EP3348418A1 - Decorated surface-structured wall or floor panel - Google Patents

Abstract

The present invention relates to a decorated and surface-structured wall or floor panel and a method for its production. The invention proposes a decorated and surface-structured wall or floor panel (100), comprising a support (110) made of a plastic composite material, a primer layer (120) arranged on a surface of the support, a decorative layer (10) arranged on the primer layer ( 130), a layer (140) of a radiation-curable lacquer or hotmelt arranged on the decorative layer, a structured plastic film (150) arranged on the layer of a radiation-curable lacquer or hotmelt, and a topcoat layer (160) arranged on the structured plastic film.

Description

The present invention relates to a decorated and surface-structured wall or floor panel. The present invention further relates to a method for producing a decorated and surface-structured wall or floor panel. In particular, the present invention relates to a decorated and surface-structured wall or floor panel based on a directly printed composite support.

Decorated panels are known per se, wherein the term wall panel also includes panels that are suitable for ceiling or door clothing. They usually consist of a carrier or core made of a solid material, for example a wood material, which is provided on at least one side with a decorative layer and a cover layer and optionally with other layers, for example, arranged between the decorative and cover layer wear layer. The decorative layer is usually a printed paper impregnated with a resin or a printing layer applied to the substrate using, for example, a suitable printing substrate.

From the document EP 2 829 415 A1 For example, a method of manufacturing a decorated wall or floor panel is known, wherein a carrier and then a panel are formed starting from a granular carrier material. In such a method, for example, a WPC can be used as a carrier material.

The production of the panels and the panels themselves may under certain circumstances still offer room for improvement. Potential for improvement may in particular be provided with regard to the applicability of the end user.

To improve the realistic impression of the panels, it is known from the prior art to understand these with a surface structure in order to achieve a haptic effect modeled on a natural material. It may be provided, for example, that in a wood decor, the structure of the grain is formed by a matching with the visual representation of the wood grain surface structure.

It is therefore the object of the present invention to provide a surface-structured decorated wall or floor panel which, with good properties, enables improved applicability. In addition, it is the object of the present invention to provide a method for producing a surface-structured decorated wall or floor panel based on a directly printed composite support.

This object is achieved by a decorticated and surface-structured panels having the features of claim 1. This object is further achieved by a method having the features of claim 11. Preferred embodiments of the invention are specified in the dependent claims, in the description or the figures, wherein Further features described or shown in the subclaims or in the description or the figures, individually or in any combination, may constitute an object of the invention, if the context does not clearly indicate otherwise.

For the purposes of this invention is a composite carrier created from a suitable plastic with the addition of a filler or solid material plate. In this case, the filler or the solid material may be both organic in nature, such as Vegetable fibers or meal, animal fibers such as animal hair, wood fibers or flour, as well as inorganic nature such as mineral in nature. Examples include minerals, mineral fibers or glass fibers. Likewise, synthetic fibers may be included as a filler.

• einen Träger aus einem Kunststoffkompositmaterial,
• eine auf einer Oberfläche der Trägerplatte angeordnete Primer-Schicht,
• eine auf der Primer-Schicht angeordnete Dekorschicht,
• eine auf der Dekorschicht angeordnete Schicht eines strahlungshärtbaren Lackes oder Hotmelts,
• eine auf der Schicht eines strahlungshärtbaren Lackes oder Hotmelts angeordnete strukturierte Kunststofffolie, sowie
• eine auf der strukturierten Kunststofffolie angeordnete Decklackschicht.

With the invention, a decorated and surface-structured wall or Bodenpaneel comprising

• a carrier made of a plastic composite material,
• a primer layer disposed on a surface of the support plate,
• a decorative layer disposed on the primer layer,
• a layer of a radiation-curable lacquer or hotmelt arranged on the decorative layer,
• a structured plastic film arranged on the layer of a radiation-curable varnish or hotmelt, and
• a topcoat layer disposed on the patterned plastic film.

For the purposes of the invention, the term "decorated wall or floor panel" or "decorative panel" is to be understood, in particular, as wall, ceiling, door or floor panels, which have a decorative pattern applied to a carrier panel and a decoration pattern. Decorative panels are used in a variety of ways, both in the field of interior design of rooms, as well as decorative cladding of buildings, for example in exhibition construction. The decorative panels often have a decor that is intended to recreate a natural material.

Examples of such modeled natural materials or decorative patterns are wood species such as maple, oak, birch, cherry, ash, walnut, chestnut, wenge or exotic woods such as panga panga, mahogany, bamboo and bubinga.

In addition, many natural materials are modeled on stone surfaces or ceramic surfaces.

Correspondingly, a "decor template" in the sense of the present invention may be understood as meaning, in particular, such an original natural material or at least a surface of one which is to be imitated or imitated by the decor.

A "carrier" may, in particular, be understood as a layer serving as a core or as a base layer in a finished panel. For example, the wearer may already impart or contribute to the panel a suitable stability.

Accordingly, a carrier material can be understood as meaning a material which forms the carrier at least to a predominant part. In particular, the carrier can consist of the carrier material.

The carrier material may comprise, for example, a plastic-containing matrix material in which a solid material or filler having a particle size of less than or equal to 800 μm, preferably less than or equal to 600 μm, is embedded.

