Uv curable paint composition

Abstract

A UV-curable acrylate paint composition comprising: - 10 to 90 parts by weight of (meth)acrylate monomers; - 10 to 90 parts by weight of (meth)acrylate oligomers; - 0.05 to 8 wt% of one or more photoinitiators relative to the total amount of the combination of (meth)acrylate monomers and (meth)acrylate oligomers; - thermoplastic beads and / or thermoplastic resin, preferably in a combined amount of at least 0.3 wt% relative to the total amount of the combination of (meth)acrylate monomers and (meth)acrylate oligomers; - optionally one or more crosslinking agents, such as aliphatic isocyanate, isocyanate acrylate or carbodiimide; - optionally additives, such as wear resistant particles, release agent, wetting agent or antifoam agent; - optionally a thermal initiator, or optionally, no thermal initiator.

Description

Technical Field

[0001] This invention relates to acrylic lacquer compositions that are curable by ultraviolet (UV) radiation, UV-LED radiation, or electron beam radiation. The invention also relates to decorative panels comprising lacquer layers, and to methods for manufacturing decorative panels comprising lacquer layers. Background Technology

[0002] It is known to apply acrylic paint compositions to decorative panels (e.g., to decorative floor panels) to improve the abrasion resistance of the decorative panels.

[0003] WO2018 / 065859A1 discloses a floor panel comprising a substrate and a top layer provided above, preferably directly above, the substrate. The top layer includes a decorative layer, a thermoplastic abrasion-resistant layer, and a paint layer provided above, preferably directly above, the abrasion-resistant layer. The floor panel has an upper surface exhibiting an embossed design with a maximum embossing depth greater than 100 micrometers. The abrasion-resistant layer and the paint layer are embossed to form the embossing. Summary of the Invention

[0004] The object of the present invention is to provide a UV-curable paint composition that can be more easily mechanically embossed to provide texture on the surface of a decorative panel to which the UV-curable paint composition is applied.

[0005] A first aspect of the present invention is a UV-curable acrylic paint composition. The UV-curable acrylic paint composition comprises: - 10 to 90 parts by weight of (meth)acrylate monomers, preferably wherein at least one (meth)acrylate monomer has a (meth)acrylate functionality of at least 2; - 10 to 90 parts by weight of (meth)acrylate oligomers; wherein at least one (meth)acrylate oligomer has a (meth)acrylate functionality of at least 2; - 0.05 to 8 wt% of one or more photoinitiators relative to the total amount of the combination of (meth)acrylate monomers and (meth)acrylate oligomers; - Thermoplastic beads and / or thermoplastic resin, preferably, in an amount of at least 0.3 wt%, more preferably at least 1 wt%, more preferably at least 3 wt%, more preferably at least 5 wt%, and preferably less than 40 wt%, more preferably less than 25 wt%, relative to the total amount of the combination of the (meth)acrylate monomer and the (meth)acrylate oligomer; - One or more crosslinking agents may be selected, such as aliphatic isocyanates, isocyanate acrylates, or carbodiimides; - Optional additives, such as wear-resistant particles, release agents, wetting agents, or defoamers.

[0006] The advantage of this UV-curable acrylic paint composition is that it can produce a coating that, after radiation curing, can still be mechanically embossed using temperature and pressure. This is achieved by the presence of thermoplastic beads and / or thermoplastic resin in the UV-curable acrylic paint composition, which provides a permanent texture to the coating.

[0007] The UV-curable acrylic varnish layer of the present invention enables the texture of the pressed element to be replicated to form the texture of the coating.

[0008] In embodiments where the coating is cured via an addition reaction between unsaturated carbon-carbon bonds during mechanical embossing operations using temperature and embossing, the presence of thermoplastic beads or thermoplastic resin has been observed to be beneficial. This is because it improves the formation of texture in the coating by temporarily hindering the curing of the coating through steric hindrance. This delays the curing of the coating during mechanical embossing operations, promotes coating flow, and allows the texture of the structured embossed element to be correctly replicated in the coating, while thermally induced curing during the embossing operation can proceed. This effect is largely observed when the coating comprises thermoplastic beads, wherein the thermoplastic beads consist of, or are composed of, thermoplastic microspheres encapsulating a gas or expandable liquid.

[0009] The UV-curable coating composition according to the invention preferably includes a thermal initiator. This embodiment is suitable when the coating is thermally cured during a mechanical embossing operation. Thermal curing can be initiated at elevated temperatures during the mechanical embossing operation via the dissociation of the thermal initiator.

[0010] Preferably, the UV-curable coating composition according to the invention does not include a thermal initiator. In such embodiments, the coating may preferably be cured by UV radiation or electron beam radiation, and the mechanical embossing operation is a purely physical operation that utilizes the plasticity of the coating for embossing without any substantial curing of the coating.

[0011] In the context of this paper, the acrylate or methacrylate functionality of a monomer or oligomer refers to the number of acrylate or methacrylate groups per molecule of that monomer or oligomer. The acrylate functionality of compounds comprising different types of molecules (which do not necessarily have the same acrylate (or methacrylate) functionality) is determined as a molar-based weighted average of the (meth)acrylate functionality of the molecules in that compound.

[0012] The functionality of (meth)acrylate is the sum of the functionality of acrylate and the functionality of methacrylate.

