Methods for producing coatings, building panels, and coated foils.

Abstract

This disclosure relates to a method for producing a coating (2), the method comprising applying a coating composition to the surface of a carrier (1), curing the coating composition into a coating (2), and then applying pressure to the coating (2). This disclosure also relates to a method for producing architectural panels, and such architectural panels, and to a method for producing coated foil, and such coated foil.

Description

[0001] This application is a divisional application of the invention patent application filed on May 23, 2018, with application number 201880032419.1 and entitled "Method for producing coatings, building panels and coated foils". Technical Field

[0002] Embodiments of the present invention relate to a method for forming a coating, a method for forming an architectural panel, such an architectural panel, a method for forming a coated foil / sheet, and such a coated foil. Background Technology

[0003] In recent years, so-called luxury vinyl tile and wood panel (LVT), WPC (wood-plastic composite), and SPC (stone-plastic composite / solid polymer core) flooring has gained increasing success. These types of flooring typically consist of a thermoplastic core, a thermoplastic decorative layer disposed on the core, a thermoplastic clear abrasion layer on the decorative layer, and a coating applied to the abrasion layer. The thermoplastic material is typically PVC. The core may contain 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 abrasion layer is typically a PVC foil, for example, 0.2-0.7 mm thick. The core, decorative layer, and clear abrasion layer are typically pressed together to form the flooring panel. The coating applied to the abrasion layer after pressing is typically a UV-cured polyurethane coating. The abrasion layer, together with the coating, provides the flooring with abrasion resistance and protects the decorative layer. After pressing, in a subsequent separate step, a UV-cured polyurethane coating is applied to the surface of the abrasion layer. By applying a UV-cured polyurethane coating as the top layer to the floor panel, the surface of the floor panel achieves a uniform gloss, that is, the floor panel acquires the gloss of the coating.

[0004] Since the embossing of the wear-resistant layer is done during the pressing process, by pressing the wear-resistant layer against an embossing plate or similar material, the coating applied after embossing can make the embossed surface of the wear-resistant layer more uniform, thus creating at least a visual effect of reduced embossing.

[0005] However, when flooring panels are subjected to wear, the coating and abrasion layer have shown to be relatively susceptible to wear, or at least to wear in a way that affects the appearance of the abrasion layer—for example, with scratches and / or loss of transparency. LVT flooring panels are less abrasion resistant than conventional laminate flooring panels. However, LVT flooring offers several advantages over, for example, laminate flooring, such as deep embossing, moisture-related dimensional stability, water resistance, and sound absorption.

[0006] As this type of flooring further develops, improvements in performance, such as abrasion and / or scratch resistance, chemical resistance, aesthetic properties, and streamlined manufacturing processes, are generally desired.

[0007] Similarly, other types of flooring also feature coatings, such as UV-curable polyurethane coatings. Wood flooring typically has a UV-curable coating, and the surface achieves a uniform gloss, specifically the gloss of the topcoat. Improving coating performance to allow for greater design variation in wood flooring would be an advantage.

[0008] WO 2016 / 113378 discloses a method for manufacturing a cover layer, comprising manufacturing a base layer, attaching a surface layer to a top surface of the base layer, attaching a top surface of a backing layer to a bottom surface of the base layer, and attaching a top surface of a fabric layer to a bottom surface of the backing layer. Thus, a sheet is provided, defined as an integral unit consisting of the surface layer, the base layer, the backing layer, and the fabric layer. In a further step, the sheet is cured. After curing the sheet, the surface layer can be mechanically embossed. After curing the sheet, in another step, a surface coating can be applied as an additional component of the surface layer on top of the abrasion-resistant layer.

[0009] US 2014 / 0255670 discloses a method for printing on wood panels. The method includes printing wood using digital printing technology, forming a decorative layer, applying a protective layer to the decorative layer comprising at least one resin, at least one radiation-curable varnish, and / or at least polyurethane, and a pre-dried and / or pre-gelled protective layer. The protective layer is only pre-dried and / or pre-gelled, and therefore not fully dried or cured. The surface of the protective layer is relatively sticky or surface-dried. The degree of pre-drying and / or pre-gelling should allow the protective layer, i.e., the resin or varnish itself, to remain free-flowing and cross-linkable. The printed wood panel with the protective layer can be further processed or finished in a short-cycle press. In the short-cycle press, the resin layer is melted and the laminate is cured to form a laminate.

[0010] US 2013 / 0011623 discloses a monolithic three-dimensional composite material. In one embodiment, the composite material includes a three-dimensional layer and an outer layer. A printed layer may be disposed on the outer layer. The printed layer may receive the abrasion-resistant layer via a coating apparatus that applies a polymer composition. The abrasion-resistant layer is allowed to cure. A heat source such as a radiant oven, gas furnace, etc., may be used to aid in the curing of the abrasion-resistant layer. During and / or after curing, the abrasion-resistant layer is allowed to reach ambient temperature. Subsequently, the surface of the abrasion-resistant layer is subjected to sufficient temperature to soften the cured abrasion-resistant layer surface by reheating with a heat source such as an infrared radiation heating oven. This step softens the surface of the abrasion-resistant layer to allow mechanical embossing by an embossing drum. Summary of the Invention

[0011] One object of at least some embodiments of the present invention is to provide an improvement on one aspect of the above-described technology and known technologies.

[0012] Another object of at least some embodiments of the present invention is to improve the coating method for a substrate intended to be pressed.

[0013] Another object of at least some embodiments of the present invention is to improve the chemical resistance of coatings used on floor surfaces.

[0014] Another object of at least some embodiments of the present invention is to allow coatings to have different gloss levels.

[0015] At least some of these and other objects and advantages, which will become apparent from the description, have been achieved by the method for manufacturing a coating according to the first aspect of the invention. The method comprises applying a coating composition / paint composition to the surface of a carrier, curing the paint composition into a coating, and subsequently applying pressure to the coating.

[0016] Curing refers to complete curing or at least curing beyond the pre-drying or pre-curing state.

[0017] One advantage of at least some embodiments of the present invention is that the coating can be applied online before pressing, and integrated with the assembly and attachment of other layers, such as in architectural panels. This allows for a more efficient and integrated production method.

[0018] At least some embodiments of the present invention allow the coating to be treated as a separate layer after curing and to be adhered to another substrate, etc., by pressing. The coating composition can be applied to a substrate in the form of an anti-stick foil or anti-stick film and peeled off from the anti-stick foil or film before pressing the coating to another substrate.

[0019] Another advantage is that improved chemical resistance has been demonstrated through press coating. It is believed that further increases in crosslinking through pressing and / or through compression coating can achieve even better chemical resistance. Higher crosslinking results in higher chemical resistance of the coating.

[0020] Furthermore, improved scratch resistance can be achieved due to the higher degree of crosslinking obtained after pressing, and / or due to the fact that the coating is compressed through the pressing operation.

[0021] Another advantage is that the coating can be embossed by pressing it against an embossing plate. In conventional processes, the substrate surface is embossed before the coating is applied. As a result, the coating may fill in shallower structures in the substrate, and the visual impression of the embossing may be difficult to discern.

[0022] It has been further demonstrated that pressure coating can reduce any damage to the coating, such as scratches. Such scratches can form during production and during processing within the production process.

[0023] Applying pressure may include pressing the coating against a pressing device that includes portions with different gloss levels, so that the coating acquires different gloss levels after pressing. Compared to methods known in the art, different gloss levels in the coating can be obtained in a simplified manner by applying the coating composition before pressing and then pressing it against a pressing device with portions having different gloss levels.

[0024] Applying pressure can include applying heat and pressure simultaneously.

[0025] The coating composition may contain a crosslinkable component / ingredient. In a crosslinkable coating system, curing the coating composition crosslinks the polymer.

[0026] After curing, the residual oligomer content of the coating composition can be less than 10%, for example, greater than 0% and less than 10%. A certain residual oligomer content corresponds to a certain residual crosslinking ability. The residual crosslinking ability of the coating composition after curing is beneficial for pressing the coating after curing.

[0027] After the coating composition has cured, it is no longer viscous. This allows for the treatment of coated / coated carriers, for example, by rolling them on rollers. Curing refers to the coating composition having passed through its pre-dried and / or pre-gelled state, for example, with a residual oligomer content of less than 10%.

[0028] The coating composition can be water-based. It has been found that water-based coating compositions retain the ability to be reshaped after curing, which is beneficial for shaping the coating during pressing, such as embossing or applying a gloss finish.

[0029] The coating composition may comprise a two-component system. The two-component system may comprise 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.

[0030] The coating composition can be UV-curable, preferably a water-based UV-curable coating composition. A UV-curable coating composition means that at least one component of the coating composition is UV-curable. Compared to purely water-based coating systems, using a UV-curable composition allows for faster curing. After curing, the UV-cured coating is no longer tacky at room temperature, for example, 25°C. The surface of the coating may be harder than that of a sintered coating composition. The UV-curable component can be a polyester / polyurethane dispersion. Alternatively, the UV-curable component can be a polyurethane / acrylic copolymer dispersion.

[0031] Before pressing, the water-based UV-curable coating composition is first completely dried to evaporate the water, followed by UV curing to solidify the UV-curable components. After drying and UV curing, the coating formed by the coating composition is pressed.

[0032] The carrier may include thermoplastic materials, preferably PVC.

[0033] The carrier can be a foil. The coating and carrier can be pressed together onto another substrate, or the coating can be peeled off from the carrier after pressing.

[0034] The foil can be thermoplastic foil. The foil can be PVC foil. The thermoplastic foil can be abrasion-resistant foil. The thermoplastic foil can be decorative thermoplastic foil, such as printed thermoplastic foil. Thus, a coated thermoplastic foil can be formed, which can be extruded onto a substrate in a subsequent step. Because the coating is cured and pressed, the coated abrasion-resistant or decorative foil can be stored and processed as regular abrasion-resistant foil.

