A SET OF INK FOR INKJET PRINTING A PLASTIC SUBSTRATE FOR BEING USED IN THE MANUFACTURING OF DECORATIVE PANELS, A METHOD FOR PRINTING ON A PLASTIC SUBSTRATE, A PRINTED PLASTIC SUBSTRATE AND A DECORATIVE PANEL

Abstract

A set of inks for inkjet printing on a plastic substrate for being used in a laminated panel may be pigmented inks. The set of inks may include a cyan ink, a yellow ink, a red ink, and a black ink.

Claims

1. A set of inks for inkjet printing on a plastic substrate for being used in laminated panel, the inks being pigmented inks, the set of inks comprising: a cyan ink; a yellow ink; a red ink; and a black ink.

2. The set of inks of claim 1, wherein the red ink comprises a first red ink and a second red ink; wherein the first red ink and the second red ink are different from each other.

3. The set of inks of claim 2, wherein the first red ink comprises at least one pigment selected from the group consisting of: C.I. pigment red 144, C.I. pigment red 254, C.I. pigment red 176 or mixed crystal thereof; and/or wherein the second red ink comprises at least one pigment selected from the group consisting of: C.I. pigment red 122, C.I. pigment red 202, C.I. pigment violet 19, C.I. pigment red 32 or a mixed crystal thereof.

4. The set of inks of claim 2, wherein the first red ink comprises at least one pigment having a hue angle between 350 and 42.

5. The set of inks of claim 2, wherein the second red ink comprises at least one pigment having a hue angle between 312 and 350.

6. The set of inks of claim 1, wherein the red ink comprises a pigment selected from the group consisting of: C.I. pigment red 144, C.I. pigment red 254, C.I. pigment red 176, C.I. pigment red 122, C.I. pigment red 202, C.I. pigment violet 19, C.I. pigment red 32 or a mixed crystal thereof.

7. The set of inks of claim 1, wherein the yellow ink comprises a pigment selected from the group consisting of: C.I. pigment yellow 110, C.I. pigment yellow 150, C.I. pigment yellow 93, C.I. pigment yellow 139 or a mixed crystal thereof.

8. The set of inks of claim 1, wherein the cyan ink comprises a phthalocyanine pigment.

9. The set of inks of claim 1, wherein the black ink comprises a carbon black pigment.

10. The set of inks of claim 1, wherein the black ink comprises a first black ink and a second black ink.

11. The set of inks of claim 10, wherein the second black ink comprises a pigment load lower than the first black ink.

12. The set of inks of claim 10, wherein the second black ink comprises a pigment load of between 0.1 and 2% based on a total weight of the second black ink.

13. The set of inks of claim 1, wherein the inks are water-based, UV based or hydro-UV based.

14. A method for manufacturing a printed plastic foil, for being used in laminated panel, the method comprising: providing the plastic foil; and inkjet printing a dcor on the plastic foil; wherein the inkjet printing is performed using the set of inks according to claim 1.

15. The method of claim 14, wherein the plastic foil is fabricated from a thermoplastic material.

16. The method of claim 14, wherein the dcor is a wood, stone, ceramic and/or cement imitating dcor.

17. The method of claim 14, wherein the method comprises: applying an ink receiver layer on a surface to be printed of the plastic foil before performing the inkjet printing.

18. A printed plastic foil for being used in laminated panel, wherein the printed foil comprises an inkjet printed dcor that is printed using the set of claim 1.

19. A method for manufacturing a printed plastic panel, for being used in laminated panel, the method comprising: providing the plastic panel; and inkjet printing a dcor directly on the plastic panel; wherein the inkjet printing is performed using the set of inks of claim 1.

20. A method for manufacturing a panel having a substrate and a top layer, the top layer including a dcor layer, the method comprising: printing the dcor layer using the set of inks according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.

[0040] 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:

[0041] FIG. 1 shows a color wheel with the indication of the hue angles;

[0042] FIG. 2 shows a portion of a wood dcor and two enlargements of a same detail of said wood dcor that are printed using one black ink and two black inks respectively;

[0043] FIG. 3 shows two schematic distribution of printed dots using one black ink and two black inks respectively;

[0044] FIG. 4 shows in perspective a panel according to the invention;

[0045] FIG. 5 shows a view according to the line V-V indicated on FIG. 4;

[0046] FIG. 6 shows on a larger scale provide a view on the area F6 illustrated in FIG. 5;

[0047] FIG. 7 shows some steps in a method for forming the panel of FIG. 4; and

[0048] FIG. 8 shows some steps in an alternative method for forming the panel of FIG. 1.

DESCRIPTION OF NON-LIMITING EMBODIMENTS

[0049] FIG. 4 illustrates a decorative panel 1 comprising a substrate 2 made of a thermoplastic material, preferably rigid PVC in the form of the so called SPC and a top layer 3 provided with a printed motif 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.