[0013] The mass ratio of (meth)acrylate monomers to (meth)acrylate oligomers in the UV-curable acrylic paint composition is preferably between 1 / 4 and 4 / 1. This embodiment offers the advantage of producing coatings of excellent quality.

[0014] Preferably, the UV-curable acrylic paint composition comprises a crosslinking agent in an amount between 0.7 wt% and 7 wt% relative to the combined mass of (meth)acrylate monomers and (meth)acrylate oligomers.

[0015] Preferably, when the UV-curable acrylic paint includes thermoplastic beads, the thermoplastic beads preferably have a glass transition temperature between 50°C and 150°C, and more preferably below 125°C. Such embodiments, using temperature and pressure for mechanical embossing, provide excellent performance in providing a permanent texture to the coating; they also provide excellent performance in terms of the coating's abrasion resistance.

[0016] In this context, the glass transition temperature is the inflection point of the phase transition, determined using DSC (differential scanning calorimetry) at a heating rate of 20°C / min.

[0017] A preferred UV-curable acrylic paint composition is characterized in that the (meth)acrylate monomers comprise, and preferably consist of, a combination of (meth)acrylate monomers with a (meth)acrylate functionality of 1 and (meth)acrylate monomers with a (meth)acrylate functionality of 2. Such embodiments provide coatings with excellent mechanical properties.

[0018] A preferred UV-curable acrylic paint composition is characterized in that the (meth)acrylate monomers comprise, and preferably consist of, a combination of (meth)acrylate monomers with a (meth)acrylate functionality of 1, (meth)acrylate monomers with a (meth)acrylate functionality of 2, and (meth)acrylate monomers with a (meth)acrylate functionality of 3. Such embodiments provide coatings with excellent mechanical properties.

[0019] Preferably, the amount of (meth)acrylate monomers with a functionality of 1 is at least 20 wt% of the total mass of (meth)acrylate monomers.

[0020] Preferably, the amount of (meth)acrylate monomers with a functionality of 2 is at least 20 wt% of the total mass of (meth)acrylate monomers.

[0021] Preferably, the amount of (meth)acrylate monomers with a functionality of 3 is at least 20 wt% of the total mass of (meth)acrylate monomers.

[0022] A preferred UV-curable acrylic paint composition is characterized in that the (meth)acrylate monomer has a molecular weight between 200 g / mol and 750 g / mol, and preferably less than 600 g / mol.

[0023] Preferably, the (meth)acrylate oligomer is selected from polyurethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, unsaturated polyester (meth)acrylates, polyether (meth)acrylate oligomers, or combinations thereof.

[0024] Unsaturated polyester (meth)acrylate oligomers refer to oligomers in which each molecule of the polyester backbone contains one or more double bonds in addition to one or more corresponding acrylate or methacrylate groups.

[0025] UV-curable acrylic paint compositions may include polyester (meth)acrylate oligomers that are not unsaturated polyester (meth)acrylate oligomers.

[0026] It is also possible that the UV-curable acrylic paint composition includes polyester (meth)acrylate oligomers that are not unsaturated polyester (meth)acrylate oligomers; or it is possible that the UV-curable acrylic paint composition includes polyester (meth)acrylate oligomers but does not include unsaturated polyester (meth)acrylate oligomers.

[0027] Alternatively, the UV-curable acrylic paint composition may comprise unsaturated polyester (meth)acrylate oligomers; and non-unsaturated polyester (meth)acrylate oligomers, preferably in a weight ratio between 4 and ¼. Such combinations provide optimal reactivity while preventing cracking during curing and preventing the coating from having excessive hardness.

[0028] A preferred UV-curable acrylic paint composition, characterized in that the UV-curable acrylic paint composition comprises an unsaturated polyester oligomer, preferably a non-(meth)acrylate unsaturated polyester oligomer.

[0029] Unsaturated polyester oligomers refer to oligomers in which each molecule of the polyester backbone includes one or more double bonds.

[0030] Non-(meth)acrylate unsaturated polyester oligomers refer to oligomers in which each molecule of the polyester backbone includes one or more double bonds, but the oligomer does not contain acrylate groups or methacrylate groups.

[0031] The UV-curable acrylic paint composition preferably includes thermoplastic beads. More preferably, the thermoplastic beads are selected from thermoplastic (meth)acrylate beads, styrene / acrylate copolymer beads, acrylate copolymer beads, thermoplastic polyurethane beads, thermoplastic polyvinylpyrrolidone beads, polymethyl methacrylate (PMMA) beads, polyvinyl chloride beads, polyvinyl butyral beads, or combinations thereof.

[0032] A preferred UV-curable acrylic paint composition is characterized in that it comprises thermoplastic beads having a D50 particle size between 5 micrometers and 250 micrometers (preferably higher than 10 micrometers, more preferably higher than 50 micrometers, and more preferably higher than 100 micrometers). The D50 particle size, determined by cumulative particle size distribution by volume as measured by laser diffraction, is the particle size at which 50% of the particles are smaller than this D50 particle size.

[0033] The UV-curable acrylic paint composition preferably includes a thermoplastic resin. This thermoplastic resin may be selected from thermoplastic (meth)acrylates, thermoplastic polyurethane resins, polyvinyl chloride resins, polyvinyl butyral resins, or combinations thereof.

