers D-A-B-C, wherein the layer D denotes one or more mutually bonded layers and is connected to the layer A directly, via a bonding layer or adhesive layer, by lamination or by mechanical connecting elements.

12. The multi-layered composite film according to claim 11, characterised in that the layer D comprises one or more of the following layers: a covering layer, a UV protection layer, a moisture protection layer, a mechanical protection layer, a layer which prevents slipping, or a (heat-melt) adhesive layer, wherein the layer D can be transparent and/or can comprise a surface profile.

13. The use of a multi-layered composite film in accordance with claim 1, wherein the multi-layered composite film is used as a floor covering or in the manufacture of a floor covering, as wall panels or roof panels or in the manufacture of wall panels or roof panels, as furniture film, in particular in the manufacture of plywood board or chipboard and/or as a graphic film, in particular a printed film.

14. A layered body comprising a multi-layered composite film in accordance with claim 1, wherein the multi-layered composite film is used as a floor covering or furniture film.

15. The floor covering according to claim 14, characterised in that it comprises at least one other layer E which is a substrate layer which adjoins the layer C and is connected to the layer C directly, via a bonding layer or adhesive layer, by lamination or by mechanical connecting elements.

16. The floor covering according to claim 15, characterised in that the substrate layer E comprises one of the following layers: a layer which prevents slipping, a heat-insulating layer, a sound-absorbing and in particular impact sound-absorbing layer, a heat-conducting layer, an adhesive layer, a plywood layer or chipboard layer, a wood-plastic composite (WPC) layer and a fibre-reinforced concrete layer.

17. A method for manufacturing a multi-layered composite film according to claim 1, characterised in that the layered composite is coextruded from the layers A and B in a first step and hot-melt laminated with the decorative substrate layer at a temperature above the fusion temperature of the layered composite in a second step, while simultaneously one or more patterns is/are plastically embossed on the visible side of the multi-layered composite film in the same step, wherein the temperature of the layered composite does not drop below the fusion temperature of the layered composite A-B between the first and second method steps.

18. The method according to claim 17, characterised in that the second method step is performed at a temperature of 150 to 300° C.

Description

[0037] FIG. 1 shows a cross-section of an embodiment of the multi-layered composite film of the invention which exhibits the layer design A-B-C. In this example, the layers are composed of:

Layer A (100 μm) ionomer;
Layer B (8 μm) maleic-anhydride-modified polyethylene as a modified plastic for the tie;
Layer C (120 μm) paper or plastic film which is printed on using casein ink and coated (10 μm) with primer.

[0038] FIG. 2 shows a cross-section of another embodiment of the multi-layered composite film, for example as a floor covering which exhibits the layer design A-B-C-E. In this example, the layers are composed of:

Layer A (100 μm) ionomer;
Layer B (8 μm) maleic-anhydride-modified polyethylene as a modified plastic for the tie;
Layer C (120 μm) paper or plastic film which is printed on using casein ink and coated (10 μm) with primer;

Layer E (2000 μm) WPC.

[0039] FIG. 3 shows a cross-section of another embodiment of the multi-layered composite film, for example as a furniture film which exhibits the layer design D-A-B-C. In this example, the layers are composed of:

Layer D (50 μm) varnish;
Layer A (110 μm) thermoplastic polyurethane;
Layer B (5 μm) maleic-anhydride-modified polyethylene as a modified plastic for the tie;
Layer C (100 μm) PET which is printed on using casein ink and coated (10 μm) with primer.

[0040] FIG. 4 shows a cross-section of another embodiment of the multi-layered composite film, for example as a furniture film which exhibits the layer design D-A-B-C-E. In this example, the layers are composed of:

Layer D (80 μm) ionomer;
Layer A (120 μm) ionomer;
Layer B (10 μm) maleic-anhydride-modified polyethylene as a modified plastic for the tie;
Layer C (90 μm) paper which is printed on using casein ink and coated (10 μm) with primer;
Layer E (1500 μm) plywood layer, wood or for example fibre-reinforced concrete.

