阅读说明：本技术 用于生产涂层、建筑镶板和经涂覆的箔的方法 (Method for producing a coating, a building panel and a coated foil ) 是由 G·齐格勒 C·伦德布拉德 P·约瑟夫松 A·赫德伦 于 2018-05-23 设计创作，主要内容包括：本公开涉及一种用于生产涂层(2)的方法,该方法包括在载体(1)的表面上施加涂料组合物,将涂料组合物固化为涂层(2),然后对涂层(2)施加压力。本公开还涉及一种用于生产建筑镶板的方法,以及这种建筑镶板,并且涉及一种用于生产经涂覆的箔的方法,以及这种经涂覆的箔。(The present disclosure relates to a method for producing a coating (2), the method comprising applying a coating composition on a surface of a carrier (1), curing the coating composition into the coating (2), and then applying pressure to the coating (2). The disclosure also relates to a method for producing a building panel, and to such a building panel, and to a method for producing a coated foil, and to such a coated foil.)

1. A method for producing a coating (2) comprising

Applying a water-based coating composition on the surface of the carrier (1; 1'),

curing the water-based coating composition into a coating layer (2),

subsequently applying pressure to the coating (2).

2. The method according to claim 1, wherein the carrier (1; 1') comprises a thermoplastic material.

3. The method according to claim 1 or 2, wherein applying pressure comprises pressing the coating composition against a pressing device (23) comprising portions having different gloss degrees, such that the coating (2) obtains different gloss degrees after pressing.

4. The method of any of claims 1-3, wherein applying pressure comprises applying heat and pressure simultaneously.

5. The method of any of claims 1-4, wherein the coating composition comprises a crosslinkable component.

6. The method of any of claims 1-5, wherein the coating composition is UV curable.

7. The method of any of claims 1-5, wherein the coating composition comprises a two-component system.

8. Method according to any one of claims 1 to 7, wherein the carrier is a foil (1), preferably a thermoplastic foil.

9. The method according to any one of claims 1 to 8, wherein applying pressure to the coating composition comprises pressing and adhering the coating (2) on the carrier (1; 1 ') onto a substrate (3), wherein the carrier (1; 1') is intermediate the coating (2) and the substrate (3).

10. The method according to any one of claims 1 to 8, further comprising peeling the coating (2) off the carrier (1; 1') prior to applying pressure, and wherein applying pressure to the coating (2) comprises pressing and attaching the coating (2) onto a substrate (3).

11. The method of any of claims 1-10, wherein the coating composition comprises abrasion and/or scratch resistant particles.

12. Method according to any one of claims 1-11, wherein the carrier (1') comprises a first foil (8) of thermoplastic and a second foil (9) of thermoplastic, wherein wear resistant particles, preferably aluminium oxide particles, are arranged between the first and second foils (8, 9).

13. The method according to any one of claims 1 to 12, wherein the coating (2) is substantially transparent.

14. A method for producing a coating (2) comprising

Applying a coating composition onto a surface of a carrier (1; 1 '), wherein the carrier (1; 1') is a thermoplastic foil,

curing the coating composition into a coating layer (2),

subsequently applying pressure to the coating (2).

15. The method according to claim 14, wherein the coating composition is a UV-curable, preferably water-based UV-curable coating composition.

16. A method of manufacturing a building panel (5), comprising:

providing a substrate (3) and at least one surface layer (1; 1', 4) arranged on the substrate (3),

applying a water-based coating composition on said at least one surface layer (1; 1', 4),

curing the water-based coating composition such that a coating layer (2) is formed on the at least one surface layer (4),

subsequently applying pressure to the coating (2) with a pressing device (23) and pressing the substrate (3) and the coated surface layer (1; 1', 4) together to form a building panel (5).

17. The method of claim 16, wherein the at least one surface layer comprises a thermoplastic material.

18. The method according to claim 16 or 17, wherein applying pressure to the coating (2) with the pressing device comprises applying heat and pressure simultaneously.

19. The method according to any one of claims 16-18, wherein applying pressure to the coating (2) with the pressing device comprises bonding together the substrate (3), the at least one surface layer (1; 1', 4) and the coating composition.

20. Method according to any of claims 16-19, wherein the pressing device (23) comprises portions having different gloss degrees, such that the coated surface layer (1; 1', 4) obtains different gloss degrees after pressing.

21. The method according to any one of claims 16-20, wherein the coating (2) is substantially transparent.

22. A method according to any one of claims 16 to 21, wherein the coating composition comprises a crosslinkable component.

23. The method of any of claims 16-22, wherein the coating composition is UV curable.

24. The method of any of claims 16-22, wherein the coating composition comprises a two-component system.

25. A method for producing a coated foil (10') comprising

Providing a first thermoplastic foil (8) and a second thermoplastic foil (9),

-applying wear resistant particles (6) on the first thermoplastic foil (8) or on the second thermoplastic foil (9),

applying the second thermoplastic foil (9) on the first thermoplastic foil (8) such that the wear resistant particles (6) are arranged between the first and second thermoplastic foils (8, 9),

applying a coating composition on the second thermoplastic foil (9),

curing the coating composition to form a coating layer (2), and

subsequently applying pressure to the coating (2).

26. A coated foil (10, 10 ') comprising a carrier (1, 1') and a cured coating (2) arranged on a surface of the carrier (1, 1 '), wherein the carrier (1, 1') comprises a thermoplastic material, wherein the cured coating (2) comprises an embossed structure and/or a different gloss obtained by a pressing device (23) after curing the coating (2).

27. Coated foil according to claim 26, wherein the carrier comprises a first thermoplastic foil (8) and a second thermoplastic foil (9) with wear resistant particles (6) arranged between them.

28. Coated foil according to any one of claims 26-27, wherein the cured coating is cross-linked.

29. Coated foil according to any one of claims 26-28, wherein the cured coating (2) is UV cured.

30. The coated foil of any one of claims 26-28, wherein the coating comprises a two-component system.

31. A building panel (5) comprising

A substrate (3) having a plurality of openings,

at least one surface layer (1; 1 ', 4) arranged on the substrate (3), wherein the at least one surface layer (1; 1', 4) comprises a thermoplastic material, and

wherein the uppermost surface layer is provided with a cured coating (2), wherein the cured coating (2) comprises an embossed structure and/or different gloss levels obtained by a pressing device (23) after curing the coating (2).

32. The building panel as claimed in claim 31, wherein the at least one surface layer (1; 1', 4) comprises at least one thermoplastic foil.

33. The building panel as claimed in claim 31 or 32, wherein the cured coating (2) is cross-linked.

34. The building panel according to any one of claims 31-33, wherein the cured coating (2) is UV cured.

35. The building panel according to any one of claims 31 to 33, wherein the coating comprises a two-component system.

Technical Field

Embodiments of the invention relate to a method of forming a coating, a method of forming a building panel, such a building panel, a method of forming a coated foil/sheet and such a coated foil.

Background

In recent years, so-called luxurious vinyl and wood (LVT), WPC (wood plastic composite) and SPC (stone plastic composite/solid polymer core) flooring have enjoyed increasing success. These types of floor panels usually comprise a thermoplastic core, a thermoplastic decorative layer arranged on the core, a thermoplastic transparent wear layer on the decorative layer and a coating applied on the wear layer. The thermoplastic material is typically PVC. The core may contain a filler, such as limestone. Although commonly referred to as WPC flooring, for some products the filler in the core may not be wood, but limestone. The wear resistant layer is typically a PVC foil, for example, having a thickness of 0.2-0.7 mm. The core, decorative layer and transparent wear layer are typically pressed together to form the floor panel. The coating applied to the wear layer after pressing is typically a UV cured polyurethane coating. The wear layer together with the coating provides wear resistance of the floor and protects the decorative layer. After pressing, a UV-curable polyurethane coating is applied on the surface of the wear layer in a subsequent separate step. By applying the UV-cured polyurethane coating as the uppermost layer to the floor panel, the surface of the floor panel obtains a uniform gloss, i.e. the floor panel obtains the gloss of the coating.

Since the embossing of the wear layer is performed during pressing, the coating applied after embossing makes the embossed surface of the wear layer more uniform by pressing the wear layer against an embossing platen or the like, resulting in an at least visually reduced embossing effect.

However, when subjecting the floor panels to wear, it has been shown that the coating and the wear layer wear relatively easily, or at least in such a way that the appearance of the wear layer is affected, e.g. has scratches and/or is no longer transparent. Compared to conventional laminate floor panels, LVT floor panels have a poor wear resistance. However, LVT floors offer several advantages over e.g. laminate floors, such as deep embossing, dimensional stability with respect to humidity, water resistance and sound absorption properties.

With the further development of this type of floor panels, it is generally desirable to improve properties such as abrasion and/or scratch resistance, chemical resistance and aesthetic properties as well as to rationalize the manufacturing process.

Likewise, other types of floor panels are also provided with a coating, for example a UV-curable polyurethane coating. Wood flooring is usually coated with a UV-curable coating and the surface of the wood flooring obtains a uniform gloss, i.e. the gloss of the uppermost paint layer. It would be an advantage to improve the coating properties to allow for increased design changes of the wood flooring.

WO 2016/113378 discloses a method for manufacturing a covering layer comprising manufacturing a base layer, attaching a surface layer to the top surface of the base layer, attaching the top surface of a backing layer to the bottom surface of the base layer and attaching the top surface of a fabric layer to the bottom surface of the backing layer. Thus, a panel is provided, which is defined as the whole consisting of the surface layer, the substrate layer, the backing layer and the fabric layer. In a further step, the slab is cured. After curing the slab, the surface layer may be mechanically embossed. After the plate has been cured, in a further step, a surface coating may be provided on top of the wear resistant layer as an additional component of the surface layer.

US 2014/0255670 discloses a method for printing a wooden board. The method comprises printing wood by means of a digital printing technique, forming a decorative layer, applying a protective layer comprising at least one resin, at least one radiation curable varnish and/or at least polyurethane on the decorative layer, and a pre-drying and/or pre-gelling protective layer. The protective layer is only pre-dried and/or pre-gelled and is therefore not yet fully dried or cured. The surface of the protective layer is rather sticky or surface dry. The degree of predrying and/or pregelling is such that the protective layer, i.e. the resin or varnish itself, is still free-flowing and crosslinkable. The board printed and provided with the protective layer can be further processed or finished in a short-cycle press. In a short cycle press, the resin layer is melted and the layer composite is cured to form a laminate.

US 2013/0011623 discloses a monolithic three-dimensional composite material. In one embodiment, a composite material includes a three-dimensional layer and an outer layer. A printed layer may be provided on the outer layer. The print layer may receive the abrasion resistant layer by a coating device that applies the polymer composition. The wear resistant layer is allowed to cure. A heat source such as a radiant oven, gas fired oven, or the like may be used to help cure the wear layer. During and/or after curing, the wear layer is allowed to attain ambient temperature. Thereafter, the surface of the wear-resistant layer is subjected to a sufficient temperature to soften the cured wear-resistant layer surface by reheating with a heat source such as an infrared radiation heating furnace. This step softens the surface of the wear layer to allow mechanical embossing by the embossing drum.

