Film composite and its production by a coating system

Description

[0001] The present invention relates to a method for producing a film composite with a polyurethane-based reactive melting compound layer using a coating system, as well as a film composite obtainable by such a method and its use.

[0002] Large-scale plastic films are typically produced by casting, calendering, or extrusion, particularly by blow molding. The materials used can vary, including cellulose acetate, polyvinyl chloride, and polyethylene. Plastic films can be single-layer or multi-layer (laminated film). The machinery used in production, such as extruders, is designed for high production volumes and is therefore relatively expensive and complex in design.

[0003] The trend towards individualization demands small batch sizes and minimal setup times, often combined with the option of digital printing. Conventional methods require long setup times for decor or color changes and generate significant material waste due to the necessary lead time. There is also a need for (composite) films with low thermal sensitivity and / or suitability for wrapping.

[0004] Especially in the absence of such facilities, there is a need for processes that avoid the acquisition of such facilities and the associated disadvantages, and also represent a cost-effective option for smaller production quantities.

[0005] Document EP 2 272 663 A1 discloses a process for producing a leather composite film using a reverse coating process, wherein a carrier strip is coated with a first plastic compound, the first plastic compound is cured in a subsequent heat treatment, and then a second plastic compound is applied to this first plastic layer as an adhesive layer. Leather is applied to the still reactive adhesive layer, and after sufficient drying / curing of the resulting leather composite film made of plastic and leather layers, the carrier strip is removed.

[0006] Document US 2016 / 130467 A1 discloses a paint replacement film with a polymer layer comprising a polyurethane produced from a formulation containing at least one blocked isocyanate. The paint replacement film comprises a top layer, and the formulation comprises at least two polyols in an OH weight equivalent ratio in the range of 4.5:1 to 1:4.5. The formulation may include a colorant, and the polyurethane may have a glass transition temperature (Tg) below 42°C. Also disclosed is a process for producing a paint replacement film by providing a backing layer, providing the liquid formulation, casting the liquid formulation onto the backing layer, and gelling the liquid formulation, thereby forming a polymer layer comprising polyurethane.

[0007] Document EP 2 799 155 A1 discloses a method for producing a seamless high-gloss surface on at least one part of a possibly coated substrate surface with an adjacent edge of an object, as well as objects obtainable in this way.

[0008] Document WO 2010 / 112511 A1 discloses an object whose surface is at least partially painted or printed, and methods for painting or printing the object, using an adhesion promoter layer containing a reactive melt.

[0009] One object of the present invention is therefore to provide such a method and films produced therefrom.

[0010] The problem is solved by a process for producing a film composite with a reactive melting compound layer based on polyurethane using a coating system comprising the steps a) optionally applying a primer to a substrate; b) applying the polyurethane-based reactive melt layer to the primer or directly to the substrate; c) applying a coating to the polyurethane-based reactive melt layer to create the film composite on the substrate; d) optionally embossing the film composite on the substrate; e) separating the film composite from the substrate.

[0011] The problem is also solved by a film composite (composite film) obtainable by the inventive method. The film composite according to the invention is suitable, for example, as a sheathing or laminating material. Accordingly, a further aspect of the present invention is the use of a film composite according to the invention for sheathing or laminating.

[0012] Surprisingly, it has been shown that the use of reactive melting compounds can produce a film composite that is inexpensive and easy to manufacture using a coating system. Thermoplastic films exhibit a certain degree of thermal sensitivity during further processing, depending on their chemical composition and orientation. This can lead to wrinkling and dimensional changes, especially in coating or bonding processes such as hot coating, where the film is subjected to temperature (melting compound, lamps, drying, etc.) and / or mechanical stresses (winding processes, roller compression, etc.).

[0013] At the same time, films are frequently used in encapsulation processes where maximum flexibility is required. Thermoplastic films, even those with improved thermal sensitivity, often exhibit low flexibility. Surprisingly, it has been shown that these disadvantages can be avoided or at least reduced by a film composite according to the invention with reactive melting compounds. Handling highly thermally sensitive films is eliminated. The resulting film composite is not thermoplastic, yet it exhibits maximum flexibility.

