Method for producing a decorated profile body
The use of a decor base as a primer and color primer layer in digital printing for profile bodies addresses setup and quality issues, reducing costs and environmental impact by integrating print dot formation and basic coloring, ensuring stable and accurate printing.
Patent Information
- Authority / Receiving Office
- AU · AU
- Patent Type
- Applications
- Current Assignee / Owner
- REHAU IND SE & CO KG
- Filing Date
- 2025-02-19
- Publication Date
- 2026-07-23
Smart Images
Figure 00000000_0000_ABST
Abstract
Description
The invention relates to a method for producing a decorated profile body, comprising the steps: - providing a substrate; - providing a decor base; and - applying a decor finish in the form of ink droplets onto the decor base in a digital printing method. Such a method is known, for example, from EP 2 247 451 B1. The cited document relates to the production of digitally printed edge bands on a polymer basis for the coating of the narrow sides of furniture panels. In this case, for example, a primer layer, which serves as an adhesion promoter between the non-polar polymer material and the print having polar properties, is first applied to a polymeric, for example PP-based, extruded substrate. The decor base is then applied onto the primer layer as a color layer, said decor base bringing about a basic coloring of the edge band and serving as a base layer for the digital printing. Digitally printed edge bands frequently also have a base layer as an underlying layer for the digital (mostly CMYK) printing as well as a digital-printing primer layer. The solvent-based base layer is necessary for the lightening of the plastic carrier layer (mostly PP), and the primer layer, which is generally transparent, is necessary for controlling the formation of the digital print dots. When the usual printing technology is used, depending on the opacity, the solvent fond plus DD primer is applied once or twice via roller printing units in an indirect gravure printing method. The fond is dried by hot air depending on the opacity required. The primer layer can as a rule be cured by means of UV irradiation. In summary, therefore, in the prior art both a decor priming is carried out and, separately, a primer layer is also applied. Due to the high number of printing units, high cleaning, set-up and adjustment times arise when changing over from one print job to the next print job relating to a different decor, and there is the risk of malfunctions of the individual printing units caused thereby. Due to possible thickening or manual thinning of the solvent ink by the person operating the machine, undesired process fluctuations may furthermore occur. In addition, the combination of solvent and UV primer gives rise over time to undesired fluctuations in manufacturing quality. Against this background, the invention is based on the object of specifying a method having the features described at the outset which provides a simplified and at the same time reliable method for producing a digitally printed profile body. According to the invention, this object is achieved in that the decor base is formed as an adhesion-promoting primer layer between substrate and decor finish and at the same time forms a color priming of the decorated profile body. The invention is based here on the realization that the decor base can both ensure an optimum print dot formation of the digital printing and at the same time also carry out a basic coloring of the decorated profile body. The set-up and adjustment time during a decor change can thereby be significantly reduced. Furthermore, printing units can be saved and the investment costs of corresponding continuously operated installations can thereby be lowered. A shortening of the necessary line length of such installations is also possible through the teaching according to the invention since fewer method steps have to be carried out. The production-engineering printing method runs more stably and thus also more accurately. This improves the manufacturing quality overall while at the same time reducing operating costs for, for example, energy, etc., and also offers ecological advantages, since preferably no solvents have to be used any longer. Within the scope of the invention, in the provision of the decor base, a coloring agent is added to a digital-print primer, which ensures the simultaneous color priming according to the invention by the decor base. The decor base according to the invention establishes the adhesion to the substrate and allows embedding of ink droplets therein. The layer thickness of the decor base expediently amounts to 2 to 30 pm, in particular 5 to 25 pm, for example 10 to 20 pm. The decor base may contain, in particular cross-linkable, acrylates, for example PU acrylates and / or polyester acrylates and / or epoxy acrylates, in particular in the form of acrylate monomers and acrylate oligomers, for example with a weight proportion of at least 10%, in particular at least 20% or at least 30%, for example at least 50%. Expediently, the acrylate proportion amounts to a maximum of 90 wt.