Disclosure of Invention

It is an object of at least some embodiments of the present invention to provide improvements to aspects of the above-described techniques and known techniques.

It is a further object of at least some embodiments of the invention to improve the coating process for substrates intended to be pressed.

It is a further object of at least some embodiments of the invention to improve the chemical resistance of coatings for floor surfaces.

It is a further object of at least some embodiments of the invention to allow for different gloss levels on the coating.

At least some of these and other objects and advantages that will be apparent from the description have been achieved by a method for manufacturing a coating according to the first aspect of the present invention. The method includes applying a coating composition to a surface of a support, curing the coating composition into a coating layer, and then applying pressure to the coating layer.

Curing means curing completely or at least beyond a predried or precured state.

One advantage of at least some embodiments of the invention is that by applying the coating prior to pressing, the coating can be applied in-line and integrated with the assembly and attachment of other layers in, for example, a building panel. Thus, a more rational and integrated production method can be achieved.

At least some embodiments of the invention allow for coatings that can be treated as a separate layer after curing, and can be adhered to another substrate or the like by pressing. The coating composition may be applied to a substrate in the form of a release foil or film and peeled from the release foil or film prior to pressing the coating onto another substrate.

Yet another advantage is that improved chemical resistance has been shown to be achieved by compression coating. It is believed that improved chemical resistance can be achieved by further increasing the degree of crosslinking by pressing and/or by compressing the coating. The higher the degree of crosslinking, the higher the chemical resistance of the coating.

Furthermore, an improved scratch resistance of the coating can be achieved due to the higher degree of crosslinking obtained after pressing and/or due to the fact that the coating is compressed by the pressing operation.

A further advantage is that the coating can be embossed by pressing it, also by pressing it against an embossing platen. In a conventional process, the surface of the substrate is embossed prior to application of the coating. Thus, the coating may fill in the shallower structures in the substrate, and the visual impression of the embossing may be difficult to distinguish.

It has further been shown that press coating can reduce any damage, such as scratches, in the coating. Such scratches may form during production as well as during handling in the production process.

Applying pressure may comprise pressing the coating against a pressing device comprising portions having different gloss levels such that the coating obtains different gloss levels after pressing. By applying the coating composition prior to pressing and then pressing against a pressing device having portions of different gloss levels, the different gloss levels in the coating can be obtained in a simplified manner compared to solutions known in the art.

Applying pressure may include applying heat and pressure simultaneously.

The coating composition may comprise crosslinkable components/ingredients. In crosslinkable coating systems, curing the coating composition crosslinks the polymer.

After curing, the residual oligomer content of the coating composition may be less than 10%, for example greater than 0% and less than 10%. Having a certain residual oligomer content corresponds to having a certain residual crosslinking capacity. The residual crosslinking capacity facilitates the pressing of the coating after curing by virtue of a certain crosslinking capacity of the coating composition remaining after curing.

After curing the coating composition, the coating composition is no longer tacky. Thus, the coated support can be treated, for example rolled on a roll. By cured is meant that the coating composition has passed through its pre-dried and/or pre-gelled state, e.g., the content of residual oligomers is less than 10%.

The coating composition may be water-based. It has been found that water-based coating compositions maintain removability after curing, thereby facilitating shaping of the coating during pressing, e.g. embossing or providing gloss.

The coating composition may comprise a two-component system. The two-component system may comprise epoxy amines, polyurethane isocyanates, isocyanate alcohols or acid alcohol systems. The coating composition may be a water-based two-component system.

The coating composition may be UV-curable, preferably a water-based UV-curable coating composition. By the coating composition being UV curable, it is meant that at least one component of the coating composition is UV curable. By using the UV-curable composition, curing can be performed at a higher speed than in a pure water-based coating system. After curing, the UV cured coating is no longer tacky at normal temperatures, e.g., 25 ℃. The surface of the coating may be harder than the sintered coating composition. The UV curable component may be a polyester/polyurethane dispersion. The UV curable component may be a polyurethane/acrylic copolymer dispersion.

Prior to pressing, the water-based UV-curable coating composition is first completely dried to evaporate water, and thereafter UV-cured to cure the UV-curable components. After drying and UV curing, the coating formed from the coating composition is pressed.

The carrier may comprise a thermoplastic material, preferably PVC.

The carrier may be a foil. The coating and the carrier may be pressed together onto a further substrate or the coating may be peeled off the carrier after pressing.

The foil may be a thermoplastic foil. The foil may be a PVC foil. The thermoplastic foil may be a wear resistant foil. The thermoplastic foil may be a decorative thermoplastic foil, such as a printed thermoplastic foil. Thereby, a coated thermoplastic foil may be formed, which may be extruded onto a substrate in a subsequent step. As the coating is cured and pressed, the coated wear resistant or decorative foil can be stored and handled as a conventional wear resistant foil.

The carrier may be a wood based substrate, preferably a wood veneer (layer/board). In one embodiment, a wood-based substrate is coated and then pressed. Thereby, the coating may for example obtain an embossed structure by pressing against an embossing press and/or obtain different gloss levels by pressing against a press having portions with different gloss levels.

Applying pressure to the coating can include pressing and attaching the coating on a carrier to the substrate, wherein the carrier is intermediate the coating and the substrate. Thereby, a coated substrate, such as a building panel, comprising a substrate and a coated carrier may be provided. The carrier may be a thermoplastic foil. The carrier may be a wood-based material. The carrier is already provided with a coating before it is attached to the substrate. Thus, the carrier may be coated in a separate process from treating the entire substrate.

Alternatively or additionally, the carrier may be attached to the substrate by an adhesive.

The method may further comprise peeling the coating from the carrier prior to applying the pressure, and wherein applying the pressure to the coating comprises pressing and attaching the coating to the substrate. In this embodiment, the carrier has the function of a temporary carrier, such as a release film or foil, and the coating can be laminated to the substrate without the carrier. Alternatively, the coating may be peeled from the carrier after pressing but before attachment to the substrate.

The coating composition may comprise scratch resistant particles, such as silica particles. Thereby, the scratch resistance of the coating can be improved. The coating composition may also comprise wear resistant particles, such as alumina particles, also known as corundum.

The carrier may comprise a thermoplastic first foil and a thermoplastic second foil, wherein wear resistant particles, preferably aluminium oxide particles, are arranged between the first foil and the second foil. The first and second foils with the wear resistant particles in between may be pre-pressed to adhere them to each other, preferably after the coating has been applied. The coated carrier thus forms a wear layer which can be stored and treated as a separate layer which can be pressed onto a substrate in a subsequent step.

The coating may be substantially transparent. The coating may be a layer commonly referred to as a varnish layer.

According to a second aspect of the invention, a method for producing a building panel is provided. The method comprises providing a substrate and at least one surface layer arranged on the substrate, applying a coating composition on the at least one surface layer, curing the coating composition such that a coating layer is formed on the at least one surface layer, subsequently applying pressure to the coating layer with a pressing device, and pressing the substrate and the coated surface layer together to form the building panel.

Pressing the coated surface layer onto the substrate may be performed separately from applying the coating composition and curing the coating composition into a coating layer. The coated surface layer may be stored and pressed onto the surface layer in a subsequent step, which may be performed by another manufacturer than the manufacturer of the coated surface layer.

Curing means curing completely or at least beyond a predried or precured state.

One advantage of at least some embodiments of the invention is that by applying the coating prior to pressing, the coating can be done in-line, integrated with assembling and attaching other layers in the building panel. Thus, a more rational and integrated production method can be achieved.

At least some embodiments of the present invention allow the coated surface layer to be treated as a separate layer after curing and attached to the substrate in a subsequent step separate from the coating step.

Yet another advantage is that improved chemical resistance has been shown to be achieved by compression coating. Thereby, a building panel with improved chemical resistance may be provided. It is believed that improved chemical resistance can be achieved by further increasing the degree of crosslinking by compression, and/or by compressing the coating. By a higher degree of crosslinking, the chemical resistance of the coating is higher.

Furthermore, an improved scratch resistance of the coating can be achieved due to the higher degree of crosslinking obtained after pressing and/or due to the fact that the coating is compressed by the pressing operation.

A further advantage is that the coating can be embossed by pressing it, also by pressing it against an embossing platen. In a conventional process, the surface of the substrate is embossed prior to application of the coating. Thereby, the coating may fill lighter structures in the substrate, and the visual impression of the embossing may be difficult to distinguish.

It has further been shown that pressing the coating can reduce any damage, such as scratches, to the substrate surface. Such scratches may form during production as well as during handling in the production process.

Applying pressure may include pressing the coating composition against a pressing device including portions having different gloss levels such that the coating obtains different gloss levels after pressing. By applying the coating composition prior to pressing and then pressing against a pressing device having portions of different gloss levels, the different gloss levels in the coating can be obtained in a simplified manner compared to solutions known in the art.

Applying pressure to the coating with the pressing device may include applying heat and pressure simultaneously.

Applying pressure to the coating with the pressing device may comprise bonding the substrate, the at least one surface layer and the coating composition together.

The coating composition may comprise a crosslinkable component. In crosslinkable coating systems, curing the coating composition crosslinks the polymer.

After curing, the coating composition may comprise a residual oligomer content of less than 10%. Having a certain residual oligomer content corresponds to having a certain residual crosslinking capacity. The residual crosslinking capacity facilitates the pressing of the coating after curing by virtue of a certain crosslinking capacity of the coating composition remaining after curing.

After curing the coating composition, for example, such that the residual oligomer content is less than 10%, the coating composition is no longer tacky. The coated support can thus be treated, for example rolled on a roller. By cured is meant that the coating composition has passed through its pre-dried and/or pre-gelled state, e.g., the content of residual oligomers is less than 10%.

The coating composition may be water-based. It has been found that water-based coating compositions maintain removability after curing, thereby facilitating shaping of the coating during pressing, e.g. embossing or providing gloss.

The coating composition may comprise a two-component system. The two-component system may comprise epoxy amines, polyurethane isocyanates, isocyanate alcohols or acid alcohol systems. The coating composition may be an epoxy amine, a polyurethane isocyanate, an isocyanate alcohol, an acidic alcohol system. The coating composition may be a water-based two-component system.

The coating composition may be UV-curable, preferably a water-based UV-curable coating composition. By the coating composition being UV curable, it is meant that at least one component of the coating composition is UV curable. By using the UV-curable composition, curing can be performed at a higher speed than in a pure water-based coating system. The cured UV cured coating did not adhere to the platen during pressing. The surface of the coating may be harder than the sintered coating composition. The UV curable component may be a polyester/polyurethane dispersion. The UV curable component may be a polyurethane/acrylic copolymer dispersion.

Prior to pressing, the water-based UV-curable coating composition is first completely dried to evaporate water, and thereafter UV-cured to cure the UV-curable components. After drying and UV curing, the coating formed from the coating composition is pressed.

The at least one surface layer may comprise a thermoplastic material, preferably PVC.

