A METHOD FOR MANUFACTURING A DÉCOR PAPER OR FOIL AND A DÉCOR PAPER OR FOIL

Abstract

A method for manufacturing a dcor paper or foil may involve providing a paper layer or a foil. The paper layer or the foil may be provided with a first printed motif that is provided by a first printing technique. A second printed motif may be provided above the first printed motif. The second printed motif may be provided by a second printing technique. The paper layer or the foil may be provided with an ink receiver layer.

Claims

1. A method for manufacturing a dcor paper or foil, the method comprising: providing a paper layer or a foil; providing the paper layer or the foil with a first printed motif, wherein the first printed motif is provided by a first printing technique; providing a second printed motif above the first printed motif, wherein the second printed motif is provided by a second printing technique; and providing the paper layer or the foil with an ink receiver layer.

2. The method according to claim 1, wherein the ink receiver layer is provided between the first printed motif and the second printed motif.

3. The method according to claim 2, wherein the ink receiver layer is transparent and/or translucent.

4. The method according to claim 3, wherein the ink receiver layer causes a difference of color variation of the first printed motif, measured before and after providing the ink receiver layer that is lower than 2 on the same spot.

5. The method according to claim 1, wherein the ink receiver layer comprises a binder and an ink destabilizing agent.

6. The method according to claim 1, wherein the ink receiver layer is free from any pigment or water absorbing substance.

7. The method according to claim 1, wherein the ink receiver layer comprises a pigment.

8. The method according to claim 1, wherein the ink receiver layer is provided according to a predetermined pattern.

9. The method according to claim 8, wherein the predetermined pattern is in register with the first printed motif and/or with the second printed motif.

10. The method according to claim 1, wherein the second printing technique is different from the first printing technique.

11. The method according to claim 1, wherein one of the printing techniques is an analog printing technique.

12. The method according to claim 1, wherein the first printed motif is a solid color motif.

13. The method according to claim 1, wherein the first printed motif is a wood or stone imitating pattern.

14. The method according to claim 1, wherein at least one of the first printed motif and the second printed motif comprises metallic, pearlescent, and/or white pigments.

15. The method according to claim 1, wherein at least one the first printed motif and the second printed motif comprises a homogeneous distribution of pigment over the entire paper layer.

16. The method according to claim 1, wherein in the first printed motif has an average color variation that is below 1.

17. The method according to claim 16, wherein the dcor paper or foil provided with the first printed motif and with the ink receiver layer shows an average color variation on the surface of the paper that is below 1.

18. The method according to claim 3, wherein the ink receiver layer causes a difference of color variation of the first printed motif, measured before and after providing the ink receiver layer that is lower than 20% on the same spot.

19. The method according to claim 1, wherein the first printed motif is obtained by printing at least a first ink that penetrates the paper layer or the foil such that the paper layer or the foil is fully colored by the first ink.

20. The method according to claim 19, wherein the first ink comprises a dye and/or a pigment and a wetting agent.

21.-74. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0064] With the intention of better showing the characteristics of the invention, in the following, as an example without any limitative character, several preferred forms of embodiments are described with reference to the accompanying drawings, wherein:

[0065] FIG. 1 shows in perspective a panel according to the invention;

[0066] FIG. 2 shows a section view according to the line II-II indicated on FIG. 1;

[0067] FIG. 3 on a larger scale provide a view on the area F3 illustrated in FIG. 2;

[0068] FIG. 4 shows some steps in a method for forming the panel of FIG. 1;

[0069] FIG. 5 shows some steps in an alternative method for forming the panel of FIG. 1.

DESCRIPTION OF NON-LIMITING EMBODIMENTS

[0070] FIGS. 1 and 2 illustrate a decorative panel 1 comprising a substrate 2 made of a wood-based material, preferably MDF or HDF and a top layer 3 provided with a dcor pattern 4, in this case imitating a wood dcor. The panel 1 can have the shape of a rectangular and oblong floor panel, with a pair of long sides 5 and a pair of short sides 6. In this case the panel 1 is provided at least at the long sides 5 with coupling means 7 allowing to lock the respective sides 5 together with the sides of a similar panel both in a direction R1 perpendicular to the plane of the coupled panels, as in a direction R2 perpendicular to the coupled sides and in the plane of the coupled panels. As illustrated in FIG. 2 such coupling means or coupling parts can basically have the shape of a tongue 8 and a groove 9, provided with additional cooperating locking means 10 allowing for said locking in the direction R2.