[0035] The carrier can be a wood-based substrate, preferably a wood veneer (layer / board). In one embodiment, a wood-based substrate is coated and then pressed. Thus, the coating can obtain an embossed structure, for example, by pressing it against an embossing device, and / or obtain different gloss levels by pressing it against pressing devices with different gloss levels.

[0036] Applying pressure to the coating can include pressing and attaching the coating on a carrier to a substrate, with the carrier positioned between the coating and the substrate. This allows for the provision of a coated substrate, such as architectural paneling, comprising a substrate and a coated carrier. The carrier can be a thermoplastic foil. The carrier can be a wood-based material. The carrier is coated before being attached to the substrate. Therefore, the carrier can be coated in a process separate from the treatment of the entire substrate.

[0037] As an alternative or supplement, the carrier can be attached to the substrate using an adhesive.

[0038] The method may further include peeling the coating from the carrier before applying pressure, and wherein applying pressure to the coating includes pressing and attaching the coating to the substrate. In this embodiment, the carrier functions as a temporary carrier, such as a release film or foil, and the coating can be pressed onto the substrate without a carrier. Alternatively, the coating may be peeled from the carrier after pressing but before attachment to the substrate.

[0039] The coating composition may contain scratch-resistant particles, such as silica particles. This improves the scratch resistance of the coating. The coating composition may also contain abrasion-resistant particles, such as alumina particles, also known as corundum.

[0040] The carrier may include a thermoplastic first foil and a thermoplastic second foil, wherein abrasion-resistant particles, preferably alumina particles, are disposed between the first foil and the second foil. The first foil and the second foil with abrasion-resistant particles therebetween may be pre-pressed to adhere them to each other, preferably after the coating has been applied. Thus, the coated carrier forms an abrasion-resistant layer, which can be stored and treated as a separate layer, and can be pressed onto a substrate in a subsequent step.

[0041] The coating can be essentially transparent. The coating can be a layer commonly referred to as a varnish layer.

[0042] According to a second aspect of the invention, a method for producing architectural panels is provided. The method includes providing a substrate and at least one surface layer disposed on the substrate, applying a coating composition to the at least one surface layer, curing the coating composition to form a coating on the at least one surface layer, subsequently applying pressure to the coating using a pressing device, and pressing the substrate and the coated surface layer together to form an architectural panel.

[0043] Pressing the coated surface layer onto the substrate can be done separately from applying the coating composition and allowing it to cure into a coating. The coated surface layer can be stored and pressed onto the substrate in a subsequent step, which can be performed by a manufacturer other than the manufacturer of the coated surface layer.

[0044] Curing refers to complete curing or at least curing beyond the pre-drying or pre-curing state.

[0045] One advantage of at least some embodiments of the present invention is that the coating can be applied online before pressing, integrating it with the assembly and attachment of other layers in the building panel. This allows for a more efficient and integrated production method.

[0046] 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.

[0047] Another advantage is that improved chemical resistance has been demonstrated through press coating. This allows for the provision of building panels with improved chemical resistance. It is believed that further increasing the degree of crosslinking through pressing, and / or through compression coating, can achieve even better chemical resistance. Higher crosslinking results in higher chemical resistance of the coating.

[0048] Furthermore, 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.

[0049] Another advantage is that the coating can be embossed by pressing it against an embossing plate. In conventional processes, the surface of the substrate is embossed before the coating is applied. This allows the coating to fill in shallower structures in the substrate, and the visual impression of the embossing may be difficult to discern.

[0050] It has been further demonstrated that pressing the coating can reduce any damage to the substrate surface, such as scratches. Such scratches can form during production and during processing within the production process.

[0051] Applying pressure may include pressing the coating composition against a pressing device that includes portions with different gloss levels, so that the coating acquires different gloss levels after pressing. Compared to methods known in the art, different gloss levels in the coating can be obtained in a simplified manner by applying the coating composition before pressing and then pressing it against a pressing device with portions having different gloss levels.

[0052] Applying pressure to a coating using a pressing device can include applying heat and pressure simultaneously.

[0053] Applying pressure to the coating using a pressing device may include bonding the substrate, the at least one surface layer, and the coating composition together.

[0054] The coating composition may contain a crosslinkable component. In a crosslinkable coating system, curing the coating composition crosslinks the polymer.

[0055] After curing, the coating composition may contain less than 10% residual oligomers. A certain amount of residual oligomers corresponds to a certain amount of residual crosslinking ability. This residual crosslinking ability, present in the cured coating composition, facilitates pressing of the coating after curing.

[0056] After the coating composition has been cured, for example, to a residual oligomer content of less than 10%, the coating composition is no longer tacky. This allows the coated carrier to be treated, for example, by rolling it on a roller. Curing refers to the coating composition having passed through its pre-dried and / or pre-gelled state, for example, with a residual oligomer content of less than 10%.

[0057] The coating composition can be water-based. It has been found that water-based coating compositions retain the ability to be reshaped after curing, which is beneficial for shaping the coating during pressing, such as embossing or applying a gloss finish.

[0058] The coating composition may comprise a two-component system. The two-component system may comprise an epoxy amine, a polyurethane isocyanate, an isocyanate alcohol, or an acid alcohol system. The coating composition may be an epoxy amine, polyurethane isocyanate, isocyanate alcohol, or acid alcohol system. The coating composition may be a water-based two-component system.

[0059] The coating composition can be UV-curable, preferably a water-based UV-curable coating composition. A UV-curable coating composition means that at least one component of the coating composition is UV-curable. Compared to purely water-based coating systems, using a UV-curable composition allows for faster curing. During pressing, the cured UV-cured coating does not adhere to the press plate. The surface of the coating may be harder compared to sintered coating compositions. The UV-curable component can be a polyester / polyurethane dispersion. Alternatively, the UV-curable component can be a polyurethane / acrylic copolymer dispersion.

[0060] Before pressing, the water-based UV-curable coating composition is first completely dried to evaporate the water, followed by UV curing to solidify the UV-curable components. After drying and UV curing, the coating formed by the coating composition is pressed.

[0061] The at least one surface layer may comprise a thermoplastic material, preferably PVC.

[0062] The at least one surface layer may include a foil.

[0063] The at least one surface layer may include a thermoplastic foil. The thermoplastic foil may be PVC foil. The thermoplastic foil may be an abrasion-resistant foil. The thermoplastic foil may be a decorative thermoplastic foil, such as a printed thermoplastic foil. Thus, a coated thermoplastic foil can be formed, which can be extruded onto a substrate in a subsequent step. Because the coating is cured and pressed, the coated abrasion-resistant or decorative foil can be stored and treated as a conventional abrasion-resistant foil.

[0064] The at least one surface layer may include a wood-based substrate, preferably a wood veneer (layer / board). In one embodiment, a wood-based substrate is coated and then pressed. Thus, the coating can obtain an embossed structure, for example, by pressing it against an embossing device, and / or obtain different gloss levels by pressing it against a pressing device with different gloss levels.

[0065] The at least one surface layer may include paper, such as decorative paper.

[0066] The coating composition may contain scratch-resistant particles, such as silica particles. This improves the abrasion resistance of the coating. The coating composition may also contain abrasion-resistant particles, such as alumina particles, also known as corundum.

[0067] The at least one surface layer may include a first thermoplastic foil and a second thermoplastic foil, wherein abrasion-resistant particles, preferably alumina particles, are disposed between the first foil and the second foil. Before or after the coating is applied, the first foil and the second foil with the abrasion-resistant particles may be pre-pressed to adhere them to each other. Thus, the coated surface layer forms an abrasion-resistant layer, which can be stored and treated as a separate layer, and can be pressed onto a substrate in subsequent steps.

[0068] The coating can be essentially transparent. The coating can be a layer commonly referred to as a varnish layer.

[0069] The substrate may include a plastic sheet, such as a thermoplastic sheet. The substrate may be a wood-based board. Wood-based boards may be or include wood veneer (panels). Wood-based boards may be or further include wood fiber-based boards, such as MDF, HDF, particleboard, etc., or plywood. The substrate may include or further include wood-based panels, such as a thin-panel core. In embodiments, the substrate may include or further include thermoplastic sheets, such as wood-plastic composites (WPC), EPC (expanded polymer core), or SPC (stone-plastic composite / solid polymer core). The substrate may include or further include mineral composite panels. The substrate may include or further include fiber cement boards. The substrate may contain or further include magnesium oxide cement boards. The substrate may include or further include ceramic panels.

[0070] The substrate may comprise paper or nonwoven fabric. The substrate may be printed paper. The substrate may include a laminate comprising a thermosetting resin.

[0071] In one embodiment, the carrier comprises a thermoplastic material, and the substrate comprises a thermoplastic material of the type described above.

[0072] In one embodiment, the carrier comprises a thermoplastic material, and the substrate comprises a finish (layer / sheet). The finish may be disposed on a sheet of the type described above.

[0073] In one embodiment, the carrier comprises a thermoplastic material, and the substrate comprises paper. The paper may be arranged on a plate of the type described above.

[0074] In one embodiment, the carrier comprises a thermoplastic material, and the substrate is formed from a powder mixture containing a binder and fillers. The substrate can be disposed on a plate of the type described above. The plate can be a waterproof plate.

[0075] According to a third aspect, an architectural panel is provided. The architectural panel includes a substrate and at least one surface layer disposed on a surface layer, wherein the uppermost surface layer is provided with a cured coating.

[0076] Cured coatings can have different gloss levels. Different gloss levels can be obtained by pressing the coating after it has cured.

[0077] The cured coating may include an embossed structure. An embossed structure can be obtained using a pressing device after the coating has cured.

[0078] The third embodiment can combine all the advantages of the second aspect already discussed above, and thus the preceding discussion also applies to the building panel.

[0079] The coating can be crosslinked. The coating can contain crosslinkable components. In a crosslinkable coating system, curing the coating composition crosslinks the polymer.

