Film composite and its production by a coating system

Abstract

The invention relates to a method for producing a composite film with a polyurethane-based reactive hot-melt layer using a coating facility, having the steps of 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 onto the polyurethane-based reactive hot-melt layer in order to produce the composite film on the support material; d) optionally embossing the composite film on the support material; and e) separating the composite film from the support material. The invention additionally relates to a composite film which can be obtained by such a method and to the use thereof.

Description

[0001] Film composite and its production using a coating system

[0002] 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.

[0003] 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.

[0004] 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.

[0005] 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.

[0006] One object of the present invention is therefore to provide such a method and films produced therefrom.

[0007] The problem is solved by a method for producing a film composite with a polyurethane-based reactive melting compound layer using a coating system, comprising the steps of: a) optionally applying a primer to a substrate; b) applying the polyurethane-based reactive melting compound layer to the primer or directly to the substrate; c) applying a coating layer to the polyurethane-based reactive melting compound 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.

[0008] 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.

[0009] 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.).

[0010] At the same time, films are frequently used in encapsulation processes where maximum flexibility is required. Thermoplastic films, whose thermal sensitivity is improved, 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. The handling of highly thermally sensitive films is eliminated. The resulting film composite is not thermoplastic, yet it exhibits maximum flexibility. In step a) of the process according to the invention, 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, the priming step a) itself can be carried out in one or more stages.

[0011] 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.

[0012] 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).

[0013] 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.

[0014] The primer can also be transparent. It is also possible that, when using a film composite, the primer forms the outer surface, for example, during encapsulation, so that the paint layer in step c) faces the surface of the encapsulated object. 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, 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 decor is referred to as "synchronous pore" or the term "EIR" (embossed-in-register). The term "true texture" is also used in the prior art.

[0015] 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.

[0016] Therefore, it is further preferred that the surface of the substrate is 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).

[0017] The adhesive layer can be applied in one or more stages and thus itself have 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 are encapsulated adhesive systems or two-component systems that are reactivated by temperature, pressure, or the application of another component during the lamination process. A decorative layer can be applied before step b) of the inventive method. This can be produced, for example, by direct printing or digital printing, preferably by digital printing.

[0018] 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.

[0019] 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.

[0020] The reactive polyurethane melt is preferably produced from isocyanate-reactive polymers and polyisocyanates, and optionally from additives.

[0021] The reactive polyurethane melt is a room-temperature solid product that is emission-free and solvent-free. The application temperature is in the range of 60°C to 150°C, preferably 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 / m³. 2Advantageously, the reactive melt layer retains a certain degree of residual elasticity even in its cured state. Curing occurs not only through physical solidification, but also, and in some cases, exclusively through moisture curing, particularly with the aid of atmospheric humidity. Complete curing can take several days. Therefore, the reactive melt is applied in a hot, liquid state, and complete curing before applying the coating is not required.

[0022] 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.

[0023] 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.

[0024] Other preferred isocyanate-reactive polymers are predominantly linear or slightly branched polyalkylene oxides, in particular polyethylene oxides, polypropylene oxides or polytetrahydrofürans (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.

[0025] The polyisocyanate is preferably a substance or a mixture of substances selected from aromatic, aliphatic or cycloaliphatic polyisocyanates having an isocyanate functionality between 1 and 4, preferably between 1.8 and 2.2, particularly preferably with an isocyanate functionality of 2.

[0026] 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 various

[0027] Diisocyanatodiphenylmethanes; hydrogenated 4,4'-MDI (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 l-methyl-2,4-phenylene diisocyanate (TDI-U), and TDI-ureas; l-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).

[0028] Lightfast, aliphatic polyisocyanates are preferred.

[0029] 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%. Particularly suitable are

[0030] Reaction products of polyether polyols, preferably polypropylene glycols, and polyester polyols with polyisocyanates, in particular 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 the derivatives of these isocyanates. Prepolymers based on aliphatic isocyanates such as HDI and IPDI are particularly preferred.

[0031] 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.

[0032] 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.

[0033] 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 step. It is then reacted with the polyisocyanate at 80 to 140°C, preferably at 100 to 120°C. The reaction in process steps 1 and / or 2 is preferably carried out at a temperature in the range of 80 to 140°C, particularly at 100 to 120°C.

[0034] The reactive polyurethane composition produced in this way is then preferably filled into containers that are impermeable to water vapor.

[0035] The reactive polyurethane melt can also contain abrasion-resistant fillers in accordance with WO 2012 / 084823 Al 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 pm) or in the range of 3.5 pm to 56 pm. 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.