[0034] A preferred UV-curable acrylic paint composition is characterized in that the UV-curable acrylic paint composition includes thermoplastic beads, wherein the thermoplastic beads include thermoplastic microspheres encapsulating gas or expandable liquid, or are composed of thermoplastic microspheres encapsulating gas or expandable liquid.

[0035] In mechanical embossing, gases can expand, or expandable liquids can evaporate and thus expand, and the shells of microspheres soften. These effects support the formation of textures in the coating during mechanical embossing.

[0036] Expandable liquids are liquids that expand when the temperature rises and they vaporize.

[0037] It includes thermoplastic microspheres containing encapsulated gas or expandable liquid, or thermoplastic beads composed of thermoplastic microspheres containing encapsulated gas or expandable liquid, which can be unexpanded beads or expanded beads.

[0038] Thermoplastic beads, wherein the thermoplastic beads comprise, or consist of, thermoplastic microspheres encapsulating gas or expandable liquid, and are available, for example, from Nouryon under the trademark Expancel.

[0039] Thermoplastic beads, wherein the thermoplastic beads comprise, or consist of, thermoplastic microspheres encapsulating a gas or an expandable liquid, as known for example in WO2014 / 198532A1 or US3,615,972.

[0040] A second aspect of the invention is a method for producing decorative panels. The method includes the following steps: - Provide substrate; - Apply a UV-curable paint composition as described in any embodiment of the first aspect of the invention to a substrate to obtain a coating on the substrate; - The coating is cured at least partially, and preferably completely, by UV radiation curing, UV-LED radiation curing, or electron beam curing; - Mechanically emboss the coating to provide texture to the coating and, optionally, the upper section of the substrate.

[0041] UV-LED radiation curing refers to curing through the radiation of LEDs (light-emitting diodes) that emit UV radiation.

[0042] In a preferred embodiment, the coating can be thermally cured during the mechanical embossing operation; preferably, this occurs at elevated temperatures during the mechanical embossing operation, via an addition reaction of carbon-carbon double bonds initiated by the thermal dissociation of a thermal initiator present in the coating. In such embodiments, the coating is preferably partially cured prior to the mechanical embossing operation by UV radiation, UV-LED radiation, or electron beam curing.

[0043] In a preferred embodiment, no thermal curing of the coating occurs during the mechanical embossing operation. In such embodiments, the UV-curable paint composition does not include a thermal initiator.

[0044] A preferred method is characterized in that the mechanical embossing step of the coating is performed at a temperature higher than the glass transition temperature of the thermoplastic beads and / or thermoplastic resin in the UV-curable paint composition. This embodiment provides an excellent process for imparting a permanent texture to the coating, replicating the structure of the structured embossed elements used in the mechanical embossing step.

[0045] After the mechanical embossing step, the coating can be post-cured by UV radiation, UV-LED radiation, or electron beam radiation. This allows the coating to be fully cured, where the texture provided in the embossing step is additionally frozen, and the coating is endowed with its mechanical properties.

[0046] However, it is also possible that the coating has already been fully cured in the UV radiation step applied before the mechanical embossing step, or in the UV-LED radiation curing step, or in the electron beam curing step.

[0047] Preferably, a UV-curable paint composition of 20 to 300 g / m² is applied, more preferably 20 to 200 g / m², more preferably greater than 50 g / m², and even more preferably greater than 100 g / m² is applied.

[0048] The preferred method is characterized in that the step of applying the UV-curable paint composition is carried out in a first step and a second step, wherein in the first step, a first UV-curable paint composition as described in any embodiment of the first aspect of the present invention is applied; and in the second step, a second UV-curable paint composition as described in any embodiment of the first aspect of the present invention is applied.

[0049] In this way, the properties of the coating on the substrate can be adjusted to achieve optimal performance. For example, the first UV-curable paint composition can be adjusted for easy embossing and for providing an inexpensive base layer; while a second UV-curable paint composition can be selected to provide the coating with excellent scratch resistance.

[0050] Preferably, the amount of the first UV-curable paint composition applied is greater than the amount of the second UV-curable paint composition applied, and the amount of the first UV-curable paint composition applied is preferably at least twice, and more preferably at least three times, the amount of the second UV-curable paint composition applied.

[0051] In a preferred method, the first UV-curable paint composition includes thermoplastic beads, and the second UV-curable paint composition includes thermoplastic beads, wherein the glass transition temperature of the thermoplastic beads in the second UV-curable paint composition is higher than the glass transition temperature of the thermoplastic beads in the first UV-curable paint composition.

[0052] This type of implementation is preferred because it results in a coating that is easy to emboss, while the surface of the coating will have excellent scratch resistance.

[0053] A preferred method is characterized in that the second UV-curable paint composition includes abrasion-reinforcing particles, such as corundum particles. The advantage of this implementation is that the cured coating will have improved scratch resistance.

[0054] The abrasion-resistant particles preferably have a particle size between 5 micrometers and 25 micrometers. This results in a coating with enhanced scratch resistance.

[0055] A preferred method is characterized in that the first UV-curable paint composition includes abrasion-reinforcing particles, such as corundum particles. This type of implementation is beneficial to the abrasion resistance of the coating.