[0014] In step a) of the inventive method, a primer is optionally applied to a substrate. As a result of applying the primer to the substrate, a primer layer is created on it. This layer can be single- or multi-layered. Consequently, priming step a) itself can be carried out in one or more stages.

[0015] However, such priming is not mandatory. It is advantageous, however, if priming is provided. Priming can be carried out using methods known to those skilled in the art. Suitable components of a coating system, such as an application roller or slot nozzle, are suitable for this purpose. Accordingly, a further aspect of the present invention is a method according to the invention, wherein the application of the primer is carried out by an application roller or slot nozzle of the coating system.

[0016] If a primer is present, it can serve as a release agent. This allows for particularly easy separation of the film composite in step e).

[0017] Furthermore, it is preferred if the primer layer is a color-imparting layer or an opacity-producing layer. If the priming is carried out in multiple stages, resulting in a multi-layered primer layer, it is preferred if at least one layer of the primer is such a color-imparting or opacity-producing layer. Accordingly, another aspect of the present invention is that the application of the primer forms at least one color-imparting layer or an opacity-producing layer. Preferably, the primer is a lacquer, in particular a UV-curing or water-based lacquer, or a lacquer that is both UV-curing and water-based. Opacity is generally achieved by titanium dioxide. The primer can be optimized in its function as a base for decorative application for various coloring processes, such as...regarding the adhesion of pigments and ideal surface tension for wetting with printing inks.

[0018] The primer can also be transparent. It is also possible that, when using the foil composite, for example during encapsulation, the primer forms the outer surface, so that the paint layer in step c) faces the surface of the encapsulated object.

[0019] Therefore, it is also possible for the primer to have an embossed structure. This can be created, for example, by digitally 3D printing the corresponding negative structure onto the surface of the substrate material, which is then transferred to it by coating it with the primer. Furthermore, a decorative element that adapts to the embossed structure can be printed after step b) and before step c). This adaptation can be achieved, for example, through data synchronization ("digitally synchronized 3D texture"). Generally, an embossing of this type that matches the decorative element is referred to as a "synchronous pore," or the term "EIR" (embossed-in-register) is also used. The term "true texture" is also used in the prior art.

[0020] If a primer is applied, a reactivated adhesive layer can be applied before the primer. This adhesive layer can then be applied to the substrate surface. In this case, the adhesive layer can act as a release agent to allow the film composite to be removed.

[0021] Therefore, it is further preferred that the surface of the substrate material be provided with a reactivated adhesive layer before the primer is applied, or that this adhesive layer serves as a primer. This is particularly preferred if a decorative layer is applied before step b).

[0022] The adhesive layer can be applied in one or more stages and thus itself consist of one or more layers. It is also possible for the adhesive layer itself to serve as a primer. The adhesive layer can be a dispersion that is reactivated by temperature, such as a polyurethane dispersion. Preferably, a thermoplastic hot melt adhesive according to the state of the art is used, which is reactivated by temperature during the lamination process. This can be, for example, a hot melt adhesive based on ethylene vinyl acetate copolymer (EVA), atactic poly-alpha olefin (APAO), metallocene polyolefin (mPO), polyamide, or polyester. A reactive hot melt adhesive based on polyurethane or polyolefin can also be used, which is reactivated by temperature within a defined time window or is protected from humidity by the substrate material.Other alternatives include encapsulated adhesive systems or two-component systems that are reactivated via temperature, pressure, or the application of another component during the lamination process.

[0023] Prior to step b) of the inventive method, a decorative layer can be applied. This can be produced, for example, by direct printing or digital printing, preferably by digital printing.