[0036] The reactive melt mass can also consist of a melt mass that cures both in moisture and with UV light, in accordance with WO 2006 / 106143 Al.

[0037] 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.

[0038] 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.

[0039] The reactive polyurethane composition thus produced preferably has a viscosity of 2,000 mPas to 100,000 mPas at 120°C, more preferably of 5,000 to 50,000 mPas at 120°C. In addition to the reactive polyurethane melt, a reactive melt based on polyolefins can also be used. This cures via the reaction of silane groups with atmospheric moisture.

[0040] 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.

[0041] The reactive melt mass can 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 mass. 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.%.

[0042] Preferably, the reactive melt layer has a thickness in the range of 20 pm to 150 pm.

[0043] 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.

[0044] 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. Preferably, the lacquer layer has a thickness of 5 g / m to 25 g / m.

[0045] 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.

[0046] 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.

[0047] Preferably, the varnish is a varnish that can be cross-linked using electron radiation or UV radiation.

[0048] All compounds containing 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.

[0049] Examples of such compounds are styrene, 1-methyl styrene, vinyl acetate, vinyl chloride, conjugated dienes such as butadiene and isoprene, vinyl ethers of Cl-C20 alkanols, but also arylnitrile, vinylcaprolactam, n-vinylformamide, C1-C4 acrylic acid and methacrylic acid esters such as methyl(meth)acrylate, ethyl(meth)acrylate, n-propyl(methacrylate) isobornyl acrylate (IBOA) and the like. Furthermore, higher-functional compounds such as trimethylol triacrylate (TMTPA), ethoxylated trimethylol triacrylate, propoxylated glycerol diacrylate, butanediol diacrylate (BDDA), hexanediol diacrylate (HDDA), tripropylene glycol diacrylate (TPGDA), dipropylene glycol diacrylate (DPGDA), pentaerythritol triacrylate (PETIA) and pentaerythritol tetraacrylate (PETTA) can also be used.

[0050] 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.

[0051] These oligomers are known from the prior art and are, for example, marketed by Rahn under the brand name Genomer. ® the company Allnex under the brand name Ebecryl ® , the company Miwon under the brand name Miramer ® from Sartomer under the CN series or from BASF under the brand name Laromer 1 ® available.

[0052] 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.

[0053] For example, these are all Norrish Type I fragmenting substances. Examples include benzophenone, camphorquinone, Quantacure (manufacturer: International Bio-Synthetics), and Omnirad photoinitiators. ® -series (IGM company), the Genocure ® -series (Rahn company) and the Speedcure TM ® -series (manufacturer Lambson).

[0054] Particularly suitable photoinitiators are those from the class of benzoins, phenylhydroxyalkonones, alpha-hydroxyketones, alpha-aminoketones, phenyl glyoxylates, monoacylphosphines (MAPO) and bisacylphosphines (BAPO).

[0055] Particularly suitable examples of photoinitiators are Speedcore 73, Ominirad 819, Speedcure MBF and Ominirad TPO.

[0056] Polymerizable photoinitiators, such as those offered by Rahn under the trade name Genopol, are also particularly suitable. ® offered.

[0057] 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, and fillers to increase scratch and micro-scratch resistance, such as glass beads or nanoparticles. Furthermore, the lacquer can also contain colored pigments. The lacquer can also contain common lacquer additives known to those skilled in the art, such as defoamers, deaerators, wetting agents, dispersing agents, leveling agents, antioxidants, and UV stabilizers, etc.

[0058] The varnish preferably has a viscosity according to Brookfield (20°C) of 200 mPas - 20,000 mPas, preferably of 500 mPas-10,000 mPas.

[0059] If a primer (step a) is applied and a paint is used for this purpose, it can also have the properties listed above.

[0060] 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.

[0061] Preferably, the carrier material has a thickness of 30 µm to 400 g / m. However, it is also possible that the carrier material is a conveyor belt of the coating system.

[0062] 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).

[0063] 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.

[0064] 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.

[0065] 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.

[0066] 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.

[0067] 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.

[0068] 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:

[0069] • Physical matting of the paint (excimer lamp)

[0070] • Smoothing and curing of the lacquer using an inert calender process

[0071] • The resulting film composite can be divided into different widths using a downstream cutting device (e.g. with rotary knives).

[0072] • Sprinkle particles after the application of the reactive melt layer to create an “anti-slip” surface.

[0073] 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 PUR-SK, dispersions, and pressure-sensitive hot melt adhesives. Application is possible, for example, via rollers or slot nozzles.

[0074] 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.

[0075] 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.

