STAINABLE SURFACE

Abstract

The invention relates to a method for producing a color-changeable decorative surface. In order to provide a decorative surface that can be changed in a particularly simple manner in terms of its coloring by the end consumer and which is particularly cost-effective and resistant, it is provided that at least one layer of a coating agent, which enables the absorption of color particles, is applied.

Claims

1. A method for producing a color-changeable decorative surface (2) comprising the steps: provide a ready-to-use, fully cured decorative surface (2) comprising a synthetic resin and/or lacquer on a backing layer (1), apply at least one layer (6) of a coating agent that allows color particles to be absorbed, dry and cure the coating agent layer (6).

2. The method according to claim 1, wherein the ready-to-use decorative surface (2) is pretreated before applying the at least one layer of a coating agent.

3. The method according to claim 2, wherein an adhesion promoter is applied for pretreatment to the decorative surface (2), wherein the adhesion promoter is applied as a separate layer before applying the coating agent layer (6), and is gelled, dried or is fully cured.

4. The method according to claim 3, wherein the adhesion promoter is applied together with the coating agent as a coating agent mixture onto the decorative surface (2).

5. The method according to claim 3, wherein the adhesion promoter comprises a UV acrylate lacquer or a UV polyurethane lacquer (PU varnish).

6. The method according to claim 1, wherein for alternative or additional pretreatment, the decorative surface (2) is corona-treated, roughened, etched with an acid or alkaline solution, powder-coated, plasma-treated, flame-treated and/or subjected to fluorination.

7. The method according to claim 1, wherein a mixture comprising a lacquer and a stain additive (7) is applied as the coating agent.

8. The method according to claim 7, wherein kaolin, chalk, alumina, silica, mica, quartz sand, silicate, silanized materials, glass spheres, glass powder, cellulose or natural fibers are used as the stain additive (7).

9. The method according to claim 7, wherein kaolin is used in a hydrated and/or calcined form as the stain additive (7).

10. The method according to claim 7, wherein the percent weight of the stain additive (7) in the coating agent is 10% by weight to 60% by weight.

11. The method according to claim 1, wherein a coating agent is used that comprises a lacquer based on an aminoplast, in particular a urea resin such as UF or MUF, of acrylate, PUR, phenol resin, nitrocellulose, or based on a mixture of at least two of the aforementioned lacquers.

12. The method according to claim 1, wherein a water-based coating agent is used.

13. The method according to claim 1, wherein the coating agent is dried by circulated air drying.

14. The method according to claim 1, wherein the coating agent is at least partially cured.

15. The method according to claim 1, wherein the coating agent is applied to the top side of the backing layer (1) using an application roller, a squeegee or a spray device.

16. A material having a ready-to-use, fully cured decorative surface (2) with a layer (6) of a coating agent with stain additives (7) applied to the top side of the decorative surface (2) that forms a porous surface and is formed to absorb and bond color particles.

17. The method according to claim 10, wherein the percent weight of the stain additive (7) in the coating agent is 20% by weight to 50% by weight.

18. The method according to claim 10, wherein the percent weight of the stain additive (7) in the coating agent is 30% by weight to 50% by weight.

19. The method according to claim 14, wherein the coating agent is fully cured after drying.

20. The method according to claim 1, wherein the coating agent is at least partially cured using UV light.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] It is shown in:

[0051] FIG. 1 schematically a color-changeable decorative surface produced according to the inventive method;

[0052] Ex. 1 describes the production of a decorative surface that can be adapted in color and produced by direct printing.

[0053] Ex. 2 describes a first method for producing a color-changeable decorative surface using a roller application device;

[0054] Ex. 3 describes a second method for producing a color-changeable decorative surface using a roller application device;

[0055] Ex. 4 describes a method for producing a color-changeable decorative surface using a spray device;

[0056] Ex. 5 describes another method for producing a color-changeable decorative surface;

[0057] Ex. 6 describes a further method for producing a color-changeable decorative surface.

DETAILED DESCRIPTION

[0058] FIG. 1 shows a side view of a backing layer 1 with a ready-to-use decorative surface 2. The backing layer 1 in this case is formed as a decorative paper 3 impregnated with synthetic resin with a decorative print. Arranged above the decorative paper is an overlay 4 which is part of the decorative surface 2. The decoration in this case shows a wood grain, but it can alternatively however also show a tile decoration, rock decoration or fantasy decoration, for example. The overlay 4 comprises a synthetic resin-saturated overlay paper that, in a cured state, is fully transparent so that the decoration is still visible.