The matrix material serves, in particular, to take up or embed the solid material in the finished carrier. The matrix material in this case has a plastic or a plastic mixture.

Depending on the desired field of application and the desired properties of the panel, the proportions of matrix material or solid material may be selectable. As a result, a good adaptability to the desired field of application is possible become. In principle, however, it may be preferred that the proportion of the solid material is greater than or equal to the proportion of the matrix material.

Examples of plastics which may preferably serve as matrix material include in particular thermoplastic materials, for example polyethylene or polypropylene or mixtures of the aforementioned plastics. It may further be preferred that the matrix material comprises polypropylene, such as in the form of LDPE, wherein the polypropylene may comprise a mixture of a homopolymer and a copolymer. In particular, a mixture of a homopolymer and a copolymer can make particularly advantageous properties possible for the matrix material, for example by being able to be formed into a carrier in a range of ≥ 180 ° C. to ≦ 200 ° C., so that a particularly effective process control, for example with exemplary line speeds in a range of 6m / min. Furthermore, the matrix material may in principle be free of a bonding agent.

As a copolymer, for example, find such a use, which is composed of, for example, consists of propylene and ethylene as monomer units, wherein the density of the copolymer may be greater than or equal to the density of the homopolymer.

By using a homopolymer, in particular, a high melt flow rate can be made possible, wherein the melt flow rate of the homopolymer may in particular be greater than that of the copolymer. This can allow a particularly good formability of the carrier during the manufacturing process. Furthermore, the homopolymer can thereby allow a particularly good embedding of the solid material. In contrast, the copolymer can in particular serve the mechanical strength of the carrier material or of the carrier, since a copolymer often has a hardness that is comparatively high, in particular with respect to the homopolymer.

With respect to the distribution of homopolymer and copolymer, it may be preferred that the homopolymer relative to the polypropylene in a proportion of ≥ 10 wt .-% to ≤ 40 wt .-%, for example in an amount of ≥ 20 wt .-% to ≦ 30 wt .-%, is present, for example in an amount of ≥ 23 wt .-% to ≤ 28 wt .-%, and / or that the copolymer based on the polypropylene in a proportion of ≥ 60 wt .-% to ≤ 90 wt .-%, for example in a proportion of ≥ 70 wt .-% to ≤ 80 wt .-%, for example in an amount of ≥ 72 wt .-% to ≤ 76 wt .-%, is present, in particular wherein Polypropylene consists of the homopolymer and the copolymer.

With respect to the solid, which is distributed in the matrix material, this has a particle size of less than 800 .mu.m, preferably less than 600 .mu.m. As a result, the solid can be distributed very finely in the matrix material. The solid may, for example, be a wood material, such as wood flour, or other material, such as a component of the rice plant, such as rice husk, rice stem and rice husk, cellulose or a mineral material, such as stone meal, Chalk or other inorganic mineral materials. It may be particularly preferred if the solid is formed from talc, for example consists thereof. In principle, the solids may not be in the form of chips, chips or grains, that is to say in the form of powder, in a limiting manner.

With regard to the use of wood as a solid, it is therefore possible to design a so-called WPC carrier, which is basically known and has great acceptance. Thus, in particular in this embodiment, a carrier according to the invention can take place by a modification of known products.

With regard to the use of talc as a solid, it may be advantageous that, in particular in this embodiment, a high stability can be made possible. In addition, such a carrier material may allow improved moisture resistance, in particular with a reduced moisture or heat-induced swelling. Under talc is understood in a conventional manner, a magnesium silicate hydrate, which may have, for example, the chemical empirical formula Mg ₃ [Si ₄ O ₁₀ (OH) ₂ ]. It can be advantageous if the specific surface density according to ISO 4352 (BET)) of the talcum particles is in a range of ≥ 4 m ² / g to ≦ 8 m ² / g, approximately in a range of ≥ 5 m ² / g to ≤ 7 m ² / g. Furthermore, it may be advantageous if the talcum is present at a bulk density according to DIN 53468 in a range of ≥ 0.15 g / cm ³ to ≤ 0.45 g / cm ³ , approximately in a range of ≥ 0.25 g / cm ³ to ≤ 0.35 g / cm ³ . It may preferably be provided that talcum is in the form of particles having a particle size D ₅₀ in a range of ≥ 3 μm to ≦ 6 μm, preferably in a range of ≥ 4 μm to ≦ 5 μm, for example of 4.5 μm, and or that the talcum is in the form of particles having a particle size D ₉₈ in a range of ≥ 10μm to ≤ 30μm, preferably in a range of ≥ 15μm to ≤ 20μm, for example of 17μm. In order to determine the particle size distribution, basically the generally known methods, such as, for example, laser diffractometry, can be used, with which particle sizes in the range of a few nanometers up to several millimeters can be determined. Using this method, it is also possible to determine D ₅₀ or D ₉₈ values, which in each case state that 50% (D ₅₀ ) or 98% (D ₉₈ ) of the measured particles are smaller than the value specified in each case.

In a particularly preferred embodiment, it may be advantageous that the solid material to at least 50 wt .-%, about at least 80 wt .-%, in particular about at least 90 wt .-%, for example at least 99 wt .-% based on the solid material is formed by talc, wherein the matrix material in an amount, based on the carrier material, from ≥ 20 wt .-% to ≤ 70 wt .-%, for example from ≥ 30 wt .-% to ≤ 55 wt. % is present and wherein the solid material, based on the carrier material, in an amount, based on the carrier material, of ≥ 30 wt .-% to ≤ 80 wt .-%, for example from ≥ 40 wt .-% to ≤ 65 wt. % is present, and where the Support material and the solid material together, based on the carrier material, in an amount of ≥ 90 wt .-% present.

