Method for Producing at Least One Carrier Material Provided With a Printed Decoration

Abstract

Provided is a method for producing 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 water-soluble CRYK ink used for the digital printing has the following composition: Colour component C: at least one cyan pigment; Colour component K: at least one black carbon pigment; Colour component Y: at least one yellow pigment; or a mixture of at least two different yellow pigments or a mixture of at least one yellow pigment and at least one red pigment; and Colour component R: at least one red pigment, or a mixture of at least two different red pigments or a mixture of at least one red pigment and at least one yellow pigment.

Claims

1. A method for producing at least one carrier material provided with a printed decoration, wherein the printed decoration is applied to the at least one carrier material by means of digital printing, wherein the water-soluble CRYK ink used for digital printing has the following composition: colour component C: at least one cyan pigment; colour component K: at least one black carbon pigment; colour component Y: at least one yellow pigment; or a mixture of at least two different yellow pigments or a mixture of at least one yellow pigment and at least one red pigment; colour component R: at least one red pigment, or a mixture of at least two different red pigments, or a mixture of at least one red pigment and at least one yellow pigment; wherein a CRYK ink with only one yellow pigment as colour component Y and only one red pigment as colour component R is excluded.

2. The method according to claim 1, wherein the colour component Y is a mixture of two yellow pigments or a mixture of a yellow pigment and a red pigment or a mixture of two yellow pigments and a red pigment.

3. The method according to claim 1, wherein the colour component Y is a mixture of a first yellow base pigment and up to 30% by weight (based on the colour component Y), preferably up to 20% by weight, of a second yellow pigment, in particular a mixture of PY 150 and 20% by weight of PY181.

4. The method according to claim 1, wherein the colour component Y is a mixture of a first yellow base pigment and up to 10% by weight (based on the colour component Y), preferably up to 5% by weight, of a red pigment, in particular from the group of quinacridone pigments, in particular a mixture of PY150 and 5% by weight of PR 207.

5. The method according to claim 1, wherein the colour component Y is a mixture of a first yellow base pigment, up to 20% by weight (based on the colour component Y), preferably up to 15% by weight of a second yellow pigment and up to 10% by weight, preferably up to 5% by weight of a red pigment, in particular from the group of quinacridone pigments, in particular a mixture of PY150 and 15% by weight PY181, 5% by weight PR207.

6. The method according to claim 1, wherein the colour component R is a mixture of two red pigments or a mixture of a red pigment and a yellow pigment or mixture of two red pigments and a yellow pigment.

7. The method according to claim 1, wherein the colour component R is a mixture of a first red base pigment and up to 60% by weight (based on the colour component R), preferably up to 50% by weight, of a second red pigment, in particular from the group of quinacridone pigments, in particular a mixture of PR254 and 50% by weight of PR207.

8. The method according to claim 1, wherein the colour component R is a mixture of a mixture of a red pigment, in particular from the group of quinacridone pigments, and a yellow pigment, in particular a mixture of PR207 and PY181.

9. The method according to claim 1, wherein the colour component R is a mixture of a first red base pigment, up to 60% by weight (based on the colour component R), preferably up to 50% by weight of a second red pigment, in particular from the group of quinacridone pigments, and a yellow pigment, in particular a mixture of PR254, 50% by weight PR207 and PY181.

10. The method according to claim 1, wherein the ink is free of an orange colour pigment.

11. 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.

12. 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.

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

14. 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%.

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

Description

EXAMPLE 1A: PRINTING ON RAW PAPER

[0169] A raw paper (paper weight: 80 g/m.sup.2) is unrolled from an unwinding device.

[0170] A decorative layer is applied by digital printing using a CRYK ink with the following composition;

TABLE-US-00003 Total pigment Pigment content Solvent Water C PC 15:3 Max. 2% 42% 56% R PY254 48% Max. 7% 30% 63% PR207 48% PY181 4% Y PY 150 Max. 4% 37% 59% K PBL 7 Max. 4% 36% 60%

[0171] Glycol is the preferred solvent.

[0172] The printing inks are applied in a quantity between 5 and 10 g/m.sup.2.

