DECORATED PANEL, METHOD FOR ITS PRODUCTION AND SYSTEM FOR CARRYING OUT THIS METHOD

Abstract

The present invention refers to a decorated panel composed as follows: a substrate; a decorative layer applied to at least part of the substrate; a photo-crosslinkable formulation applied directly or indirectly on a part of the substrate and/or on the decorative layer, that is, with the interposition of further layers of intermediate material on at least a part of the substrate and in one or more layers, containing at least one photo-crosslinkable resin; at least one thermoplastic resin; at least one polymerization initiator including but not limited to UV photoinitiators, organic peroxides, Electron Beam.

Claims

1. A decorated panel comprising: a. A substrate; b. A decorative layer applied to at least part of the substrate; c. A photo cross-linked formulation applied directly or indirectly on a part of the said substrate and/or on a decorative layer, i.e. with the interposition of further layers of intermediate material on at least a part of the substrate and one or more of said layers, containing: i. At least one light crosslinkable resin; ii. At least one thermoplastic resin; iii. At least one polymerization initiator including but not limited to UV photoinitiators, organic peroxides, Electron Beam.

2. Panel according to claim 1, wherein the substrate comprises at least two opposite faces spaced apart by a predetermined thickness and on at least some areas and/or on the entire surface of one of said faces, in particular the front face, at least one wear and/or scratch resistant layer is applied.

3. A panel according to claim 1 or 2, wherein the photoreticulable resin is comprised in the group of cationic photoreticulable resins, in the group of radical photoreticulable resins and/or their combinations or mixtures.

4. A panel according to one or more of the preceding claims, wherein the photo-crosslinkable resin contains non-crosslinkable resins such as epoxy, polyurethane, acrylic resins and/or their combinations or mixtures.

5. A panel according to one or more of any of the preceding claims in which the photoreticulable resin is subjected to a secondary polymerization process (dual-cure).

6. A panel according to one or more of the preceding claims in which the thermoplastic resin is selected from the resins of the following list: polybenzimidazole (PBI), polycarbonate (PC), polyethylene (PE), polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), polypropylene (PP), polystyrene (PS) or polystyrene, polyvinyl chloride (PVC), polyamide (PA), acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), polytetrafluoroethylene (PTFE), polyethersulfone (PES), polyoxymethylene (POM), polyvinyl acetate (PVAC), ethylene vinyl acetate copolymer (EVA), copolymers and/or combinations or mixtures of the above.

7. A panel according to any one or more of the preceding claims in which the thermoplastic resin is contained between 1% and its limit of solubility in the photo-crosslinkable resin.

8. A panel according to any one or more of the preceding claims in which the thermoplastic resin is dispersed in the photoreticulable resin.

9. A panel according to any one or more of the preceding claims according to which the photo-crosslinkable formulation contains at least one substance selected from: water, solvents, surface tension modifiers, photo-crosslinkable resins, photoinitiators, slip agents, wetters, oils, light stabilizers, antioxidants, defoamers, humectants, biocides, dyes, plasticizers, fillers, aluminum oxide, pigments and/or their combinations or mixtures.

10. Panel according to any one or more of the preceding claims in which the photoreticulable formulation is textured.

11. Panel according to one or more of any of the preceding claims in which the application of the decoration layer is done by digital printing.

12. Decorated panel according to any one or more of the preceding claims, in which the decorated panel is heat treated.

13. Panel according to claim 12 according to which an opaque surface is generated after the heat treatment.

14. Decorated panel according to any one or more of the preceding claims in which the substrate is made up of plastic, wood, wood-derived material (HDF/MDF), metal, fiber cement, ceramic and/or combinations of the preceding ones.

15. Decorated panel according to any one or more of the preceding claims used for the production of coverings, floors and furniture.