Thus, it may be advantageous that the carrier material consists to a large extent of the solid material and the matrix material. Particularly preferably, it can be provided that the matrix material and the solid material are present together, based on the carrier material, in an amount of ≥ 97% by weight, for example in an amount of 100% by weight, the carrier material thus being composed of the matrix material and the solid material.

Particularly preferably, the carrier material may consist of at least one polymeric, in particular thermoplastic, plastic, for example, as a plastic mixture as matrix material, talc and optionally an adhesion promoter. In particular, in this embodiment, a production can be particularly cost-effective and process management can be particularly simple.

For example, the carrier material may further comprise a fiber material that, based on the carrier material, in an amount of> 0 wt .-% to ≤ 20 wt .-%, in particular from ≥ 3 wt .-% to ≤ 12 wt .-%, may be present from about ≥ 5 wt .-% to ≤ 10 wt .-%. With regard to the fiber material, it may be provided that the fiber material comprises fibers which are selected from the group consisting of vegetable, animal, mineral or even artificial fibers

Alternatively, it can be provided for example for wood, in particular for wood flour, that its particle size is between> 0μm and ≤600μm with a preferred particle size distribution D ₅₀ of ≥400μm.

Furthermore, the support material can have between ≥0% by weight and ≦ 10% by weight of further additives, such as, for example, flow aids, heat stabilizers or UV stabilizers.

According to one embodiment of the invention, the carrier material may comprise, for example, a matrix material comprising a plastic, a solid material and a fiber material, the solid material being at least 50% by weight, in particular at least 80% by weight, in particular at least 95% by weight. , based on the solid material, is formed by talc, wherein the matrix material in an amount, based on the carrier material, of ≥ 20 wt .-% to ≤ 70 wt .-%, in particular from ≥ 30 wt .-% to ≤ 55 wt .-%, in particular from ≥ 35 wt .-% to ≤ 45 wt .-%, is present and wherein the solid material, based on the carrier material, in an amount of ≥ 30 wt .-% to ≤ 75 wt .-%, in particular from ≥ 40 wt .-% to ≤ 65 wt .-%, in particular from ≥ 45 wt .-% to ≤ 60 wt .-%, and wherein the fiber material, based on the carrier material, in an amount of> 0 wt. % to ≦ 20% by weight, in particular from ≥ 3% by weight to ≦ 12% by weight, for example of ≥ 5 Wt .-% to ≤ 10 wt .-% is present, and wherein the matrix material, the fiber material and the solid material together, based on the carrier material (20), in an amount of ≥ 95 wt .-%, in particular ≥ 97 wt. %.

In this case, it may be preferred for the fiber material to have fibers having a length in a range of ≦ 10 μm, preferably in a range of ≦ 5 μm, in a range of ≥ 2 μm to ≦ 5 μm, for example in a range of ≥ 3 μm to ≦ 4μm have. Surprisingly, it has been found that such fibers can provide high stability, but with significant advantages in manufacturability. Thus, this embodiment is particularly in departure from the solutions of the prior art, in which, insofar as fibers were contained in a material, have a comparatively long length in order to achieve a desired effect. Because in the prior art usually fiber lengths were used in the millimeter range. Surprisingly, it has become pointed out that, especially in the predefined embodiment of the carrier material with matrix material, solid material and fiber material in the above proportions allow fibers in the above-described range, a significant improvement in stability.

Furthermore, it may be preferred for the fiber material to have fibers which have a diameter or a thickness of ≥ 5 μm to ≦ 30 μm, for example in a range of ≥ 7 μm to ≦ 20 μm. This embodiment can also allow a significant improvement in the stability, in particular in the previously defined carrier material with matrix material, solid material and fiber material in the proportions described above, wherein processability is not or not significantly worsened by the presence of the fibers. Thus, even in this embodiment, a very high quality product without production-specific disadvantages can be made possible.

It may further be preferred that the fiber material comprises fibers selected from the group consisting of vegetable, animal, mineral or even artificial fibers. Examples of vegetable fibers include, for example, cellulose fibers, lignose fibers, as well as fibers from straw, corn straw, bamboo, leaves, algae extracts, hemp, cotton or oil palm fibers. Examples of animal fiber materials are keratin-based materials such as wool or horsehair. From the aforementioned fibers, for example, cellulose may be of particular advantage. Examples of mineral fiber materials are mineral wool or glass wool. Examples of artificial fibers include, for example, synthetic fibers such as polyester fibers or polytetrafluoroethylene (PTFE). Plant and animal fibers may have the advantage of a particularly good ecological balance, whereas mineral fibers or artificial fibers may have advantages in terms of heat and moisture resistance.

Insofar as the fiber material comprises synthetic fibers, it may be advantageous that the melting temperature of the plastic fibers is higher than the melting temperature of the matrix material. This refinement can in turn bring about production-specific advantages. For producing a carrier from the predefined carrier material, it may be advantageous to melt the carrier material or the matrix material and to form a carrier under pressure, as described below. In this embodiment, it can be prevented in such a process that the plastic fibers also melt, which could at least partially cancel the above-described advantages of the fiber material. Thus, in particular in this embodiment, a well processable manufacturing process can be made possible while ensuring the desired properties. Exemplary plastic fibers include, for example, polytetrafluoroethylene (PTFE).