The at least one surface layer may comprise a foil.

The at least one surface layer may comprise a thermoplastic foil. The thermoplastic foil may be a PVC foil. The thermoplastic foil may be a wear resistant foil. The thermoplastic foil may be a decorative thermoplastic foil, such as a printed thermoplastic foil. Thereby, a coated thermoplastic foil may be formed, which may be extruded onto a substrate in a subsequent step. As the coating is cured and pressed, the coated wear resistant or decorative foil can be stored and handled as a conventional wear resistant foil.

The at least one surface layer may comprise a wood based substrate, preferably a wood veneer (layer/board). In one embodiment, a wood-based substrate is coated and then pressed. Thereby, the coating may for example obtain an embossed structure by pressing against an embossing press and/or obtain different gloss levels by pressing against a press having portions with different gloss levels.

The at least one surface layer may comprise paper, such as decor paper.

The coating composition may comprise scratch resistant particles, such as silica particles. Thereby, the wear resistance of the coating can be improved. The coating composition may also comprise wear resistant particles, such as alumina particles, also known as corundum.

The at least one surface layer may comprise a first thermoplastic foil and a second thermoplastic foil, wherein between the first foil and the second foil wear resistant particles, preferably aluminium oxide particles, are arranged. The first and second foils with the wear resistant particles in between may be pre-pressed to adhere to each other before or after the coating has been applied. The coated surface layer thus forms a wear resistant layer which can be stored and treated as a separate layer, which can be laminated to a substrate in a subsequent step.

The coating may be substantially transparent. The coating may be a layer commonly referred to as a varnish layer.

The substrate may comprise a plastic sheet, such as a thermoplastic sheet. The substrate may be a wood-based board. Wood based panels may be or include wood veneer (board). The wood based board may be or further comprise a wood fibre based board, such as MDF, HDF, particle board, etc., or plywood. The substrate may comprise or further comprise a wooden panel, such as a sheet core. In embodiments, the substrate may comprise or further comprise a thermoplastic sheet, such as a Wood Plastic Composite (WPC), EPC (expanded polymer core) or SPC (stone plastic composite/solid polymer core). The substrate may comprise or further comprise a mineral composite panel. The substrate may comprise or further comprise a fiber cement board. The substrate may comprise or further comprise a magnesia cement board. The substrate may comprise or further comprise a ceramic plate.

The substrate may comprise paper or non-woven fabric. The substrate may be a printing paper. The substrate may comprise a laminate comprising a thermosetting resin.

In one embodiment, the carrier comprises a thermoplastic material and the substrate comprises a thermoplastic material of the type described above.

In one embodiment, the carrier comprises a thermoplastic material and the substrate comprises a facing (layer/sheet). The veneer may be arranged on a board of the type described above.

In one embodiment, the carrier comprises a thermoplastic material and the substrate comprises paper. The paper may be arranged on a board of the type described above.

In one embodiment, the carrier comprises a thermoplastic material and the substrate is formed from a powder mixture comprising a binder and a filler. The substrate may be arranged on a plate of the type described above. The panel may be a waterproof panel.

According to a third aspect, a building panel is provided. The building panel comprises a substrate and at least one surface layer arranged on the surface layer, wherein the uppermost surface layer is provided with a cured coating.

The cured coating may comprise different gloss levels. Different gloss levels can be obtained by the pressing device after curing the coating.

The cured coating may comprise an embossed structure. The embossed structure may be obtained by a pressing device after curing the coating.

Embodiments of the third aspect may combine all the advantages of the second aspect already discussed above, whereby the foregoing discussion also applies to the building panel.

The coating may be crosslinked. The coating may comprise a crosslinkable component. In crosslinkable coating systems, curing the coating composition crosslinks the polymer.

The coating may be water-based, preferably a water-based UV-curable coating composition. It has been found that water-based coating compositions maintain removability after curing, thereby facilitating shaping of the coating during pressing, e.g. embossing or providing gloss.

The coating may comprise a two-component system. The two-component system can be an epoxy amine, a polyurethane isocyanate, an isocyanate alcohol or an acid alcohol system. The coating composition may be an epoxy amine, a polyurethane isocyanate, an isocyanate alcohol or an acid alcohol system. The coating may be a water-based two-component system.

The coating may be UV cured, preferably a water based UV cured coating. The coating is UV cured means that at least one component of the coating composition is UV cured. By using the UV-curable composition, curing can be performed at a higher speed than in a pure water-based coating system. The cured UV cured coating did not adhere to the platen during pressing. The surface of the coating may be harder than the sintered coating composition. The UV curable component may be a polyester/polyurethane dispersion. The UV curable component may be a polyurethane/acrylic copolymer dispersion.

The at least one surface layer may comprise a thermoplastic material, preferably PVC.

The at least one surface layer may comprise a foil.

The at least one surface layer may comprise a thermoplastic foil. The thermoplastic foil may be a PVC foil. The thermoplastic foil may be a wear resistant foil. The thermoplastic foil may be a decorative thermoplastic foil, such as a printed thermoplastic foil.

The surface layer may be a wood based substrate, preferably a wood veneer (layer/board). In one embodiment, a wood-based substrate is coated and then pressed. Thereby, the coating may be provided on the embossed structure, for example by pressing against an embossing press, and/or different gloss levels may be obtained by pressing against a press having portions with different gloss levels.

The coating may comprise scratch-resistant particles, such as silica particles. Thereby, the scratch resistance of the coating can be improved. The coating may also comprise wear resistant particles, preferably aluminium oxide particles, also known as corundum.

The at least one surface layer may comprise a first thermoplastic foil and a second thermoplastic foil, wherein wear resistant particles, such as aluminium oxide particles, are arranged between the first foil and the second foil.

The coating may be substantially transparent. The coating may be a layer commonly referred to as a varnish layer.

The substrate may comprise a plastic sheet, such as a thermoplastic sheet. The substrate may be a wood-based board. Wood based panels may be or include wood veneer (board). The wood based board may be or comprise a wood fibre based board, such as MDF, HDF, particle board, etc., or a plywood board. The substrate may comprise or further comprise a wooden panel, such as a sheet core. In embodiments, the substrate may comprise or further comprise a thermoplastic sheet, such as WPC (wood plastic composite), Expanded Polymer Core (EPC), Stone Plastic Composite (SPC) or Solid Polymer Core (SPC). The substrate may comprise or further comprise a mineral composite panel. The substrate may comprise or further comprise a fiber cement board. The substrate may be a magnesia cement board. The substrate may comprise or further comprise a ceramic plate.

The substrate may comprise paper or non-woven fabric. The substrate may be a printing paper. The substrate may be formed from a powder mixture that includes a binder and a filler that are pressed onto the surface layer.

According to a fourth aspect, a coated foil is provided. The coated foil comprises a carrier and a cured coating arranged on a surface of the carrier.

The cured coating may comprise an embossed structure. The embossed structure may be obtained by a pressing device after curing.

The cured coating may comprise different gloss levels. Different gloss levels can be obtained by the pressing device after curing.

The embodiment of the fourth aspect of the invention has all the advantages of the first aspect of the invention already described above, whereby the above description applies equally to the coated foil.

The coating may be crosslinked.

The coating may be a UV cured coating, preferably a water based UV cured coating. The coating is UV cured means that at least one component of the coating composition is UV cured. By using the UV-curable composition, curing can be performed at a higher speed than in a pure water-based coating system. The cured UV cured coating did not adhere to the platen during pressing. The surface of the coating may be harder than the sintered coating composition. The UV curable component may be a polyester/polyurethane dispersion. The UV curable component may be a polyurethane/acrylic copolymer dispersion.

The coating may comprise a two-component system. The coating may comprise epoxy amines, polyurethane isocyanates, isocyanate alcohols or acid alcohol systems. The coating may be a water-based two-component system.

The carrier may comprise a thermoplastic material. The carrier may be a foil, for example a thermoplastic foil.

The coating may comprise scratch-resistant particles, such as silica particles. Thereby, the scratch resistance of the coating can be further improved. The coating may also contain wear resistant particles, such as alumina particles, also known as corundum.

The carrier may comprise a first thermoplastic foil and a second thermoplastic foil between which the wear resistant particles are arranged.

The coating may be substantially transparent. The coating may be a layer commonly referred to as a varnish layer.

The coating may comprise portions having different gloss levels.

According to a fifth aspect, a method for producing a coated foil is provided. The method includes providing a first thermoplastic foil and a second thermoplastic foil, applying wear resistant particles on the first thermoplastic foil or the second thermoplastic foil, applying the second thermoplastic foil on the first thermoplastic foil such that the wear resistant particles are disposed between the first thermoplastic foil and the second thermoplastic foil, applying a coating composition on the second thermoplastic foil, curing the coating composition such that a coating layer is formed, and then applying pressure to the coating layer.

The coating is applied on the surface of the second foil facing away from/towards the wear resistant particles.

Curing means curing completely or at least beyond a predried or precured state.

One advantage of at least some embodiments of the invention is that by applying the coating prior to pressing, the coating can be applied on-line/on-the-fly, integrated with assembly and attachment to other layers in, for example, a building panel. Thereby, an already coated foil may be provided, without the need for an additional surface treatment after the foil has been attached to the substrate.

At least some embodiments of the invention allow for coatings that can be treated as a separate layer after curing and can be adhered to another substrate or the like by pressing in a subsequent operation.

Yet another advantage is that improved chemical resistance has been shown to be achieved by compression coating. It is believed that improved chemical resistance can be achieved by further increasing the degree of crosslinking by pressing and/or by compressing the coating. By a higher degree of crosslinking, the chemical resistance of the coating is higher.

Furthermore, an improved scratch resistance of the coating can be achieved due to the higher degree of crosslinking obtained after pressing and/or due to the fact that the coating is compressed by the pressing operation.

A further advantage is that the coating can be embossed by pressing it, also by pressing it against an embossing platen. In a conventional process, the surface of the substrate is embossed prior to application of the coating. Thereby, the coating may fill lighter structures in the substrate, and the visual impression of the embossing may be difficult to distinguish.

By including wear resistant particles between the first foil and the second foil, the scratch resistance of the foil is increased, thereby providing a coated foil with improved wear resistance.

It has further been shown that press coating can reduce any damage, such as scratching, in the coating. Such scratches may form during production as well as during handling in the production process.

Applying pressure may comprise pressing the coating against a pressing device comprising portions having different gloss levels such that the coating obtains different gloss levels after pressing. By applying the coating composition prior to pressing and then pressing against a pressing device having portions of different gloss levels, the different gloss levels in the coating can be obtained in a simplified manner compared to solutions known in the art.

The coating composition may comprise scratch resistant particles, such as silica particles. Thereby, the scratch resistance of the coating can be further improved. The coating composition may also comprise wear resistant particles, such as alumina particles, also known as corundum.

The coating composition may comprise a crosslinkable component. In crosslinkable coating systems, curing the coating composition crosslinks the polymer.