[0041] FIG. 5 shows a schematic and typical design of the method in accordance with the invention, wherein a composite made of a layer A, which consists for example of ionomer, is coextruded in the nozzle 1 at a temperature of 200 to 280° C. with a (substrate-side) tie layer B as a molten mass 2 and then immediately connected on the substrate side, at the same temperature, to a layer of paper C/3 which is printed on and which is fed via a roller 4, for example a rubber roller. The layer C and the layered composite A-B are hot-melt laminated and simultaneously embossed on the visible side between the embossing roller 5 and the roller 4 at temperatures in the range of for example 150 to 300° C. simultaneously or immediately after they have been converged.

EXAMPLES

Example 1

[0042] A multi-layered composite film exhibiting the following sequence of layers was manufactured according to the method in accordance with the invention, wherein the layers A and B were coextruded at 250° C. and then immediately hot-melt laminated with the layer of film C (which has a wood grain pattern printed on it in casein ink and is provided with primer) while still at 230° C. and at a pressing force of 30 kN, wherein a plastic wood-texture pattern was embossed on the visible side.

Layer A (300 μm) ionomer (Surlyn® 1706 by Dupont);
Layer B (10 μm) maleic-anhydride-modified polyethylene as a modified plastic for the tie;
Layer C (120 μm) polypropylene film which is printed on using casein ink and coated (10 μm) with primer.

[0043] Table 1 lists some parameters for characterising the multi-layered composite film of Example 1.

TABLE-US-00001 TABLE 1 Overall thickness A-B-C 431 μm Embossing depth index I.sub.P (averaged from 14.1 two measurement values, dimensionless) Density 0.973 g/cm.sup.3 Grammage 4.189 g/100 cm.sup.2 Young's modulus, longitudinal 458 Mpa Young's modulus, transverse 406 Mpa Maximum force, longitudinal 177 N (6.47 SO mm.sup.2) Maximum force, transverse 159 N (6.47 SO mm.sup.2) Maximum elongation, longitudinal 246% Maximum elongation, transverse 201% Elongation at rupture, longitudinal 246% Elongation at rupture, transverse 201% Tensile strength, longitudinal 27 Mpa Tensile strength, transverse 25 Mpa Tearing strength, longitudinal 27 Mpa Tearing strength, transverse 25 Mpa Breaking force, longitudinal 175 N Breaking force, transverse 159 N (DIN EN ISO 527-3/1B/200) The average surface roughness R.sub.Z was determined using the MAHR perfometer.

Example 2

[0044] A multi-layered composite film exhibiting each of the following sequences of layers was manufactured according to the method in accordance with the invention, wherein the layers A and B were coextruded at 250° C. and then immediately hot-melt laminated with a layer of paper C (which has a wood grain pattern printed on it in casein ink and is provided with 15 μm of primer) while still at 230° C. and at a pressing force of 30 kN, wherein a plastic wood-texture pattern was embossed on the visible side.

Film 2a

[0045] Layer A (50 μm) ionomer (Surlyn® 1706 by Dupont de Nemours);
Layer B (10 μm) maleic-anhydride-modified polyethylene as a modified plastic for the tie;
Layer C (105 μm) decorative paper which is printed on using casein ink and coated (15 μm) with primer.
Overall thickness A-B-C: 165 μm

Film 2b

[0046] Layer A (250 μm) ionomer (Surlyn® 1706 by Dupont de Nemours);
Layer B (10 μm) maleic-anhydride-modified polyethylene as a modified plastic for the tie;
Layer C (105 μm) decorative paper which is printed on using casein ink and coated (15 μm) with primer.
Overall thickness A-B-C: 365 μm

[0047] The layered composite films were laminated with chipboard/hot-melt adhesion and tested for scratch resistance (DIN 438-2), abrasion resistance, wear resistance (DIN EN 13329) and resistance to staining (DIN 438-2), wherein the layered composites in accordance with the invention exhibit good to very good results throughout.