[0056] More preferably, the abrasion-reinforcing particles in the first UV-curable paint composition are larger than the abrasion-reinforcing particles in the second UV-curable paint composition; and / or the abrasion-reinforcing particles in the first UV-curable paint composition have a D50 particle size between 20 micrometers and 80 micrometers. Such embodiments not only provide improved abrasion resistance of the coating but also enhanced scratch resistance.

[0057] A preferred method is characterized in that the temperature of the coating is at least 35°C during the mechanical embossing step. More preferably, the temperature of the coating during the mechanical embossing step is higher than the glass transition temperature of the thermoplastic beads and / or thermoplastic resin in the UV-curable paint composition. This embodiment provides good results in the mechanical embossing step of the coating.

[0058] The substrate preferably includes a printed décor. Combined with the texture provided in the mechanical embossing process, an imitation of natural materials such as wood can be achieved.

[0059] The preferred method is characterized by a step of mechanically embossing the coating to provide texture to at least the upper part of the coating and optionally the substrate, such that the texture is obtained in a manner that aligns with the printed decoration. This allows for a very realistic imitation of natural materials such as wood.

[0060] The substrate can be selected from printed boards, preferably digital printed boards (e.g., polypropylene-based boards, polyethylene-based boards, polyester-based boards, magnesium oxide-based boards, wood fiberboard or wood chipboard), printed films (e.g., printed PVC films, printed PP films or printed PET films, or printed polyurethane films), transparent thermoplastic films (e.g., PVC films, PP films or PET films), or printed paper, preferably resin-impregnated printed paper.

[0061] The preferred method is characterized by including a step of applying an adhesive layer to the substrate prior to the step of applying the UV-curable paint composition.

[0062] The adhesive layer can preferably be a polyurethane adhesive layer, and more preferably applied as a radiation-curable waterborne polyurethane dispersion.

[0063] The preferred method is characterized in that it includes the step of applying a polyurethane layer onto a coating provided by a UV-curable paint composition; preferably, the polyurethane layer is applied as a radiation-curable waterborne polyurethane dispersion.

[0064] This type of implementation is preferred because the application of a finishing layer on the coating provides additional or improved properties to the coated product. For example, a polyurethane layer can provide a resilient topcoat and / or excellent scratch resistance.

[0065] One aspect of the invention also relates to an intermediate product for the production of decorative panels. This intermediate product is obtained prior to the step of mechanically embossing a coating according to the method of the second aspect of the invention, thereby providing texture to at least the upper portion of the coating and optionally the substrate.

[0066] The intermediate product can be stored, and its coating can be mechanically embossed in subsequent processes to provide texture to the coating and, optionally, at least the upper part of the substrate.

[0067] The preferred method is characterized in that the UV-curable acrylic paint composition includes thermoplastic beads, wherein the thermoplastic beads comprise or consist of thermoplastic microspheres encapsulating gas or expandable liquid; preferably, heat is applied during the mechanical embossing step of the coating, causing the gas or expandable liquid to expand while the shell of the microspheres softens.

[0068] A third aspect of the invention is a decorative panel. The decorative panel includes a board, printed decoration, and a wear-resistant layer. The wear-resistant layer includes and is preferably composed of a coating. The coating is an acrylic coating comprising thermoplastic beads and / or a thermoplastic resin.

[0069] The acrylate coating preferably comprises thermoplastic beads and / or thermoplastic resin, and preferably, the total amount of the acrylate coating is at least 0.3 wt%, more preferably at least 1 wt%, more preferably at least 3 wt%, more preferably at least 5 wt%, and preferably less than 40 wt%, more preferably less than 25 wt%.

[0070] The acrylic coating may optionally include additives, such as abrasion-resistant particles.

[0071] The acrylate coating is preferably a UV-cured or electron beam-cured acrylate coating.

[0072] The preferred decorative panel is characterized in that the acrylate coating comprises at least a (meth)acrylate obtained from oligomers selected from: polyurethane (meth)acrylate, epoxy (meth)acrylate, polyester (meth)acrylate oligomer, unsaturated polyester (meth)acrylate oligomer, polyether (meth)acrylate, or combinations thereof.

[0073] The acrylate coating is preferably obtained from a paint composition comprising at least an unsaturated polyester oligomer, more preferably a non-(meth)acrylate unsaturated polyester oligomer.

[0074] The preferred decorative panel is characterized in that the acrylic coating includes thermoplastic beads, wherein the thermoplastic beads are selected from thermoplastic (meth)acrylate beads, thermoplastic polyurethane beads, styrene / acrylate copolymer beads, acrylate copolymer beads, thermoplastic polyvinylpyrrolidone beads, polymethyl methacrylate (PMMA) beads, polyvinyl chloride beads, polyvinyl butyral beads, or combinations thereof.

[0075] The preferred decorative panel is characterized in that the acrylic coating includes thermoplastic beads, wherein the thermoplastic beads comprise, or consist of, thermoplastic microspheres encapsulating gas or expandable liquid.

[0076] The preferred decorative panel is characterized in that the acrylate coating comprises a thermoplastic resin, wherein the thermoplastic resin is selected from thermoplastic (meth)acrylate, thermoplastic polyurethane resin, polyvinyl chloride resin, polyvinyl butyral resin, or a combination thereof.