After curing, the residual oligomer content of the coating composition may be less than 10%. Having a certain residual oligomer content corresponds to having a certain residual crosslinking capacity. The residual crosslinking capacity allows the coating to be pressed after curing by a certain crosslinking capacity of the coating composition remaining after curing.

After curing the coating composition, the coating composition is no longer tacky. The coated support can thus be treated, for example rolled on a roller. By curing is meant that the coating composition has passed through its pre-drying stage/or pre-gelling period/stage.

The coating composition may be water-based, preferably a water-based UV-curable coating composition. It has been found that water-based coating compositions maintain removability after curing, thereby facilitating shaping of the coating during pressing, e.g. embossing or providing gloss.

The coating composition may comprise a two-component system. The coating composition may be an epoxy amine, a polyurethane isocyanate, an isocyanate alcohol or an acid alcohol system. The coating composition may be an epoxy amine, a polyurethane isocyanate, an isocyanate alcohol or an acid alcohol system. The coating composition may be a water-based two-component system.

The coating composition may be UV-curable, preferably a water-based UV-curable coating composition. By the coating composition being UV curable, it is meant that at least one component of the coating composition is UV curable. By using the UV-curable composition, curing can be performed at a higher speed than in a pure water-based coating system. The cured UV cured coating did not adhere to the platen during pressing. The surface of the coating may be harder than the sintered coating composition. The UV curable component may be a polyester/polyurethane dispersion. The UV curable component may be a polyurethane/acrylic copolymer dispersion.

Applying pressure to the coating may include pressing and attaching the coating on the coated foil to the substrate. Thereby, a coated substrate, such as a building panel, comprising a substrate and a coating foil may be provided. The coated foil may already be provided with a coating before being attached to the substrate. Thereby, the coated foil may be coated in a separate process from treating the entire substrate.

The method may comprise applying pressure to the first foil and the second foil prior to attaching the coated foil to the substrate to attach the first foil and the second foil to each other. This pre-pressing step may be performed before or after the coating composition is applied.

The coating may be substantially transparent. The coating may be a layer commonly referred to as a varnish layer.

The coating may comprise portions having different gloss levels.

According to a sixth aspect, a coated foil is provided. The coated foil comprises a first thermoplastic foil and a second thermoplastic foil between which wear resistant particles are arranged, wherein the coating is arranged on a surface of the first thermoplastic foil facing away from the second thermoplastic foil.

The coating may comprise different gloss levels obtained by a pressing device.

The coating may comprise an embossed structure obtained by a pressing device.

The embodiment of the sixth aspect of the invention has all the advantages of the fifth aspect of the invention already described above, whereby the above description applies equally to the coated foil.

The coating may be crosslinked.

The coating may be a UV cured coating, preferably a water based UV cured coating.

The coating may comprise scratch-resistant particles, such as silica particles. Thereby, the scratch resistance of the coating can be further improved. The coating may also contain wear resistant particles, such as alumina particles, also known as corundum.

The coating may be substantially transparent. The coating may be a layer commonly referred to as a varnish layer.

Drawings

The invention will be described in more detail, by way of example, with reference to the accompanying schematic drawings, which show embodiments of the invention.

Fig. 1A shows a method for producing a coated carrier.

Fig. 1B shows a method for producing a building panel.

Fig. 1C shows a method for producing a building panel.

Fig. 2 shows a method for producing a building panel.

Fig. 3 shows a method for producing a coated foil.

Detailed Description

Fig. 1A shows a method for producing a coated carrier 10. A carrier 1 is provided. The support 1 may be a release foil, for example a fluoroplastic foil, or a permanent support, for example a thermoplastic foil. The thermoplastic foil may comprise, for example, polyvinyl chloride (PVC), Polyurethane (PU), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), cross-linked Polyethylene (PEX), Polyethylene (PE), polyester, Polystyrene (PS), polypropylene (PP), Polycarbonate (PC), polyvinyl acetate (PVAc), Ethylene Vinyl Acetate (EVA), polyacrylate, methacrylate, and/or combinations thereof. The thermoplastic material may comprise an ionomer such as polyethylene. The thermoplastic material may be a casting resin or a hot melt. The carrier 1 may have a thickness of 0.05-1 mm. The thermoplastic foil may be printed and/or coloured such that the thermoplastic foil forms a decorative foil.

In one embodiment, the carrier 1 is a wood veneer layer. The wood veneer layer may have a thickness of about 0.2 to 1 mm. The wood veneer can be made of any type of wood veneer. In one embodiment, the wood veneer layer is an oak veneer layer.

The coating composition is applied on the surface of the carrier 1 by means of a coating device 20. The coating composition may be a coating conventionally referred to as a varnish. The coating composition may be applied by roll coating, curtain coating, spray coating, dip coating, and the like.

The coating composition may be crosslinkable. The coating composition may be radiation curable, preferably UV curable. The coating composition is preferably water-based, e.g., a UV curable water-based composition. The aqueous-based UV curable composition may comprise a polyester/polyurethane dispersion. The water-based UV curable composition may comprise a polyurethane/acrylic copolymer dispersion. The water-based UV-curable composition may further comprise a photoinitiator, a thickener, an additive, and the like.

The coating composition may be a two-component system, such as an epoxy amine system, a polyurethane isocyanate system, an isocyanate alcohol system, an acidic alcohol system, and the like.

The coating composition may be applied in one or more layers. The total amount of coating composition applied, converted to an amount corresponding to 100% coating components and 0% water and solvent, may be 5-200g/m2, for example more than 5g/m2, preferably more than 10g/m 2.

The coating composition may comprise abrasion-resistant particles and/or scratch-resistant particles. Preferably, the coating composition comprises scratch resistant particles. Alternatively or in addition, the scratch-resistant particles can be applied on the coating composition while on the support and while the coating composition is still wet.

The wear resistant particles may be alumina particles, such as corundum. Alternatively, or in addition, the wear resistant particles may be silicon carbide, quartz, silica, glass beads, glass spheres, diamond particles, hard plastics, reinforced polymers and organics, or combinations thereof.

The average particle diameter of the wear resistant particles is preferably in the range of 10-200 μm, preferably in the range of 50-120 μm, e.g. 50-100 μm. The wear resistant particles may have a spherical or irregular shape. The wear resistant particles may be surface treated. The wear resistant particles may be silane treated particles. The amount of wear resistant particles applied may be from 10 to 100g/m2, preferably from 10 to 50g/m2, more preferably from 20 to 30g/m 2.

The scratch resistant particles may be or comprise nanoscale silica particles, preferably fused silica particles. The scratch-resistant particles may be disk-shaped particles, the width/thickness ratio of which is preferably equal to or more than 3:1, more preferably equal to or more than 5: 1. Such disc-shaped particles are oriented along the surface of the foil, thereby improving the scratch resistance of the foil. The scratch-resistant particles may have an average particle diameter of 1 to 100. mu.m, preferably 10 to 50 μm, more preferably 20 to 30 μm. The average particle diameter of the scratch-resistant particles may be less than 50 μm, preferably less than 45 μm. The scratch-resistant particles can be applied in an amount of from 0.5 to 20g/m2, preferably from 0.5 to 10g/m2, more preferably from 0.5 to 5g/m 2.

The coating composition may comprise conventional additives. The coating composition may further comprise functional additives, such as antistatic additives and/or antimicrobial additives.

The coating composition may be transparent. However, the coating composition may also be pigmented.

The coating composition may be applied as one or more layers to form a coating on the carrier 1.

After the coating composition has been applied on the carrier 1, the coating composition is cured so that a coating layer 2 is formed. If the coating composition is UV curable, UV radiation is applied to cure the coating composition. If the coating composition is a water-based UV-curable coating composition, the coating composition is first dried by IR or in an oven in a drying device 21 and then cured by applying UV radiation to the coating in a UV radiation device 22. If the coating composition is a two-component system, the coating composition is dried, for example, in an oven or at ambient temperature (not shown).

After curing, the coated carrier 10 is formed.

Preferably, the coating composition retains some crosslinking ability after curing. After curing, the residual oligomer content of the coating composition may be less than 10%. Having a certain residual oligomer content corresponds to having a certain residual crosslinking capacity. Thus, the coating composition may be further crosslinked and/or compressed during the pressing in a subsequent step.

The coated carrier 10 formed by the method described with reference to fig. 1 may be stored after the coating composition has been cured. As will be further described with reference to fig. 1B and 1C, the coated carrier 10 may be coated onto a substrate, or wherein the carrier is a release foil, the coating 2 may be applied to a substrate without the carrier 1. The coated carrier 10 may be used as a coated wear resistant foil. In an embodiment, wherein the carrier is a decorative thermoplastic foil, the coated carrier 10 may be a coated decorative foil.

In fig. 1B, the coated carrier 10 formed as described above with reference to fig. 1A is intended to form a portion of a building panel 5. The building panels 5 may be floor panels, wall panels, ceiling panel furniture parts, etc. For example, the building panels may be of the type known as LVT or WPC.

In the embodiment shown in fig. 1B, the coated carrier 10 forms a coated wear resistant foil in the building panel 5. In the embodiment shown in fig. 1B, the coated wear resistant foil comprises a thermoplastic material. The thermoplastic material may be polyvinyl chloride (PVC), Polyurethane (PU), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), cross-linked Polyethylene (PEX), Polyethylene (PE), polyester, Polystyrene (PS), polypropylene (PP), Polycarbonate (PC), polyvinyl acetate (PVAc), Ethylene Vinyl Acetate (EVA), polyacrylate, methacrylate, and/or combinations thereof. The thermoplastic material may comprise an ionomer such as polyethylene. The thermoplastic material may be a casting resin or a hot melt. Preferably, the coating the carrier 10 comprises abrasion-and/or scratch-resistant particles of the type described above, preferably scratch-resistant particles of the type described above.

In fig. 1B, a substrate 3 is provided. The substrate may comprise a thermoplastic material. The substrate 3 may comprise a thermoplastic material and a filler, such as WPC (wood plastic composite), Expanded Polymer Core (EPC), Stone Plastic Composite (SPC) or Solid Polymer Core (SPC), or any other type of polymer core comprising a filler and a thermoplastic material. The core may be extruded or calendered. The thermoplastic material may include polyvinyl chloride (PVC), Polyurethane (PU), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), cross-linked Polyethylene (PEX), Polyethylene (PE), polyester, Polystyrene (PS), polypropylene (PP), Polycarbonate (PC), polyvinyl acetate (PVAc), Ethylene Vinyl Acetate (EVA), polyacrylate, methacrylate, and/or combinations thereof. The thermoplastic material may comprise an ionomer such as polyethylene. The thermoplastic material may be a casting resin or a hot melt.

In other embodiments, the substrate 3 may comprise a wood-based substrate, such as a wood veneer, or may be or comprise a wood fiber-based board, such as MDF, HDF, particle board, or the like, or plywood. In other embodiments, the substrate may comprise paper, such as decor paper. In other embodiments, the substrate may be formed from a dry powder mixture that includes a binder and a filler that are pressed to the surface layer.