The edge regions of a panel according to the invention can be structured or profiled, in order to provide in particular detachable connecting elements. In this regard, in the case of a profiling according to the invention it can be provided that a decorative and / or functional profile is introduced by means of suitable material-removing tools at least into a part of the edges of the decorative panel. In this case, a functional profile is understood, for example, to mean the introduction of a tongue and / or groove profile into an edge in order to make decorative panels connectable to each other via the introduced profilings. Particularly in the case of tongue and / or groove profiles, elastic materials are advantageous, since such profiles alone can be produced by them, which are particularly easy to handle and stable. In particular, no further materials are necessary to produce the fasteners.

A decorative substrate or primer to be provided according to the invention is applied to at least a portion of the substrate. For example, initially a primer can be applied in particular as a decorative substrate for printing processes. For example, this primer can be be applied in a thickness of ≥ 10μm to ≤ 60 microns. In this case, the primer used may be a liquid radiation-curing mixture based on a urethane or a urethane acrylate, optionally with one or more of a photoinitiator, a reactive diluent, a UV stabilizer, a rheology agent such as a thickener, radical scavenger, leveling agent, defoamer or preservative, pigment and / or or a dye.
In addition to the primer, a white colored primer may be applied. For example, the primer may have polyurethane, be designed as a polyurethane varnish, for example, and be provided with white pigments.

The decor or the decorative layer can be produced by a printing process, wherein both flexographic printing, offset printing or screen printing methods, and in particular digital printing techniques, such as inkjet method or laser printing method are suitable. The decorative layer can be formed from a particular radiation-curable ink and / or ink. For example, a UV-curable ink or ink may be used.

It is also possible, if appropriate, first to carry out pretreatment of the carrier for electrostatic discharge and, if appropriate, subsequent electrostatic charging, before printing. This may in particular serve to avoid the occurrence of blurring in the course of decor application.

The lacquer applied to the decorative layer to form a layer of a radiation-curable lacquer preferably comprises an acrylate, a diacylate, a methacrylate, a urethane, urethane acrylate or mixtures of these. In addition, such a lacquer may contain other constituents such as in particular a photoinitiator, a reactive diluent, a UV stabilizer, a rheology agent such as a thickener, a radical scavenger, a flow control agent, a defoamer or a preservative, a pigment and / or a dye. Of course, several and / or different of the aforementioned components may be contained in such a paint.

According to one embodiment of the invention, it may be provided, for example, that the paint is a diacrylate in a concentration between ≥ 20 wt .-% and ≤ 60 wt .-% and a methacrylate in a concentration between ≥ 1 wt .-% and ≤ 20 wt .-% having.

As the photoinitiator for radiation-curable varnishes or compositions used in the present invention, for example, compounds of the group selected from benzophenones such as benzophenones, 4,4-bis (diethylamino) benzophenone, and 3,3 ', 4,4'-tetramethoxybenzophenone, anthraquinones such as t-butylanthraquinones and 2-ethylanthraquinones, thioxanthones such as 2,4-diethylthioxanthone, isopropylthioxanthone and 2,4-dichlorothioxanthone; Acetophenones such as diethoxyacetophenone, 2,2-dimethoxyphenylacetophenone, 2-hydroxy-2-methyl-1-phenylpropan-1-one, benzyldimethylketal, 1-hydroxycyclohexylphenylketone, 2-methyl-2-morpholino (4-methylthiophenyl) propan-1-one , 2-methyl-1- (4-methylthiophenyl) -2-morpholino-propan-1-one, 2-benzyl-2-dimethylamino-1- (4-morpholinophenyl) -butanone and trichloroacetophenone; Benzoin ethers such as benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether and benzoin isobutyl ether; Acylphosphine oxides such as 2,4,6-trimethylbenzoyldiphenylphosphine oxides, bis (2,6-dimethoxybenzoyl) -2,4,4-trimethylpentylphosphine oxides, and bis (2,4,6-trimethylbenzoyl) -phenylphosphine oxide, methylbenzoyl formate, 1,7-bisacridinylheptane, 9 Phenyl acridine and azo compounds such as azobisisobutyronitrile, diazonium compounds, and tetracene compounds.

In this case, a photoinitiator may, for example, be present in a concentration of between 0.5 and 5% by weight in the coating composition.

A hotmelt in the context of the invention is a preferably solvent-free and at room temperature more or less solid hot melt adhesive, which is applied to the decorative layer in the hot state and produces a firm connection of the plastic film to this on cooling.

A hotmelt suitable according to the invention preferably has a base polymer and optionally a resin constituent, stabilizers, waxes and / or nucleating agents. Suitable base polymers may preferably be selected from the group consisting of polyamide, polyethylene, amorphous polyalphaolefins, ethylene-vinyl acetate copolymers, polyester elastomers, polyurethane elastomers, copolyamide elastomers and vinylpyrrolidone / vinyl acetate copolymers.

Suitable resin components may preferably be selected from the group consisting of rosin, terpene resins and hydrocarbon resins.