[0050] FIG. 5 and FIG. 6 show that the top layer 3 comprises a decorative foil 11 and a wear layer 12 provided on top of the decorative foil 11. The decorative foil 11 comprises a thermoplastic foil 13 for example made of PVC, and the digitally printed dcor 4. The decorative foil 11 further comprises an inkjet receiving layer 14. In the example the inkjet receiving layer comprises a binder and a cationic metal salts. The binder preferably comprises water-based dispersion of terpolymer vinyl chloride, vinyl acetate ethylene; water-based dispersion or copolymer vinyl chloride, vinyl acetate; water-based aliphatic PU dispersion; other non-blocking water-based acrylics dispersions. The inkjet receiving layer further comprise a cross linker, a metal salt and other additives like dispersant, coupling agent, wetting agent or PH modifiers.

[0051] In the example, the wear layer 12 is a transparent thermoplastic foil, preferably made of PVC.

[0052] Between the decorative foil 11 and the wear layer 12 is provided an adhesion layer 15 comprising water-based dispersion of terpolymer vinyl chloride, vinyl acetate ethylene; water-based dispersion or copolymer vinyl chloride, vinyl acetate; water-based aliphatic PU dispersion; other non-blocking water-based acrylics dispersions, thereby strongly improving lamination between the decorative foil and the wear layer.

[0053] FIG. 7 shows some step of a method for manufacturing the panel 1. In the method is illustrated a step S1 of providing the thermoplastic foil 13 by uncoiling it from a first roll 16. The foil 13 is then provided, on at least one surface, with the inkjet receiving layer 14, for example with a doctor blade or a sprayer, in a step S2.

[0054] The coated foil 13 is then printed (step S3) in a single pass printer 20 using pigment containing water-based inks.

[0055] After printing, the obtained decorative foil 11 is coiled again in a second roll 17 and then stocked, as indicated in step S4.

[0056] For the production of the panel 1, the decorative foil 11 can be uncoiled from second roll 17 in a step S5 and then coated with the adhesion layer 15 in a step S6. The decorative foil 11 can then be cut into sheets 18, in a step S7. The sheets 18 are then sandwiched between a support 2 and a wear layer 12 and then thermally laminated to form the panel 1.

[0057] In FIG. 8 it is shown an alternative method for manufacturing a panel 1 that differs from that of FIG. 4 in that the printed motif is provided directly on the substrate 2 instead of on a foil 13. As a consequence, also the panel 1 differs from the panel 1 in that the top layer 3 is free from the decorative foil 11, as the dcor layer is printed directly on the substrate 2.

[0058] In the variant of FIG. 8 a substrate board 2 is firstly coated with the inkjet receiver layer 14, and then printed using a single pass printer 20 using pigment containing water-based inks.

[0059] After printing, the printed substrate 2 is coated with the adhesion layer 15 and then thermal laminated with the wear layer 12.

[0060] In the examples the printed motif 4 is obtained by jetting a set of multiple inks. Said set of inks comprises six inks and comprises, preferably is constituted by: cyan, yellow, a first red ink, a second red ink, a first black ink and a second black ink.

[0061] Cyan ink comprises a phthalocyanine pigment.

[0062] Yellow ink comprises a C.I. pigment yellow 110. Alternative pigments for yellow ink, are C.I. pigment yellow 150, C.I. pigment yellow 93, C.I. pigment yellow 139 or a mixed crystal thereof.

[0063] First red ink comprises one warm red pigment having a hue angle between 350 and 42, in particular C.I. pigment red 254, as shown in FIG. 1.

[0064] Said second red ink comprises one warm red pigment having a hue angle between 312 and 350, in particular C.I. pigment red 254 as shown in FIG. 1.

[0065] Both the first and the second black ink comprise carbon black pigment. The first black ink comprises pigment load between 2 and 7% by weight and the second black ink comprises a pigment load between 0.1 and 2% by weight.

[0066] Each ink of the set comprises a viscosity below 15 mPas at a temperature between 25 and 45 C.

[0067] Each ink of the set comprises a water content between 25 to 80% by weight; 1-20% of polymer resin, preferably PUD resin or acrylic resin; 0.1 to 3% weight of surfynol 104E as wetting agent; a cosolvent in an amount of 2 to 40%, preferably 1,2 propanediol; 0-6% by weight of Dowanol DPnP; 2-40% by weight of 1,2 hexanediol; 1-10% by weight of dispersant; 0.1-1% by weight of pH adjuster.

[0068] As it is shown in FIGS. 2 to 3 the use of two black inks provides for a sharper image definition.

[0069] It is generally noted that the dimensions of the represented top layer 3 and its components is, in the figures, drawn out of scale in order to better illustrate the invention.