In the embodiment shown in fig. 11B, a decorative layer 4 is provided and arranged on the surface of the substrate 3. It is also conceivable that the substrate 3 is provided with a decorative pattern, for example a print. In such an embodiment, the coated carrier 10 is disposed directly on the surface of the substrate 3 (not shown). It is also conceivable that the thermoplastic foil forming the carrier 1 of the coated carrier 10 has a decorative design, for example a print. In such an embodiment, the coated carrier 10 is disposed directly on the surface of the substrate 3 (not shown).

The decorative layer 4 may comprise a thermoplastic material. The thermoplastic material may be polyvinyl chloride (PVC), Polyurethane (PU), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), cross-linked Polyethylene (PEX), Polyethylene (PE), polyester, Polystyrene (PS), polypropylene (PP), Polycarbonate (PC), polyvinyl acetate (PVAc), Ethylene Vinyl Acetate (EVA), polyacrylate, methacrylate, and/or combinations thereof. The thermoplastic material may comprise an ionomer such as polyethylene. The thermoplastic material may be a casting resin or a hot melt. The decor layer can be provided with a decorative pattern, for example a print.

In other embodiments, the decorative layer 4 may comprise a wood veneer or paper, such as a decorative paper.

The coated carrier 10 is arranged on the decorative layer 4. In an alternative embodiment, the coating may be peeled off from the carrier 1 in the form of a release foil and subsequently arranged directly on the decorative layer 4 or on the substrate 3.

In an embodiment, an adhesive may be provided between the decorative layer 4 and the substrate 3.

Thereafter, the substrate 3, the decorative layer 4 and the coated carrier 10 with the cured coating 2 are pressed together in a pressing device 23, so that the layers adhere to each other and form the building panel 5. The pressing device 23 may be static or continuous. Preferably, heat is also applied during pressing. The pressure applied may be 5-100bar, for example applied within 5-500 seconds. The temperature may be 80-300 deg.C, such as 100-. The temperature may be about 140 ℃.

The pressing device 23 may have different gloss levels. The pressing surface of the pressing device 23 may have a high gloss portion, or even an ultra-high gloss portion, and a matte portion. The different gloss levels are provided by means of micro-embossing or micro-structuring with a maximum depth of 30 μm. The higher the depth of the microstructure, the more matt the part or parts have. The lower the depth of the microstructure, the more lustrous the portion or portions. When the coated support 10 is pressed against the microstructure, the coated support 10 obtains portions with different gloss levels. The depth of the micro-embossing may vary over the entire surface of the pressing device 23, so that a varying gloss is obtained. When pressing the coated support 10 against the microstructure, the coated support 10 obtains portions with different gloss levels, which correspond to the gloss level of the pressing surface of the pressing device 23. The gloss may vary across the surface of the coated support 10. By different gloss it is preferably meant that the gloss of the first part or group of parts is different from the gloss of the second part or group of parts. The first portion or set of portions may have a higher gloss than the second portion or set of portions. The first portion or set of portions may have a first gloss level and the second portion or set of portions may have a second gloss level that is higher or lower than the first gloss level.

The pressing device 23 may also be provided with protrusions for forming a macroscopic embossing or macroscopic structure in the coating of the coated carrier. The macrostructures may also be aligned with the decorative pattern or printed pattern of the decorative layer.

The pressing device 23 may comprise a metal surface provided with different gloss levels as described above. The metal surface of the pressing device is adapted to directly contact the coating 2 of the coated carrier 10. The pressing device 23 may be a pressing cylinder or a pressing plate with different gloss degrees, wherein the pressing cylinder or the pressing plate directly contacts the surface of the coated carrier 10.

In one embodiment, the pressing device 23 may comprise structured foils with different gloss levels. The structured foil is adapted to directly contact the surface of the coated carrier. The structured foil may be arranged between the coated carrier and a press plate, press belt or press drum during pressing.

The surface of the coated carrier 10 may be provided with a release agent to prevent the coated carrier from adhering to the press during pressing at elevated pressing temperatures. Since no additional layers need to be applied on the coated carrier 10, a release agent can be applied on the coated carrier 10, facilitating the pressing operation.

After pressing, the coated carrier 10 may have portions with different gloss levels. The different gloss levels are formed by microstructures in the coating preferably having a maximum depth of 30 μm. Different gloss levels can be formed in register with the decorative pattern or printed motif of the decorative layer 4.

The coating of the coated carrier 10 may also be provided with embossed portions during pressing. The pressing device 23, for example a press plate, a press cylinder, a press belt or a structured foil, can provide the coated support 10 with protrusions forming embossments or macrostructures in the coating. Alternatively, the embossed portion may be formed in a separate step from forming the portion having the different glossiness. The embossing is preferably aligned with the decorative pattern or printed pattern. The embossing preferably cooperates with portions of the coated support 10 having different gloss levels. The embossed portions in the wear layer preferably have a depth of more than 100 μm.

By pressing the coated carrier 10 with the optional intermediate decorative layer 4 onto the substrate 3, a building panel 5 is formed.

In fig. 1C, the coated carrier 10 formed as described above with reference to fig. 1A is intended to form part of a building panel 5. The building panels 5 may be floor panels, wall panels, ceiling panels, furniture parts, etc.

In the embodiment described with reference to fig. 1C, the carrier 1 is a wood veneer layer. The wood veneer layer may have a thickness of about 0.2 to 1 mm. The facing layer may be made of any type of facing layer. In one embodiment, the wood veneer layer is an oak veneer layer. Thus, the coated wood veneer layer 10 is formed by the method described above with reference to FIG. 1A.

In the embodiment shown in fig. 1C, the coated wood veneer layer 10 forms a surface of the building panel 5. In fig. 1C, the coated wood veneer layer 10 is disposed on the substrate 3 and adhered to the substrate 3. The substrate 3 may be a wood-based board. The wood based board may be a wood fibre based board, such as MDF, HDF, particle board, etc., or a plywood board. The substrate 3 may be a wooden board, for example a thin plate core. In other embodiments, the substrate may be a thermoplastic sheet, such as WPC (wood plastic composite), Expanded Polymer Core (EPC), Stone Plastic Composite (SPC), or Solid Polymer Core (SPC). The substrate 3 may be a mineral composite plate. The substrate may be a fiber cement board. The substrate 3 may be a magnesia cement board. The substrate may be a ceramic plate. The substrate 3 may be a plastic plate, such as a thermoplastic plate. In other embodiments, the substrate 3 may be a carrier, such as a paper sheet or a nonwoven fabric. The wood based substrate 3 may preferably be printed by means of a digital printer.

The coated wood veneer layer 10 with the cured coating 2 is pressed in a pressing device 23, preferably while adhering to the substrate. The coated wood veneer layer 10 may be attached to the substrate 3 under pressure. An adhesive layer may be applied on the coated wood trim panel layer 10 and/or the substrate 3. The adhesive layer may comprise a thermoplastic adhesive. The thermoplastic adhesive may be polyvinyl chloride (PVC), Polyethylene (PE), polypropylene (PP), Polyurethane (PU), polyvinyl alcohol (PVOH), polyvinyl butyral (PVB), and/or polyvinyl acetate (PVAc), or combinations thereof. The adhesive layer may comprise a hot melt or pressure sensitive adhesive.

The pressing device 23 may be static or continuous. Preferably, heat is also applied. The pressure applied may be 5-100bar, for example applied within 5-500 seconds. The temperature may be 80-300 deg.C, such as 100-. The temperature may be about 140 ℃.

The pressing device 23 may have different gloss levels. The pressing surface of the pressing device 23 may have a high gloss portion, or even an ultra-high gloss portion and a matte portion. The different gloss levels are provided by micro-embossing or micro-structuring with a maximum depth of 30 μm. The higher the depth of the microstructure, the more matt the part or parts have. The lower the depth of the microstructure, the more lustrous the portion or portions. When the coated wood veneer layer 10 is pressed against the microstructure, the coated wood veneer layer 10 obtains portions having different gloss levels. The depth of the micro-embossing may vary over the entire surface of the pressing device 23, so that a varying gloss is obtained. When pressing the coated wood veneer layer 10 against the microstructure, the coated wood veneer layer 10 obtains portions with different gloss levels, which correspond to the gloss level of the pressing surface of the pressing device 23. The gloss level may vary across the surface of the coated wood veneer layer 10. By different gloss it is preferably meant that the gloss of the first part or group of parts is different from the gloss of the second part or group of parts. The first portion or set of portions may have a higher gloss than the second portion or set of portions. The first portion or set of portions may have a first gloss level and the second portion or set of portions may have a second gloss level that is higher or lower than the first gloss level.

The pressing device 23 may also be provided with macro-embossing or macro-structured protrusions for forming a coating of the coated wood veneer layer 10. The macrostructures may also be aligned with the wood grain pattern of the coated wood veneer layer 10.

The pressing device 23 may comprise a metal surface provided with different gloss levels as described above. The metal surface of the pressing device 23 is adapted to directly contact the surface of the coated support. The pressing device 23 may be a press cylinder or a press plate with different gloss degrees, wherein the press cylinder or press plate directly contacts the surface of the coated carrier.

In one embodiment, the pressing device 23 may comprise structured foils with different gloss levels. The structural foil is adapted to directly contact the surface of the coated wood veneer layer 10. The structural foil may be arranged between the coated wood veneer layer 10 and a press plate, press belt or press drum during pressing.

In order to avoid that the coated carrier adheres to the pressing device 23, the surface of the coated wood veneer layer 10 may be provided with a release agent. Since no additional layers need to be applied over the coated wood veneer layer 10, a release agent may be applied over the coated wood veneer layer 10 to facilitate the pressing operation.

After pressing, the coated wood veneer layer 10 may have portions with different gloss levels. The different gloss levels are formed by microstructures in the surface preferably having a maximum depth of 30 μm. The different gloss levels may be formed in registration with the wood grain pattern of the coated wood veneer layer 10.

The surface of the coated wood veneer layer 10 may also be provided with embossed portions during pressing. The pressing device 23, such as a press plate, a press drum, a press belt or a structured foil, may be provided with protrusions forming embossments or macrostructures in the coated wood veneer layer 10. Alternatively, the embossed portion may be formed in a separate step from forming the portion having the different glossiness. The embossing is preferably aligned with the wood grain pattern. The embossing preferably cooperates with portions of the coated wood veneer layer 10 having different gloss levels. The embossed portions in the wear layer preferably have a depth of more than 100 μm.

Thereby, a building panel 5 is formed, which building panel 5 comprises a coated wood veneer layer 10 attached to the substrate 3.

In the embodiment described with reference to fig. 1C, the carrier 1 may comprise paper, for example decor paper, instead of a wood veneer layer.

In fig. 2, an integrated method of forming a coated building panel 5 is shown. In fig. 2, a substrate 3 and at least one surface layer are provided. In the embodiment shown in fig. 2, the surface layer comprises the decorative layer 4 and the carrier 1.