Suitable stabilizers may preferably be selected from the group consisting of antioxidants, such as phenols or peroxide decomposers, metal deactivators and light stabilizers.

As waxes, a hotmelt usable according to the invention may preferably comprise beeswax, fruit wax or carnauba wax, as well as synthetic or partially systhetic waxes.

According to one embodiment of the invention, the structured plastic film may consist of a plastic which is selected from the group consisting of polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polycarbonate (PC), polybutylene terephthalate (PBT), a polytrimethylene terephthalate ( PTT), a copolymer or a block copolymer of these.

The plastic film preferably has a thickness between> 60 μm and ≤500 μm, preferably between> 80 μm and ≤350 μm, in particular between ≥100 μm and ≤300 μm, such as 120 μm, 140 μm, 160 μm, 180 μm, 200 μm, 220 μm, 240 μm, 260 μm or 280 μm on. Such a thickness has proven to be particularly suitable with regard to the ease of handling in the production process of the decorative panel as well as the haptic impression achievable with it.

According to a further preferred embodiment, the structured plastic film has an embossing depth of between 60 μm and 180 μm. In particular, it is advantageous if the embossing depth is less than the layer thickness of the plastic film. In this case, the thickness of the film in unembossed areas is to be understood as the layer thickness.

According to a further preferred embodiment of the invention, the embossing depth is between 25% and 65% of the layer thickness of the plastic film.

According to one embodiment of the invention, the lacquer applied to the structured plastic layer for forming a topcoat layer comprises an acrylate, a diacylate, a methacrylate, a urethane, urethane acrylate or mixtures thereof. In addition, such a lacquer may contain other constituents such as in particular a photoinitiator, a reactive diluent, a UV stabilizer, a rheology agent such as a thickener, a radical scavenger, a flow control agent, a defoamer or a preservative, a pigment and / or a dye. Of course, several and / or different of the aforementioned components may be contained in such a paint.

According to a further embodiment of the invention, it can be provided that the topcoat layer is formed from a plurality of lacquer layers or by a multiple application of lacquer compositions of the same or different Composition is formed. It can also be provided that at least one lacquer layer or a lacquer coating has a lacquer composition which has hard material such as titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, aluminum oxide (corundum), zirconium oxide or mixtures of these in order to increase wear resistance increase the formed layer. Likewise, it can be provided that at least one lacquer layer or a lacquer coating has a lacquer composition which has a solid, for example glass ball, glass ellipses or even cellulose fibers in order to increase the wear resistance of the layer formed. It can also be provided that a lacquer layer or a lacquer coating has a lacquer composition which has both hard materials and solid of the aforementioned type.

• a) Bereitstellen eines Trägers aus einem Kunststoffkompositmaterial;
• b) Aufbringen einer Primer-Schicht auf eine Oberfläche des bereitgestellten Trägers;
• c) Aufbringen einer Dekorschicht auf die in Schritt b) aufgebrachte Primer-Schicht mittels eines Direktdruckverfahrens;
• d) Aufbringen einer Schicht eines strahlungshärtbaren Lackes oder Hotmelts auf die in Schritt c) aufgebrachte Dekorschicht;
  anschließend entweder
• e1) Aufbringen einer nicht oder nicht strukturierten Kunststofffolie auf die noch nicht oder noch nicht vollständig ausgehärtete Schicht des in Schritt d) aufgebrachten strahlungshärtbaren Lackes oder Hotmelts;
• e2) Aushärten der in Schritt d) aufgebrachten Schicht eines strahlungshärtbaren Lackes oder Hotmelts mittels Einwirkung geeigneter elektromagnetischer Strahlung bzw. Abkühlung, wobei die in Schritt e1) aufgebrachte Kunststofffolie an den übrigen Schichtaufbau angebunden wird;
• e3) Strukturieren der in Schritt e1) aufgebrachten nicht strukturierten Kunststofffolie durch eine Prägemittel zur Ausbildung einer strukturierten Kunststofffolie;
  oder
• e1') Aufbringen einer strukturierten Kunststofffolie auf die noch nicht oder noch nicht vollständig ausgehärtete Schicht des in Schritt d) aufgebrachten strahlungshärtbaren Lackes oder Hotmelts;
• e2`) Aushärten der Schicht des in Schritt d) aufgebrachten strahlungshärtbaren Lackes oder eines Hotmelts mittels Einwirkung geeigneter elektromagnetischer Strahlung bzw. Abkühlung, wobei die in Schritt e1') aufgebrachte Kunststofffolie an den übrigen Schichtaufbau angebunden wird;
  anschließend
• f) Aufbringen wenigstens einer Deckschicht aus einem strahlungshärtbaren Lack auf die strukturierte Kunststofffolie; und
• g) Aushärten der in Schritt f) aufgebrachten wenigstens einen Deckschicht.

