Method for the Production of at Least One Carrier Material Provided With a Print Decoration

Abstract

Provided is a method for the production of at least one carrier material provided with a print decoration. The print decoration is applied to the at least one carrier material by means of digital printing. The ink used for digital printing is a water-soluble CRYK ink containing at least one cyan pigment, at least one red pigment from the group of quinacridone pigments, the yellow pigment PY181, and at least one black carbon pigment.

Claims

1. A method for the production of at least one carrier material provided with a print decoration, wherein the print decoration is applied to the at least one carrier material by means of digital printing, wherein the ink used for digital printing is a water-soluble CRYK ink containing at least one cyan pigment, at least one red pigment from the group of quinacridone pigments, the yellow pigment PY181 and at least one black carbon pigment.

2. The method according to claim 1, wherein the at least one cyan pigment is a copper phthalocyanine pigment, preferably C.I. Pigment Blue 15:3 or C.I. Pigment Blue 15:4, more preferably C.I. Pigment Blue 15:3.

3. The method according to claim 1, wherein the at least one red pigment is selected from the group of quinacridone pigments containing 2,9-dimethylquinacridone (pigment red 122), 2,9-dichloroquinacridone (pigment red 202), mixed crystal of quinacridone and 4,11-dichloroquinacridone (pigment red 207) and 3,10-dichloroquinacridone (pigment red 209), wherein pigment Red 207 is in particular preferred.

4. The method according to claim 1, wherein the black carbon pigment is a carbon black pigment, in particular selected from the group consisting of Regal™ 400R, Mogul™, L, Elftex™ 320 from Cabot Co, or Carbon Black FW18, Special Black™ 250, Special Black™ 350, Special Black™ 550, Printex™ 25, Printex™ 35, Printex™ 55, Printex™ 90, Printex™ 150T from DEGUSSA Co, MA8 from MITSUBISHI CHEMICAL Co, and C.I. Pigment Black 7 and C.I. Pigment Black 11.

5. The method according to claim 1, wherein the pigment concentration is more than 2% by weight, preferably between 2.2 and 6% by weight, more preferably between 2.5 and 5% by weight, based on the total weight of the ink.

6. The method according to claim 1, wherein the water content in the ink is at least 50%, preferably at least 55%.

7. The method according to claim 1, wherein the ink contains at least one organic solvent in a proportion of less than 45%, preferably less than 43%.

8. The method according to claim 1, wherein the at least one carrier material to be printed is a base paper.

9. The method according to claim 8, wherein the at least one base paper is at least one paper web without impregnation with at least one ink-receiving layer containing white pigments.

10. The method according to claim 1, wherein the at least one carrier material to be printed is pre-treated, impregnated paper.

11. The method according to claim 10, wherein the at least one impregnated paper is an impregnated paper web having at least one primer layer and at least one ink receiving layer containing white pigments.

12. The method according to claim 8, wherein the paper is impregnated with at least one resin after printing.

13. The method according to claim 8, wherein the printed and impregnated paper is pressed with a material board, at least one protective paper and optionally a backing paper.

14. The method according to claim 1, wherein the at least one carrier materials is at least one material board, in particular a wood material board, such as MDF board, HDF board, OSB board, chipboard or WPC, plastic board such as SPC (stone plastic composite), cement fibre board, which has at least one primer containing white pigments.

15. The method according to claim 14, wherein the printed wood-based panel is provided with at least one wear protection layer.

Description

DESCRIPTION OF THE INVENTION

Example 1a: Printing on Base Paper

[0144] A raw paper (paper weight: 80 g/m.sup.2) is unrolled from an unwinding device.

[0145] Application of a decorative layer by digital printing using a CRYK ink with the following composition: PB15:3 2.0 wt %, PR207 2.0 wt %, PY181 2.0 wt %, PBL7 2.0 wt %; glycol 41%, water 51%; density 1.07 g/cm.sup.3; VOC 29%, 305 g/l; flash point >100° C.

[0146] The printing inks are applied in a quantity between 5 and 10 g/m.sup.2.

[0147] After printing, the printed paper can be provided with a melamine-formaldehyde resin layer as a protective layer. This protective layer serves to protect the printed decorations and enables intermediate storage.

[0148] The paper is then dried in a convection dryer or by NIR (near infrared) to a moisture content of about 6 wt % so that the resin layer is in the B state.