%, for example a maximum of 80 wt.%. The decor base can be formed as a one-component (1K) coating or alternatively also as a two-component (2K) coating. In the latter case, the stated materials come into consideration as the first component. For the second component, crosslinkers on the basis of isocyanates can be used. The 2K application is suitable in particular for high requirements on moisture resistance, for example in the case of kitchen or bathroom furniture, and for improving adhesion on critical substrates, if appropriate in the case of polyolefin plastics as material for the substrate. The pigment content in the decor base can amount to at least 5 wt.%, for example at least 10 or at least 15 wt.%, for example at least 20 wt.%, wherein, for example, titanium dioxide can be used as pigment. The decor base is preferably of single-layer construction, although a multi-layer construction is not excluded. Overall, the layer structure of the profile body is simplified by the teaching according to the invention. Expediently, the decor base is applied over the full surface onto the substrate in an opaque manner, so that the decor base together with the decor finish forms the decor of the decorated profile body. That is to say, in particular, that the appearance of the decor is determined solely by decor base and decor finish. Alternatively, however, it is also within the scope of the invention to apply the decor base onto the substrate only in regions. In this case, expediently the appearance of the substrate also contributes to the overall appearance of the decorated profile body. The decor base may be applied, for example as a color layer, onto the already produced substrate. Within the scope of the invention, it is fundamentally the case here that the application of the decor base takes place by means of roller application, for example with the aid of at least one anilox roller. Within the scope of the invention, however, it is also the case that the decor base is coextruded with the substrate and, in this connection, the decor base in particular can be formed as a polymer layer. Expediently, the surface tension of the decor base is set before the application of the decor finish by means of irradiation, in particular in the form of UV irradiation, for example by means of LED lamps. The UV irradiation may in this case take place with a wavelength of 200 to 450 nm, for example 300 to 450 nm or 350 to 450 nm, in particular 380 to 420 nm. An optimum print dot formation of the digital printing is thereby ensured, i.e. the ink droplets applied in the digital printing stand cleanly on the decor base and can cure in this state, whereby a clean printed image is ensured. According to a preferred embodiment of the invention, first a UV irradiation and thus deep curing of the decor base takes place in order to improve its attachment to the substrate. Then a UV irradiation of the decor base takes place with at least one, preferably two, UV emitter(s), for example [Hg], in order to cure it through and to set its surface tension specifically for the print dot formation. For providing the color priming, the decor base may contain color pigments. According to a preferred embodiment of the invention, the decor base is colored white for the color priming of the decorated profile body. As color, for example specifically RAL9003, RAL9010 or also RAL9016 may be used here. Titanium dioxide may be used in particular as color pigment. Alternatively or additionally to white pigments such as titanium dioxide (Color Index (CI): PW 6), black pigments such as furnace black (CI: PBk 7) and / or chromatic pigments such as, for example, yellow (CI: PY 42, PY 83, PY 110, PY 128, PY 138, PY 184) and / or orange (CI: PO 64, PO 73) and / or brown (CI: PBr 24) and / or red (CI: PR 48:4, PR 101, PR 122, PR 149, PR 254) and / or blue (CI: PB 15:3, PB 29) and / or green (PG 7) may also be used as color pigments. It is understood that one of the above-mentioned pigments may be used as color pigment or also the combination of at least two of the above-mentioned pigments. Expediently, only the decor base is applied as an intermediate layer between substrate and decor finish. The decor finish may be provided with a transparent lacquer layer, preferably forming the outer surface of the decorated profile body, which