[0024] In step b), a polyurethane-based reactive melt layer is applied to the primer or directly to the substrate. This layer is therefore in direct contact with the primer layer or the surface of the substrate. However, it is also possible for one or more additional layers to be created through intermediate steps, so that these layer(s) lie between the substrate surface and the reactive melt layer. For example, a decorative layer may be present, such as one located between the reactive melt layer and the primer.

[0025] The reactive melt layer can be applied in a single or multiple layer. Accordingly, the entire reactive melt layer can be single or multiple layers.

[0026] The reactive polyurethane melt is preferably produced from isocyanate-reactive polymers and polyisocyanates, and optionally from additives.

[0027] The reactive polyurethane melt is a product that is solid at room temperature and is emission- and solvent-free. The temperature at which the reactive melt is applied is in the range of 60°C to 150°C, preferably from 100°C to 140°C. The product has a Brookfield viscosity at 120°C in the range of 1,000 mPas to 30,000 mPas, preferably 4,000 mPas to 10,000 mPas. The density of the reactive melt is typically 1.1 g / m². Advantageously, the reactive melt layer retains a certain degree of residual elasticity even in the cured state. Curing occurs not only through physical solidification but also, and in particular, exclusively through moisture curing, especially with the aid of atmospheric humidity. Complete curing can take several days.The reactive melting mass is therefore applied in a hot-liquid state, and it is not necessary for it to fully cure before applying the coating.

[0028] Preferred isocyanate-reactive polymers are predominantly linear but also branched polyesters, in particular di- and trifunctional polyethylene and polypropylene glycols, polytetrahydrofurans, as well as polyamides and mixtures thereof. The corresponding copolymers, especially block copolymers, can also be used.

[0029] Particularly preferred are polyester polyols that can be liquid, glassy amorphous, or crystalline and have a number-average molecular weight between 400 and 25,000 g / mol, particularly between 1,000 and 10,000 g / mol, and especially between 2,000 and 6,000 g / mol. Such particularly suitable polyester polyols are available commercially, for example, under the name Dynacoll® from Degussa AG. Other suitable polyester polyols include polycaprolactone polyesters, polycarbonate polyesters, and polyester polyols based on fatty acids.

[0030] Other preferred isocyanate-reactive polymers are predominantly linear or slightly branched polyalkylene oxides, in particular polyethylene oxides, polypropylene oxides or polytetrahydrofurans (polyoxytetramethylene oxides), with a number-average molecular weight between 250 and 12000 g / mol, preferably with a number-average molecular weight between 500 and 4000 g / mol.

[0031] The polyisocyanate is preferably a substance or a mixture of substances selected from aromatic, aliphatic or cycloaliphatic polyisocyanates with an isocyanate functionality between 1 and 4, preferably between 1.8 and 2.2, particularly preferably with the isocyanate functionality 2.

[0032] Particularly preferred is the polyisocyanate with a molecular mass < 500, a substance or a mixture of substances from the following list: diisocyanatodiphenylmethanes (MDIs), in particular 4,4'-diisocyanatodiphenylmethane and 2,4'-diisocyanatodiphenylmethane, as well as mixtures of different diisocyanatodiphenylmethanes; hydrogenated 4,4'-MDI (up to 4-isocyanatocyclohexyl)methane and hydrogenated 2,4'-MDI; tetramethylxylylene diisocyanate (TMXDI); xylylene diisocyanate (XDI); 1,5-diisocyanatonaphthalene (NDI); diisocyanatotoluenes (TDIs), in particular 2,4-diisocyanatotoluene, as well as TDI-urethdiones, in particular dimeric 1-methyl-2,4-phenylene diisocyanate (TDI-U), and TDI-ureas; 1-Isocyanato-3-isocyanatomethyl-3,5,5-trimethylcyclohexane (IPDI) and its isomers and derivatives, in particular di-, tri- and polymers, as well as IPDI isocyanurate (IPDI-T); 3,3'-Dimethylbiphenyl-4,4'-diisocyanate (TODI); 3,3'-Diisocyanato-4,4'-dimethyl-N,N'-diphenylurea (TDIH);Hexamethylene-1,6-diisocyanate (HDI) and methylene-bis-(4-isocyanatocyclohexane) (H12MDI).;

[0033] Lightfast, aliphatic polyisocyanates are preferred.