Example 1b: Printing on Base Paper With Ink-Receiving Layer

[0149] A base paper (paper weight: 80 g/m.sup.2) is unrolled from an unwinding device. A pigmented (TiO.sub.2) ink receptive layer (synthetic silicate with polyvinyl alcohol as binder) (layer thickness 40 μm; after drying at 125° C. dry basis weight 4 g/m.sup.2) and a primer layer are then applied and the layer structure is dried.

[0150] After drying, a decorative layer is applied to the paper thus obtained (paper weight: 80 g/m.sup.2) by digital printing using a CRYK ink with the above composition. The inks are applied in an amount between 5 and 10 g/m.sup.2.

[0151] After printing, the printed paper can be provided with a melamine-formaldehyde resin layer as a protective layer. This protective layer serves to protect the printed decorations and enables intermediate storage.

[0152] The paper is then dried in a convection dryer or by NIR (near infrared) to a moisture content of about 6 wt % so that the resin layer is in the B state.

Example 2a: Printing of a First Impregnate With Ink-Receiving Layer

[0153] The paper to be printed is impregnated on the front and back with a liquid melamine resin in an impregnation device. In the process, approx. 50 g melamine resin/m.sup.2 with a solids content of approx. 50% is applied.

[0154] Subsequently, a pigmented (TiO.sub.2) ink receptive layer (synthetic silicate with polyvinyl alcohol as binder) (layer thickness 40 μm; after drying at 125° C. dry basis weight 4 g/m.sup.2) and a primer layer are applied and the layer structure is dried.

[0155] After drying, a decorative layer is applied to the resulting impregnate (paper weight: 80 g/m.sup.2) by digital printing using a CRYK ink with the above composition. The inks are .sup.2applied in an amount between 5 and 10 g/m.

[0156] After printing, the printed paper can be coated with a melamine-formaldehyde resin layer as a protective layer.

[0157] The paper is then dried in a convection dryer or by NIR (near infrared) to a moisture content of about 6 wt % so that the resin layer is in the B state.

Example 2b: Printing of a Second Impregnate With Ink-Receiving Layer

[0158] The paper to be printed is coated in an application device with melamine resin powder in a quantity of 25 g/m.sup.2 using tribo guns. The melamine resin powder contained the usual auxiliary materials such as hardener, release agent, etc. Then the powder is melted by infrared radiation.

[0159] Subsequently, a pigmented (TiO.sub.2) ink receptive layer (synthetic silicate with polyvinyl alcohol as binder) (layer thickness 40 μm; after drying at 125° C. dry basis weight 4 g/m.sup.2) and a primer layer are applied and the layer structure is dried.

[0160] After drying, a decorative layer is applied to the resulting impregnate (paper weight: 80 g/m.sup.2) by digital printing using a CRYK ink with the above composition. The inks are applied in an amount between 5 and 10 g/m.sup.2.

[0161] After printing, the printed paper can be coated with a melamine-formaldehyde resin layer as a protective layer.

[0162] The paper is then dried in a convection dryer or by NIR (near infrared) to a moisture content of about 6 wt % so that the resin layer is in the B state.

Example 2c: Printing of a Third Impregnate

[0163] The paper to be printed is impregnated on the front and back with a melamine resin in an impregnation device. In the process, approx. 50 g melamine resin/m.sup.2 with a solids content of approx. 50% is applied.

[0164] Before the dryer, the resin on the side of the impregnate to be printed is removed with a special device (e.g. a knife doctor blade) so that fibres remain free to take up the printer's ink.

[0165] After drying, a decorative layer is applied to the resulting impregnate (paper weight: 80 g/m.sup.2) by digital printing using a CRYK ink with the above composition. The inks are applied in an amount between 5 and 10 g/m.sup.2.

[0166] Further drying of the printed impregnate is not necessary, as the digital printing ink only introduces a small amount of moisture.

Example 3: Printing a Plate With Liquid Overlay

[0167] An HDF board (fibreboard with increased bulk density) is first pre-coated with an aqueous synthetic resin (melamine-formaldehyde resin). The application quantity is 20-50 g resin liquid/m.sup.2 (solids content: approx. 55%). The resin contains the usual additives such as wetting agents, hardeners, release agents and defoamers. The applied resin is then dried in a convection dryer or a near-infrared oven to a moisture content of approx. 20%. Then several coats of a water-based pigmented base coat are applied (5-8×). After each application, the base coat is dried using a convection dryer or a near-infrared dryer.