[0080] The coating may be water-based, preferably a water-based UV-curable coating composition. It has been found that water-based coating compositions retain the ability to be reshaped after curing, which is beneficial for shaping the coating during pressing, such as embossing or applying a gloss finish.

[0081] The coating may comprise a two-component system. The two-component system may be an epoxy amine, polyurethane isocyanate, isocyanate alcohol, or acid-alcohol system. The coating composition may be an epoxy amine, polyurethane isocyanate, isocyanate alcohol, or acid-alcohol system. The coating may be a water-based two-component system.

[0082] The coating can be UV-curable, preferably a water-based UV-curable coating. A UV-curable coating means that at least one component of the coating composition is UV-curable. Compared to purely water-based coating systems, curing can be achieved at a higher speed by using a UV-curable composition. During pressing, the cured UV-cured coating does not adhere to the press plate. The surface of the coating may be harder than that of a sintered coating composition. The UV-curable component can be a polyester / polyurethane dispersion. Alternatively, the UV-curable component can be a polyurethane / acrylic copolymer dispersion.

[0083] The at least one surface layer may comprise a thermoplastic material, preferably PVC.

[0084] The at least one surface layer may include a foil.

[0085] The at least one surface layer may include a thermoplastic foil. The thermoplastic foil may be PVC foil. The thermoplastic foil may be abrasion-resistant foil. The thermoplastic foil may be decorative thermoplastic foil, such as printed thermoplastic foil.

[0086] The surface layer can be a wood-based substrate, preferably a wood veneer (layer / board). In one embodiment, a wood-based substrate is coated and then pressed. Thus, the coating can be applied to the embossed structure, for example, by pressing it against an embossing device, and / or different gloss levels can be obtained by pressing it against pressing devices with different gloss levels.

[0087] The coating may contain scratch-resistant particles, such as silica particles. This improves the coating's scratch resistance. The coating may also contain abrasion-resistant particles, preferably alumina particles, also known as corundum.

[0088] The at least one surface layer may include a first thermoplastic foil and a second thermoplastic foil, wherein wear-resistant particles, such as alumina particles, are arranged between the first foil and the second foil.

[0089] The coating can be essentially transparent. The coating can be a layer commonly referred to as a varnish layer.

[0090] The substrate may include a plastic sheet, such as a thermoplastic sheet. The substrate may be a wood-based board. Wood-based boards may be or include wood veneer (panels). Wood-based boards may be or include wood fiber-based boards, such as MDF, HDF, particleboard, etc., or plywood. The substrate may include or further include wood-based panels, such as a thin-panel core. In embodiments, the substrate may include or further include thermoplastic sheets, such as WPC (wood-plastic composite), expanded polymer core (EPC), stone-plastic composite (SPC), or solid polymer core (SPC). The substrate may include or further include a mineral composite board. The substrate may include or further include a fiber cement board. The substrate may be a magnesium oxide cement board. The substrate may include or further include a ceramic plate.

[0091] The substrate may comprise paper or nonwoven fabric. The substrate may be printed paper. The substrate may be formed from a powder mixture comprising adhesives and fillers pressed onto a surface layer.

[0092] According to a fourth aspect, a coated foil / coated foil is provided. The coated foil includes a carrier and a cured coating disposed on the surface of the carrier.

[0093] The cured coating may include an embossed structure. An embossed structure can be obtained after curing using a pressing device.

[0094] Cured coatings can have different gloss levels. Different gloss levels can be obtained after curing using a pressing device.

[0095] The embodiments of the fourth aspect of the invention have all the advantages of the first aspect of the invention as described above, and therefore the foregoing description is also applicable to the coated foil.

[0096] The coating can be cross-linked.

[0097] The coating can be a UV-curable coating, preferably a water-based UV-curable coating. A UV-curable coating means that at least one component of the coating composition is UV-curable. Compared to purely water-based coating systems, curing can be achieved at a higher speed by using a UV-curable composition. During pressing, the cured UV-cured coating does not adhere to the press plate. The surface of the coating may be harder than that of a sintered coating composition. The UV-curable component can be a polyester / polyurethane dispersion. The UV-curable component can be a polyurethane / acrylic copolymer dispersion.

[0098] The coating may comprise a two-component system. The coating may comprise an epoxy amine, polyurethane isocyanate, isocyanate alcohol, or acid-alcohol system. The coating may be a water-based two-component system.

[0099] The carrier can contain thermoplastic materials. The carrier can be a foil, such as thermoplastic foil.

[0100] The coating may contain scratch-resistant particles, such as silica particles. This further improves the coating's scratch resistance. The coating may also contain abrasion-resistant particles, such as alumina particles, also known as corundum.

[0101] The carrier may include a first thermoplastic foil and a second thermoplastic foil, with wear-resistant particles arranged between them.

[0102] The coating can be essentially transparent. The coating can be a layer commonly referred to as a varnish layer.

[0103] The coating may include portions with different gloss levels.

[0104] 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 abrasion-resistant particles to the first or second thermoplastic foil; applying the second thermoplastic foil to the first thermoplastic foil such that the abrasion-resistant particles are disposed between the first and second thermoplastic foils; applying a coating composition to the second thermoplastic foil; curing the coating composition to form a coating; and subsequently applying pressure to the coating.

[0105] The coating is applied to the surface of the second foil facing away from the wear-resistant particles / in the direction away from the wear-resistant particles.

[0106] Curing refers to complete curing or at least curing beyond the pre-drying or pre-curing state.

[0107] One advantage of at least some embodiments of the present invention is that coating can be applied online / on the spot by applying the coating before pressing, integrating it with other layers assembled and attached, for example, in architectural panels. Thus, a pre-coated foil can be provided, requiring no additional surface treatment after the foil has been attached to the substrate.

[0108] At least some embodiments of the present invention allow the coating to be treated as a separate layer after curing and to be attached to another substrate, etc., by pressing in subsequent operations.

[0109] Another advantage is that improved chemical resistance has been demonstrated through press coating. It is believed that further increasing the degree of crosslinking through pressing and / or through compression coating can achieve even better chemical resistance. Higher degrees of crosslinking result in higher chemical resistance in the coating.

[0110] Furthermore, 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 through the pressing operation.

[0111] Another advantage is that the coating can be embossed by pressing it against an embossing plate. In conventional processes, the surface of the substrate is embossed before the coating is applied. This allows the coating to fill in shallower structures in the substrate, and the visual impression of the embossing may be difficult to discern.

[0112] By including abrasion-resistant particles between the first foil and the second foil, the scratch resistance of the foil is improved, thereby providing a coated foil with improved abrasion resistance.

[0113] It has been further demonstrated that pressure coating can reduce any damage to the coating, such as scratches. Such scratches can form during production and during processing within the production process.

[0114] Applying pressure may include pressing the coating against a pressing device that includes portions with different gloss levels, so that the coating acquires different gloss levels after pressing. Compared to methods known in the art, different gloss levels in the coating can be obtained in a simplified manner by applying the coating composition before pressing and then pressing it against a pressing device with portions having different gloss levels.

[0115] The coating composition may contain scratch-resistant particles, such as silica particles. This can further improve the scratch resistance of the coating. The coating composition may also contain abrasion-resistant particles, such as alumina particles, also known as corundum.

[0116] The coating composition may contain a crosslinkable component. In a crosslinkable coating system, curing the coating composition crosslinks the polymer.

[0117] After curing, the residual oligomer content of the coating composition can be less than 10%. A certain residual oligomer content corresponds to a certain residual crosslinking ability. This residual crosslinking ability allows the coating to be pressed after curing.

[0118] After the coating composition has cured, it is no longer viscous. This allows the coated carrier to be processed, for example, by rolling it on a roller. Curing refers to the coating composition having passed its pre-drying stage / or pre-gelling period / stage.

[0119] 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 the ability to be reshaped after curing, which is beneficial for shaping the coating during pressing, such as embossing or applying a gloss finish.

[0120] The coating composition may comprise a two-component system. The coating composition may be an epoxy amine, polyurethane isocyanate, isocyanate alcohol, or acid-alcohol system. The coating composition may be an epoxy amine, polyurethane isocyanate, isocyanate alcohol, or acid-alcohol system. The coating composition may be a water-based two-component system.

[0121] The coating composition can be UV-curable, preferably a water-based UV-curable coating composition. A UV-curable coating composition means that at least one component of the coating composition is UV-curable. Compared to purely water-based coating systems, using a UV-curable composition allows for faster curing. During pressing, the cured UV-cured coating does not adhere to the press plate. The surface of the coating may be harder compared to sintered coating compositions. The UV-curable component can be a polyester / polyurethane dispersion. Alternatively, the UV-curable component can be a polyurethane / acrylic copolymer dispersion.

[0122] Applying pressure to the coating can include pressing the coating on the coating foil onto and attaching it to a substrate. This allows for the provision of a coated substrate, such as architectural paneling, comprising a substrate and a coating foil. The coating foil may already have a coating on it before being attached to the substrate. Thus, the coating foil can be applied in a separate process from processing the entire substrate.

[0123] The method may include applying pressure to a first foil and a second foil before attaching the coated foil to a substrate to cause the first foil and the second foil to adhere to each other. This pre-pressing step may be performed before or after the application of the coating composition.

[0124] The coating can be essentially transparent. The coating can be a layer commonly referred to as a varnish layer.

[0125] The coating may include portions with different gloss levels.

[0126] According to a sixth aspect, a coated foil is provided. The coated foil includes a first thermoplastic foil and a second thermoplastic foil, with abrasion-resistant particles disposed therebetween, wherein a coating is disposed on the surface of the first thermoplastic foil facing away from the second thermoplastic foil.

[0127] The coating may include different gloss levels obtained by a pressing device.

[0128] The coating may include an embossed structure obtained by a pressing device.