[0071] FIGS. 2 and 3 shows that the top layer 3 comprises dcor paper 11 and a wear layer 12 provided on top of the dcor paper 11. In the example, the wear layer 12 preferably comprises a transparent sheet of paper impregnated with resin, preferably melamine The dcor paper 11 comprises a paper layer 13 for example a dcor base paper, and a first printed motif 14 provided directly on the paper layer 13. The first printed motif 14 and is an analog printed motif and it preferably comprise a uniform color, for example grey. In the example, the first printed motif 14 comprises an average color variation (E) on the surface of the paper that is below 1, preferably below 0.5.

[0072] The dcor paper 11 further comprises an ink receiver layer 15 provided on top of said first printed motif 14. In the example the ink receiver layer 15 comprises a binder and is free from any water absorbing substance or pigment. The binder preferably comprises polyvinyl alcohol. The ink receiver layer 15 further comprise a cross linker, a metal salt and other additives like dispersant, coupling agent, wetting agent or pH modifiers. The ink receiver layer 15 is transparent so that the first printed motif 14 is visible on the top layer 3 of the panel 1 and forms part of the dcor pattern 4. The combination of the first printed motif 14 and the ink receiver layer 15 there upon has a color variation (E) with a maximum value of 2, preferably with a maximum value of 1, even more preferably with a maximum value of 0.5. In fact, the ink receiver layer 15 is sufficiently transparent to cause a difference of color variation (CIELab) of the first printed motif 14 below, measured on the same spot between before and after providing said ink receiver layer 15 that is lower than the 20%, preferably lower than the 15%.

[0073] The dcor paper further comprises a second printed motif 16, that in the example is a digitally printed motif imitating a wood nerve pattern. The second printed motif 16 is provided on the ink receiver layer 15. The second printed motif 16 and the first printed motif 14 together form the dcor pattern 4. The dcor paper 11 printed with the second printed motif 16 shows average color variation (E) on the surface of the paper that is above 0.5, preferably above 1.

[0074] FIG. 4 shows some step of a method for manufacturing the panel 1. In the method is illustrated a step S1 of providing the paper layer 13 by uncoiling it from a first roll 17. The foil 13 is then provided, on at least a top surface, with the first printed motif 14 in a first printing step S2 that involves an analogue printing technique, for example rotogravure printing via a rotogravure printer 18.

[0075] The paper layer 13 provided with the first printed motif 14 is then provided, on at least its top surface, with the inkjet receiving layer 15, for example with a rotogravure printing unit, offset printing or doctor blade or a sprayer, in a step S3.

[0076] The paper layer 13 is then provided with the second printed motif 16 in a second printing step S4. Said second printing step S4 is preferably a digital printing operation and is performed by means of a single pass printer 19 using water-based ink comprising pigments. Preferably, in this said second printing step S4 the paper is provided with an amount of dry pigment that is lower to 10 g/sqm.

[0077] After printing, the obtained dcor paper 11 is coiled again in a second roll 20 and then stocked, as indicated in step S5.

[0078] For the production of the panel 1, the dcor paper 11 can be uncoiled from the second roll 20 in a step S6 and then impregnated with a resin, preferably melamine resin, in an impregnation step S7. The dcor paper 11 can then be cut into sheets 21, in a cutting step S8. The sheet 21 of dcor paper 11 is then sandwiched between the support 2 and the wear layer 12 and then laminated to form the panel 1 under action of heat and pressure.

[0079] In FIG. 5 it is shown an alternative method that differs from that of FIG. 4 in that after the second printing step S4 the decorative foil 11 is immediately impregnated with the resin in the impregnation step S7, then cut S8 into sheets 21 which are laminated onto between substrates 2 and wear layers 12 to form panels 1.

[0080] The present invention is in no way limited to the hereinabove described embodiments, but may be realized according to different variants without leaving the scope of the present invention.