With regard to the method, the object of the present invention is achieved by a method for producing a decorated and surface-structured wall or floor panel, comprising the method steps:

• a) providing a support made of a plastic composite material;
• b) applying a primer layer to a surface of the provided carrier;
• c) applying a decorative layer to the primer layer applied in step b) by means of a direct printing method;
• d) applying a layer of a radiation-curable varnish or hotmelt to the decorative layer applied in step c);
  then either
• e1) applying a non-structured or unstructured plastic film to the not yet or not yet completely cured layer of the radiation-curable coating or hotmelt applied in step d);
• e2) curing the layer of a radiation-curable lacquer or hotmelt applied in step d) by means of the action of suitable electromagnetic radiation or cooling, wherein the plastic film applied in step e1) adjoins the remaining layer structure is tied up;
• e3) structuring the unstructured plastic film applied in step e1) by embossing means to form a structured plastic film;
  or
• e1 ') applying a structured plastic film on the not yet or not completely cured layer of the applied in step d) radiation-curable varnish or hot melt;
• e2`) curing the layer of the radiation-curable lacquer applied in step d) or of a hotmelt by means of the action of suitable electromagnetic radiation or cooling, wherein the plastic film applied in step e1 ') is bonded to the remaining layer structure;
  subsequently
• f) applying at least one cover layer of a radiation-curable lacquer to the structured plastic film; and
• g) curing the applied in step f) at least one cover layer.

For the purposes of the present invention, a non-structured plastic film is understood as meaning a plastic film which is not completely or only partially structured and which receives additional structuring in the course of the further process.

For the purposes of the present invention, an incompletely cured layer of the radiation-curable lacquer applied in step d) is one that has already been gelled by suitable measures, such as, for example, exposure to low intensity electromagnetic radiation and / or short duration has completely cured and so far still contains radically polymerizable constituents. The same applies to an incompletely cured hot-melt layer, which is accordingly changed in its viscosity by cooling.

Before the primer layer is applied to a surface of the provided carrier, it may be provided that the corresponding surface of the carrier is pretreated by means of a corona and / or plasma treatment. As a result, improved adhesion of the primer layer to the surface can be achieved.

The application of the primer layer can be effected, for example, by means of rollers, such as rubber rollers, by means of doctoring, by means of pouring devices, by means of spraying devices or a combination of the aforementioned devices.
For applying the decorative layer to the primer layer applied in step b) by means of a direct printing method, flexo printing, offset printing or screen printing methods, in particular, as well as in particular digital printing techniques, such as, for example, inkjet methods or laser printing methods are suitable.

Subsequent to the application of the decorative layer, an application of a layer of a radiation-curable lacquer or a hotmelt takes place. The application of this lacquer layer can take place, for example, by means of rollers, such as rubber rollers, by means of doctoring, by means of pouring devices, by means of spraying devices or a combination of the aforementioned devices.

Optionally, it may be provided according to the invention that the applied lacquer layer is partially cured by the action of electromagnetic radiation, such as UV radiation or microwave radiation, wherein this partial curing is carried out with the proviso that the applied layer still has a residual fluidity and is not fully cured.

Optionally, it may be provided according to the invention that the applied hotmelt layer is partially cured by cooling, this partial hardening with the proviso takes place that the applied layer still has a residual fluidity and is not fully cured.

Following the application of paint or Hotmeltauftrag a structured or unstructured plastic film is applied to the still flowable paint bed or Hotmeltbett. This can be done for example by means of a calender in a calendering step. In this case, the plastic film can be at least partially pressed into the paint bed. Preferably, the application of the plastic film takes place while avoiding the inclusion of air bubbles between the paint layer and the plastic film.

After the application of the plastic film to the lacquer layer or the hotmelt layer, the latter is cured by the action of suitable electromagnetic radiation, whereby the film applied thereto is firmly bonded to the hitherto performed layer structure.

According to one embodiment of the method, an embossing roller, a embossing plate or an embossing stamp having an embossing depth which is smaller than the thickness of the plastic film applied in step e1) are used as embossing means in step e3). In particular, it may be provided that the embossing agent has an embossing depth between 25% and 65% of the layer thickness of the plastic film.

Preferably, the embossing takes place under the action of heat. For this purpose, it may be provided that the plastic film is heated by means of suitable devices, such as IR emitters, at least superficially. It can also be provided that the embossing means is heated by means of suitable means. Finally, a combination of these possibilities can be provided, in which both the plastic film is preheated by means of eg IR lamps and then with correspondingly heated embossing means, a structure is embossed in the plastic film.

Preferably, the heat action is controlled such that the plastic film is heated to a temperature in the range between 30% and 80%, preferably 40% and 70% of the melting temperature of the plastic film material. It has been shown that with such a heating rate, a good embossing result can be achieved without substantially adversely affecting the durability of the film.

Thus, it can be provided, for example, that when using a PET film, the heat is controlled so that a surface temperature of the film of 130 ° C is not exceeded.

According to one embodiment of the invention, it may be provided that, prior to the embossing of the applied plastic film, an embossing lacquer is applied to the latter, which has sufficient flexibility to be embossed in a subsequent embossing step. Such an embossing lacquer is preferably likewise a radiation-curable lacquer composition.

In one embodiment of the invention, it is provided that takes place through the structuring of the plastic film in accordance with the decor image to haptically support the realistic appearance of the decor. For this purpose, it may be provided that the decorative image has so-called register markings, by means of which the embossing means or the already structured plastic film are aligned with respect to the decor, in order to ensure a structuring which is synchronous with the decoration.

According to a further embodiment of the invention, it may be provided that the side facing the carrier of the plastic film prior to application to the not yet or not fully cured layer of the applied in step d) radiation-curable varnish a corona treatment and / or plasma treatment subjected. As a result, an improvement in the adhesion of the film to the radiation-curable lacquer layer can be achieved.