The substrate 3 may comprise a thermoplastic material. The substrate 3 may comprise a thermoplastic material and a filler, such as WPC (wood plastic composite), EPC (expanded polymer core), SPC (stone plastic composite/solid polymer core), or any other type of polymer core comprising a filler and a thermoplastic material. The substrate may be extruded or calendered. The thermoplastic material may include polyvinyl chloride (PVC), Polyurethane (PU), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), cross-linked Polyethylene (PEX), Polyethylene (PE), polyester, Polystyrene (PS), polypropylene (PP), Polycarbonate (PC), polyvinyl acetate (PVAc), Ethylene Vinyl Acetate (EVA), polyacrylate, methacrylate, and/or combinations thereof. The thermoplastic material may comprise an ionomer such as polyethylene. The thermoplastic material may be a casting resin or a hot melt.

In one embodiment, the substrate 3 may comprise a wood-based board. The wood based board may be a wood fibre based board, such as MDF, HDF, particle board, etc., or a plywood board. The substrate 3 may be a wooden board, for example a thin plate core. In other embodiments, the substrate may be a thermoplastic sheet, such as a Wood Plastic Composite (WPC), EPC (expanded polymer core), or SPC (stone plastic composite/solid polymer core). The substrate 3 may be a mineral composite plate. The substrate 3 may be a fiber cement board. The substrate 3 may be a magnesia cement board. The substrate 3 may be a ceramic plate. The substrate 3 may be a plastic plate, such as a thermoplastic plate. In other embodiments, the substrate 3 may be a carrier, such as a paper sheet or a nonwoven fabric.

The decorative layer 4 may comprise a thermoplastic material. The thermoplastic material may be polyvinyl chloride (PVC), Polyurethane (PU), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), cross-linked Polyethylene (PEX), Polyethylene (PE), polyester, Polystyrene (PS), polypropylene (PP), Polycarbonate (PC), polyvinyl acetate (PVAc), Ethylene Vinyl Acetate (EVA), polyacrylate, methacrylate, and/or combinations thereof. The thermoplastic material may comprise an ionomer such as polyethylene. The thermoplastic material may be a casting resin or a hot melt. The decorative layer may be provided with decorative patterns, such as printing.

In other embodiments, the decorative layer 4 may comprise a wood veneer or paper, such as a decorative paper. It is also conceivable that the substrate 3 is provided with a decorative pattern, for example a print. In such an embodiment, the carrier 1 is arranged directly on the surface of the substrate 3. It is also conceivable for the carrier 1 of the coated carrier 10 to have a decorative pattern, for example a print. In such an embodiment, the carrier 1 is arranged directly on the surface of the substrate 3.

The carrier 1 may be a thermoplastic foil. The thermoplastic foil may comprise, for example, polyvinyl chloride (PVC), Polyurethane (PU), polyethylene terephthalate (PET), polyvinyl butyral (PVB), polybutylene terephthalate (PBT), cross-linked Polyethylene (PEX), Polyethylene (PE), polyester, Polystyrene (PS), polypropylene (PP), Polycarbonate (PC), polyvinyl acetate (PVAc), Ethylene Vinyl Acetate (EVA), polyacrylate, methacrylate, and/or combinations thereof. The thermoplastic material may comprise an ionomer such as polyethylene. The thermoplastic material may be a casting resin or a hot melt. The carrier 1 may have a thickness of 0.05-1 mm. The thermoplastic foil may be printed and/or coloured such that the thermoplastic foil forms a decorative foil.

The coating composition is applied on the surface of the carrier 1 by means of a coating device 20. The coating composition may be a coating conventionally referred to as a varnish. The coating composition may be applied by roll coating, curtain coating, dip coating, spray coating, and the like.

The coating composition is crosslinkable. The coating composition may be radiation curable, preferably UV curable. The coating composition is preferably water-based, e.g., a UV curable water-based composition. The aqueous-based UV curable composition may comprise a polyester/polyurethane dispersion. The water-based UV curable composition may comprise a polyurethane/acrylic copolymer dispersion. The water-based UV-curable composition may further comprise a photoinitiator, a thickener, an additive, and the like.

The coating composition may be a two-component system, such as an epoxy amine system, a polyurethane isocyanate system, an isocyanate alcohol system, an acidic alcohol system, and the like.

The coating composition may be applied in one or more layers. The total amount of coating composition applied, converted to an amount corresponding to 100% coating components and 0% water and solvent, may be 5-200g/m2, for example more than 5g/m2, preferably more than 10g/m 2.

The coating composition may comprise wear resistant particles and/or scratch resistant particles. Preferably, the coating composition comprises scratch resistant particles. Alternatively or in addition, the scratch-resistant particles can be applied to the coating composition applied to the support while the coating composition is still wet.

The wear resistant particles may be alumina particles, such as corundum. Alternatively, or in addition, the wear resistant particles may be silicon carbide, quartz, silica, glass beads, glass spheres, diamond particles, hard plastics, reinforced polymers and organics, or combinations thereof.

The average particle diameter of the wear resistant particles is preferably in the range of 10-200 μm, preferably in the range of 50-120 μm, e.g. 50-100 μm. The wear resistant particles may have a spherical or irregular shape. The wear resistant particles may be surface treated. The wear resistant particles may be silane treated particles. The amount of wear resistant particles applied may be from 10 to 100g/m2, preferably from 10 to 50g/m2, more preferably from 20 to 30g/m 2.

The scratch resistant particles may be or comprise nanoscale silica particles, preferably fused silica particles. The scratch resistant particles may be disc-shaped particles, the width/thickness ratio of which is preferably equal to or more than 3:1, more preferably equal to or more than 5: 1. such disc-shaped particles are oriented along the surface of the foil, thereby improving the scratch resistance of the foil. The scratch-resistant particles may have an average particle diameter of 1 to 100. mu.m, preferably 10 to 50 μm, more preferably 20 to 30 μm. The average particle diameter of the scratch-resistant particles may be less than 50 μm, preferably less than 45 μm. The scratch-resistant particles can be applied in an amount of from 0.5 to 20g/m2, preferably from 0.5 to 10g/m2, more preferably from 0.5 to 5g/m 2.

The coating composition may comprise conventional additives. The coating composition may further comprise functional additives, such as antistatic additives and/or antimicrobial additives.

The coating composition may be transparent. However, the coating composition may also be pigmented.

The coating composition may be applied to the support 1 in one or more layers.

After the coating composition has been applied on the carrier 1, the coating composition is cured so that a coating layer 2 is formed. If the coating composition is UV curable, UV radiation is applied to cure the coating composition. If the coating composition is a water-based UV-curable coating composition, the coating composition is first dried by IR or in an oven in a drying device 21 and then cured by applying UV radiation to the coating composition in a UV radiation device 22. If the coating composition is a two-component system, the coating composition is dried, for example, in an oven or at ambient temperature.

After curing, the coated carrier 10 is formed.

Preferably, the coating composition retains some crosslinking ability after curing. After curing, the residual oligomer content of the coating composition may be less than 10%. Having a certain residual oligomer content corresponds to having a certain residual crosslinking capacity. Thus, the coating composition may be further crosslinked during the pressing in the subsequent step.

In the embodiment shown in fig. 2, the substrate, the decorative layer 4 and the coated carrier 10 with the cured coating 2 are pressed together with a coating step in a pressing device 23. Preferably, the pressing device 23 is continuous. Preferably, heat is also applied. The pressure applied may be 5-100bar, for example applied within 5-500 seconds. The temperature may be 80-300 deg.C, such as 100-. The temperature may be about 140 ℃.

The pressing device 23 may have different gloss levels. The pressing surface of the pressing device 23 may have a high gloss portion, or even an ultra-high gloss portion and a matte portion. The different gloss levels are provided by micro-embossing or micro-structuring with a maximum depth of 30 μm. The higher the depth of the microstructure, the more matt the part or parts have. The lower the depth of the microstructure, the more lustrous the portion or portions. When the coating 2 is pressed against the microstructure, the coating 2 obtains portions with different gloss levels. The depth of the micro-embossing may vary over the entire surface of the pressing device 23, so that a varying gloss is obtained. When the coating 2 is pressed against the microstructure, the coating 2 obtains portions with different gloss levels, which correspond to the gloss levels of the pressing surfaces of the pressing device 23. The gloss level may vary over the entire surface of the coating 2. By different gloss it is preferably meant that the gloss of the first part or group of parts is different from the gloss of the second part or group of parts. The first portion or set of portions may have a higher gloss than the second portion or set of portions. The first portion or set of portions may have a first gloss level and the second portion or set of portions may have a second gloss level that is higher or lower than the first gloss level.

The pressing device 23 may also be provided with protrusions for forming a macroscopic embossing or macroscopic structure of the surface of the coated carrier. The macrostructures may also be aligned with the decorative pattern or printed pattern of decorative layer 4.

The pressing device 23 may comprise a metal surface provided with different gloss levels as described above. The metal surface of the pressing device 23 is adapted to directly contact the surface of the coating 2. The pressing device 23 may be a pressing cylinder or a pressing plate having different gloss degrees, wherein the pressing cylinder or the pressing plate directly contacts the surface of the coating support 10.

In one embodiment, the pressing device 23 may comprise structured foils with different gloss levels. The structured foil is adapted to directly contact the surface of the coating 2. The structured foil may be arranged between the coating 2 and a press plate, press belt or press drum during pressing.

The coating 2 may be provided with a release agent to avoid that the coating 2 adheres to the press. Since no additional layers need to be applied on the coating 2, a release agent can be applied on the coating 2, thereby facilitating the pressing operation.

After pressing, the coating 2 may comprise portions having different gloss levels. The different gloss levels are formed by microstructures in the surface preferably having a maximum depth of 30 μm. Different gloss levels may be formed in register with the decorative pattern or printed pattern of the decorative layer.

The coating 2 may also be provided with embossed portions during pressing. The pressing device 23, for example a press plate, a press cylinder, a press belt or a structured foil, can be provided with protrusions forming embossments or macrostructures in the coating 2. Alternatively, the embossed portion may be formed in a separate step from forming the portion having the different glossiness. The embossing is preferably aligned with the decorative pattern or printed pattern. The embossing preferably cooperates with portions of the coated support having different gloss levels. The embossed portions in the wear layer preferably have a depth of more than 100 μm.

By pressing the coated carrier 10 with the optional intermediate decorative layer 4 onto the substrate 3, a building panel 5 is formed.

In fig. 3, an alternative method of forming a coated foil 10' is shown. In this embodiment, the coated foil 10' comprises a first foil 8 and a second foil 9.

The first foil 8 comprises a first thermoplastic material. The first thermoplastic material may be polyvinyl chloride (PVC), polyester, polypropylene (PP), Polyethylene (PE), Polystyrene (PS), Polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or combinations thereof.

Preferably, the first foil 8 is formed of a thermoplastic material. The first foil 8 may consist essentially of a thermoplastic material and optional additives. The additives may be plasticizers, stabilizers, lubricants, degassing agents, coupling agents, compatibilizers, crosslinking agents, and the like.

In one embodiment, the first foil 1 is a PVC foil.