[0081] Further, as is clear from the content of the description, the present invention relates to one or more of the items as listed below, numbered from 1 to 78: [0082] 1.A method for manufacturing a dcor paper or foil (11) comprising the steps of providing a paper layer or a foil (S1), providing said paper layer or foil (13) with a first printed motif (14), wherein said first printed motif (14) is provided by means of a first printing technique (S2), providing a second printed motif (16) above said first printed motif (14), wherein said second printed motif (16) is provided by means of a second printing technique (S4), wherein the method comprises the step of providing said paper layer or foil (13) with an ink receiver layer (15). [0083] 2.The method according to item 1, wherein said ink receiver layer (15) is provided between the first printed motif (14) and the second printed motif (16). [0084] 3.The method according to item 2, wherein said ink receiver layer (15) is transparent and/or translucent. [0085] 4.The method according to item 3, wherein in case the ink receiver layer (15) is provided upon at least one between the first printed motif (14) and the second printed motif (16), it causes a difference of color variation (E) of the printed motif (14, 16) below, measured between before and after providing said ink receiver layer (16) that is lower than 2, preferably lower than 1, even more preferably lower than 0.5 on the same spot. [0086] 5.The method according to any of the preceding items, wherein the ink receiver layer comprises a binder and an ink destabilizing agent, preferably a metal salt. [0087] 6.The method according to any of the preceding items, wherein the ink receiver layer is free from any pigment or water absorbing substance. [0088] 7.The method according to any of the items from 1 to 5, wherein the ink receiver layer comprises a pigment, preferably silica. [0089] 8.The method according to any of the preceding items, wherein said ink receiver layer (15) is provided according to a predetermined pattern. [0090] 9.The method according to item 8, wherein said predetermined pattern is in register with the first printed motif (14) and/or with the second printed motif (16). [0091] 10.The method according to any of the preceding items, wherein the second printing technique (S4) is different from the first printing technique (S2). [0092] 11.The method according to any of the preceding items, wherein one of said printing techniques is an analog printing technique, preferably rotogravure, screen or flexographic printing. [0093] 12.The method according to any of the preceding items, wherein said first printed motif (14) is a solid color motif, preferably grey, white yellow, brown or beige. [0094] 13.The method according to anyone of items from 1 to 12, wherein said first printed motif (14) is a wood or stone imitating pattern. [0095] 14.The method according to any of the preceding items, wherein at least one between said first printed motif (14) and said second printed motif (16) comprises metallic, pearlescent, and/or white pigments. [0096] 15.The method according to any of the preceding items, wherein at least one between said first printed motif (14) and said second printed motif (16) comprises a homogeneous distribution of pigment over the entire paper layer. [0097] 16.The method according to any of the preceding items, wherein in that at least said first printed motif (14) comprises an average color variation (E) that is below 1, preferably below 0.5. [0098] 17.The method according to item 16, wherein dcor paper or foil provided with the first printed motif and with the ink receiver layer shows an average color variation (E) on the surface of the paper that is below 1, preferably below 0.5. [0099] 18.The method according to item 3, wherein in case the ink receiver layer (15) is provided upon at least one between the first printed motif (14) and the second printed motif (16), it causes a difference of color variation (E) of the printed motif (14, 16) below, measured between before and after providing said ink receiver layer (16) that is lower than 20% preferably lower than 15% on the same spot. [0100] 19.The method according to any of the preceding items, wherein said first printed motif (14) is obtained by printing at least a first ink that penetrates the paper layer (13) or foil such that the paper or foil is fully colored by said ink. [0101] 20.The method according to item 19, wherein said first ink comprises a dye and/or a pigment and a wetting agent. [0102] 21.The method according to any of the preceding items, wherein said second printed motif (16) is a wood or stone imitating pattern. [0103] 22.The method according to any of the preceding items, wherein said first printed motif (14) and said second printed motif (16) together form a decorative pattern (4) of the dcor paper or foil (11). [0104] 23.The method according to any of the preceding items, wherein at least one of said printing techniques is a digital printing technique. [0105] 24.The method according to item 23, wherein said digital printing technique is inkjet printing, preferably single pass inkjet printing. [0106] 25.The method according to item 23 or 24, wherein said digital printing technique is performed by printing at least a pigment containing water-based ink. [0107] 26.The method