16. A method for manufacturing a panel according to one or more of the preceding claims 1 to 16 which method involves the following steps: optional surface processing to prepare a substrate; preparation of a photo-crosslinkable formulation of at least one coating/painting layer, in particular of at least one anti-wear and/or anti-scratch layer according to one or more of the forms and embodiments described above; application of said photoreticulable formulation on at least one of the surfaces of said substrate by means of techniques selected from those in the following list: roller application, application by spraying, application by veil, application by drawing, application by slot-die, application by spatula and/or spreading for the formation of said anti-wear and/or anti-scratch layer; photoreticulation of the said anti-wear and/or anti-scratch layer; final heat treatment of heating of the combination of substrate and anti-wear and/or anti-scratch layer.

17. A method according to claim 16, wherein upstream of said final heat treatment step and/or before or after photo cross-linking step of said at least one anti-wear and/or anti-scratch layer, there is provided a step of three-dimensional forming of the exposed surface, of the said layer, or of the surface opposite to the substrate, that is a step of generating a three-dimensional structure comprising a combination of recesses and protrusions distributed according to a predetermined pattern on said surface.

18. Method according to claim 17, wherein said forming step provides applying a forming liquid on the non-crosslinked or partially crosslinked surface, i.e., non-gelled or partially gelled, by means of an inkjet printer which distributes said liquid as a function of a digital distribution model corresponding to the provision of recesses and protrusions along the surface of said at least one anti-wear and/or anti-scratch layer and the subsequent elimination of said forming liquid in a drying and/or mechanical, hydraulic, suction phase and/or blowing which can take place before, after and/or simultaneously with the photo cross-linking phase of the said anti-wear and/or anti-scratch layer and/or with the final heat treatment phase of the said anti-wear and/or anti-scratch layer.

19. Method according to one or more of claims 16 to 18 in which the steps of application in succession of at least one, some or all of the layers present in the following list are provided: an optional layer of grouting; an adhesion primer of a colored base; a colored base layer, preferably white; an adhesion primer of a decoration layer on said colored base layer; a decoration layer, with the anti-wear and/or anti-scratch layer (s) applied to the decoration layer.

20. Method according to one or more of the preceding claims 16 to 19 in which the application of the three-dimensional structure in said at least one anti-wear and/or anti-scratch layer is made in register with the chromatic aspect of the decoration layer, or with the image which constitutes the said decoration.

21. Plant for implementing the method according to one or more of claims 16 to 20 for the construction of a panel according to one or more of the previous claims 1 to 15 and which plant includes: at least one station for applying at least one anti-wear and/or anti-scratch layer on the surface of at least one face of a substrate; at least one surface forming station of said at least one anti-wear and/or anti-scratch layer; at least one photoreticulation station of the said wear and/or anti-scratch layer and at least one heat treatment station for heating said substrate with said at least one anti-wear and/or anti-scratch layer.

22. Plant according to claim 21, in which one or more of the following stations are provided in succession and according to the order of citation: a first station for preparing at least one surface of a substrate by polishing the surface of the substrate; a station for applying a putty to at least one surface of the substrate; a drying and/or crosslinking station for said putty; a polishing station for said putty; a station for applying a primer of a colored base, preferably white on said surface of the substrate and/or on said layer of putty; a drying and/or crosslinking station of said colored base layer; a station for applying a printing primer for a decoration layer; a drying and/or crosslinking station of said printing primer; a station for applying said decoration layer to said primer layer; a drying and/or crosslinking station of said decoration layer; a station for applying at least one anti-wear and/or anti-scratch layer; an optional drying and/or crosslinking station at least partially of said at least one anti-wear and/or anti-scratch layer; optionally at least one further station for applying at least one further anti-wear and/or anti-scratch layer and associated an optional drying and/or at least partial crosslinking station of said at least one anti-wear and/or anti-scratch layer; a station for applying at least one finishing layer; an optional drying and/or at least partial crosslinking station of said at least one finishing layer; a three-dimensional forming station, according to a predetermined model; a final crosslinking and/or final heating heat treatment station; an optional elimination station of selected parts of the thickness of the at least one anti-wear and/or anti-scratch layer possibly in combination with at least one finishing layer superimposed on it.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0137] Some exemplary embodiments of the present invention will be described in greater detail below with reference to the attached drawings, in which:

[0138] FIG. 1 illustrates the succession of layers to produce the decorated panel object of the invention. In particular, the figure represents a decorated panel in plastic material that can be used for flooring.