[0129] The embodiments of the sixth aspect of the present invention have all the advantages of the fifth aspect of the present invention as described above, and therefore the foregoing description is also applicable to the coated foil.

[0130] The coating can be cross-linked.

[0131] The coating can be a UV-cured coating, preferably a water-based UV-cured coating.

[0132] The coating may contain scratch-resistant particles, such as silica particles. This further improves the coating's scratch resistance. The coating may also contain abrasion-resistant particles, such as alumina particles, also known as corundum.

[0133] The coating can be essentially transparent. The coating can be a layer commonly referred to as a varnish layer. Attached Figure Description

[0134] The invention will be described in more detail by way of example with reference to the accompanying schematic diagrams, which illustrate embodiments of the invention.

[0135] Figure 1A A method for producing coated carriers is shown.

[0136] Figure 1B A method for producing building panels is shown.

[0137] Figure 1C A method for producing building panels is shown.

[0138] Figure 2 A method for producing building panels is shown.

[0139] Figure 3 A method for producing coated foil is shown. Detailed Implementation

[0140] Figure 1AA method for producing a coated carrier 10 is shown. A carrier 1 is provided. The carrier 1 may be an anti-stick foil, such as a fluoroplastic foil, or a permanent carrier, such as a thermoplastic foil. The thermoplastic foil may contain, 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 include, for example, an ionomer of 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 colored, such that the thermoplastic foil forms a decorative foil.

[0141] 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 may be made of any type of wood veneer. In one embodiment, the wood veneer layer is an oak veneer layer.

[0142] The coating composition is applied to the surface of the carrier 1 via the coating device 20. This coating composition can be a coating conventionally known as a varnish. The coating composition can be applied by roller coating, curtain coating, spraying, dip coating, or other methods.

[0143] The coating composition may be crosslinkable. The coating composition may be radiation-curable, preferably UV-curable. The coating composition is preferably water-based, such as a UV-curable water-based composition. The water-based UV-curable composition may contain a polyester / polyurethane dispersion. The water-based UV-curable composition may contain a polyurethane / acrylic copolymer dispersion. The water-based UV-curable composition may further contain photoinitiators, thickeners, additives, etc.

[0144] The coating composition can be a two-component system, such as an epoxy amine system, a polyurethane isocyanate system, an isocyanate alcohol system, an acid alcohol system, etc.

[0145] The coating composition can be applied in one or more layers. The total amount of coating composition applied, corresponding to 100% of the coating components and 0% of water and solvent, can be 5-200 g / m2, for example, more than 5 g / m2, preferably more than 10 g / m2.

[0146] The coating composition may contain abrasion-resistant particles and / or scratch-resistant particles. Preferably, the coating composition contains scratch-resistant particles. Alternatively or as an adjunct, scratch-resistant particles may be applied to the coating composition while it is on a carrier and while the coating composition is still wet.

[0147] Wear-resistant particles can be alumina particles, such as corundum. Alternatively, or as a supplement, wear-resistant particles can be corundum, quartz, silica, glass, glass beads, glass spheres, diamond particles, hard plastics, reinforced polymers and organic materials, or combinations thereof.

[0148] The average particle size of the wear-resistant particles is preferably in the range of 10-200 μm, more preferably in the range of 50-120 μm, for example, 50-100 μm. The wear-resistant particles can have a spherical or irregular shape. The wear-resistant particles can be surface-treated. The wear-resistant particles can be silane-treated particles. The application amount of the wear-resistant particles can be 10-100 g / m², preferably 10-50 g / m², more preferably 20-30 g / m².

[0149] The scratch-resistant particles can be or include nanoscale silica particles, preferably fused silica particles. The scratch-resistant particles can be disc-shaped particles with a width / thickness ratio preferably equal to or greater than 3:1, more preferably equal to or greater than 5:1. These disc-shaped particles are oriented along the surface of the foil, thereby improving the scratch resistance of the foil. The scratch-resistant particles can have an average particle size of 1-100 μm, preferably 10-50 μm, more preferably 20-30 μm. The average particle size of the scratch-resistant particles can be less than 50 μm, preferably less than 45 μm. The application amount of the scratch-resistant particles can be 0.5-20 g / m², preferably 0.5-10 g / m², more preferably 0.5-5 g / m².

[0150] The coating composition may contain conventional additives. The coating composition may further contain functional additives, such as antistatic additives and / or antibacterial additives.

[0151] The coating composition can be transparent. However, the coating composition can also be colored.

[0152] The coating composition can be applied as one or more layers to form a coating on the carrier 1.

[0153] After the coating composition has been applied to the carrier 1, the coating composition is cured to form the coating 2. If the coating composition is UV-curable, UV radiation is applied to cure it. If the coating composition is a water-based UV-curable coating composition, it is first dried in a drying device 21 by IR or in an oven, 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, it is dried, for example, in an oven or at room temperature (not shown).

[0154] After curing, a coated carrier 10 is formed.

[0155] Preferably, the coating composition retains a certain degree of crosslinking ability after curing. After curing, the residual oligomer content of the coating composition can be less than 10%. A certain residual oligomer content corresponds to a certain residual crosslinking ability. Therefore, the coating composition can be further crosslinked and / or compressed during the subsequent pressing process.

[0156] The coated carrier 10, formed by the method described with reference to FIG. 1, can be stored after the coating composition has cured. Figure 1B and 1C Further described, the coated carrier 10 can be coated onto a substrate, or, where the carrier is a peel-off foil, the coating 2 can be applied to a substrate without the carrier 1. The coated carrier 10 can be used as a coated abrasion-resistant foil. In one embodiment, where the carrier is a decorative thermoplastic foil, the coated carrier 10 can be a coated decorative foil.

[0157] exist Figure 1B In the above reference Figure 1A The formed coating carrier 10 is intended to form part of the architectural panel 5. The architectural panel 5 can be a floor panel, wall panel, ceiling panel, furniture component, etc. For example, the architectural panel can belong to the type known as LVT or WPC.

[0158] exist Figure 1B In the illustrated embodiment, the coated carrier 10 forms a coated abrasion-resistant foil in the building panel 5. Figure 1B In the illustrated embodiment, the coated abrasion-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 include, for example, ionomers of polyethylene. The thermoplastic material may be a cast resin or a hot melt. Preferably, the coating on the coating carrier 10 comprises abrasion-resistant and / or scratch-resistant particles of the type described above, and more preferably, scratch-resistant particles of the type described above.

[0159] exist Figure 1BThe substrate 3 is provided. The substrate may contain a thermoplastic material. The substrate 3 may include a thermoplastic material and fillers, 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 including fillers and 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 include, for example, an ionomer of polyethylene. The thermoplastic material may be a cast resin or a hot melt.

[0160] In other embodiments, the substrate 3 may include a wood-based substrate, such as a wood veneer, or may be or include a wood fiber-based board, such as MDF, HDF, particleboard, or plywood. In other embodiments, the substrate may include paper, such as decorative paper. In other embodiments, the substrate may be formed from a dry powder mixture comprising an adhesive and filler pressed onto a surface layer.

[0161] exist Figure 1B In the illustrated embodiment, a decorative layer 4 is provided and disposed on the surface of a substrate 3. It is also conceivable that the substrate 3 may be provided with a decorative pattern, such as 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 of the carrier 1 forming the coated carrier 10 has a decorative design, such as a print. In such an embodiment, the coated carrier 10 is disposed directly on the surface of the substrate 3 (not shown).

[0162] 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 include, for example, ionomers of polyethylene. The thermoplastic material may be a cast resin or a hot melt. The decorative layer may be provided with decorative patterns, such as printing.

[0163] In other embodiments, the decorative layer 4 may include a wood veneer or paper, such as decorative paper.

[0164] The coated carrier 10 is disposed on the decorative layer 4. In an alternative embodiment, the coating can be peeled off from the carrier 1 in the form of a peel-off foil and then disposed directly on the decorative layer 4 or the substrate 3.

[0165] In one embodiment, an adhesive may be provided between the decorative layer 4 and the substrate 3.

[0166] Subsequently, the substrate 3, decorative layer 4, and coated carrier 10 with cured coating 2 are pressed together in the pressurizing device 23, causing the layers to adhere to each other and forming the building panel 5. The pressing device 23 can be static or continuous. Preferably, heat is also applied during pressing. The applied pressure can be 5-100 bar, for example, applied over 5-500 seconds. The temperature can be 80-300°C, for example 100-250°C, for example 120-180°C, for example 130-150°C. The temperature can be about 140°C.

[0167] The pressing device 23 can have different gloss levels. The pressing surface of the pressing device 23 can have high-gloss portions, or even ultra-high-gloss portions, and matte portions. Different gloss levels are provided using micro-embossing or microstructures with a maximum depth of 30 μm. The higher the depth of the microstructure, the more matte the texture of that portion or portions. The lower the depth of the microstructure, the more glossy the portion or portions. When the coated carrier 10 is pressed against the microstructure, the coated carrier 10 obtains portions with different gloss levels. The depth of the micro-embossing can vary across the entire surface of the pressing device 23, thereby obtaining varying gloss levels. When the coated carrier 10 is pressed against the microstructure, the coated carrier 10 obtains portions with different gloss levels, corresponding to the gloss level of the pressing surface of the pressing device 23. The gloss level can vary across the entire surface of the coated carrier 10. Different gloss levels preferably refer to the gloss level of a first portion or a first group of portions being different from the gloss level of a second portion or a second group of portions. The first part or the first group of parts may have a higher gloss level than the second part or the second group of parts. The first part or the first group of parts may have a first gloss level, while the second part or the second group of parts may have a second gloss level that is higher or lower than the first gloss level.

[0168] The pressing device 23 may also be provided with protrusions for forming macroscopic embossing or macroscopic structures in the coating of the coated carrier. The macroscopic structures may also be aligned with the decorative patterns or printed designs of the decorative layer.