[0076] The invention is explained in more detail with reference to the following figure and examples, without the present invention being limited to these.

[0077] Examples

[0078] Example 1 Floor foil: Highly abrasion-resistant, split-resistant, bonding and embossing via reactivation

[0079] An exemplary film composite according to the invention has the following layer structure:

[0080] 1. Thermally reactivated opaque adhesive (e.g. EVA SK Kleiberit 743.6)

[0081] 2. Primer: opaque, white, UV curing (e.g., UV lacquer Kleiberit 653.1.33)

[0082] 3. Digital printing: UV-curing inks applied via single-pass printers

[0083] 4. Reactive melt-in-the-mold layer on polyurethane base with corundum (e.g. PUR HotCoating Kleiberit 717.6)

[0084] 5. UV-curing acrylic lacquer: scratch-resistant, optionally physically matted (e.g., Kleiberit 659.0.04 UV lacquer)

[0085] Further processing is possible: short-cycle presses or laminating lines with a heated calender roll, application of textures via press plates / diees or embossing rollers. Example 2: Terrace decking film: Highly abrasion-resistant, tear-resistant, weather-resistant. An exemplary film composite according to the invention has the following layer structure:

[0086] 1. Primer: opaque, white, UV curing, optimized wetting properties (e.g. UV lacquer Kleiberit 653.1.33)

[0087] 2. Digital printing: UV-curing inks applied via single-pass printers

[0088] 3. Reactive melt-in-place coating on polyurethane base, containing corundum, with UV absorbers (e.g. PUR HotCoating Kleiberit 9383 / 627)

[0089] 4. UV-curing acrylic lacquer: scratch-resistant, weather-resistant, flexible (e.g., Kleiberit 659.2.22 UV lacquer)

[0090] 5. Embossed / Anti-slip surface

[0091] Further processing is possible: coating system with PUR hot melt adhesive.

[0092] It shows the figure:

[0093] Fig. 1 shows a coating system for the production of film composites according to the invention.

[0094] In the coating unit 1, a carrier film 2 is fed from a roll 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. [List of reference numerals]

[0095] 1 coating system

[0096] 2 carrier films, 3 roll units

[0097] 4 primer units

[0098] 5 printing units

[0099] 6 coating units

[0100] 7 Painting unit 8 Curing unit

[0101] 9 minting units

[0102] 10 foil composite

Claims

Patent claims 1. A method for producing a film composite with a polyurethane-based reactive melt layer using a coating system, comprising the steps of: 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 layer 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.

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 serves as a release agent.

4. Method according to one of claims 1 to 3, characterized in that the melt mass layer and the lacquer layer are each applied in a single layer.

5. Method according to one of claims 1 to 4, characterized in that the reactive melt mass layer has a thickness in the range of 20 pm to 150 pm.

6. Method according to any one of claims 1 to 5, characterized in that the lacquer layer has a thickness in the range of 5 pm to 25 pm.

7. Method according to any one of claims 1 to 6, characterized in that the application of the primer forms at least one color-imparting layer or one opacity-achieving layer and is preferably a varnish, in particular a UV-curing or a water-based or a varnish that is both UV-curing and water-based.

8. Method according to one of claims 1 to 7, characterized in that, prior to applying the primer, the surface of the carrier material is provided with a reactivatable adhesive layer or this adhesive layer serves as a 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 by an application roller or slot nozzle of the coating system.

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

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

13. Method according to any one of claims 1 to 12, characterized in that the carrier material has a thickness of 30 pm to 400 gm.

14. Method according to one of claims 1 to 13, characterized in that the carrier material is a conveyor belt of the coating system.

15. Method according to one of claims 1 to 14, characterized in that the application of the reactive melt mass layer is carried out by an application roller with or without a smoothing roller or slot nozzle with or without a roller bar of the coating system.

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

17. Method according to any one of claims 1 to 16, characterized in that the reactive melt layer is a reactive polyurethane melt, which is preferably made 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 foil composite is provided.

19. Method according to one of claims 1 to 18, characterized in that the embossing is carried out by an embossing roller of the coating system.

20. Method according to one of claims 1 to 19, characterized in that the separation of the film composite from the carrier material is carried out by peeling after crystallization or reaction of the reactive melt layer.

21. Method according to one of claims 1 to 20, characterized in that the reactive melt mass layer contains at least one filler, in particular an abrasion-resistant filler.

22. Method according to one of claims 1 to 21, characterized in that the coating system is a roll-to-roll system.

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

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

25. Laminated film obtainable by a method according to any one of claims 1 to 24.

26. Use of a film composite according to claim 25 for sheathing or laminating.