The first foil 8 may have a thickness of 0.1-1 mm. Preferably, the thickness of the first foil 8 is less than 0.5mm, more preferably about 100 μm, preferably measured after pressing, e.g. in the final product. The first foil 8 may be a decorative foil.

The wear resistant particles 6 may be applied on the first foil 8 by a dispersing/spreading device 24. The wear resistant particles may be alumina particles, such as corundum. Alternatively, or in addition, the wear resistant particles 6 may be silicon carbide, quartz, silica, glass beads, glass spheres, diamond particles, hard plastics, reinforced polymers and organics, or combinations thereof.

The average particle diameter of the wear resistant particles 6 is preferably in the range of 10-200 μm, preferably in the range of 50-120 μm, e.g. 50-100 μm. The average particle size of the wear resistant particles 6 may be less than 50 μm, preferably less than 45 μm. The wear resistant particles 6 may have a spherical or irregular shape. The wear resistant particles 6 may be surface treated. The wear resistant particles 6 may be silane treated particles.

The wear resistant particles 6 may have a refractive index similar to the refractive index of the second foil. The wear resistant particles 6 may have a refractive index of 1.4-1.9. In an embodiment, the wear resistant particles may have a refractive index of 1.4-1.9, preferably 1.5-1.8, e.g. 1.7-1.8. In an embodiment, the refractive index of the wear resistant particles 6 may differ from the refractive index of the second foil by no more than ± 20%.

The amount of wear resistant particles 6 applied may be 10-100g/m2, preferably 10-50g/m2, more preferably 20-30g/m 2. After the wear resistant particles 6 have been applied on the first foil 8, a second foil 9 is provided and arranged on the first foil 9. Thereby, the wear resistant particles 6 are encapsulated by the first foil 8 and the second foil 9.

As an alternative or in addition to applying the wear resistant particles 6 on the first foil 8, wear resistant particles may be applied on the second foil 9. In this embodiment, the second foil 9 with the wear resistant particles 6 is arranged on the first foil 8 and vice versa.

The second foil 9 comprises a second thermoplastic material. The second thermoplastic material may be the same as the material in the first foil 8 or may be different from the thermoplastic material of the first foil 8. The second thermoplastic material may be polyvinyl chloride (PVC), polyester, polypropylene (PP), Polyethylene (PE), Polystyrene (PS), Polyurethane (PU), polyethylene terephthalate (PET), polyacrylate, methacrylate, polycarbonate, polyvinyl butyral, polybutylene terephthalate, or combinations thereof.

Preferably, the second foil 9 is formed of a thermoplastic material. The second foil may consist essentially of a thermoplastic material and optionally additives. The additives may be plasticizers, stabilizers, lubricants, degassing agents, coupling agents, compatibilizers, crosslinking agents, and the like.

In one embodiment, the first foil 8 is a PVC foil and the second foil 9 is a PU foil.

The second foil 9 may be provided as a foil produced in a separate production step. The second foil 9 may be provided as a continuous web.

In other embodiments, the second foil 9 may be formed by an extrusion process, such as extrusion coating or extrusion lamination of the second foil 9 on the first foil 8.

The second foil 9 may have a thickness of 0.01-1 mm. Preferably, the thickness of the second foil 9 is less than 0.5mm, more preferably about 90-110 μm, preferably measured after pressing, e.g. in the final product. In embodiments where the second foil is a PVC foil, the thickness may be about 100 μm. In embodiments where the second foil is a PU foil, the thickness may be about 40-60 μm, for example 50 μm.

The thickness of the first foil 8 may exceed the thickness of the second foil 9. The thickness of the first foil 8 may exceed the thickness of the second foil 9, in particular if the first foil 8 comprises PVC and the second foil 9 comprises PU.

The average particle size of the wear resistant particles 6 may be smaller than the thickness of the second foil 9. However, the average particle size of the wear resistant particles 6 may be larger than the thickness of the second foil 9. During pressing, the wear resistant particles 6 are pressed into the first foil 8 such that the wear resistant particles 6 do not protrude beyond the upper surface of the second foil 9 after pressing, although the average particle size of the wear resistant particles 6 exceeds the thickness 9 of the second foil.

Thereafter the first and second foils 8, 9 are attached to each other to form a wear resistant foil 1' comprising the first foil 8 and the second foil 9, and wherein at least a part of the wear resistant particles are arranged between the first foil and the second foil.

The wear resistant foil 1' is preferably transparent, or at least substantially transparent.

The first foil 8 and the second foil 9 may be attached to each other by being pressed together, for example in a calendering/laminating process. As shown in fig. 3, the first foil 8 and the second foil 9 are pressed in a continuous press 25. The first foil 8 and the second foil 9 may be attached together by separate pressure, by heat and pressure, by pressure and adhesive or by heat, pressure and adhesive. Preferably, both pressure and heat are applied in order to attach the first and second foils to each other. Instead of or in addition to the calendering process, continuous or static pressing may also be used. The pressing operation may be, for example, a hot-hot process, a hot-cold process, or the like. The pressing may be performed with a stamp or a press roll having an embossed pattern, thereby forming an embossed structure in the wear resistant foil 1'.

Depending on the thermoplastic material and process used, the pressure applied may be 5-100bar, for example applied within 5-500 seconds. The temperature may be 80-300 deg.C, such as 100-. The temperature may be about 140 ℃.

After attaching the layers to each other, for example by pressing, the wear resistant particles 6 are surrounded by a first foil 8 and a second foil 9. Preferably, the wear resistant particles are completely surrounded by the first foil 8 and the second foil 9. Preferably, the wear resistant particles do not protrude beyond the surface of the second foil 9 facing away from the first foil 8. Thereby, a wear resistant foil 1' with a smooth surface can be formed.

As described above with reference to fig. 1A, the wear-resistant foil 1' constituting the carrier formed of the first foil 8 and the second foil 9 is coated by applying the coating composition on the surface of the second foil 9. The coating composition may be a coating conventionally referred to as a varnish. The coating composition may be applied by roll coating, curtain coating, dip coating, spray coating, and the like.

The coating composition is crosslinkable. The coating composition may be radiation curable, preferably UV curable. The coating composition is preferably water-based, e.g., a UV curable water-based composition. The aqueous-based UV curable composition may comprise a polyester/polyurethane dispersion. The water-based UV curable composition may comprise a polyurethane/acrylic copolymer dispersion. The water-based UV-curable composition may further comprise a photoinitiator, a thickener, an additive, and the like.

The coating composition may be a two-component system, such as an epoxy amine system, a polyurethane isocyanate system, an isocyanate alcohol system, an acidic alcohol system, and the like.

The coating composition may be applied in one or more layers. The total amount of coating composition applied, converted to an amount corresponding to 100% coating components and 0% solvent, may be 5-200g/m2, for example more than 5g/m2, preferably more than 10g/m 2.

The coating composition may comprise wear resistant particles and/or scratch resistant particles. Preferably, the coating composition comprises scratch resistant particles. Alternatively or in addition, the scratch-resistant particles can be applied to the coating composition applied to the support while the coating composition is still wet.

The scratch resistant particles may be or comprise nanoscale silica particles, preferably fused silica particles. The scratch-resistant particles may be disk-shaped particles, the width/thickness ratio of which is preferably equal to or more than 3:1, more preferably equal to or more than 5: 1. Such disc-shaped particles are oriented along the surface of the foil, thereby improving the scratch resistance of the foil. The scratch-resistant particles may have an average particle diameter of 1 to 100. mu.m, preferably 10 to 50 μm, more preferably 20 to 30 μm. The average particle diameter of the scratch-resistant particles may be less than 50 μm, preferably less than 45 μm. The scratch-resistant particles can be applied in an amount of from 0.5 to 20g/m2, preferably from 0.5 to 10g/m2, more preferably from 0.5 to 5g/m 2.

The coating composition may comprise conventional additives. The coating composition may further comprise functional additives, such as antistatic additives and/or antimicrobial additives.

The coating composition may be transparent. However, the coating composition may also be pigmented.

The coating composition may be applied in one or more layers on the second foil 9.

After the coating composition has been applied on the carrier 1', the coating composition is cured so that a coating layer 2 is formed. If the coating composition is UV curable, UV radiation is applied to cure the coating composition. If the coating composition is a water-based UV-curable coating composition, the coating composition is first dried by IR or in an oven in a drying device 21 and then cured by applying UV radiation 22 to the coating composition in a UV radiation device 22. If the coating composition is a two-component system, the coating composition is dried, for example, in an oven or at ambient temperature.

After curing, the coated foil 10 is formed.

Preferably, the coating composition retains some crosslinking ability after curing. After curing, the residual oligomer content of the coating composition may be less than 10%. Thus, the coating composition may be further crosslinked during the pressing in the subsequent step.

In one embodiment, the second foil 9 is coated in the above-described manner before the first foil 8 and the second foil 9 are attached to each other, preferably by pressing.

The coated carrier 10' formed by the method described with reference to fig. 3 may be stored after the coating composition has been cured. As previously described with reference to fig. 1B, a coating foil 10' may be applied to the substrate 3 with the optional decorative layer 4. The coated foil 10' may be used as a coated wear resistant foil. In an embodiment, wherein the carrier is a decorative thermoplastic foil, the coated carrier 10 may be a coated decorative foil.

It is contemplated that there are many variations of the embodiments described herein that are still within the scope of the invention as defined by the appended claims. For example, it is conceivable that more than one wear resistant foil may be arranged on the core for forming the building panel. It is also contemplated that one or more additional coating layers may be applied to the compressed coating layer after compression.

It is also conceivable that already formed building panels can be coated by the above-described method. In this embodiment, when the coating composition is applied on a carrier, the carrier forms a part of the building panel. After application of the coating composition, the coating composition is cured to a coating and then pressed as described above.

An exemplary UV-curable water-based composition may include:

the UV-curable composition may constitute from 60 to 90 wt%, for example from 70 to 85 wt% of the composition;

the photoinitiator may constitute from 0.1 to 5% by weight of the composition, for example from 0.5 to 2.5% by weight;

water may constitute from 1 to 25 wt%, for example from 5 to 15 wt% of the composition;

the solvent may constitute from 0.1 to 10% by weight of the composition, for example from 0.5 to 10% by weight;

optionally thickeners may be used, which may constitute from 0.0 to 15 wt%, for example from 0.1 to 10 wt% of the composition;

optionally, abrasion resistant particles may be used, which may constitute from 0.0 to 15 wt%, for example from 0.1 to 10 wt% of the composition;

matting agents may optionally be used, which may constitute from 0.0 to 15 wt%, for example from 0.1 to 10 wt% of the composition;

additives (e.g. defoamers/wetting agents) may optionally be used, which may constitute from 0.0 to 15 wt%, e.g. from 0.1 to 10 wt% of the composition.

An exemplary solvent may be dipropylene glycol methyl ether.

Examples of the invention

Example 1: the painted PVC foil is on a PVC foil with wear resistant particles.