[0077] The coating preferably comprises thermoplastic beads having a D50 particle size between 5 micrometers and 250 micrometers (and preferably greater than 10 micrometers, more preferably greater than 50 micrometers, more preferably greater than 100 micrometers); wherein the D50 particle size determined by the cumulative particle size distribution by volume measured by laser diffraction is the particle size at which 50% of the particles are smaller than the D50 particle size.

[0078] In preferred decorative panels that include thermoplastic beads, the glass transition temperature of the thermoplastic beads is higher than that of the resin in the coating.

[0079] This type of implementation is advantageous because texture can be provided by hot-pressing the cured coating.

[0080] The preferred decorative panel is characterized in that the coating is obtained from a UV-curable paint composition according to any embodiment of the first aspect of the invention, and / or the decorative panel is obtained according to the method according to any embodiment of the second aspect of the invention; wherein the coating includes a texture.

[0081] The substrate of the preferred decorative panel includes a board, wherein the printed decoration is digitally printed on the board, preferably wherein the board is selected from polypropylene-based boards, polyethylene-based boards, polyester-based boards, magnesium oxide-based boards, wood fiberboard, or wood chipboard.

[0082] Optionally, the wear-resistant layer includes a transparent thermoplastic film (e.g., PVC film, PP film, or PET film) between the plate and the coating.

[0083] Printed decorations can be provided by printing decorations on paper. Printed decorations can be applied to resin-impregnated paper. The resin used to impregnate the paper can be a thermosetting resin, such as melamine resin, acrylic resin, or a combination thereof.

[0084] Paper, including printed decorations, can be laminated onto a board, preferably wherein the board is selected from polypropylene-based boards, polyethylene-based boards, polyester-based boards, magnesium oxide-based boards, wood fiberboard, or wood chipboard.

[0085] Printed decorations can be provided by printing decorations on thermoplastic films, preferably on PVC films, PP films or PET films.

[0086] A thermoplastic film, including printed decorations, can be laminated onto a board, preferably wherein the board is selected from polypropylene-based boards, polyethylene-based boards, polyester-based boards, magnesium oxide-based boards, wood fiberboard, or wood chipboard.

[0087] Decorative panels may include a transparent thermoplastic film disposed between a printed thermoplastic film and a coating.

[0088] The preferred decorative panel is characterized in that the wear-resistant layer includes an additional coating on top of the coating, wherein the glass transition temperature of the additional coating is higher than that of the coating.

[0089] The advantage of this implementation is that the decorative panel has good wear resistance and excellent scratch resistance.

[0090] Another advantage of this implementation is that the thermoplastic beads in the coating are more flexible and require less energy to melt and deform during mechanical embossing at elevated temperatures, while the additional coating will have higher hardness, which is beneficial to the wear resistance of the wear layer of the decorative panel.

[0091] The wear-resistant layer may include an additional coating on top of the coating, wherein the additional coating is an acrylic coating comprising thermoplastic beads, wherein the coating comprises thermoplastic beads, and wherein the glass transition temperature of the thermoplastic beads in the additional coating is higher than that of the thermoplastic beads in the coating.

[0092] The advantage of this implementation is that the decorative panel has excellent scratch resistance, while also having excellent ability to provide texture to the decorative panel through a hot-pressing process.

[0093] The wear-resistant layer may include an additional coating on top of the main coating, wherein the additional coating does not include thermoplastic beads, and preferably does not include thermoplastic resin. This embodiment provides a decorative panel with excellent scratch resistance.

[0094] Preferably, the decorative panel has an additional coating thickness of less than 25% of the original coating thickness. This implementation allows the coating to be derived from an inexpensive formulation and combined with a more expensive additional coating that provides superior performance to the decorative panel, such as in terms of abrasion and scratch resistance. This reduces the overall cost of the individual coatings on the decorative panel.

[0095] As an example, the thickness of the additional coating can be between 10 micrometers and 20 micrometers, and the thickness of the coating can be 100 micrometers.

[0096] The preferred decorative panel is characterized by an adhesive layer provided between the coating and the panel. This type of decorative panel has better abrasion resistance.

[0097] The adhesive layer is preferably a polyurethane adhesive layer, and more preferably applied with a radiation-curable waterborne polyurethane dispersion.

[0098] The preferred decorative panel is characterized in that the decorative layer comprises a polyurethane layer, wherein the polyurethane layer is provided on and preferably in contact with the printed decoration. The polyurethane layer provides the decorative panel with improved abrasion resistance.

[0099] Preferably, the polyurethane layer is applied with a radiation-curable waterborne polyurethane dispersion.

[0100] The preferred decorative panel is characterized in that it includes a top layer, wherein the top layer is in contact with the coating. The top layer provides the decorative panel with improved properties, such as scratch resistance and abrasion resistance.

[0101] Preferably, the top layer is a polyurethane layer; more preferably, the polyurethane layer is applied as a UV-curable waterborne polyurethane dispersion. The advantage of a polyurethane top layer is that it provides a degree of elasticity to the surface of the decorative layer, which is beneficial for abrasion resistance, including scratch resistance.

[0102] Preferably, the abrasion-resistant layer of the decorative panel provides a texture, preferably aligned with the printed decoration.