[0070] The invention is further disclosed by the following item list as defined by the below numbered items. [0071] 1.A set of inks for inkjet printing on plastic substrate, for example a plastic panel or a plastic foil for being used in laminated panel, preferably floor, wall or furniture panels, said inks being pigmented inks, wherein said set of inks comprises: a cyan ink, a yellow ink, at least a red ink and at least a black ink. [0072] 2.The set of inks of item 1, wherein said set of inks comprises a first red ink and a second red ink wherein said first and second red ink are different each other, for example they comprise different pigments. [0073] 3.The set of inks of item 1 or 2, wherein said first red ink comprises at least one pigment selected in the group consisting of: C.I. pigment red 144, C.I. pigment red 254, C.I. pigment red 176 or mixed crystal thereof; and/or wherein said second red ink comprises at least one pigment selected in the group consisting of: C.I. pigment red 122, C.I. pigment red 202, C.I. pigment violet 19, C.I. pigment red 32 or a mixed crystal thereof. [0074] 4.The set of inks of item 2 or 3, wherein said first red ink comprises at least one pigment having a hue angle between 350 and 42, for example wherein said first red ink comprises a mixture of pigments and wherein each of said pigments has a hue angle between 350 and 42. [0075] 5.The set of inks any of items from 2 to 4, wherein said second red ink comprises at least one pigment having a hue angle between 312 and 350, for example wherein said second red ink comprises a mixture of pigments and wherein each of said pigments has a hue angle between 312 and 350. [0076] 6.The set of inks according to any preceding items, wherein said red ink comprises a pigment selected in the group consisting of: C.I. pigment red 144, C.I. pigment red 254, C.I. pigment red 176, C.I. pigment red 122, C.I. pigment red 202, C.I. pigment violet 19, C.I. pigment red 32 or a mixed crystal thereof. [0077] 7.The set of inks according to any preceding items, wherein said yellow ink comprises a pigment selected form selected in the group consisting of: C.I. pigment yellow 110, C.I. pigment yellow 150, C.I. pigment yellow 93, C.I. pigment yellow 139 or a mixed crystal thereof. [0078] 8.The set of inks according to any preceding items, wherein the cyan pigment comprises a phthalocyanine pigment. [0079] 9.The set of inks according to any preceding items, wherein said black pigment comprises a carbon black pigment. [0080] 10.The set of inks according to any preceding items, wherein it comprises a first and a second black ink, preferably said second black ink having a lower color intensity than the first black ink. [0081] 11.The set of inks of item 10, wherein said second black ink comprises a pigment load lower than the first black ink, preferably said pigment load of the second black ink is at least 4, more preferably at least 5 times lower than the first black ink. [0082] 12.The set of inks of item 10 or 11, wherein said second black ink comprises a pigment load comprised between 0.1 and 2% based on the total weight of the ink. [0083] 13.The set of inks to any preceding items, wherein said inks are water-based, UV based or hydro-UV based. [0084] 14.A method for manufacturing a printed plastic foil, for being used in laminated panel, preferably floor, wall or furniture panels, comprising the step of providing said plastic foil and the step of inkjet printing a dcor on said plastic foil, wherein said step of inkjet printing is performed using the set of inks according to any preceding items. [0085] 15.The method of item 14, wherein the plastic foil is made of a thermoplastic material for example vinyl-based, polyolefins, or polyesters, preferably selected from the group consisting of: polyvinyl chloride (PVC), polyethylene (PE) and polypropylene (PP), polyamides (PA), polyurethane (PU), polystyrene (PS), acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate (PMMA), polycarbonate (PC), polyethylene terephthalate (PET), polyetheretherketone (PEEK) or mixtures or co-polymers thereof. [0086] 16.The method of item 14 or 15, wherein said dcor is a wood, stone, ceramic and/or cement imitating dcor. [0087] 17.The method to any of items from 14 to 16, wherein said method comprises the step of applying an ink receiver layer on the surface to be printed of said plastic foil before performing said inkjet printing. [0088] 18.A printed plastic foil for being used in laminated panel, preferably floor, wall or furniture panels, wherein said printed foil comprises an inkjet printed dcor that is printed using the set of inks of to any of items from 1 to 13 or manufactured in a method according to any of items from 14 to 17. [0089] 19.A method for manufacturing a printed plastic panel, for being used in laminated panel, preferably floor, wall or furniture panels, comprising the step of providing said plastic panel and the step of inkjet printing a dcor directly on said plastic panel, wherein said step of inkjet printing is performed using the set of inks according to any of the times from 1 to 13. [0090] 20.A method for manufacturing a panel, preferably floor, wall or furniture panels, comprising a substrate, preferably made of thermoplastic material, and a top layer, said top layer comprising a dcor layer, wherein said dcor layer is printed using the set of inks according to any of the times from 1 to 13, preferably said top layer further comprises a wear layer, for example wherein said wear layer is made of thermoplastic material.