according to any of the preceding items, wherein said second printed motif (16) is in register with the first printed motif (14). [0108] 27.The method according to any of the preceding items, wherein said paper is dcor base paper. [0109] 28.The method according to any of the preceding items, wherein said starting paper layer or foil has a base weight of 40 to 130 grams per square meter, e.g. between 60 and grams per square meter. [0110] 29.The method according to any of the preceding items, wherein the obtained dcor paper has a Gurley value of between 10 and 60 seconds, and preferably between 12 and seconds. [0111] 30.The method according to any of the preceding items, wherein the obtained dcor paper (11) shows an increase of the Gurley value of less than 30% more preferably less than 20% based on the initial Gurley value of the starting paper layer (13). [0112] 31.The method according to any of the preceding items, wherein the foil is a thermoplastic foil, preferably a PVC foil. [0113] 32.The method according to any of the preceding items, wherein the first and the second printing technique are performed in line. [0114] 33.The method according to any of the preceding items, wherein said ink receiver layer is provided in a coating step performed in line with at least one of said first and second printing technique. [0115] 34.The method according to any of the preceding items, wherein said paper layer or foil is uncoiled from a first roll, provided with the first printed motif and/or the second printed motif and wound up again in a second roller. [0116] 35.A dcor paper or foil (11) comprising on one of its surfaces a first printed motif (14) and a second printed motif (16) above said first printed motif (14), wherein it comprises an ink receiver layer (15). [0117] 36.The dcor paper or foil (11) according to item 35, wherein said ink receiver layer (15) is provided between the first printed motif (14) and the second printed motif (16). [0118] 37.The dcor paper or foil (11) according to item 35 or 36, wherein said ink receiver layer (15) is transparent and/or translucent. [0119] 38.The dcor paper or foil (11) according to any items from 35 to 37, wherein the ink receiver layer comprises a binder and an ink destabilizing agent, preferably a metal salt. [0120] 39.The dcor paper or foil (11) according to any items from 35 to 38, wherein the ink receiver layer is free from any pigment or water absorbing substance. [0121] 40.The dcor paper or foil (11) according to any items from 35 to 38, wherein the ink receiver layer comprises a pigment, preferably silica. [0122] 41.The dcor paper or foil (11) according to any items from 35 to 40, wherein said ink receiver layer (15) is disposed according to a predetermined pattern. [0123] 42.The dcor paper or foil (11) according to any items from 35 to 41, wherein said predetermined pattern is in register with the first printed motif (14) and/or with the second printed motif (16). [0124] 43.The dcor paper or foil (11) according to any items from 35 to 42, wherein the first and the second printed motif are obtained via different printing techniques. [0125] 44.The dcor paper or foil (11) according to any items from 35 to 43, wherein one of said printed motifs is an analog printed motif, preferably rotogravure or flexography printed motif. [0126] 45.The dcor paper or foil (11) according to any items from 35 to 44, wherein said first printed motif (14) is a solid color motif, preferably grey, white yellow, brown or beige. [0127] 46.The dcor paper or foil (11) according to any items from 35 to 45, wherein at least one between said first printed motif (14) and said second printed motif is a wood or stone imitating pattern. [0128] 47.The dcor paper or foil (11) according to any items from 35 to 46, wherein at least one between said first printed motif (14) and said second printed motif (16) comprises metallic, pearlescent, and/or white pigments. [0129] 48.The dcor paper or foil (11) according to any items from 35 to 47, wherein at least one between said first printed motif (14) and said second printed motif (16) comprises a homogeneous distribution of pigment over the entire paper layer. [0130] 49.The dcor paper or foil (11) according to any items from 35 to 48, wherein the dcor paper or foil provided with the first and second printed motif shows an average color variation (E) on the surface of the paper that is above 0.5, preferably above 1 [0131] 50.The dcor paper or foil (11) according to any items from 35 to 49, wherein said first printed motif (14) comprises a first ink that penetrates the paper layer (13) or foil such that the paper or foil is fully colored by said ink. [0132] 51.The dcor paper or foil (11) according to item 50, wherein said first ink comprises a dye and/or a pigment and a wetting agent. [0133] 52.The dcor paper or foil (11) according to any items from 35 to 51, comprising a decorative pattern (4) that is formed by said first printed motif (14) and said second printed motif (16) together. [0134] 53.The dcor paper or foil (11) according to any items from 35 to 52, wherein at least one of said printed motif is a digital printed motif. [0135] 54.The dcor paper or foil (11) according to any items from 35 to 53, wherein said second printed motif (16) is in register with the first printed motif (14). [0136] 55.The dcor paper (11) according to any items from 35 to 54, wherein said paper is dcor base paper. [0137] 56.The dcor paper (11) according to any items from 35 to 57, wherein it shows a Gurley value of between 10 and 60 seconds, and preferably between 12 and 50 seconds. [0138] 57.The dcor foil (11) according to any items from 35 to 54, wherein the foil is a thermoplastic foil, preferably a PVC foil. [0139] 58.A method for manufacturing a panel, preferably a floor, wall or ceiling panel, of the type comprising a support and a top layer wherein the top layer comprises a dcor paper or foil according to any of the items from 35 to 57 or obtained with the method according to any items from 1 to 34, wherein the method comprises the step of providing said dcor paper (11) and the step of laminating said dcor paper on top of said substrate. [0140] 59.The method according to item 58, wherein it comprises impregnating said dcor paper (11) with a resin, preferably melamine, before said lamination step. [0141] 60.The method according to item 58 or 59, wherein said lamination step is performed through of application of heat and/or pressure. [0142] 61.The method according to any item from 58 to 60, wherein before said lamination step, said dcor paper or foil is sandwiched between the support and a wear layer. [0143] 62.The method according to item 61, wherein said wear layer comprises a sheet of paper impregnated with resin, preferably melamine, or a transparent thermoplastic sheet, preferably PVC. [0144] 63.The method according to any item from 58 to 62, wherein said substrate is made of a wood-based material, preferably HDF or MDF, or of a thermoplastic material, preferably PVC. [0145] 64.The method according to any item from 58 to 63, wherein said step of lamination provides for a laminated board and wherein the method comprises the steps of cutting said boards into multiple panels. [0146] 65.The method according to any item from 58 to 64, wherein it comprises the step of providing said panel with coupling element, preferably by milling. [0147] 66.The method according to any item from 58 to 65, wherein it comprises the steps of the method according to any item from 1 to 34. [0148] 67.A panel obtained by the method according to any of the items from 58 to 66. [0149] 68.A panel preferably a floor, wall or ceiling panel, of the type comprising a support and a top layer wherein the top layer comprises a dcor paper or foil according to any of the items from 35 to 57 or obtained with the method according to any items from 1 to 34. [0150] 69.The panel according to item 68, wherein the top layer comprises a wear layer for example a sheet of paper impregnated with resin, preferably melamine, or a transparent thermoplastic sheet, preferably PVC. [0151] 70.The panel according to item 68 or 69, wherein said substrate is made of a wood-based material, preferably HDF or MDF, or of a thermoplastic material, preferably PVC. [0152] 71.The panel according to any item from 68 to 70, wherein it comprises edges provided with coupling elements for coupling with coupling elements of adjacent panel. [0153] 72.A method for manufacturing a dcor paper or foil (11) comprising the steps of providing a paper layer or a foil (S1), providing said paper layer or foil (13) with a first printed motif (14), wherein said first printed motif (14) is provided by means of a first printing technique (S2), providing a second printed motif (16) above said first printed motif (14), wherein said second printed motif (16) is provided by means of a second printing technique (S4), wherein said second printing technique is different from said first printing technique, and wherein at least one between said first and second printed pattern is provided with at least one between a white, pearlescent, metallic or functional ink. [0154] 73.The method according to item 72, wherein one between the first and the second printing technique is a digital printing technique for printing a digital printed pattern. [0155] 74.The method according to item 73, wherein the paper or foil is provided with an ink receiver layer before being printed with the digital printing technique. [0156] 75.The method according to any of the items from 72 to 74, that comprises one or more of the features described in items from 1 to 34. [0157] 76.A method for manufacturing a dcor paper or foil (11) comprising the steps of providing a paper layer or a foil (S1), providing said paper layer or foil (13) with a first printed motif (14), wherein said first printed motif (14) is provided by means of a first printing technique (S2), providing a second printed motif (16) above said first printed motif (14), wherein said second printed motif (16) is provided by means of a second printing technique (S4), wherein said second printing technique is different from the first printing technique, wherein at least one between the first and the second printing technique is a digital printing technique for printing a digital printed pattern and wherein the paper or foil is provided with an ink receiver layer before being printed with the digital printing technique. [0158] 77.The method according to item 76, wherein the digital printing technique is the first printing technique. [0159] 78.The method according to item 76 or 77, that comprises one or more of the features described in items from 1 to 34.