[0034] Isocyanoterminated prepolymers with low residual monomer content are preferred as polyisocyanates, especially when prepolymers based on aliphatic isocyanates are used. This requires that they are low in monomers, i.e., their residual monomer content is not greater than 0.5 wt%, preferably less than 0.3 wt%, and particularly preferably less than 0.1 wt%. Suitable products include, in particular, reaction products of polyether polyols, preferably polypropylene glycols, and polyester polyols with polyisocyanates, especially diisocyanato-diphenylmethanes, diisocyanato-toluenes, diisocyanato-hexane, isocyanato-3-isocyanatomethyl-3,5,5-trimethylcyclohexane (IPDI), hexamethylene-1,6-diisocyanate (HDI), and / or H₁₂MDI, as well as derivatives of these isocyanates. Prepolymers based on aliphatic isocyanates such as HDI and IPDI are particularly preferred.

[0035] Such monomer-poor, isocyanate-terminated prepolymers are produced by reacting polyether polyols with an excess of polyisocyanates. After the reaction, any remaining monomeric isocyanate is optionally removed using a thin-film evaporator.

[0036] The reactive polyurethane melt can also be produced in a two-step process according to patent EP1831277B2. In a first step, the isocyanate-reactive polymers are reacted with a molar deficit of a polyisocyanate with a molecular weight < 500 g / mol, and then in a second step, the prepolymer from the first step is reacted with the isocyanate-terminated prepolymers described above in a molar excess.

[0037] In an advantageous process for the production of the thermoplastic polyurethane, the isocyanate-reactive polymer or the mixture of isocyanate-reactive polymers is dehydrated under vacuum at 120°C in the first process stage. It is then reacted with the polyisocyanate at 80 to 140°C, preferably at 100 to 120°C.

[0038] The conversion in process steps 1 and / or 2 is preferably carried out at a temperature in the range of 80 to 140°C, in particular from 100 to 120°C.

[0039] The reactive polyurethane composition produced in this way is then preferably filled into containers that are impermeable to water vapor.

[0040] The reactive polyurethane melt can also contain abrasion-resistant fillers in accordance with WO 2012 / 084823 A1 if increased abrasion resistance is required in the application, as is often the case in flooring. Accordingly, the melt can have an inorganic filler component, wherein the filler component contains particles of at least one filler having a Mohs hardness of at least 6, preferably at least 7. The particles of the at least one filler preferably have a mean particle diameter in the nanoparticle range (< 1 µm) or in the range of 3.5 µm to 56 µm. The at least one filler can be, for example, a metal oxide, silicon dioxide, metal carbide, silicon carbide, metal nitride, silicon nitride, or boron nitride. Suitable materials include corundum, emery, spinel, and / or zirconium oxide.

[0041] The reactive melting mass can also consist of a melting mass that cures both in moisture and with UV light, in accordance with WO 2006 / 106143 A1.

[0042] In particular, the reactive polyurethane composition may also contain auxiliary substances, especially fillers, non-reactive polymers, sticky resins, waxes, plasticizers, additives, light stabilizers, leveling agents, accelerators, adhesion promoters, pigments, catalysts, stabilizers and / or solvents.

[0043] The non-reactive polymers can preferably be polyolefins, polyacrylates, and polymers based on ethylene and vinyl acetate with vinyl acetate contents of 0 to 80 wt.%, preferably 0.1 to 801 wt.%, or polyacrylates and mixtures thereof.

[0044] The reactive polyurethane composition thus produced preferably has a viscosity of 2,000 mPas to 100,000 mPas at 120°C, preferably of 5,000 to 50,000 mPas at 120°C.