[0139] FIG. 2 shows, similarly to FIG. 1, a decorated panel in HDF that can be used for flooring.

[0140] FIG. 3 schematically shows a first embodiment of the three-dimensional structuring method, i.e., surface embossing of the wear-resistant and/or scratch-resistant layer of the panel according to the present invention.

[0141] FIG. 4 schematically shows a second embodiment of the three-dimensional structuring method, i.e., surface embossing of the wear-resistant and/or scratch-resistant layer of the panel according to the present invention.

[0142] In the present description, as well as in the preceding introductory parts and in the claims, the terms crosslinking, photoreticulation and polymerization are to be considered equivalent to each other and falling within the more generic definition of crosslinking or polymerization or gelling by means of energy irradiation.

[0143] Furthermore, in the present description as well as in the preceding introductory parts and in the claims the terms embossing, forming, texturing, three-dimensional surface configuration are to be considered equivalent and falling within the more generic definition of three-dimensional surface forming comprising a distribution of alternating grooves and protrusions according to a predetermined distribution design.

[0144] In FIG. 1 a painting cycle for SPC is schematized while in FIG. 2 a painting cycle for HDF is schematized.

[0145] According to some embodiments, the painting cycle object of the invention can be performed using conventional techniques in use, such as roller/spray/veil/die/slot-die.

[0146] Typically, the paint object of the invention is advantageously used for the production of furniture and/or floors. The preparation and finishing cycle depends on the material to be decorated and on the desired performance.

[0147] With reference to the example of a typical cycle for the decoration of SPC (Stone Plastic Composite), a material currently in vogue for the production of flooring, it involves the following processes:

TABLE-US-00001 TABLE 1 Operation application typy g/m2 note Smoothing optional of the substrate Adhesion roll UV 8/10 optional primer White base roll UV 20/40  One or more applications Primer for roll UV 8/10 optional print Digital roll UV optional print of decor Anti-wear roll UV 80/200 One or more layer applications The quantity depends on the degree of abrasion resistance desired Finishing roll UV 10/20  Optional. For scratch protection and to obtain the desired degree of opacity

[0148] In order to obtain different aesthetic effects, the wear layer and the finishing layer can have different degrees of opacity. In fact, if the wear layer has a higher degree of gloss than the finishing layer, a pore will be obtained, or a hollow in the three-dimensional, shiny structure, which will consequently be highlighted.

[0149] On the contrary, if the wear layer and the finishing layer have the same degree of gloss, the pore will be less evident but with a more natural effect.

[0150] As previously highlighted in the present description, each layer or at least some of the layers of the painting cycle can consist of a formulation according to the more general composition of the present invention, that is, comprising: [0151] i. At least one light crosslinkable resin; [0152] ii. At least one thermoplastic resin; [0153] iii. At least one polymerization initiator, including but not limited to UV photoinitiators, organic peroxides, Electron Beam,

[0154] The different layers differing in relation to the quantity and/or type of said components and/or in relation to the presence of one or more different additives and/or different quantities of said one or more additives.

[0155] In a preferred form of the invention, the painting cycle is heat treated. Temperature and time are a function of the molecular weight and chemical nature of the resin itself. Typically, the heat treatment takes place after the photopolymerization step.

[0156] Surprisingly, after heat treatment, a dull surface is formed. The heat treatment can take place by means of hot air or by direct irradiation with IR, NIR rays.