[0169] The pressing device 23 may include a metal surface having 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 cylinder or plate with different gloss levels, wherein the cylinder or plate directly contacts the surface of the coated carrier 10.

[0170] In one embodiment, the pressing device 23 may include a structural foil with a different gloss level. The structural foil is adapted to directly contact the surface of the coated carrier. The structural foil may be arranged between the coated carrier and the pressure plate, pressure belt, or pressure cylinder during pressing.

[0171] The surface of the coated carrier 10 may be provided with a release agent to prevent the coated carrier from adhering to the pressing device during pressing at elevated pressing temperatures. Since no additional layer needs to be applied to the coated carrier 10, the release agent can be applied to the coated carrier 10, which facilitates the pressing operation.

[0172] After pressing, the coated carrier 10 may have portions with different gloss levels. These different gloss levels are formed by a microstructure in the coating, preferably with a maximum depth of 30 μm. Different gloss levels can be formed in alignment with the decorative patterns or printed designs of the decorative layer 4.

[0173] The coating of the coated carrier 10 may also have embossed portions during pressing. The pressing device 23—e.g., a pressing plate, cylinder, belt, or structural foil—may have protrusions forming embossing or macrostructures in the coating of the coated carrier 10. Alternatively, the embossed portions may be formed in a separate step from the formation of portions with different gloss levels. Embossing is preferably aligned with decorative patterns or printed designs. Embossing is preferably matched with portions of the coated carrier 10 with different gloss levels. The embossed portions in the abrasion-resistant layer preferably have a depth exceeding 100 μm.

[0174] The architectural panel 5 is formed by pressing the coated carrier 10 and optional intermediate decorative layer 4 onto the base 3.

[0175] exist Figure 1C In the above reference Figure 1A The formed coated carrier 10 is intended to form part of the architectural panel 5. The architectural panel 5 may be a floor panel, wall panel, ceiling panel, furniture component, etc.

[0176] Reference Figure 1C In the described 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 veneer layer can be made of any type of veneer layer. In one embodiment, the wood veneer layer is an oak veneer layer. Therefore, by referring to the above... Figure 1AThe described method forms a coated wood veneer layer 10.

[0177] exist Figure 1C In the illustrated embodiment, the coated wood veneer layer 10 forms the surface of the architectural panel 5. Figure 1C In this embodiment, a coated wood veneer layer 10 is disposed on and attached to a substrate 3. The substrate 3 can be a wood-based board. The wood-based board can be a wood fiber-based board, such as MDF, HDF, particleboard, or plywood. The substrate 3 can be a wood panel, such as a thin-panel core. In other embodiments, the substrate can be a thermoplastic board, such as WPC (wood-plastic composite), expanded polymer core (EPC), stone-plastic composite (SPC), or solid polymer core (SPC). The substrate 3 can be a mineral composite board. The substrate can be a fiber cement board. The substrate 3 can be a magnesium oxide cement board. The substrate can be a ceramic board. The substrate 3 can be a plastic board, such as a thermoplastic board. In other embodiments, the substrate 3 can be a carrier, such as paper or nonwoven fabric. The wood-based substrate 3 can preferably be printed using a digital printing press.

[0178] The coated wood veneer layer 10 with the cured coating 2 is pressed in a pressing device 23, preferably simultaneously adhering to a substrate. The coated wood veneer layer 10 can be adhered to the substrate 3 under pressure. An adhesive layer can be applied to the coated wood veneer panel layer 10 and / or the substrate 3. The adhesive layer may contain 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 contain a hot-melt or pressure-sensitive adhesive.

[0179] The pressing device 23 can be static or continuous. Preferably, heat is also applied. The applied pressure can be 5-100 bar, for example, applied over 5-500 seconds. The temperature can be 80-300°C, for example 100-250°C, for example 120-180°C, for example 130-150°C. The temperature can be about 140°C.

[0180] The pressing device 23 can have different gloss levels. The pressing surface of the pressing device 23 can have high-gloss portions, or even ultra-high-gloss portions, and matte portions. Different gloss levels are provided by micro-embossing or microstructures with a maximum depth of 30 μm. The higher the depth of the microstructure, the more matte the texture of that portion or portions. The lower the depth of the microstructure, the more glossy the portion or portions. When the coated wood veneer layer 10 is pressed against the microstructure, the coated wood veneer layer 10 obtains portions with different gloss levels. The depth of the micro-embossing can vary across the entire surface of the pressing device 23, thereby obtaining varying gloss levels. When the coated wood veneer layer 10 is pressed against the microstructure, the coated wood veneer layer 10 obtains portions with different gloss levels, corresponding to the gloss level of the pressing surface of the pressing device 23. The gloss level can vary across the surface of the coated wood veneer layer 10. Different gloss levels preferably refer to the gloss level of a first portion or group of portions being different from the gloss level of a second portion or group of portions. The first part or the first group of parts may have a higher gloss level than the second part or the second group of parts. The first part or the first group of parts may have a first gloss level, while the second part or the second group of parts may have a second gloss level that is higher or lower than the first gloss level.

[0181] The pressing device 23 may also be provided with protrusions for forming a macroscopic embossing or macroscopic structure of the coating on the coated wood veneer layer 10. This macroscopic structure may also be aligned with the wood grain pattern of the coated wood veneer layer 10.

[0182] The pressing device 23 may include a metal surface having different gloss levels as described above. The metal surface of the pressing device 23 is adapted to directly contact the surface of the coated carrier. The pressing device 23 may be a cylinder or plate with different gloss levels, wherein the cylinder or plate directly contacts the surface of the coated carrier.

[0183] In one embodiment, the pressing device 23 may include a structural foil with a different gloss level. The structural foil is adapted to be in direct contact with the surface of the coated wood veneer layer 10. The structural foil may be disposed between the coated wood veneer layer 10 and the pressing plate, pressing belt, or pressing cylinder during pressing.

[0184] To prevent the coated carrier from adhering to the pressing device 23, a release agent may be provided on the surface of the coated wood veneer layer 10. Since no additional layer needs to be applied to the coated wood veneer layer 10, the release agent can be applied to the coated wood veneer layer 10, which facilitates the pressing operation.

[0185] After pressing, the coated wood veneer layer 10 may have portions with different gloss levels. These different gloss levels are formed by a microstructure in the surface, preferably with a maximum depth of 30 μm. These different gloss levels can be aligned with the wood grain pattern of the coated wood veneer layer 10.

[0186] The surface of the coated wood veneer layer 10 may also have embossed portions during pressing. The pressing device 23—e.g., a pressing plate, cylinder, belt, or structural foil—may have protrusions forming embossing or macrostructure in the coated wood veneer layer 10. Alternatively, the embossed portions may be formed in a separate step from the formation of portions with different gloss levels. The embossing is preferably aligned with the wood grain pattern. The embossing preferably mates with portions of the coated wood veneer layer 10 with different gloss levels. The embossed portions in the abrasion layer preferably have a depth exceeding 100 μm.

[0187] This results in an architectural panel 5, which includes a coated wood veneer layer 10 attached to a substrate 3.

[0188] Reference Figure 1C In the described embodiments, as an alternative to the wood veneer layer, the carrier 1 may include paper, such as decorative paper.

[0189] exist Figure 2 This illustrates a one-piece method for forming the coated architectural panel 5. Figure 2 In this process, a substrate 3 and at least one surface layer are provided. Figure 2 In the embodiment shown, the surface layer includes a decorative layer 4 and a carrier 1.

[0190] Substrate 3 may comprise a thermoplastic material. Substrate 3 may include a thermoplastic material and fillers, such as WPC (wood-plastic composite), EPC (expanded polymer core), SPC (stone-plastic composite / solid polymer core), or any other type of polymer core including fillers and thermoplastic material. The substrate may be extruded or calendered. Thermoplastic materials 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. Thermoplastic materials may include, for example, ionomers of polyethylene. Thermoplastic materials may be cast resins or hot melts.

[0191] In one embodiment, substrate 3 may comprise a wood-based board. The wood-based board may be a wood fiber-based board, such as MDF, HDF, particleboard, or plywood. Substrate 3 may be a wood panel, such as a thin-panel core. In other embodiments, the substrate may be a thermoplastic board, such as wood-plastic composite (WPC), EPC (expanded polymer core), or SPC (stone-plastic composite / solid polymer core). Substrate 3 may be a mineral composite board. Substrate 3 may be a fiber cement board. Substrate 3 may be a magnesium oxide cement board. Substrate 3 may be a ceramic board. Substrate 3 may be a plastic board, such as a thermoplastic board. In other embodiments, substrate 3 may be a carrier, such as paper or nonwoven fabric.

[0192] 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 include, for example, ionomers of polyethylene. The thermoplastic material may be a cast resin or a hot melt. The decorative layer may be provided with decorative patterns, such as printing.

[0193] In other embodiments, the decorative layer 4 may include a wood veneer or paper, such as decorative paper. It is also conceivable that the substrate 3 may be provided with a decorative pattern, such as a print. In such embodiments, the carrier 1 is disposed directly on the surface of the substrate 3. It is also conceivable that the carrier 1 of the coated carrier 10 has a decorative pattern, such as a print. In such embodiments, the carrier 1 is disposed directly on the surface of the substrate 3.

[0194] The carrier 1 can be a thermoplastic foil. The thermoplastic foil can 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 can include, for example, ionomers of polyethylene. The thermoplastic material can be a casting resin or a hot melt. The carrier 1 can have a thickness of 0.05-1 mm. The thermoplastic foil can be printed and / or colored, thereby forming a decorative foil.

[0195] The coating composition is applied to the surface of the carrier 1 via the coating device 20. This coating composition can be a coating conventionally known as a varnish. The coating composition can be applied by roller coating, curtain coating, dip coating, spraying, or other methods.