[0103] The preferred decorative panel is characterized in that it includes coupling members at at least two opposite edges for coupling the decorative panel to a second such decorative panel at their respective side edges; wherein, in the coupled state, a locking mechanism is provided in a direction perpendicular to the surface of the coupled decorative panel; and a locking mechanism is also provided in a direction perpendicular to the coupled side edges and parallel to the surface of the coupled decorative panel; wherein the coupling member includes a male coupling part (convex coupling part) at one of the two opposite edges; and wherein the coupling member includes a female coupling part (concave coupling part) at the other of the two opposite edges.

[0104] The preferred decorative panel is characterized in that the coupling member is configured on one hand as a tenon, providing the male coupling member, and on the other hand as a bordered mortise formed by an upper lip and a lower lip, providing the female coupling member. In the coupled state, the tenon and mortise provide locking in a direction perpendicular to the surface of the coupled decorative panel. The tenon and female coupling member include a locking member, wherein, in the coupled state, the locking member provides locking in a direction perpendicular to the side edges of the coupling and parallel to the surface of the coupled decorative panel. Preferably, the locking member includes a protrusion at the lower lip and a corresponding recess at the bottom of the tenon. Preferably, the lower lip extends further than the upper lip.

[0105] Coupling components allow decorative panels to be easily coupled to each other, for example, in floor coverings, wall coverings, or ceiling coverings.

[0106] Decorative panels can be flooring, wall panels, or ceiling panels. Decorative panels can also be furniture panels, referring to boards used in the manufacture of furniture (such as cabinets) or boards used in furniture.

[0107] Decorative panels may include a backing layer at the bottom. This backing layer may be a balancing layer and / or a sound-absorbing layer. Attached Figure Description

[0108] To better illustrate the features of the invention, several preferred embodiments are described below by way of example without any limitation, with reference to the accompanying drawings, wherein: Figure 1 The method according to the present invention is shown; Figure 2 An example of a decorative panel according to the invention is shown; Figure 3 It shows Figure 2 Details of the decorative panels; Figure 4 With Figure 3 The same view shows the decorative panel according to the invention; Figure 5 With Figure 3 The same view shows a decorative panel according to the invention; and Figure 6 With Figure 3 The same view shows the decorative panel according to the invention. Detailed Implementation

[0109] Figure 1 An embodiment of method 1 according to the present invention is shown. Printing paper 3 impregnated with a thermosetting resin is provided as a substrate. A UV-curable paint composition 5 is applied to the printing paper 3 via a coating apparatus 6, thereby obtaining a coating 8 on the printing paper 3. The coating is at least partially cured by UV radiation, for example by a UV radiation lamp 10 or a UV radiation LED lamp. The coating is mechanically embossed at elevated temperatures by a texture pressing element, in the illustrated embodiment a continuous belt press 12, thereby providing texture to the coating.

[0110] It is possible that the intermediate product is stored after the UV radiation curing step and then subjected to a mechanical embossing step at elevated temperatures. This step may simultaneously include laminating a coated resin-impregnated printing paper layer onto a board, such as a high-density fiberboard, for example, using a single-layer press.

[0111] Figure 1 The UV-curable acrylic paint composition used in the examples includes: - 10 to 90 parts by weight of (meth)acrylate monomers, wherein at least one (meth)acrylate monomer has a (meth)acrylate functionality of at least 2; - 10 to 90 parts by weight of (meth)acrylate oligomers, wherein at least one (meth)acrylate oligomer has a (meth)acrylate functionality of at least 2; - 0.05 to 8 wt% of one or more photoinitiators relative to the total amount of the combination of the (meth)acrylate monomer and the (meth)acrylate oligomer; - Thermoplastic beads, preferably, are in a total amount between 0.3 wt% (and preferably at least 5 wt%) and 40 wt% relative to the total amount of the combination of the (meth)acrylate monomer and the (meth)acrylate oligomer.

[0112] UV-curable acrylic paint compositions may optionally include one or more crosslinking agents. UV-curable acrylic paint compositions may optionally include additives such as abrasion-resistant particles, release agents, wetting agents, or defoamers.

[0113] exist Figure 1In the method embodiment shown, the step of mechanically embossing the coating is performed at a temperature higher than the glass transition temperature of the thermoplastic beads.

[0114] Optionally, the coating can be post-cured by UV radiation after the mechanical embossing step. However, it is also possible that the coating has already been substantially fully cured after the mechanical embossing step.

[0115] In the illustrated embodiment, 150 grams of UV-curable paint composition is applied to each square meter of resin-impregnated printing paper.

[0116] The texture obtained in the mechanical embossing step can be a texture that is registered with the printed decoration of resin-impregnated printing paper.

[0117] Instead of thermoplastic beads, or in addition to thermoplastic beads, UV-curable paint compositions may include thermoplastic resins.

[0118] Figure 2 An embodiment of the decorative panel 14 according to the present invention is shown. Figure 3 It shows Figure 2 Details indicated in F3. Decorative panel 14 includes panel 16, printed decoration, and abrasion layer 18. Abrasion layer includes coating 8. The coating is a UV-cured acrylic coating 8 comprising thermoplastic beads 20. The amount of thermoplastic beads 20 included in the acrylic coating 8 is between 5 wt% and 40 wt% relative to the weight of the acrylic coating 8.