[0157] Below is an example of a preferred and non-limiting painting cycle of the present invention:

Example 1

[0158] A varnish base is prepared consisting of: [0159] HDDA acrylate monomer: difference to 100% [0160] TMPTA acrylate monomer: 20% [0161] CN981 acrylate oligomer: 10% [0162] thermoplastic resin (see table 2) [0163] photoinitiator IRGACURE 1173: 3% [0164] TPO photoinitiator: 0.1-5% (5% for white)

[0165] Titanium oxide (20%) is then added to the base to prepare the white base paint or aluminum oxide (25%) to prepare the shatterproof paint or the wear layer.

[0166] The line used for decoration and finishing is composed of normal or reverse roller machines for the application of paints, 6-color single-pass printer for decoration, single-pass jet-printer for texturing, or for the application of the texturing liquid, brushing members for the removal of the areas treated with the texturizing liquid.

[0167] The application and printing speed is 30 m/min. The white paint is applied by roller with 2 applications of 15 g/m2 to a substrate of SPC of 2.5 mm and gelled with 2 Ga lamps of 120 W/cm.

[0168] The substrate is printed with the decoration layer and then a first coat of shatterproof paint (30 g/m2) is applied which is gelled with 1 120 W/cm Hg lamp followed by another application of a second layer of the same material of 150 g/m2. This second layer is subjected to the three-dimensional forming process, i.e., texturization and is subsequently gelled with 2 120 W/cm Hg lamps.

[0169] Subsequently, a finishing layer is then applied in an amount of 10 g/m2 to ensure scratch resistance and the desired gloss, the substrate is then dried with 4 Hg lamps of 120 w/cm.

[0170] The substrate was tested according to EN16511:2019, some data of which are shown in table 2 with reference to the use of different types of thermoplastic resins:

TABLE-US-00002 Type Ref. polyamide PVC PVC-Ac PE Thermoplastic ORGASOL SOLVIN VINNOL PEW- resin 2002 550 GA H 4 40/50 Content % 0 8 10 10 15 Taber AC1 AC4 AC4 AC3 AC2 abrasion Dimensional 4 h@80 c. NOK OK OK OK OK stability <1 mm <1 mm <1 mm <1mm

[0171] FIG. 3 shows a schematic example of the texturing process according to one of the preferred but non-limiting embodiments of the anti-wear and/or anti-scratch layer.

[0172] With reference to FIG. 3, step 1 shows a more generic embodiment of the present invention in which only the application of an anti-wear and/or anti-scratch layer indicated with 20 on a substrate 10 is provided.

[0173] Step 1 provides for the application of said layer 10 made according to one or more of the embodiments and/or variants previously described and preferably by means of a technique that does not involve the use of spraying or ink-jet techniques.

[0174] Step 2 shows the application of an embossing liquid indicated with 30, preferably by means of a digital printing process and in particular by means of an ink-jet printing process 40. In this case the described technique is applied with a forming liquid of the type on aqueous basis as specifically and in detail described in WO2018069874.

[0175] Step 3 provides for the action of polymerization and/or drying of the layer, for example by irradiation of photonic energy or the like, which leads to step 4 to the finished panel to which it is possible to further apply a finishing layer as shown in the fine examples of FIGS. 1 and 2.

[0176] FIG. 4 shows similarly to FIG. 3 the steps of an alternative three-dimensional forming process of the at least one anti-wear layer 20 applied to a substrate 10. In this case, step 4 further provides for the removal by means of removal members 50 of the areas on which the embossing liquid 30 is applied. The composition of this embossing liquid as well as the nature of the interaction between the forming liquid 30 and the material of the anti-wear layer 20 are described in detail in document WO2020039361.

[0177] FIG. 4 also shows the step 5 of application of the finishing layer 60 which can be similarly envisaged also in the example of FIG. 3.

[0178] Following the step of application of the finishing layer or at the end of the process, if the finishing layer is not provided, the step of heating the heat treatment of the set of layers applied to the substrate is provided even if not illustrated.