[0168] In the following, the base coated plate is printed with a motif using a digital printer. Approx. 6-8 g/m.sup.2 of the water-based CRYK digital printing ink is used.

[0169] After drying of the decorative layer, approx. 70 g of melamine resin fl. (solids content: 55% by weight) containing the usual additives (hardener, wetting agent, etc.) is applied to the printed board surface. A melamine resin is also applied to the underside of the board with the first roller application unit (application quantity: 60 g resin fl./m.sup.2, solids content: approx. 55% by weight).

[0170] Afterwards 14 g corundum/m.sup.2 (F 200) are sprinkled on the surface with a sprinkling apparatus. A distance of approx. 5 m to the dryer allows the corundum to sink into the melamine resin. Then the board passes through a circulating air dryer. Then a melamine resin layer (solids content: 55% by weight) is applied in a quantity of 25 g/m.sup.2. This also contains the usual additives. A melamine resin is also applied to the underside of the board using a roller application unit (application quantity: 50 g resin fl./m.sup.2, solids content: approx. 55% by weight). Again, the board is dried in a circulating air dryer.

[0171] Then a melamine resin is applied to the surface of the board, which also contains glass beads. These have a diameter of 60-80 μm. The application quantity of the resin is approx. 20 g melamine resin fl./m.sup.2 (solids content: 61.5 wt %). In addition to the hardener and the wetting agent, the formulation also contains a release agent. The application quantity of glass beads is approx. 3 g/m.sup.2. A melamine resin is also applied to the underside of the board using a roller application unit (application quantity: 40 g resin fl./m.sup.2, solids content: approx. 55 wt %). The board is again dried in a circulating air dryer and then coated again with a melamine resin containing glass beads. Cellulose (Vivapur 302) is included as a further component. Again approx. 20 g melamine resin fl./m.sup.2 (solids content: 61.6 wt %) are applied. Again approx. 3 g glass beads and 0.25 g cellulose/m.sup.2 are applied. In addition to the hardener and the wetting agent, the formulations also contain a release agent. A melamine resin is also applied to the underside of the board using a roller application unit (application quantity: 30 g resin fl./m.sup.2, solids content: approx. 55% by weight). The resin is again dried in a circulating air dryer and then the board is pressed in a short cycle press at 200° C. and a pressure of 400 N/cm.sup.2. The pressing time was 10 seconds. A press plate with a wooden structure was used as the structure generator.

Example 4: Printing a Plate With Powder Overlay

[0172] In a production line, 8 mm HDF is separated, cleaned of dust with the help of brushes and then transported further via roller conveyors.

[0173] In an application device, they are then coated with melamine resin powder in an amount of 25 g/m.sup.2 using tribo guns. The melamine resin powder contained the usual auxiliary materials such as hardener, release agent, etc. The powder is then melted-on by infrared radiation.

[0174] The base coated panel is then coated with a colour base coat multiple coats with subsequent intermediate drying (circulating air). The colour is a mixture of casein and pigment (titanium dioxide). The application quantity per application is approx. 5 g fl./m.sup.2. The application is repeated at least five times. This is followed by the application of a primer (application quantity: 10-20 g fl./m.sup.2) with circulating air drying.

[0175] The plate is then printed with a digital printer using the aqueous CRYK ink. The application quantities of ink are 3 to 15 g fl./m.sup.2. The ink is dried via IR radiation or circulating air.

[0176] Corundum is sprinkled onto the print with a sprinkling device (application quantity: 20 g corundum/m.sup.2, F 180).

[0177] Afterwards, melamine resin powder is again applied with a tribo gun (application quantity: 80 g/m.sup.2). This melamine resin powder is again gelled with the aid of an IR radiator. The melamine resin powder contained the usual auxiliary materials such as hardeners, release agents, etc.

[0178] Then the board is pressed in a KT press together with a counter-impregnate. The pressing conditions were: T=200° C., p=40 kg/cm.sup.2 and t=25 sec. The pressed board was then visually inspected and no abnormalities were found. The surface tests subsequently carried out in accordance with DIN EN 15468-August 2018 also showed no abnormalities. All requirements of stress class 32 were met.