[0196] The coating composition is crosslinkable. The coating composition may be radiation-curable, preferably UV-curable. The coating composition is preferably water-based, such as a UV-curable water-based composition. The water-based UV-curable composition may contain a polyester / polyurethane dispersion. The water-based UV-curable composition may contain a polyurethane / acrylic copolymer dispersion. The water-based UV-curable composition may further contain photoinitiators, thickeners, additives, etc.

[0197] The coating composition can be a two-component system, such as an epoxy amine system, a polyurethane isocyanate system, an isocyanate alcohol system, an acid alcohol system, etc.

[0198] The coating composition can be applied in one or more layers. The total amount of coating composition applied, corresponding to 100% of the coating components and 0% of water and solvent, can be 5-200 g / m2, for example, more than 5 g / m2, preferably more than 10 g / m2.

[0199] The coating composition may contain abrasion-resistant particles and / or scratch-resistant particles. Preferably, the coating composition contains scratch-resistant particles. Alternatively or additionally, when the coating composition is still wet, the scratch-resistant particles may be applied to the coating composition applied to the carrier.

[0200] Wear-resistant particles can be alumina particles, such as corundum. Alternatively, or as a supplement, wear-resistant particles can be corundum, quartz, silica, glass, glass beads, glass spheres, diamond particles, hard plastics, reinforced polymers and organic materials, or combinations thereof.

[0201] The average particle size of the wear-resistant particles is preferably in the range of 10-200 μm, more preferably in the range of 50-120 μm, for example, 50-100 μm. The wear-resistant particles can have a spherical or irregular shape. The wear-resistant particles can be surface-treated. The wear-resistant particles can be silane-treated particles. The application amount of the wear-resistant particles can be 10-100 g / m², preferably 10-50 g / m², more preferably 20-30 g / m².

[0202] The scratch-resistant particles can be or include nanoscale silica particles, preferably fused silica particles. The scratch-resistant particles can be disc-shaped particles with a width / thickness ratio preferably equal to or greater than 3:1, more preferably equal to or greater than 5:1. These disc-shaped particles are oriented along the surface of the foil, thereby improving the scratch resistance of the foil. The scratch-resistant particles can have an average particle size of 1-100 μm, preferably 10-50 μm, more preferably 20-30 μm. The average particle size of the scratch-resistant particles can be less than 50 μm, preferably less than 45 μm. The application amount of the scratch-resistant particles can be 0.5-20 g / m², preferably 0.5-10 g / m², more preferably 0.5-5 g / m².

[0203] The coating composition may contain conventional additives. The coating composition may further contain functional additives, such as antistatic additives and / or antibacterial additives.

[0204] The coating composition can be transparent. However, the coating composition can also be colored.

[0205] The coating composition can be applied to the carrier 1 in one or more layers.

[0206] After the coating composition has been applied to the carrier 1, it is cured to form the coating 2. If the coating composition is UV-curable, UV radiation is applied to cure it. If the coating composition is a water-based UV-curable coating composition, it is first dried in a drying device 21 by IR or in an oven, and then cured by applying UV radiation to it in a UV radiation device 22. If the coating composition is a two-component system, it is dried, for example, in an oven or at room temperature.

[0207] After curing, a coated carrier 10 is formed.

[0208] Preferably, the coating composition retains a certain degree of crosslinking ability after curing. After curing, the residual oligomer content of the coating composition can be less than 10%. A certain residual oligomer content corresponds to a certain residual crosslinking ability. Therefore, the coating composition can be further crosslinked during the subsequent pressing process.

[0209] exist Figure 2 In the illustrated embodiment, in the pressing device 23, a coating step is used to press the substrate, decorative layer 4, and coated carrier 10 with cured coating 2 together. Preferably, the pressing device 23 is continuous. Preferably, heat is also applied. The applied pressure can be 5-100 bar, for example, applied over 5-500 seconds. The temperature can be 80-300°C, for example 100-250°C, for example 120-180°C, for example 130-150°C. The temperature can be approximately 140°C.

[0210] The pressing device 23 can have different gloss levels. The pressing surface of the pressing device 23 can have high-gloss portions, or even ultra-high-gloss portions and matte portions. Different gloss levels are provided by micro-embossing or microstructures with a maximum depth of 30 μm. The higher the depth of the microstructure, the more matte the texture of that portion or portions. The lower the depth of the microstructure, the more glossy 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 can vary across the entire surface of the pressing device 23, thereby obtaining varying gloss levels. When the coating 2 is pressed against the microstructure, the coating 2 obtains portions with different gloss levels, corresponding to the gloss level of the pressing surface of the pressing device 23. The gloss level can vary across the entire surface of the coating 2. Different gloss levels preferably refer to the gloss level of a first portion or group of portions being different from the gloss level of a second portion or group of portions. The first portion or group of portions can have a higher gloss level than the second portion or group of portions. The first part or the first group of parts may have a first gloss level, while the second part or the second group of parts may have a second gloss level that is higher or lower than the first gloss level.

[0211] The pressing device 23 may also be provided with protrusions for forming macroscopic embossing or macroscopic structures on the surface of the coated carrier. The macroscopic structures may also be aligned with the decorative patterns or printed designs of the decorative layer 4.

[0212] The pressing device 23 may include a metal surface having 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 cylinder or plate with different gloss levels, wherein the cylinder or plate directly contacts the surface of the coating carrier 10.

[0213] In one embodiment, the pressing device 23 may include a structural foil with a different gloss level. The structural foil is adapted to directly contact the surface of the coating 2. The structural foil may be arranged between the coating 2 and a pressure plate, pressure belt, or pressure cylinder during pressing.

[0214] Coating 2 may be provided with a release agent to prevent it from adhering to the pressing device. Since no additional layer needs to be applied to coating 2, the release agent can be applied to coating 2, which is beneficial for the pressing operation.

[0215] After pressing, coating 2 may include portions with different gloss levels. These different gloss levels are formed through a microstructure in the surface, preferably with a maximum depth of 30 μm. Different gloss levels can be formed in alignment with decorative patterns or printed designs in the decorative layer.

[0216] Coating 2 may also have embossed portions during pressing. The pressing device 23—e.g., a pressing plate, cylinder, belt, or structural foil—may have protrusions in coating 2 forming embossing or macrostructure. Alternatively, the embossed portions may be formed in a separate step from forming portions with different gloss levels. Embossing is preferably aligned with decorative patterns or printed designs. Embossing is preferably matched with portions of the coated carrier having different gloss levels. The embossed portions in the abrasion-resistant layer preferably have a depth exceeding 100 μm.

[0217] The architectural panel 5 is formed by pressing the coated carrier 10 and optional intermediate decorative layer 4 onto the base 3.

[0218] exist Figure 3 An alternative method for forming the coated foil 10' is shown in the figure. In this embodiment, the coated foil 10' includes a first foil 8 and a second foil 9.

[0219] 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 a combination thereof.

[0220] 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, etc.

[0221] In one embodiment, the first foil 1 is a PVC foil.

[0222] The first foil 8 may have a thickness of 0.1-1 mm. Preferably, the thickness of the first foil 8 is less than 0.5 mm, more preferably about 100 μm, and is preferably measured after pressing, for example, in the final product. The first foil 8 may be a decorative foil.

[0223] The wear-resistant particles 6 can be applied to the first foil 8 via the dispersion / distribution device 24. The wear-resistant particles can be alumina particles, such as corundum. Alternatively, or additionally, the wear-resistant particles 6 can be corundum, quartz, silica, glass, glass beads, glass spheres, diamond particles, hard plastics, reinforced polymers, and organic materials or combinations thereof.

[0224] The average particle size of the wear-resistant particles 6 is preferably in the range of 10-200 μm, more preferably in the range of 50-120 μm, for example 50-100 μm. The average particle size of the wear-resistant particles 6 can be less than 50 μm, preferably less than 45 μm. The wear-resistant particles 6 can have a spherical or irregular shape. The wear-resistant particles 6 can be surface-treated. The wear-resistant particles 6 can be silane-treated particles.

[0225] The wear-resistant particles 6 may have a refractive index similar to that of the second foil. The wear-resistant particles 6 may have a refractive index of 1.4-1.9. In one embodiment, the wear-resistant particles may have a refractive index of 1.4-1.9, preferably 1.5-1.8, for example 1.7-1.8. In another 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%.

[0226] The amount of wear-resistant particles 6 applied can be 10-100 g / m², preferably 10-50 g / m², and more preferably 20-30 g / m². After the wear-resistant particles 6 have been applied to the first foil 8, a second foil 9 is provided and disposed on the first foil 9. Thus, the wear-resistant particles 6 are encapsulated by the first foil 8 and the second foil 9.

[0227] As an alternative to or supplement to applying the wear-resistant particles 6 to the first foil 8, the wear-resistant particles can be applied to the second foil 9. In this embodiment, the second foil 9 having the wear-resistant particles 6 is arranged on the first foil 8, and vice versa.

[0228] 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 it 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 a combination thereof.

[0229] Preferably, the second foil 9 is formed of a thermoplastic material. The second foil may consist substantially of a thermoplastic material and optionally additives. The additives may be plasticizers, stabilizers, lubricants, degassing agents, coupling agents, compatibilizers, crosslinking agents, etc.

[0230] In one embodiment, the first foil 8 is a PVC foil and the second foil 9 is a PU foil.

[0231] The second foil 9 can be supplied as a foil produced in a separate production step. The second foil 9 can also be supplied as a continuous roll.

[0232] In other embodiments, the second foil 9 can be formed by an extrusion process, such as extrusion coating or extrusion lamination of the second foil 9 onto the first foil 8.

[0233] The second foil 9 may have a thickness of 0.01-1 mm. Preferably, the thickness of the second foil 9 is less than 0.5 mm, more preferably about 90-110 μm, preferably measured after pressing, for example, 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.

[0234] The thickness of the first foil 8 can exceed the thickness of the second foil 9. In particular, if the first foil 8 contains PVC and the second foil 9 contains PU, then the thickness of the first foil 8 can exceed the thickness of the second foil 9.