[0119] Thermoplastic beads can be selected from thermoplastic (meth)acrylate beads, thermoplastic polyurethane beads, styrene / acrylate copolymer beads, acrylate copolymer beads, thermoplastic polyvinylpyrrolidone beads, polymethyl methacrylate (PMMA) beads, polyvinyl chloride beads, polyvinyl butyral beads, or combinations thereof.

[0120] Instead of thermoplastic beads, or in addition to thermoplastic beads, the coating may include thermoplastic resin.

[0121] Acrylic coatings may include additives such as abrasion-resistant particles.

[0122] In the illustrated embodiment, board 16 is high-density fiberboard (HDF); however, other boards may also be used.

[0123] In the illustrated embodiment, the printed decoration is provided by resin-impregnated printing paper 3. Other means may also be used to provide the printed decoration.

[0124] The coating includes a texture 22 that is aligned with the printed decoration.

[0125] In the illustrated embodiment, an adhesive layer 24 is provided between the resin-impregnated printing paper 3 and the coating 8. The adhesive layer in this embodiment is a polyurethane adhesive layer, applied using a radiation-curable aqueous polyurethane dispersion. The polyurethane adhesive layer is in contact with the printing paper 3. This adhesive layer 24 is optional.

[0126] The decorative panel of this embodiment is provided with coupling members at at least two opposite edges for coupling the decorative panel and the second such decorative panel at their respective side edges. The coupling members include a male coupling member at one of the two opposite edges and a female coupling member at the other of the two opposite edges.

[0127] The male coupling component is constructed as a tenon 26. The female coupling component is constructed as a mortise 27 formed by an upper lip 28 and a lower lip 29. The lower lip 29 extends further than the upper lip 28.

[0128] In the coupled state, the tongue 26 and the mortise 27 provide locking in a direction perpendicular to the surface of the coupled decorative panel. The tongue 26 and the female coupling member include locking members 30 and 31, which provide locking in a direction perpendicular to the side edges of the coupling and parallel to the surface of the coupled decorative panel in the coupled state. The locking members include a protrusion 30 at the lower lip 29 and a corresponding recess 31 at the bottom of the tongue 26.

[0129] Optionally, the panel may include a balancing layer 21 at the bottom of the decorative panel 14.

[0130] Figure 4 With Figure 3 A similar view illustrates an embodiment of the decorative panel according to the invention.

[0131] The decorative panel includes a PVC-based board 16. A PVC-based board refers to a board comprising a PVC matrix and fillers, such as inorganic fillers. The decorative panel includes a printed PVC film 33 to provide printed decoration. The decorative panel includes a wear-resistant layer 18. A transparent thermoplastic PVC film 34 is disposed between the printed thermoplastic film 33 and the coating 8. The coating 8 is a UV-cured acrylic coating comprising thermoplastic beads 20. The amount of thermoplastic beads 20 included in the acrylic coating is between 5 wt% and 40 wt% relative to the weight of the acrylic coating.

[0132] Thermoplastic beads 20 may be selected from thermoplastic (meth)acrylate beads, thermoplastic polyurethane beads, styrene / acrylate copolymer beads, acrylate copolymer beads, thermoplastic polyvinylpyrrolidone beads, polymethyl methacrylate (PMMA) beads, polyvinyl chloride beads, polyvinyl butyral beads, or combinations thereof.

[0133] Instead of thermoplastic beads 20, or in addition to thermoplastic beads 20, the coating may include a thermoplastic resin.

[0134] Acrylic coatings may include additives such as abrasion-resistant particles.

[0135] The coating 8 includes a texture 22 that is aligned with the printed decoration.

[0136] Figure 5 With Figure 3 The same view shows a decorative panel according to the invention. The decorative panel includes a high-density fiber (HDF) board 16, a resin-impregnated printed paper 3, and an abrasion-resistant layer 18. The abrasion-resistant layer 18 includes a coating 8 and an additional coating 36 on top of the coating 8. The coating 8 is 100 micrometers thick, and the additional coating 36 is 15 micrometers thick.

[0137] Coating 8 is a UV-cured acrylic coating comprising thermoplastic beads 20. The amount of thermoplastic beads included in the coating is between 5 wt% and 40 wt% relative to the weight of the acrylic coating. The thermoplastic beads in the coating may be selected from thermoplastic (meth)acrylate beads, thermoplastic polyurethane beads, styrene / acrylate copolymer beads, acrylate copolymer beads, thermoplastic polyvinylpyrrolidone beads, polymethyl methacrylate (PMMA) beads, polyvinyl chloride beads, polyvinyl butyral beads, or combinations thereof. Instead of thermoplastic beads, or in addition to thermoplastic beads, the coating may comprise a thermoplastic resin.

[0138] The additional coating 36 is a UV-cured acrylic coating comprising thermoplastic beads 20. The amount of thermoplastic beads included in the additional coating is between 5 wt% and 40 wt% relative to the weight of the acrylic coating. The thermoplastic beads in the coating may be selected from thermoplastic (meth)acrylate beads, thermoplastic polyurethane beads, styrene / acrylate copolymer beads, acrylate copolymer beads, thermoplastic polyvinylpyrrolidone beads, polymethyl methacrylate (PMMA) beads, polyvinyl chloride beads, polyvinyl butyral beads, or combinations thereof. Instead of thermoplastic beads, or in addition to thermoplastic beads, the additional coating may comprise a thermoplastic resin.