[0059] A material board 8 is formed below the backing layer 1. The material board 8 consists of a wood composite, in this case a chipboard. Alternatively, materials consisting of other materials or other wood composite boards such as the MDF boards, HDF boards, etc. can also be used. The backing layer is securely adhered to the material board.

[0060] Moreover, additional intermediate layers can be arranged between the material board 8 and the decorative paper 3. For example another paper layer (not shown here) such as kraft paper can also be arranged instead of a wood composite board.

[0061] Just like the overlay 4, the decorative paper 3 has also been impregnated with synthetic resin. In this case, a melamine was used for both layers. The synthetic resin surface 2 was adhered to the material board in a short cycle process (not shown here) under the effect of pressure and heat, and in so doing was fully cured. In this case, a structural decoration (not shown here) was stamped into the surface of the overlay 4.

[0062] In order to subsequently modify the color of the synthetic resin surface 2, i.e., render it stainable, the synthetic resin surface was pretreated. To accomplish this, a liquid adhesion promoter 5 was applied in this case to the structured synthetic resin surface 2. This is done using a spray device (not shown here), alternatively for example using a roller device. The adhesion promoter 5 was then gelled.

[0063] Subsequently, a layer 6 of a coating agent was applied to the adhesion promoter 5. The coating agent is formed as a UV lacquer based on acrylate. In this case, it contains a stain additive 7 that however is optional. It was applied using a roller arrangement (not shown here) onto the adhesion promoter 5. After applying the layer 6, it and the adhesion promoter 5, also based on a UV lacquer, were fully cured using UV light.

[0064] Alternatively or in addition, it is also possible to apply the adhesion promoter 5 together with the coating agent as a mixture onto the decorative surface 2. Alternatively or in addition, a mechanical pretreatment of the decorative surface 2 could also have been done. This would be possible for example through a corona pretreatment, fluorination, through grinding, through etching, or through a plasma or flame treatment. Of course, the coating agent application would also be possible without adhesion promoter, or respectively pretreatment.

[0065] In addition to the improved bonding ability to the decorative surface, or respectively of the stain to the coating agent, the existing stain additives 7 form the layer 6 as a porous surface (not shown here), i.e., the stain additives 7 are present in the layer 6 distributed very evenly. Kaolin (not shown here) is mixed in the coating agent as the stain additive 7. The percent weight ratio between the liquid coating agent and kaolin was 1:1 before application.

[0066] To subsequently change the color of the synthetic resin surface 2, a stain, for example solvent-based, water-based or oil-based is applied to the layer 6. The colorings in the stain are absorbed by the coating agent layer, or respectively bond chemically thereto. Moreover, the color particles from the stain penetrate into the coating agent layer due to the porosity. The solvents evaporate. This changes the overall colored appearance of the synthetic resin surface 2. Finally, a fixing layer can be applied.

[0067] In the aforementioned example, a ready-to-use lacquer surface can also be alternatively used instead of the synthetic resin surface. This can include for example printed paint pores that represent a structural decoration.

Example 1

[0068] In a further exemplary embodiment, a decorative surface produced in direct printing is provided. The decorative surface is fully cured and ready to use. To produce the decorative surface, a wood composite board, in this case an MDF board, was prepared by grinding and priming processes for direct printing. The color decoration is printed directly on the primer layer(s), in this case by roller printing. Alternatively, the color decoration could also be printed by digital printing. Finally, the color decoration was provided with a protective layer that consists of several thin layers of a clear varnish. The clear lacquer is based on a UV acrylate lacquer.

[0069] Moreover, a structuring of the surface was created over the protective layer. All the layers of the decorative surface were fully cured. This was done in this case using UV light.

[0070] Then a coating agent is applied to the ready-to-use decorative surface produced in this manner. Application is accomplished using an application roller. In this case as well, the coating agent includes an optional stain additive so that the coating agent is for example a lacquer/kaolin mixture that was mixed at a weight ratio of 1:1. Optionally, the decorative surface can be pretreated using a corona treatment for particularly effective adhesion of the coating agent on the decorative surface. A UV acrylate lacquer was used for the lacquer of the coating agent. Then the coating agent was applied using a spray device, alternatively a roller device, to the pretreated decorative surface, dried and then fully cured using UV light. The wood composite board with the directly printed decorative surface and the layer of coating agent arranged on the surface can now be stained; i.e., a stain containing color particles can be applied to the surface both industrially as well as by the end customer. This can for example be done using a cylinder, a brush, a roller or a cloth as well. In so doing, the color particles are bond to the coating agent, or respectively penetrate into the porous surface of the coating agent formed by the kaolin and are fixed there. After removing the excess stain and drying the stain, there is a change in color to the decorative surface, wherein the decoration is still visible. To protect the stained coating agent layer, another protective layer (fixing layer) such as a lacquer layer can also be finally applied.