[0235] The average particle size of the wear-resistant particles 6 can be smaller than the thickness of the second foil 9. However, the average particle size of the wear-resistant particles 6 can 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, even though the average particle size of the wear-resistant particles 6 exceeds the thickness 9 of the second foil.

[0236] The first and second foils 8 and 9 are then attached to each other to form a wear-resistant foil 1' comprising the first foil 8 and the second foil 9, wherein at least a portion of the wear-resistant particles are arranged between the first foil and the second foil.

[0237] The abrasion-resistant foil 1' is preferably transparent, or at least substantially transparent.

[0238] The first foil 8 and the second foil 9 can be attached to each other, for example, by being pressed together during a calendering / lamination process. Figure 3 As shown, 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 can be attached together by individual pressure, by heating and pressurizing, by pressurizing and adhesive, or by heating, pressurizing and adhesive. Preferably, both pressure and heat are applied to attach the first foil and the second foil to each other. Continuous or static pressing can also be used as an alternative to or supplement to the calendering process. The pressing operation can be, for example, a hot-to-hot process, a hot-to-cold process, etc. Pressing can be performed using a die or roller with an embossed pattern, thereby forming an embossed structure in the abrasion-resistant foil 1'.

[0239] Depending on the thermoplastic material and process used, the applied pressure can be 5-100 bar, applied over 5-500 seconds. The temperature can be 80-300°C, for example 100-250°C, 120-180°C, or 130-150°C. A temperature of approximately 140°C is also possible.

[0240] After the layers are attached to each other, for example by pressing, the wear-resistant particles 6 are surrounded by the first foil 8 and the 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. Thus, a wear-resistant foil 1' with a smooth surface can be formed.

[0241] As referenced above Figure 1A The wear-resistant foil 1', which forms a carrier and is composed of a first foil 8 and a second foil 9, is coated by applying a coating composition to the surface of the second foil 9. This coating composition can be a coating conventionally known as a varnish. The coating composition can be applied by roller coating, curtain coating, dip coating, spraying, or other methods.

[0242] The coating composition is crosslinkable. The coating composition may be radiation-curable, preferably UV-curable. The coating composition is preferably water-based, such as a UV-curable water-based composition. The water-based UV-curable composition may contain a polyester / polyurethane dispersion. The water-based UV-curable composition may contain a polyurethane / acrylic copolymer dispersion. The water-based UV-curable composition may further contain photoinitiators, thickeners, additives, etc.

[0243] The coating composition can be a two-component system, such as an epoxy amine system, a polyurethane isocyanate system, an isocyanate alcohol system, an acid alcohol system, etc.

[0244] The coating composition can be applied in one or more layers. The total amount of coating composition applied, corresponding to 100% of the coating components and 0% of the solvent, can be 5-200 g / m2, for example, more than 5 g / m2, preferably more than 10 g / m2.

[0245] The coating composition may contain abrasion-resistant particles and / or scratch-resistant particles. Preferably, the coating composition contains scratch-resistant particles. Alternatively or additionally, when the coating composition is still wet, the scratch-resistant particles may be applied to the coating composition applied to the carrier.

[0246] The scratch-resistant particles can be or include nanoscale silica particles, preferably fused silica particles. The scratch-resistant particles can be disc-shaped particles with a width / thickness ratio preferably equal to or greater than 3:1, more preferably equal to or greater than 5:1. These disc-shaped particles are oriented along the surface of the foil, thereby improving the scratch resistance of the foil. The scratch-resistant particles can have an average particle size of 1-100 μm, preferably 10-50 μm, more preferably 20-30 μm. The average particle size of the scratch-resistant particles can be less than 50 μm, preferably less than 45 μm. The application amount of the scratch-resistant particles can be 0.5-20 g / m², preferably 0.5-10 g / m², more preferably 0.5-5 g / m².

[0247] The coating composition may contain conventional additives. The coating composition may further contain functional additives, such as antistatic additives and / or antibacterial additives.

[0248] The coating composition can be transparent. However, the coating composition can also be colored.

[0249] The coating composition can be applied to the second foil 9 in one or more layers.

[0250] After the coating composition has been applied to the carrier 1', the coating composition is cured to form the coating 2. If the coating composition is UV-curable, UV radiation is applied to cure it. If the coating composition is a water-based UV-curable coating composition, it is first dried in a drying device 21 by IR or in an oven, and then cured by applying UV radiation 22 to it in a UV radiation device 22. If the coating composition is a two-component system, it is dried, for example, in an oven or at room temperature.

[0251] After curing, a coated foil 10 is formed.

[0252] Preferably, the coating composition retains a certain degree of crosslinking ability after curing. After curing, the residual oligomer content of the coating composition can be less than 10%. Therefore, the coating composition can be further crosslinked during the subsequent pressing process.

[0253] In one embodiment, the second foil 9 is coated in the manner described above before the first foil 8 and the second foil 9 are preferably attached to each other by pressing.

[0254] It can be stored after the coating composition has cured, according to the reference. Figure 3 The method described forms the coated carrier 10'. As previously referenced. Figure 1B As described, the coated foil 10' can be applied to a substrate 3 having an optional decorative layer 4. The coated foil 10' can be used as a coated abrasion-resistant foil. In one embodiment, where the carrier is a decorative thermoplastic foil, the coated carrier 10 can be a coated decorative foil.

[0255] It is conceivable that many variations exist in the embodiments described herein, which are still within the scope of the invention as defined by the appended claims. For example, it is conceivable that more than one abrasion-resistant foil may be arranged on the core for forming a building panel. It is also conceivable that one or more additional coatings may be applied to the pressed coating after pressing.

[0256] It is also conceivable that pre-formed building panels can be coated using the methods described above. In this embodiment, the carrier forms part of the building panel when the coating composition is applied to it. After the coating composition is applied, it is cured into a coating and then pressed as described above.

[0257] Exemplary UV-curable water-based compositions may include: - The UV-curable composition may comprise 60 to 90 wt% of the composition, for example, 70 to 85 wt%; - The photoinitiator may comprise 0.1 to 5 wt% of the composition, for example, 0.5 to 2.5 wt%; - Water may comprise 1 to 25 wt% of the composition, for example 5 to 15 wt%; - The solvent may comprise 0.1 to 10 wt% of the composition, for example, 0.5 to 10 wt%; - A thickener may optionally be used, which may comprise 0.0 to 15 wt% of the composition, for example, 0.1 to 10 wt%; - Abrasion-resistant particles may optionally be used, which may comprise 0.0 to 15 wt% of the composition, for example, 0.1 to 10 wt%; - Optionally, a matting agent may be used, which may comprise 0.0 to 15 wt% of the composition, for example, 0.1 to 10 wt%; -Optional additives (e.g., defoamers / wetting agents) may be used, which may account for 0.0 to 15 wt% of the composition, for example 0.1 to 10 wt%.

[0258] An example solvent could be dipropylene glycol methyl ether.

[0259] Example

[0260] Example 1: Painted PVC foil on PVC foil with abrasion-resistant particles.

[0261] A first PVC abrasion-resistant layer foil with a thickness of 0.1 mm was positioned on a decorative PVC foil with a thickness of 0.03 mm. 25 g / m² of Al₂O₃ particles were applied to the first abrasion-resistant layer foil using a dispersion device. A second PVC abrasion-resistant layer foil with a thickness of 0.1 mm was coated with a UV-curable water-based coating composition of 60 g / m² according to Table 1, dried in an oven at 50°C for 10 minutes, and then UV-cured. The second PVC abrasion-resistant layer foil was positioned on the first abrasion-resistant layer foil containing Al₂O₃ particles. The decorative foil, the first abrasion-resistant layer foil, and the second abrasion-resistant layer foil were laminated onto a PVC core using a temperature of 140°C, a pressure of 10 bar, and a pressing time of 60 seconds. The resulting product was found to have improved scratch resistance and chemical resistance. The resulting product, tested in a Taber abrasion tester according to the test method in EN 13329, exhibited abrasion resistance exceeding 5000 revolutions.

[0262] Table 1: UV-curable water-based compositions

[0263] Example 2: Painted PVC foil on pre-pressed PVC foil with abrasion-resistant particles.

[0264] Al₂O₃ particles at a thickness of 25 g / m² were applied to a first PVC abrasion-resistant foil with a thickness of 0.1 mm using a dispersion device. A second PVC abrasion-resistant foil with a thickness of 0.1 mm was coated with a UV-curable water-based coating composition according to Table 1 (60 g / m²), dried in an oven at 50°C for 10 minutes, and then UV-cured. The second PVC abrasion-resistant foil was positioned on top of the first abrasion-resistant foil containing the Al₂O₃ particles. In a first pressing step, the first and second abrasion-resistant foils were laminated using a temperature of 120°C, a pressure of 10 bar, and a pressing time of 60 seconds. In a second pressing step, the laminated abrasion-resistant layer was laminated onto a decorative PVC foil with a thickness of 0.03 mm and then onto the PVC core material using a temperature of 140°C, a pressure of 10 bar, and a pressing time of 60 seconds. The resulting product was found to have improved scratch resistance and chemical resistance. The resulting product, tested in a Taber abrasion tester according to the test method in EN 13329, exhibited abrasion resistance exceeding 5000 revolutions.

[0265] Example 3: Painted PVC foil on pre-pressed PVC foil.

[0266] The thickness of the first PVC abrasion-resistant foil is 0.1 mm. A second PVC abrasion-resistant foil with a thickness of 0.1 mm is coated with a UV-curable water-based coating composition of 60 g / m² according to Table 1, dried in an oven at 50°C for 10 minutes, and then UV-cured. The second PVC abrasion-resistant foil is positioned on top of the first PVC abrasion-resistant foil. In the first pressing step, the first and second abrasion-resistant foils are laminated using a temperature of 120°C, a pressure of 10 bar, and a pressing time of 60 seconds. In the second pressing step, the laminated abrasion-resistant layer is laminated onto a 0.03 mm thick PVC decorative foil and PVC core material using a temperature of 140°C, a pressure of 10 bar, and a pressing time of 60 seconds. The resulting product was found to have improved scratch resistance and chemical resistance. The resulting product, tested in a Taber abrasion tester according to the test method in EN13329, exhibited abrasion resistance exceeding 1900 revolutions.