lacquer layer is preferably cured after its application onto the decor finish by means of UV irradiation, for example with the aid of corresponding LED lamps. The lacquer layer may be formed translucent, for example in order to realize a desired matt appearance. Within the scope of the invention, however, it is in particular also the case that the lacquer layer is formed transparent. Expediently, the substrate is produced from a polymeric material, in particular PP, ABS, PMMA or PVC. The substrate may in particular be formed as an extruded or calendared profile, preferably as an edge band or wall connection profile, or as a film, for example with a layer thickness of less than 0.5 mm, in particular less than 0.3 mm. The invention also relates to a decorated profile body having the described structure according to the invention. In the following, the invention is explained in detail with reference to a drawing merely representing one exemplary embodiment. The figures show schematically: Fig. 1 a layer structure of a decorated profile body according to the prior art, Fig. 2 a structure according to the invention of a decorated profile body, and Fig. 3 a method for producing the profile body shown in Fig. 2. Fig. 1 shows a layer structure of a decorated profile body 10 as it is described in the prior art according to EP 2 247 451 B1. The profile body 10 comprises, as a basis, a polymeric substrate 20 with an underside 210 and an upper side 220. Applied onto the upper side 220 of this substrate 20 is a primer layer 30, which ensures a good chemical attachment of a universal base layer 40 arranged above it to the substrate 20. Applied onto the universal base layer 40 is an individual base layer 50, which together with the universal base layer 40 forms a decor base of the profile body 20. The individual base layer 50 has depressions 510 and elevations 520. A decor finish 60 is introduced into the depressions 510 by a digital printing method, which decor finish together with the decor base forms the decor of the profile body 10. On the outside, a protective clear lacquer layer 70 is finally provided. In the production of a decorated profile body 1 according to the invention in accordance with Fig. 2, a substrate 2 and a decor base 4 are likewise provided. A decor finish 6 is applied onto the decor base 4 in a digital printing method in the form of ink droplets 100 (see Fig. 3). According to the invention, the decor base 4 is now formed as an adhesion-promoting primer layer between substrate 2 and decor finish 6 and at the same time forms a color priming of the decorated profile body 1. The decor base 4 was applied in an opaque manner over the full surface onto the substrate 2, so that the decor base 4 together with the decor finish 6 forms the decor of the decorated profile body 1. As an alternative thereto, however, merely partial covering of the substrate 2 with the decor base 4 is also within the scope of the invention (not shown). In the exemplary embodiment, the decor base 4 was applied onto the already produced polymeric substrate 2, which was made, for example, of PP, ABS, PMMA or PVC. The surface tension of the decor base 4 was specifically set before the application of the decor finish 6 by means of a UV irradiation with LED lamps. An optimum print dot formation of the digital printing is thereby ensured, i.e. the ink droplets 100 of the decor finish 6 applied in the digital printing stand cleanly on the decor base 4 and can cure in this state, whereby a clean printed image is ensured. In the exemplary embodiment, the UV irradiation takes place with a wavelength of 395 nm. The decor base 6 was colored white for the color priming of the decorated profile body 1, for example the decor base has the color RAL 9016 (“Traffic white”). It can furthermore be seen that only the decor base 4 is applied as an intermediate layer between substrate 2 and decor finish 6. Furthermore, the decor finish 6 was provided with a transparent lacquer layer 7, in particular transparent, forming the outer surface of the decorated profile body. In the exemplary embodiment, this was cured after its application onto the decor finish 6 by means of UV irradiation. The substrate 2 according to Fig. 2 is formed as an extruded or calendared edge band profile for the coating of the narrow side of a furniture panel. The layer thicknesses of the individual layers 2, 4, and 7 amount, for example, respectively to: substrate 2: 0.3 - 5 mm, in particular 0.3 to 2 mm, decor base: 2 to 30 pm, in particular 5 to 20 pm, lacquer layer 5 to 25 pm, in particular 10 to 20 pm. Fig. 3 shows a continuous method for producing a decorated profile body 1 according to Fig. 2. It can be seen that the decor base 4 is applied with