Alternatively or in addition to the corona and / or plasma treatment described above, the side of the plastic film facing the carrier plate, an adhesive primer is applied.

According to one embodiment of the invention, it may be provided that a composition comprising swelling agent and / or solvent suitable for the plastic film material is applied as the adhesion primer. Such a composition may, for example, acetone, methyl ethyl ketone, ethyl acetate, isobutyl acetate, tetrahydrofuran, dimethyl sulfoxide, sulfolane, acetonitrile, nitromethane, γ-butyrolactone or mixtures thereof.

According to a preferred embodiment, such a composition can have, for example, between ≥ 5% by weight and ≦ 35% by weight of isobutyl acetate and between ≥ 2% by weight and ≦ 65% by weight of methyl ethyl ketone.

According to the invention, it may be provided that the method is interrupted by method steps e2) or e2 ') or e3) and thus before the application of the top layer in step (f). In this case, a storable intermediate product or semifinished product is obtained, which can be further processed temporally and / or spatially from the previous production process by application of the cover layer, optionally with prior structuring. The invention thus expressly also encompasses a method for producing such an intermediate product, which then consists of a carrier, a primer layer, a decorative layer, a layer of a radiation-curable lacquer or a hotmelt and a plastic film arranged on the decorative layer.

On the after process step e2 ') or e3) layer composite according to the invention a topcoat layer of a radiation-curable lacquer is applied.

According to a further embodiment of the invention, it may be provided that the topcoat layer is formed by a multiple application of coating compositions of the same or different composition and the corresponding step f) is carried out repeatedly. It can also be provided that at least one lacquer layer or a lacquer coating has a lacquer composition which comprises hard materials such as titanium nitride, titanium carbide, silicon nitride, silicon carbide, boron carbide, tungsten carbide, tantalum carbide, aluminum oxide (corundum), zirconium oxide or mixtures of these in order to increase wear resistance increase the formed layer. Likewise, it can be provided that at least one lacquer layer or a lacquer coating has a lacquer composition which has a solid, for example glass ball, glass ellipses or even cellulose fibers in order to increase the wear resistance of the layer formed. It can also be provided that a lacquer layer or a lacquer coating has a lacquer composition which has both hard materials and solid of the aforementioned type.

Finally, in step g), the curing of the topcoat layer applied in step f) takes place. In a repetition of step f) in the manner described above, it may be provided that step g) is also repeated, optionally with the proviso that between the repetition of step f) no complete curing of the applied paint composition takes place, but only a partial cure or angling and a final curing by a correspondingly long and / or intense exposure to suitable electromagnetic radiation, such as UV radiation or microwave radiation takes place.

• Fig. 1 zeigt schematisch den Aufbau eines erfindungsgemäßen dekorierten und oberflächenstrukturierten Wand- oder Bodenpaneels;
• Fig. 2 zeigt schematisch ein Zwischenprodukt, wie es im Rahmen des erfindungsgemäßen Verfahrens erhalten werden kann;
• Fig. 2 zeigt schematisch ein weiteres Zwischenprodukt, wie es im Rahmen des erfindungsgemäßen Verfahrens erhalten werden kann.

The invention is explained below with reference to the figures and an embodiment.

• Fig. 1 shows schematically the structure of a decorated and surface-structured wall or floor panel according to the invention;
• Fig. 2 schematically shows an intermediate product, as can be obtained in the context of the method according to the invention;
• Fig. 2 schematically shows another intermediate, as can be obtained in the context of the method according to the invention.

Fig. 1 schematically shows the structure of a decorated and surface-structured wall and or floor panel 100 according to the invention in this case, the panel has a preferably made of a Kunststoffkompositmaterial carrier 110. On a surface of the carrier 110, a primer layer 120 is arranged, which can also serve as a printing substrate for the decorative layer 130 arranged above. The decorative layer 130 can be applied to the primer layer 120 by means of a direct printing method such as, for example, flexographic printing, offset printing or screen printing methods, and in particular by means of digital printing techniques, such as, for example, inkjet methods or laser printing methods. On the decorative layer 130, in turn, a layer 140 of a radiation-curable lacquer or a hotmelt is arranged, by means of which the structured plastic film 150 arranged on the layer 140 is connected to the layer composite. Above the structured plastic film 150, a topcoat layer 160 is disposed. It may be provided that the topcoat layer 160 to improve the wear resistance hard materials and / or solids and / or fibers. In any case, the topcoat layer is designed such that it does not completely or not completely level the surface structure caused by the structured plastic film, so that it is at least partially haptically perceptible on the surface of the wall or floor panel.

Fig. 2 schematically shows an intermediate 101, as can be obtained in the context of the method according to the invention. The layers 110, 120, 130 and 140 correspond to those from the Fig. 1 known layers. Instead of an already pre-structured plastic film has the in Fig. 2 shown intermediate product a not or not finally structured plastic film 151. In an optionally temporally and / or spatially separate further processing step, the surface of the intermediate product 101 formed by the plastic film can be structured by means of suitable embossing means, in particular under the action of heat. In a further optionally temporally and / or spatially separate further processing step, the application of a topcoat layer can then take place.