[0045] In addition to reactive polyurethane melting compound, a reactive polyolefin-based melting compound can also be used. This cures through the reaction of silane groups with atmospheric moisture.

[0046] Preferably, the reactive melt layer is a moisture-curing layer. It is further preferred that this is a reactive polyurethane melt layer (PUR-SK), preferably made from isocyanate-reactive polymers and polyisocyanates, and optionally with additives. In particular, a lightfast PUR-SK as described above is preferred.

[0047] The reactive melt may contain additives, such as fillers, in particular abrasion-resistant fillers, as described above. The inorganic filler component preferably comprises a proportion in the range of 5 wt.% to 60 wt.% based on the total weight of the reactive melt. More preferably, the proportion is in the range of 10 wt.% to 50 wt.%, and even more preferably in the range of 15 wt.% to 30 wt.%.

[0048] Preferably, the reactive melt layer has a thickness in the range of 20 µm to 150 µm.

[0049] The reactive melt layer can be applied using methods known to those skilled in the art. Suitable means of the coating system for producing a reactive melt layer are known. Preferably, the reactive melt layer is applied by an application roller with or without a smoothing roller or a slot die with or without a roller bar of the coating system.

[0050] In step c) of the inventive process, a lacquer layer is applied. By applying the lacquer layer to the polyurethane-based reactive melt layer, the film composite can be created on the substrate. The lacquer layer can be applied in one or more stages. Accordingly, a single- or multi-layered structure of the lacquer layer is possible. Preferably, however, the lacquer layer is applied in a single layer. In particular, it is preferred that the melt layer and the lacquer layer are each applied in a single layer.

[0051] Preferably, the lacquer layer has a thickness of 5 µm to 25 µm.

[0052] The coating possesses the flexibility required for roll materials. It can significantly determine the gloss level of the film composite. It can be optimized for physical matting (excimer coating) – all the way to specific high-gloss properties (flow characteristics, suitability for inert calendering (ICC) processes). Simultaneously, the coating layer or the entire film composite can be embossed using ICC technology.

[0053] The coating can be formulated to exhibit chemical and physical properties depending on the application of the film composite (scratch resistance, outdoor weathering, etc.). Such coatings are known in the prior art.

[0054] Preferably, the varnish is a varnish that can be cross-linked using electron radiation or UV radiation.

[0055] All compounds that preferably contain one or more functional groups polymerizable by electron and / or UV radiation can be used as components polymerizable by irradiation. Compounds with olefinically unsaturated functional groups are preferred.

[0056] Examples of such compounds include styrene, 1-methylstyrene, vinyl acetate, vinyl chloride, conjugated dienes such as butadiene and isoprene, vinyl ethers of C1-C20 alkanols, as well as arylnitrile, vinylcaprolactam, n-vinylformamide, C1-C4 acrylic acid, and methacrylic acid esters such as methyl(meth)acrylate, ethyl(meth)acrylate, n-propyl(meth)acrylate, isobornyl acrylate (IBOA), and the like. Furthermore, higher-functionality compounds such as trimethylol triacrylate (TMTPA), ethoxylated trimethylol triacrylate, propoxylated glycerol diacrylate, butanediol diacrylate (BDDA), hexanediol diarylate (HDDA), tripropylene glycol diacrylate (TPGDA), dipropylene glycol diacrylate (DPGDA), pentaerythritol triacrylate (PETIA), and pentaerythritol tetraacrylate (PETTA) can also be used.

[0057] In addition, so-called oligomers can also be used. Examples of oligomers include aliphatic and aromatic epoxy acrylates, aliphatic and aromatic urethane acrylates, polyester acrylates, polyether acrylates and amine-functionalized polyether acrylates, as well as unsaturated polyester resins.

[0058] These oligomers are known from the prior art and are available, for example, from Rahn under the brand name Genomer ®<, from Allnex under the brand name Ebecryl ®<, from Miwon under the brand name Miramer ®<, from Sartomer under the CN series, or from BASF under the brand name Laromer l ®<.