[0173] The printed paper can be provided with a melamine-formaldehyde resin layer as a protective layer after printing. This protective layer serves to protect the printed decorations and enables intermediate storage.

[0174] The paper is then dried in a convection dryer or by NIR (near infrared) to a moisture content of approx. 6 wt % so that the resin layer is in the B state.

EXAMPLE 1B: PRINTING ON RAW PAPER WITH INK-RECEIVING LAYER

[0175] A raw paper (paper weight: 80 g/m.sup.2) is unrolled from an unwinding device. Then 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.

[0176] 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.

[0177] The printed paper can be provided with a melamine-formaldehyde resin layer as a protective layer after printing. This protective layer serves to protect the printed decorations and allows for intermediate storage.

[0178] The paper is then dried in a convection dryer or by NIR (near infrared) to a moisture content of approx. 6 wt % so that the resin layer is in the B state.

EXAMPLE 2A: PRINTING OF A FIRST IMPREGNATE WITH INK-RECEIVING LAYER

[0179] The paper to be printed is impregnated on the front and back with a liquid melamine resin in an impregnation device. Approx. 50 g melamine resin/m.sup.2 with a solids content of approx. 50% is applied.

[0180] 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.

[0181] 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.

[0182] The printed paper can be coated with a melamine-formaldehyde resin layer as a protective layer after printing.

[0183] The paper is then dried in a convection dryer or by NIR (near infrared) to a moisture content of approx. 6 wt % so that the resin layer is in the B state.

EXAMPLE 2B: PRINTING OF A SECOND IMPREGNATE WITH INK-RECEIVING LAYER

[0184] The paper to be printed is coated with melamine resin powder in an application device in a quantity of 25 g/m.sup.2 using tribo guns. The melamine resin powder contained the usual additives such as hardeners, release agents, etc. The powder is then melted-on by infrared radiation.

[0185] 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.

[0186] 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.

[0187] The printed paper can be coated with a melamine-formaldehyde resin layer as a protective layer after printing.

[0188] The paper is then dried in a convection dryer or by NIR (near infrared) to a moisture content of approx. 6 wt % so that the resin layer is in the B state.

EXAMPLE 2C: PRINTING A THIRD IMPREGNATE

[0189] The paper to be printed is impregnated on the front and back with a melamine resin in an impregnation device. Approx. 50 g melamine resin/m.sup.2 with a solids content of approx. 50% is applied.

[0190] 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 receive the printer's ink.

[0191] 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.

[0192] Further drying of the printed impregnate is not necessary as the digital printing ink introduces only little moisture.

EXAMPLE 3: PRINTING A BOARD WITH LIQUID OVERLAY

[0193] 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. Afterwards, the applied resin is dried in a convection dryer or a near-infrared oven to a humidity of approx. 20%. Then several coats of a water-based, pigmented base coat are applied (5-8 x). After each application, the base coat is dried using a convection dryer or a near-infrared dryer.

[0194] In the following, the base coated panel 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.

[0195] After the decorative layer has dried, 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 panel surface in a first roller application unit. 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).

[0196] 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. The board then 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 wt %). Again, the board is dried in a circulating air dryer.

[0197] 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 with 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. Another component is cellulose (Vivapur 302). 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 BOARD WITH POWDER OVERLAY

[0198] In a production line, 8 mm HDF is separated, cleaned of dust with the help of brushes and then transported further via roller conveyors.

[0199] 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 hardeners, release agents, etc. The powder is then melted-on by infrared radiation.

[0200] Afterwards, the base coated panel is coated with a colour base coat in multiple coats with subsequent intermediate drying (circulating air). The colour base coat is a mixture of casein and pigment (titanium dioxide). The application quantity per coat 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.

[0201] Afterwards, the panel is printed with a digital printer using the aqueous CRYK ink. The application rates of ink are 3 to 15 g fl./m.sup.2. The ink is dried via IR radiation or circulating air.

[0202] Corundum is sprinkled onto the print with a sprinkling device (application quantity: 20 g corundum/m.sup.2, F 180).

[0203] 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 help of an IR radiator. The melamine resin powder contained the usual additives such as hardener, release agent, etc.

[0204] The board is then 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 panel 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.