[0071] Another initial product for producing a subsequently changeable decorative surface can for example be finish films. These have for example a backing layer consisting of paper or plastic. A decoration is printed on this backing layer, and a protective layer is arranged above the decoration. The decoration and the protective layer are completely dried, or respectively cured.

[0072] Normally, a finish film is adhered/laminated using a lamination system and for example with a hot melt adhesive to a material such as a wood composite board. The decorative surface of the finish film can also be subjected to a pretreatment corresponding to the above-described examples before or after lamination, so that a layer of the coating agent with stain additives is then applied, dried, or respectively fully cured so that the finish film has a subsequently color-changeable decorative surface.

Example 2

[0073] Starting with a ready-to-use decorative surface with a color decoration and a structural decoration based on lacquer or based on synthetic resin, a coating agent is rolled onto the ready-to-use decorative surface using a roller application device. The coating agent is formed as an aqueous solution. The coating agent forms in particular an at least largely transparent layer so that the color decoration remains visible even through the coating agent layer. As the coating agent, for example a Hydro Special stain FT by the company Hesse or a Hydro UV stain FT also by the company Hesse can be used. When applying, between approximately 8 g/m.sup.2 and 14 g/m.sup.2 is rolled onto the decorative surface. Then the layer of coating agent is dried during which the water evaporates. Drying is done at approximately 40 C. and over approximately 20 sec. Drying can for example be performed by drying with circulating air.

[0074] In order to increase the strength, such as for example the scratch resistance of the layer consisting of coating agent, the dried coating agent layer is at least partially cured using UV light, i.e., at least initially cross-linked (gelled). This allows the backing layers with the decorative surfaces and the coating agent layer to be easily stackable and transported without them sticking together. The at least partial curing is done in particular using a UV lamp based on gallium.

[0075] Rolling is done with a rubber roller, in particular a sponge rubber roller. The rubber roller has for example a hardness between 30-40 Shore A.

Example 3

[0076] In contrast to producing the ready-to-use decorative surface from example 2, the production method from example 3 only differs in terms of the coating agent used. In this second possible embodiment of the method, a UV primer by the company Hesse is used as the coating agent, in particular UG 7541-FT. This is applied at an amount between 10 g/m.sup.2 to 15 g/m.sup.2.

Example 4

[0077] In this case as well, starting from a ready-to-use decorative surface with a color decoration and a structural decoration based on lacquer or based on artificial synthetic resin, a coating agent is applied. The application is carried out using a spray device. For example Hydro special stain or the solvent-based stain FT by the company Hesse is used as the coating agent. The coating agent is applied at an amount between 15 g/m.sup.2 to 30 g/m.sup.2. This is followed by drying over approximately 3 min. to 4 min. Drying can be performed by drying with circulating air. This is preferably done at temperatures of 30 C. to 40 C.

[0078] Finally, the coating agent is at least partially cross-linked (gelled) or fully cured with UV light corresponding to examples 2 and 3.

[0079] The decorative surfaces from examples 2 to 4 are prepared for applying a stain after curing, or respectively partial curing (gelling, partial cross-linking). All commercially available colored stains that for example are provided for wood or wood-containing materials are suitable as the stain. Accordingly for example water-based stains, oil-based stains or stains with other solvents can be used. Moreover, preferably colored stains are used that at least contain a slight amount of a binder (polymer) for improving the bond to the coating agent layer.

[0080] After applying and drying and possibly curing the stain with the associated change in color of the decorative surface, a fixation layer that moreover functions as a protective layer can be applied. The fixation layer prevents the stain layer from being removed from the coating agent layer under stress (mechanical, chemical).

[0081] The fixation layer can also be applied by means of roller application or a spray device. In a particularly preferred embodiment of roller application that in particular can be done industrially, first a layer of Hesse UV topcoat, such as UU 7333 at an amount of approximately 3 g/m.sup.2 to 5 g/m.sup.2 is applied and gelled with UV light, for example with a mercury-based UV lamp at 80 W. Then a second layer of the same topcoat is applied using the same application amount. Both layers are then cured using the aforementioned UV lamp, wherein to do this, for example 2-3 curing passes can also be carried out.