A first PVC wear layer foil having a thickness of 0.1mm was positioned on a decorative PVC foil having a thickness of 0.03 mm. 25g/m2Al2O3 particles were applied on the first wear layer foil using a dispersion device. A second PVC abrasion resistant layer foil having a thickness of 0.1mm was painted with a UV curable water based coating composition according to Table 1 of 60g/m2, dried in an oven at 50 ℃ for 10 minutes and then UV cured. A second PVC wear layer foil was positioned on the first wear layer foil with Al2O3 particles. The decorative foil, the first wear layer foil and the second wear layer foil were laminated onto the PVC core using a temperature of 140 ℃, a pressure of 10 bar and a pressing time of 60 seconds. The resulting product was found to have improved scratch and chemical resistance. The product obtained has an abrasion resistance of more than 5000 revolutions, tested in a Taber abrasion tester according to the test method in EN 13329.

Table 1: UV-curable water-based composition

Example 2: the painted PVC foil is on the pre-pressed PVC foil with wear resistant particles.

25g/m2 of Al2O3 particles were applied on a first PVC abrasion resistant layer foil with a thickness of 0.1mm using a dispersion device. A second PVC abrasion resistant layer foil having a thickness of 0.1mm was painted with a UV curable water based coating composition according to Table 1 of 60g/m2, dried in an oven at 50 ℃ for 10 minutes and then UV cured. A second PVC wear layer foil was positioned on the first wear layer foil with Al2O3 particles. In a first pressing step, the first and second wear layer foils were laminated using a temperature of 120 ℃, a pressure of 10 bar and a pressing time of 60 seconds. In a second pressing step, the laminated wear layer was laminated to a decorative PVC foil having a thickness of 0.03mm and to a PVC core material using a temperature of 140 ℃, a pressure of 10 bar and a pressing time of 60 seconds. The resulting product was found to have improved scratch and chemical resistance. The product obtained has an abrasion resistance of more than 5000 revolutions, tested in a Taber abrasion tester according to the test method in EN 13329.

Example 3: the painted PVC foil is on the pre-pressed PVC foil.

The thickness of the first PVC abrasion-resistant layer foil is 0.1 mm. A second PVC abrasion resistant layer foil having a thickness of 0.1mm was painted with a UV curable water based coating composition according to Table 1 of 60g/m2, dried in an oven at 50 ℃ for 10 minutes and then UV cured. A second PVC wear layer foil is positioned on top of the first PVC wear layer foil. In a first pressing step, the first and second wear layer foils were laminated using a temperature of 120 ℃, a pressure of 10 bar and a pressing time of 60 seconds. In a second pressing step, the laminated wear layer was laminated to a PVC decorative foil and a PVC core material having a thickness of 0.03mm using a temperature of 140 ℃, a pressure of 10 bar and a pressing time of 60 seconds. The resulting product was found to have improved scratch and chemical resistance. The product obtained has an abrasion resistance of more than 1900 revolutions, tested in a Taber abrasion tester according to the test method in EN 13329.

Example 4: painted PVC foil is on PVC foil.

A first PVC wear layer foil having a thickness of 0.1mm was positioned on a decorative PVC foil having a thickness of 0.03 mm. A second PVC abrasion resistant layer foil having a thickness of 0.1mm was painted with a UV curable water based coating composition according to Table 1 of 60g/m2, dried in an oven at 50 ℃ for 10 minutes and then UV cured. A second PVC wear layer foil is positioned on top of the first PVC wear layer foil. The first and second wear layer foils were laminated to the PVC core material using a temperature of 140 ℃, a pressure of 10 bar and a pressing time of 60 seconds. The resulting product was found to have improved scratch and chemical resistance. The product obtained has an abrasion resistance of more than 1900 revolutions, tested in a Taber abrasion tester according to the test method in EN 13329.

Example 5: the painted PU foil is on a PVC foil with wear resistant particles.

A PVC wear layer foil with a thickness of 0.1mm was positioned on a decorative foil with a thickness of 0.03 mm. 25g/m2Al2O3 particles were applied to the PVC abrasion resistant layer foil using a dispersion apparatus. A PU abrasion resistant layer foil having a thickness of 0.05mm was painted with a UV-curable water-based coating composition of 60g/m2 according to Table 1, dried in an oven at 50 ℃ for 10 minutes and then UV-cured. The PU wear layer foil was positioned on a PVC wear layer foil with Al2O3 particles. The PU wear layer foil and the PVC wear layer foil were laminated onto the PVC core material using a temperature of 140 ℃, a pressure of 10 bar and a pressing time of 60 seconds. The resulting product was found to have improved scratch and chemical resistance. The product obtained has an abrasion resistance of more than 5000 revolutions, tested in a Taber abrasion tester according to the test method in EN 13329.

Example 6: the painted PU foil is on a pre-pressed PVC foil with wear resistant particles.

25g/m2 of Al2O3 particles were applied on a PVC abrasion resistant layer foil with a thickness of 0.1mm using a dispersion device. A PU abrasion resistant layer foil having a thickness of 0.05mm was painted with a UV-curable water-based coating composition of 60g/m2 according to Table 1, dried in an oven at 50 ℃ for 10 minutes and then UV-cured. The PU wear layer foil was positioned on a PVC wear layer foil with Al2O3 particles. In a first pressing step, two foils were laminated using a temperature of 120 ℃, a pressure of 10 bar and a pressing time of 60 seconds. In a second pressing step, the laminated wear layer was laminated to a decorative PVC foil and PVC core material having a thickness of 0.03mm using a temperature of 140 ℃, a pressure of 10 bar and a pressing time of 60 seconds. The resulting product was found to have improved scratch and chemical resistance. The product obtained has an abrasion resistance of more than 5000 revolutions, tested in a Taber abrasion tester according to the test method in EN 13329.

Example 7: the painted PU foil is on the pre-pressed PVC foil.

The thickness of the PVC wear-resistant layer foil is 0.1 mm. A PU abrasion resistant layer foil having a thickness of 0.05mm was painted with a UV-curable water-based coating composition of 60g/m2 according to Table 1, dried in an oven at 50 ℃ for 10 minutes and then UV-cured. The PU wear layer foil is positioned on top of the PVC wear layer foil. In a first pressing step, two foils were laminated using a temperature of 120 ℃, a pressure of 10 bar and a pressing time of 60 seconds. In a second pressing step, the laminated wear layer was laminated to a decorative PVC foil and PVC core material having a thickness of 0.03mm using a temperature of 140 ℃, a pressure of 10 bar and a pressing time of 60 seconds. The resulting product was found to have improved scratch and chemical resistance. The product obtained has an abrasion resistance of more than 2100 revolutions, tested in a Taber abrasion tester according to the test method in EN 13329.

Example 8: painted PU foil on PVC foil.

A PVC wear layer foil with a thickness of 0.1mm was positioned on a decorative PVC foil with a thickness of 0.03 mm. A PU abrasion resistant layer foil having a thickness of 0.05mm was painted with a UV-curable water-based coating composition of 60g/m2 according to Table 1, dried in an oven at 50 ℃ for 10 minutes and then UV-cured. The PU wear layer foil is positioned on top of the PVC wear layer foil. Three foils were laminated to the PVC core material using a temperature of 140 ℃, a pressure of 10 bar and a pressing time of 60 seconds. The resulting product was found to have improved scratch and chemical resistance. The product obtained has an abrasion resistance of more than 2100 revolutions, tested in a Taber abrasion tester according to the test method in EN 13329.

Example 9: painted PVC wear layer

The PVC abrasion resistant layer was painted with a UV curable water based coating composition according to Table 1 at 60g/m2, dried in an oven at 50 ℃ for 10 minutes and then UV cured. The painted PVC wear layer was pressed using a temperature of 140 ℃, a pressure of 10 bar and a pressing time of 60 seconds. In a second pressing step, the painted wear layer was laminated to a decorative PVC foil having a thickness of 0.03mm and to a PVC core material using a temperature of 140 ℃, a pressure of 10 bar and a pressing time of 60 seconds. The resulting product was found to have improved scratch and chemical resistance. The product obtained has an abrasion resistance of more than 5000 revolutions, tested in a Taber abrasion tester according to the test method in EN 13329.

Example 10: painted LVT with PVC wear layer

The LVT product comprising a PVC core material and a decorative PVC foil with a PVC wear layer on top was painted with a water-based composition UV curable according to table 1 at 60g/m2, oven dried at 50 ℃ for 10 minutes and then UV cured. The painted LVT was pressed using a temperature of 140 ℃, a pressure of 10 bar and a pressing time of 60 seconds. The LVT products were found to have improved scratch and chemical resistance. The LVT products were tested in a Taber abrasion tester with an abrasion resistance of more than 5000 revolutions according to the test method in EN 13329.

Example 11: painted LVT with PU wear layer

The LVT product comprising a PVC core material and a decorative PVC foil product with a PU wear layer on top was painted with a water-based composition UV curable according to table 1 at 60g/m2, oven dried at 50 ℃ for 10 minutes and then UV cured. The painted LVT was pressed using a temperature of 140 ℃, a pressure of 10 bar and a pressing time of 60 seconds. The LVT products were found to have improved scratch and chemical resistance. The LVT products were tested in a Taber abrasion tester with an abrasion resistance of more than 5000 revolutions according to the test method in EN 13329.

Example 12: the painted PU wear-resistant layer is arranged on the veneer

A wood veneer layer with a thickness of 0.6mm was attached to the PVC core material by means of PU powder. A first PU wear layer foil having a thickness of 0.05mm was disposed on the wood veneer layer. 25g/m2Al2O3 was applied on the first PU abrasion resistant layer foil using a dispersion apparatus. A second PU wear layer having a thickness of 0.05mm was applied on the PU wear layer foil with Al2O3 particles. The second PU abrasion resistant layer was painted with a water-based UV-curable coating composition according to table 1 of 60g/m2, dried in an oven at 50 ℃ for 10 minutes and then UV-cured. The wood veneer layer, the first PU wear layer foil and the second painted PU wear layer foil were laminated onto the PVC core material using a temperature of 140 ℃, a pressure of 10 bar and a pressing time of 60 seconds. The resulting product was found to have improved scratch and chemical resistance. The product obtained has an abrasion resistance higher than 2400 revolutions, tested in a Taber abrasion tester according to the test method in EN 13329.

Example 13: painted PVC foil on PVC foil

A first PVC wear layer foil having a thickness of 0.1mm was positioned on a decorative PVC foil having a thickness of 0.03 mm. A second PVC abrasion resistant layer foil having a thickness of 0.1mm was painted with 60g/m2 of a 2-component (PU isocyanate) water-based paint composition, and then dried in an oven at 50 ℃ for 20 minutes and then dried at normal temperature for 2 days. A second PVC wear layer foil is positioned on top of the first PVC wear layer foil. The first and second wear layer foils were laminated to the PVC core material using a temperature of 140 ℃, a pressure of 10 bar and a pressing time of 60 seconds. The resulting product was found to have improved scratch and chemical resistance. The product obtained has an abrasion resistance of more than 1900 revolutions, tested in a Taber abrasion tester according to the test method in EN 13329.