[0059] Preferably, substances and mixtures of substances can be used as photoinitiators for the radical reaction which, when irradiated with light with a wavelength of approximately 240 to approximately 480 nm, are capable of initiating a radical polymerization of olefinically unsaturated double bonds. Suitable photoinitiators are described, for example, in "Advances in Polymer Science, Volume 14," Springer Berlin 1974.

[0060] For example, these are all Norrish Type I fragmenting substances. Examples include benzophenone, camphorquinone, Quantacure (manufacturer: International Bio-Synthetics), photoinitiators of the Omnirad® series (IGM), the Genocure® series (Rahn), and the Speedcure™ series (manufacturer: Lambson).

[0061] Particularly suitable photoinitiators are those from the class of benzoins, phenylhydroxyalkonones, alpha-hydroxyketones, alpha-aminoketones, phenylglyoxylates, monoacylphosphines (MAPO) and bisacylphosphines (BAPO).

[0062] Particularly suitable examples of photoinitiators are Speedcore 73, Ominirad 819, Speedcure MBF and Ominirad TPO.

[0063] Polymerizable photoinitiators, such as those offered by Rahn under the trade name Genopol®, are also particularly suitable.

[0064] The lacquer can be transparent or pigmented. If the lacquer is pigmented, it preferably contains titanium dioxide as a filler. However, the lacquer can also contain other fillers such as chalk, talc, as well as fillers to increase scratch and micro-scratch resistance, such as glass beads or nanoparticles. Furthermore, the lacquer can also contain colored pigments.

[0065] The paint may also contain additives commonly used in paints, which are known to experts, such as defoamers, deaerators, wetting agents, dispersing agents, leveling agents, antioxidants and UV stabilizers, etc.

[0066] The varnish preferably has a viscosity according to Brookfield (20°C) of 200 mPas - 20,000 mPas, preferably of 500 mPas-10,000 mPas.

[0067] If a primer (step a) is applied and a paint is used for this purpose, it can also have the properties listed above.

[0068] The substrate material can be a metal foil, a CPL (Continuous Pressure Laminate), melamine paper, release paper, silicone-coated sheet material, or a plastic film, or it can contain at least one or more of these materials. A plastic film is particularly preferred. High dimensional stability and mechanical strength under thermal stress are advantageous when selecting the substrate material. The ease of removal from the primer or the reactive melt layer can also be a factor in the choice of substrate material.

[0069] Preferably, the carrier material has a thickness of 30 µm to 400 µm. However, it is also possible that the carrier material is a conveyor belt of the coating system.

[0070] The substrate material can simultaneously be a carrier for printing inks that are introduced into the reactive melt layer using the transfer printing process (sublimation).

[0071] Furthermore, step d) can involve embossing the film composite onto the substrate. However, this step can also be omitted. The embossing can be done using an embossing roller in the coating system or by pressing on textured web material.

[0072] In step e), the film composite is separated from the substrate. Preferably, the film composite is separated from the substrate by peeling it off after crystallization or reaction of the reactive melt layer. Preferably, after separation in step e), the substrate can be reused in the process according to the invention, optionally after cleaning. Accordingly, it is preferred that the substrate is reused for the process according to the invention.

[0073] Preferably, the coating system is a roll-to-roll system. A roll-to-roll system is understood to be a processing system in which rolled material, in the context of the present invention the carrier material, is fed into the system and, after processing, the desired product, in the context of the present invention the film composite, also comes out as a roll.

[0074] Both the film composite and the carrier material are preferably produced in roll form. The materials can be precisely wound onto interchangeable cores using an edge guide, allowing them to be further processed in laminating processes using standard fixtures.

[0075] Accordingly, in a preferred embodiment, after separation in step e) of the inventive method, the inventive film composite is obtained as a roll, which can be obtained by winding. It is also preferred that the substrate is available as a roll before step a), which is unwound for processing in the coating system.