[0082] To apply the fixation layer by a spray device, in particular the following lacquers by the company Hesse are suitable: [0083] 1. UV topcoat, such as UU 7333 at an application amount of 3 g/m.sup.2 to 5 g/m.sup.2 in two layers corresponding to the above-described roller application; [0084] 2. Hydro UV single coat paint HUE 8656 with an application amount of 100 g/m.sup.2 to 120 g/m.sup.2, [0085] 3. Hydro top seal HE 65 09 with a single-layer application and an application amount of 100 g/m.sup.2 to 120 g/m.sup.2. [0086] 4. PUR multicoat lacquer DE 4503 with an application amount of 100 g/m.sup.2 to 120 g/m.sup.2.

[0087] The lacquers are dried and/or cured corresponding to their specifications, or respectively for example gelled between the individual application passes in the event of multilayer application.

[0088] An alternate color change can for example be carried out using a lacquer layer instead of a stain. In this case, a lacquer layer, in particular a colored lacquer, is applied to the at least partially cured coating agent layer and dried and/or cured, for example using UV light.

[0089] The coating agent layer functions inter alia as an adhesion promoter, both when applying the stain as well as when applying the lacquer. Consequently, the coating agent is formed to adhere to the ready-to-use decorative surface of synthetic resin or lacquer, or respectively to form a bond with the decorative surface. On the other hand, the coating agent layer enables the stain, or respectively the lacquer application to adhere to it, or respectively the option of forming a bond with its surface.

Example 5

[0090] In a lacquer application alternative to the stain application on the coating agent layer, the coating agent layer also prevents the lacquer from sagging so that a structured colored surface can be produced when there is a structured surface that already has a slight amount of colored lacquer. This renders the lacquer application on the coating agent layer particularly suitable to produce for example surfaces such as white ash, etc. in which the pore structure of the surface remains largely retained but corresponds in color to the lacquer color. The surfaces obtained thereby are very similar to color painted real wood surfaces with pore structures, and are visually and haptically superior to the known surfaces produced for example using of film. Lacquering the coating agent layer can in particular be used for interior construction surfaces such as for example door surfaces.

Example 6

[0091] Another exemplary embodiment for producing a color-changeable decorative surface provides applying at least one layer of a coating agent onto a ready-to-use decorative layer consisting of lacquer or synthetic resin. When using a coating agent without a stain additive, for example a multicoat lacquer based on acrylic resins that can be used as a primer, for example the coating agent Hydro-UV multicoat lacquer HUE 8656X by the company Hesse-Lignal can be used.

[0092] The coating agent is applied at an amount between 10 g/m.sup.2 to 30 g/m.sup.2. Application is done in particular by a roller application using a rubber roller. The rubber roller preferably has a Shore A hardness of 40 (Shore A 40).

[0093] Then the coating agent layer is dried and cured, preferably at temperatures between 60 C. and 180. The drying time is between 10-20 sec.

[0094] The aforementioned coating agent without a stain additive also forms a ready-to use stainable surface after drying and curing that has sufficient porosity for subsequently applied color particles to be able to accumulate in and on the outer coating agent layer. Curing is done in particular with UV light, for example a mercury UV lamp with 100-400 MJ/m.sup.2. For very even curing, preferably 5 mercury UV lamps of 120 W each are used.

[0095] To subsequently modify the color of this decorative surface, for example conventional stains based on water or other solvents can be used. Accordingly for example, the stain Parquet-Colour by the company Hesse-Lignal can be used. The stained and dried surface can moreover be subsequently resealed with a corresponding protective layer. For this, a multicoat lacquer based on a two-component PUR acrylic resin lacquer is useful. Accordingly for example the coating agent PUR SUN-CAPE DE 4800X by the company Hesse-Lignal can be used.

[0096] When the coating agent layer is applied onto a decorative surface that is subsequently bonded to a material such as for example when applied to a laminate (HDL, CPL, etc.), the stainable decorative surface can be laminated onto the material. This is preferably done using a PUR hot melt adhesive at 130 C.+/10 in a calender with a linear pressure between 50 N/m and 80 N/m. The preferred parameters ensure that the laminated decorative surface can also be stained even after lamination.