[0267] Example 4: Painted PVC foil on PVC foil.

[0268] A first PVC abrasion-resistant foil with a thickness of 0.1 mm was positioned on a decorative PVC foil with a thickness of 0.03 mm. A second PVC abrasion-resistant foil with a thickness of 0.1 mm was coated with a UV-curable water-based coating composition according to Table 1 (60 g / m²), dried in an oven at 50°C for 10 minutes, and then UV-cured. The second PVC abrasion-resistant foil was positioned on top of the first PVC abrasion-resistant foil. The first and second abrasion-resistant foils were laminated onto the PVC core material using a temperature of 140°C, a pressure of 10 bar, and a pressing time of 60 seconds. The resulting product was found to have improved scratch resistance and chemical resistance. The product tested in a Taber abrasion tester according to the test method in EN 13329 showed abrasion resistance exceeding 1900 revolutions.

[0269] Example 5: Painted PU foil on PVC foil with abrasion-resistant particles.

[0270] A 0.1 mm thick PVC abrasion-resistant foil was positioned on a 0.03 mm thick decorative foil. 25 g / m² Al₂O₃ particles were applied to the PVC abrasion-resistant foil using a dispersion device. A 0.05 mm thick PU abrasion-resistant foil was coated with a 60 g / m² UV-curable water-based coating composition according to Table 1, dried in a 50°C oven for 10 minutes, and then UV-cured. This PU abrasion-resistant foil was then positioned on the PVC abrasion-resistant foil containing Al₂O₃ particles. The PU and PVC abrasion-resistant foils were laminated onto a PVC core material using a temperature of 140°C, a pressure of 10 bar, and a pressing time of 60 seconds. The resulting product was found to have improved scratch resistance and chemical resistance. The product tested in a Taber abrasion tester according to the test method in EN 13329 showed abrasion resistance exceeding 5000 revolutions.

[0271] Example 6: Painted PU foil on pre-pressed PVC foil with abrasion-resistant particles.

[0272] Al₂O₃ particles at a density of 25 g / m² were applied to a 0.1 mm thick PVC abrasion-resistant foil using a dispersion device. A 0.05 mm thick PU abrasion-resistant foil was coated with a 60 g / m² UV-curable water-based coating composition according to Table 1, dried in a 50°C oven for 10 minutes, and then UV-cured. This PU abrasion-resistant foil was positioned onto the PVC abrasion-resistant foil containing Al₂O₃ particles. In a first pressing step, the two foils were laminated at a temperature of 120°C, a pressure of 10 bar, and a pressing time of 60 seconds. In a second pressing step, the laminated abrasion-resistant layer was laminated onto a 0.03 mm thick decorative PVC foil and PVC core material using a temperature of 140°C, a pressure of 10 bar, and a pressing time of 60 seconds. The resulting product was found to have improved scratch resistance and chemical resistance. The product tested in a Taber abrasion tester according to the test method in EN 13329 showed abrasion resistance exceeding 5000 revolutions.

[0273] Example 7: Painted PU foil on pre-pressed PVC foil.

[0274] The PVC abrasion-resistant foil has a thickness of 0.1 mm. A 0.05 mm thick PU abrasion-resistant foil was coated with a 60 g / m² UV-curable water-based coating composition according to Table 1, dried in an oven at 50°C for 10 minutes, and then UV-cured. This PU abrasion-resistant foil was positioned on top of the PVC abrasion-resistant foil. In the first pressing step, the two foils were laminated using a temperature of 120°C, a pressure of 10 bar, and a pressing time of 60 seconds. In the second pressing step, the laminated abrasion-resistant layer was laminated onto a 0.03 mm thick decorative PVC foil and PVC core material using a temperature of 140°C, a pressure of 10 bar, and a pressing time of 60 seconds. The resulting product was found to have improved scratch resistance and chemical resistance. The product tested in a Taber abrasion tester according to the test method in EN13329 showed abrasion resistance exceeding 2100 revolutions.

[0275] Example 8: Painted PU foil on PVC foil.

[0276] A 0.1 mm thick PVC abrasion-resistant foil was positioned on a 0.03 mm thick decorative PVC foil. A 0.05 mm thick PU abrasion-resistant foil was coated with a 60 g / m² UV-curable water-based coating composition according to Table 1, dried in an oven at 50°C for 10 minutes, and then UV-cured. This PU abrasion-resistant foil was positioned on top of the PVC abrasion-resistant foil. The three foil layers were pressed onto the PVC core material using a temperature of 140°C, a pressure of 10 bar, and a pressing time of 60 seconds. The resulting product was found to have improved scratch resistance and chemical resistance. The resulting product, tested in a Taber abrasion tester according to the test method in EN 13329, exhibited abrasion resistance exceeding 2100 revolutions.

[0277] Example 9: Painted PVC wear-resistant layer

[0278] The PVC abrasion layer was coated with a 60 g / m² UV-curable water-based coating composition according to Table 1, dried in an oven at 50°C for 10 minutes, and then UV cured. The coated PVC abrasion layer was pressed using a temperature of 140°C, a pressure of 10 bar, and a pressing time of 60 seconds. In a second pressing step, the coated abrasion layer was laminated onto a 0.03 mm thick decorative PVC foil and then onto the PVC core material using a temperature of 140°C, a pressure of 10 bar, and a pressing time of 60 seconds. The resulting product was found to have improved scratch resistance and chemical resistance. The product tested in a Taber abrasion tester according to the test method in EN13329 showed abrasion resistance exceeding 5000 revolutions.

[0279] Example 10: Painted LVT with PVC abrasion layer

[0280] An LVT product comprising a PVC core material and a decorative PVC foil with a top PVC abrasion layer was coated with a 60 g / m² UV-curable water-based composition according to Table 1, dried in an oven at 50°C for 10 minutes, and then UV cured. The coated LVT was pressed at a temperature of 140°C, a pressure of 10 bar, and a pressing time of 60 seconds. Improved scratch and chemical resistance were found in the LVT product. Abrasion resistance exceeding 5000 revolutions was tested in a Taber abrasion tester according to the test method in EN 13329.

[0281] Example 11: Painted LVT with PU abrasion-resistant layer

[0282] An LVT product comprising a PVC core material and a decorative PVC foil product with a PU abrasion-resistant layer on top was coated with a 60 g / m² UV-curable water-based composition according to Table 1, dried in an oven at 50°C for 10 minutes, and then UV-cured. The coated LVT was pressed using a temperature of 140°C, a pressure of 10 bar, and a pressing time of 60 seconds. Improved scratch resistance and chemical resistance were found in the LVT product. Abrasion resistance exceeding 5000 revolutions was tested in a Taber abrasion tester according to the test method in EN13329.

[0283] Example 12: Painted PU wear-resistant layer on the decorative panel

[0284] A 0.6 mm thick wood veneer layer was attached to a PVC core material using PU powder. A first PU abrasion-resistant layer foil with a thickness of 0.05 mm was placed on the wood veneer layer. 25 g / m² Al₂O₃ was applied to the first PU abrasion-resistant layer foil using a dispersion device. A second PU abrasion-resistant layer with a thickness of 0.05 mm was applied to the PU abrasion-resistant layer foil containing Al₂O₃ particles. The second PU abrasion-resistant layer was coated with a 60 g / m² UV-curable water-based coating composition according to Table 1, dried in an oven at 50°C for 10 minutes, and then UV-cured. The wood veneer layer, the first PU abrasion-resistant layer foil, and the second coated PU abrasion-resistant layer foil were laminated onto the PVC core material using a temperature of 140°C, a pressure of 10 bar, and a pressing time of 60 seconds. The resulting product was found to have improved scratch resistance and chemical resistance. The product tested in a Taber abrasion tester according to the test method in EN 13329 showed abrasion resistance greater than 2400 revolutions.

[0285] Example 13: Painted PVC foil on PVC foil

[0286] A first PVC abrasion-resistant foil with a thickness of 0.1 mm was positioned on a decorative PVC foil with a thickness of 0.03 mm. A second PVC abrasion-resistant foil with a thickness of 0.1 mm was coated with a 60 g / m² two-component (PU isocyanate) water-based coating composition, then dried in an oven at 50°C for 20 minutes, followed by drying at room temperature for 2 days. The second PVC abrasion-resistant foil was positioned on top of the first PVC abrasion-resistant foil. The first and second abrasion-resistant foils were laminated onto the PVC core material using a temperature of 140°C, a pressure of 10 bar, and a pressing time of 60 seconds. The resulting product was found to have improved scratch resistance and chemical resistance. The product tested in a Taber abrasion tester according to the test method in EN13329 showed abrasion resistance exceeding 1900 revolutions.

Claims

1. A method for producing a coating (2), comprising: The water-based coating composition is applied to the surface of a carrier (1; 1'). The water-based coating composition is cured into a coating (2). Pressure is then applied 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 includes pressing the coating composition against a pressing device (23) that includes portions with different gloss levels, so that the coating (2) acquires different gloss levels after pressing.

4. The method according to any one of claims 1-3, wherein, Applying pressure includes applying heat and pressure simultaneously.

5. The method according to any one of claims 1-4, wherein, The coating composition contains a crosslinkable component.

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

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

8. The 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 includes pressing the coating (2) on the carrier (1; 1') and attaching it to the substrate (3), wherein the carrier (1; 1') is located between 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) from the carrier (1; 1') before applying pressure, wherein applying pressure to the coating (2) comprises pressing the coating (2) and attaching it to the substrate (3).

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