[0076] The method according to the invention can include further steps. For example, smoothing the reactive melt layer after step b) and before step c) is possible. At least one of the following steps is also possible: Physical matting of the lacquer (excimer lamp). Smoothing and curing of the lacquer via an inert calender process. The resulting film composite can be divided into different widths using a downstream cutting device (e.g., with rotary knives). Particles are sprinkled in after the application of the reactive melt layer to create an "anti-slip" surface.

[0077] The film composite according to the invention can be used, for example, for wrapping or laminating. The film composite can be pre-coated with an adhesive layer. Suitable adhesives include, for example, hot melt adhesives, which can be thermoplastic or reactive, in particular polyurethane-based adhesives, dispersions, and pressure-sensitive hot melt adhesives. Application is possible, for example, via rollers or slot nozzles.

[0078] The manufactured film composite can serve as a replacement for conventional films. One area of ​​application could be flooring. Here, it would be particularly suitable as a replacement for TPU, PET, or PVC films.

[0079] Outdoor applications are also conceivable, particularly as a replacement for PMMA films, for example as window films, for facades or profiles. Further application possibilities include decking and furniture, especially for creating a soft touch and textures.

[0080] The invention is explained in more detail with reference to the following figure and examples, without the present invention being limited to these. Examples Example 1 Floor foil: Highly abrasion-resistant, split-resistant, bonding and embossing via reactivation

[0081] An exemplary film composite according to the invention has the following layer structure: 1. Thermally reactivated adhesive, opaque (e.g., EVA SK Kleiberit 743.6) 2. Primer: opaque, white, UV-curing (e.g., UV Lacquer Kleiberit 653.1.33) 3. Digital printing: UV-curing inks applied via single-pass printer 4. Reactive hot-melt polyurethane coating with corundum (e.g., PUR HotCoating Kleiberit 717.6) 5. UV-curing acrylic lacquer: scratch-resistant, optionally physically matted (e.g., UV Lacquer Kleiberit 659.0.04)

[0082] Further processing can take place: short-cycle presses or laminating machines with heated calender rolls, application of textures via press plates / matrices or embossing rollers. Example 2: Terrace decking Foil: Highly abrasion-resistant, tear-resistant, weather-resistant

[0083] An exemplary film composite according to the invention has the following layer structure: 1. Primer: opaque, white, UV-curing, optimized wetting properties (e.g., Kleiberit 653.1.33 UV varnish) 2. Digital printing: UV-curing inks applied via single-pass printer 3. Reactive hot-melt polyurethane coating, corundum-containing, with UV absorbers (e.g., Kleiberit 9383 / 627 PUR HotCoating) 4. UV-curing acrylic varnish: scratch-resistant, weather-resistant, flexible (e.g., Kleiberit 659.2.22 UV varnish) 5. Embossing / anti-slip surface

[0084] Further processing is possible: coating system with PUR hot melt adhesive.

[0085] It shows the figure: Fig. 1 a coating system for the production of film composites according to the invention

[0086] In the coating unit 1, a carrier film 2 is fed from a roller unit 3 to a priming unit 4, where the carrier film 2 is primed and optionally provided with reactivated adhesive on its surface. The carrier film 2 then passes through a printing unit 5, which enables printing on the primed carrier film surface. Subsequently, the carrier film surface is coated with a polyurethane-based reactive melt compound in a downstream coating unit 6. A UV lacquer layer is then applied in a coating unit 7. The curing unit 8, in the form of a UV lamp, cures the UV lacquer. Embossing then takes place in an embossing unit 9, followed by the separation and winding of the carrier film 2 and the film composite 10 according to the invention. Reference symbol list

[0087] 1 Coating unit 2 Carrier film 3 Roll unit 4 Primer unit 5 Printing unit 6 Coating unit 7 Painting unit 8 Curing unit 9 Embossing unit 10 Film assembly

Claims

1. Method for producing a composite film (10) having a polyurethane-based reactive hot-melt layer with the aid of a coating apparatus (1), which contains the steps a) optionally applying a primer onto a support material; b) applying the polyurethane-based reactive hot-melt layer onto the primer or directly onto the support material; c) applying a lacquer layer on the polyurethane-based reactive hot-melt layer in order to produce the composite film (10) on the support material; d) optionally embossing the composite film (10) on the support material; e) separating the composite film (10) from the support material.