Fig. 3 schematically shows an intermediate product 102, as can be obtained in the context of the method according to the invention. The layers 110, 120, 130 and 140 correspond to those from the Fig. 1 known layers. The layer 152 represents in the embodiment shown a structured plastic film. This can either be an already pre-structured plastic film, or an unstructured plastic film as shown in FIG Fig. 2 is shown, which was structured in an optionally temporally and / or spatially separate further processing step by means of suitable embossing means, in particular under the action of heat. In a further optionally temporally and / or spatially separate further processing step, the application of a topcoat layer can then take place.

Reference numerals:

100

Wall or floor panel

101

intermediate

102

intermediate

110

carrier

120

Primer layer

130

decorative layer

140

radiation curable lacquer layer or hotmelt layer

150

textured plastic film

151

unstructured plastic film

152

textured plastic film

160

Topcoat

Claims (15)

Decorated and surface-structured wall or floor panel (100) comprising a support (110) made of a plastic composite material, a primer layer (120) arranged on a surface of the carrier (110), a decorative layer (130) arranged on the primer layer (120), a layer (140) of a radiation-curable lacquer or a hotmelt arranged on the decorative layer (130), - A structured on the layer (140) of a radiation-curable varnish or hot melt structured plastic film (150, 152), and - A arranged on the structured plastic film topcoat layer (160). Decorated and surface-structured wall or floor panel according to claim 1, wherein the support (110) comprises a plastic matrix material in which a solid material and / or a fiber material are embedded. Decorated and surface-structured wall or floor panel according to one of the preceding claims, wherein the primer layer (120) comprises a radiation-cured urethane and / or urethane acrylate. The decorated and surface structured wall or floor panel of any of the preceding claims, wherein the decorative layer (130) comprises at least one more radiation-curable ink composition. Decorated and surface-structured wall or floor panel according to one of the preceding claims, wherein on the decorative layer (130) for forming a layer (140) of a radiation-curable lacquer applied lacquer comprises an acrylate, a diacrylylate, a methacrylate, a urethane, urethane acrylate or mixtures thereof , Decorated and surface-structured wall or floor panel according to one of the preceding claims, wherein the structured plastic film (150) consists of a plastic which is selected from the group consisting of polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polycarbonate ( PC), polybutylene terephthalate (PBT), a polytrimethylene terephthalate (PTT), a copolymer or a block copolymer thereof. Decorated and surface-structured wall or floor panel according to one of the preceding claims, wherein the structured plastic film has a thickness between> 60μm and ≤500μm, preferably between ≥80μm and ≤350μm, in particular between ≥100μm and ≤300μm. Decorated and surface-structured wall or floor panel according to one of the preceding claims, wherein the structured plastic film has an embossing depth between 60μm and 180μm. Decorated and surface-structured wall or floor panel according to one of the preceding claims, wherein the lacquer applied to the structured plastic layer for forming a topcoat layer (160) comprises an acrylate, a diacylate, a methacrylate, a urethane, urethane acrylate or mixtures thereof. Decorated and surface-structured wall or floor panel according to one of the preceding claims, wherein the panel has on at least two opposite edges complementary locking means by means of which panels can be joined together to form a connected wall or floor covering. Method for producing a decorated and surface-structured wall or floor panel (100), comprising the method steps: a) providing a support (110) made of a plastic composite material; b) applying a primer layer (120) to a surface of the provided carrier; c) applying a decorative layer (130) to the primer layer applied in step b) by means of a direct printing method; d) applying a layer (140) of a radiation-curable lacquer or a hotmelt to the decorative layer applied in step c);
then either e1) applying a non-structured plastic film (151) to the not yet or not yet fully cured layer (140) of the radiation-curable lacquer applied in step d) or of a hotmelt; e2) curing the layer (140) of a radiation-curable lacquer or hotmelt applied in step d) by the action of suitable electromagnetic radiation or cooling, wherein the plastic film (151) applied in step e1) is bonded to the remaining layer structure; e3) structuring the unstructured plastic film (151) applied in step e1) by embossing means to form a structured plastic film (152);
or e1 ') applying a structured plastic film (150) to the not yet or not completely cured layer (140) of the applied in step d) radiation-curable varnish or a hot melt; e2 ') hardening of the layer (140) of the radiation-curable lacquer or hotmelt applied in step d) by the action of suitable electromagnetic radiation or cooling, wherein the plastic film (150) applied in step e1`) is bonded to the remaining layer structure;
subsequently f) applying at least one cover layer (160) of a radiation-curable lacquer on the structured plastic film; and g) curing the in step f) applied at least one cover layer (160). Method according to claim 11, wherein an embossing roll, embossing plate or embossing stamp having an embossing depth which is less than the thickness of the plastic film (151) applied in step e1) is used as embossing means in step e3). Method according to one of claims 11 or 12, wherein step e3) takes place under heat and the heat action is controlled such that the plastic film (151) to a temperature in the range between 30% and 80%, preferably 40% and 70% of the melting temperature of the Plastic film material is heated. Method according to one of claims 11 to 13, wherein the side of the plastic film (150, 151) facing the support before application to the not yet fully cured layer (140) of the radiation-curable lacquer or hotmelt of a corona applied in step d) Treatment and / or plasma treatment is subjected and / or the carrier plate facing side of the plastic film (150, 151) an adhesive primer is applied. A process according to claim 14, wherein a composition comprising swelling agent and / or solvent suitable for the plastic film material is applied as the adhesion primer.

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