a conventional roller arrangement 50 onto the web-shaped polymeric substrate 2, which moves continuously in the web direction at the speed v. The applied decor base 4 is cured by means of an LED-UV emitter arrangement 300 and the surface tension of the still liquid decor base 4 is thereby specifically set. The emitter arrangement consists of one UV emitter (395 nm wavelength) for deep curing of the decor base 4, which ensures good attachment of the decor base 4 to the substrate 2, and at least one downstream UV emitter, for example two, for the general curing of the decor base 4 and the control of the print dot formation. Thereafter, ink droplets 100 are applied by means of digital printheads 200, for example in CMYK printing, onto the decor base 4, which ink droplets form the decor finish 6. Due to the specifically set surface tension of the decor base 4, a very clean application of the decor finish by means of the ink droplets 100 is possible. The ink droplets 100 may be cured after their application, for example by means of UV radiation (not shown in more detail). As already described, the decor base 4 is formed as an adhesion-promoting primer layer and at the same time forms a color priming of the decorated profile body 1. For this purpose, color particles are added to the liquid 5, which is applied onto the substrate 2 for formation of the decor base. Finally, the decor finish 6 is provided with a clear lacquer layer 7, which is likewise applied with a roller arrangement 50'. The corresponding clear-lacquer liquid 5' is cured after its application onto the decor finish 6 by means of a UV emitter 400. Within the scope of the invention, it is the case that the decor base 4 and / or the clear lacquer layer 7 are likewise applied by means of digital printing as an alternative to roller application. - Claims -
Claims
1. Method for producing a decorated profile body (1) comprising the steps:- providing a substrate (2);- providing a decor base (4);- applying a decor finish (6) in the form of ink droplets (100) onto the decor base (4) in a digital printing method,characterized in that the decor base (4) is formed as an adhesion-promoting primer layer between substrate (2) and decor finish (6) and at the same time forms a color priming of the decorated profile body (1).
2. Method according to claim 1, characterized in that the decor base (4) containsacrylates, preferably cross-linkable acrylates.
3. Method according to claim 1 or 2, characterized in that the decor base (4) isapplied over the full surface onto the substrate (2) in a opaque manner, so that the decor base (4) together with the decor finish (6) forms the decor of the decorated profile body (1).
4. Method according to any one of claims 1 to 3, characterized in that the decorbase (4) is applied onto the already produced substrate (2) or is coextruded with the substrate (2).
5. Method according to any one of claims 1 to 4, characterized in that the surfacetension of the decor base (2) is set before the application of the decor finish (6) by means of irradiation, in particular in the form of UV irradiation.
6. Method according to claim 5, characterized in that the UV irradiation is effectedat a wavelength of 200 to 450 nm, for example 350 to 450 nm, in particular 380 to 420 nm.
7. Method according to any one of claims 1 to 6, characterized in that the decorbase (6) is colored white for the color priming of the decorated profile body (1).
8. Method according to any one of claims 1 to 7, characterized in that only thedecor base (4) is applied as an intermediate layer between substrate (2) and decor finish (6).
9. Method according to any one of claims 1 to 8, characterized in that the decorfinish (6) is provided with a transparent lacquer layer (7), preferably forming the outer surface of the decorated profile body (1), which layer is preferably cured after its application onto the decor finish (6) by means of UV irradiation.
10. Method according to any one of claims 1 to 9, characterized in that the substrate (2) is produced from a polymeric material, in particular PP, ABS, PMMA or PVC.
11. Method according to any one of claims 1 to 10, characterized in that the substrate (2) is formed as an extruded or calendared profile, preferably as an edge band or wall connection profile, or as a film, for example with a layer thickness of less than 0.5 mm, in particular less than 0.3 mm.
12. Decorated profile body (1), comprising- a substrate (2),- a decor base (4), and- a decor finish (6) applied onto the decor base (4), characterized in that the decor base (4) is formed as an adhesion-promoting primer layer between substrate (2) and decor finish (6) and at the same time forms a color priming of the decorated profile body (1).