2. Method according to Claim 1, characterized in that the primer is provided.

3. Method according to Claim 1 or 2, characterized in that the primer is used as a separating agent.

4. Method according to one of Claims 1 to 3, characterized in that the hot-melt layer and the lacquer layer are each applied in one coat.

5. Method according to one of Claims 1 to 4, characterized in that the reactive hot-melt layer has a thickness in the range of from 20 µm to 150 µm.

6. Method according to one of Claims 1 to 5, characterized in that the lacquer layer has a thickness in the range of from 5 µm to 25 µm.

7. Method according to one of Claims 1 to 6, characterized in that the application of the primer forms at least one colouring layer or an opacifying layer and is preferably a lacquer, in particular a UV-curing or a water-based or both a UV-curing and a water-based lacquer.

8. Method according to one of Claims 1 to 7, characterized in that the surface of the support material is provided with a reactivatable adhesive layer before the application of the primer, or this adhesive layer is used as the primer.

9. Method according to one of Claims 1 to 8, characterized in that a decorative layer is produced before step b), preferably by digital printing.

10. Method according to one of Claims 1 to 7, characterized in that the application of the primer is carried out using an applicator roller or slit die of the coating apparatus (1).

11. Method according to one of Claims 1 to 10, characterized in that the primer comprises an embossed structure and a decoration which is matched to the embossed structure is printed on, preferably after step b) and before step c).

12. Method according to one of Claims 1 to 11, characterized in that the support material is or at least contains a metal foil, a CPL laminate, melamine paper, separating paper, silicone-coated web material or a plastic film, in particular a plastic film.

13. Method according to one of Claims 1 to 12, characterized in that the support material has a thickness of from 30 µm to 400 µm.

14. Method according to one of Claims 1 to 13, characterized in that the support material is a conveyor belt of the coating apparatus (1).

15. Method according to one of Claims 1 to 14, characterized in that the application of the reactive hot-melt layer is carried out using an applicator roller with or without a smoothing roller or a slit die with or without a roll bar of the coating apparatus (1).

16. Method according to one of Claims 1 to 15, characterized in that the reactive hot-melt layer is a moisture-curing layer.

17. Method according to one of Claims 1 to 16, characterized in that the reactive hot-melt layer is a reactive polyurethane hot-melt, which is preferably obtainable from isocyanate-reactive polymers and polyisocyanates, and optionally additives.

18. Method according to one of Claims 1 to 17, characterized in that the embossing of the composite film (10) is provided.

19. Method according to one of Claims 1 to 18, characterized in that the embossing is carried out using an embossing roller of the coating apparatus (1).

20. Method according to one of Claims 1 to 19, characterized in that the separation of the composite film (10) from the support material is carried out by peeling after crystallization or full reaction of the reactive hot-melt layer.

21. Method according to one of Claims 1 to 20, characterized in that the reactive hot-melt layer contains at least one filler, in particular an abrasionresistant filler.

22. Method according to one of Claims 1 to 21, characterized in that the coating apparatus (1) is a roll-to-roll apparatus.

23. Method according to one of Claims 1 to 22, characterized in that the lacquer of the lacquer layer in step c) can be crosslinked by means of electron radiation or UV radiation.

24. Method according to one of Claims 1 to 23, characterized in that the support material is reused for the method.

25. Composite film (10) obtainable by a method according to one of Claims 1 to 24.

26. Use of a composite film (10) according to Claim 25 for cladding or for lining.