[0139] In this embodiment, the glass transition temperature of the thermoplastic beads in the additional coating is higher than that of the thermoplastic beads in the coating.

[0140] However, it is also possible that the additional coating does not include thermoplastic beads or thermoplastic resin.

[0141] In the illustrated embodiment, the glass transition temperature of the additional coating 36 is higher than that of the coating 8.

[0142] The wear-resistant layer 18 includes a texture that is aligned with the printed decoration, wherein at least the coating 8 and the additional coating are embossed 36.

[0143] Figure 6 With Figure 3 The same view shows a decorative panel according to the invention. The decorative panel includes a high-density fiber (HDF) board 16, a resin-impregnated printed paper 3, and an abrasion-resistant layer 18. The abrasion-resistant layer 18 includes a coating 8 and a top layer 38 on top of the coating. The coating 8 is 100 micrometers thick, and the top layer 38 is 15 micrometers thick.

[0144] Coating 8 is a UV-cured acrylate coating comprising thermoplastic beads 20. The amount of thermoplastic beads included in the coating is between 5 wt% and 40 wt% relative to the weight of the acrylate coating. The thermoplastic beads in the coating may be selected from thermoplastic (meth)acrylate beads, thermoplastic polyurethane beads, styrene / acrylate copolymer beads, acrylate copolymer beads, thermoplastic polyvinylpyrrolidone beads, polymethyl methacrylate (PMMA) beads, polyvinyl chloride beads, polyvinyl butyral beads, or combinations thereof. Instead of thermoplastic beads, or in addition to thermoplastic beads, the coating may comprise a thermoplastic resin.

[0145] Top layer 38 is in contact with coating 8. Top layer 38 is a polyurethane layer applied with a UV-curable waterborne polyurethane dispersion.

[0146] In one embodiment of the invention, the UV-curable acrylic paint composition comprises 3 wt% thermoplastic beads consisting of thermoplastic microspheres encapsulated with a gas. The thermoplastic microspheres have a D50 diameter of 21 micrometers. The UV-curable acrylic paint composition also includes a thermal initiator. The UV-curable paint composition has been applied to resin-impregnated printing paper. The coating applied in this manner has been partially cured using UV radiation. In a short-cycle press, at elevated temperatures, the coating is embossed using a textured press plate, wherein the thermoplastic microspheres expand, the thermal initiator dissociates, and thermal curing of the coating is initiated by the addition reaction of acrylate groups in the coating. It has been shown that the presence of thermoplastic beads delays the thermal curing of the coating, thereby facilitating the replication of the texture of the textured press plate onto the coating.

[0147] In one embodiment of the invention, the UV-curable acrylic paint composition comprises 0.35 wt% thermoplastic beads consisting of thermoplastic microspheres of encapsulated gas. The thermoplastic microspheres have a D50 diameter of 40 micrometers. The UV-curable acrylic paint composition also includes a thermal initiator. The UV-curable paint composition has been applied to resin-impregnated printing paper. The coating applied in this manner has been partially cured using UV radiation. In a short-cycle press, the coating is embossed using a textured platen at elevated temperatures, and the thermal initiator has dissociated and initiated thermal curing of the coating via an addition reaction of acrylate groups in the coating. It has been shown that the presence of thermoplastic beads delays the thermal curing of the coating, thereby facilitating the replication of the texture of the textured platen onto the coating.

[0148] This invention is by no means limited to the embodiments described and shown in the accompanying drawings. Rather, it can be implemented in various forms and sizes without departing from the scope of the invention.

Claims

1. A UV-curable acrylic paint composition, wherein, The UV-curable acrylic paint composition includes: - 10 to 90 parts by weight of (meth)acrylate monomers, preferably wherein at least one (meth)acrylate monomer has a (meth)acrylate functionality of at least 2; - 10 to 90 parts by weight of (meth)acrylate oligomers, wherein at least one (meth)acrylate oligomer has a (meth)acrylate functionality of at least 2; - 0.05 to 8 wt% of one or more photoinitiators relative to the total amount of the combination of the (meth)acrylate monomer and the (meth)acrylate oligomer; - Thermoplastic beads and / or thermoplastic resin, preferably, in a total amount of at least 0.3 wt% relative to the total amount of the combination of the (meth)acrylate monomer and the (meth)acrylate oligomer, and preferably less than 40 wt%, more preferably less than 25 wt%; - One or more crosslinking agents may be selected, such as aliphatic isocyanates, isocyanate acrylates, or carbodiimides; - Optional additives, such as abrasion-resistant particles, release agents, wetting agents, or defoamers; - Optional thermal initiator, or optionally, no thermal initiator.

2. The UV-curable acrylic paint composition according to claim 1, characterized in that, The (meth)acrylate monomer comprises, and preferably consists of, a combination of (meth)acrylate monomers with a (meth)acrylate functionality of 1 and (meth)acrylate monomers with a (meth)acrylate functionality of 2.

3. The UV-curable acrylic paint composition according to any one of the preceding claims, characterized in that, The (meth)acrylate monomers comprise, and preferably consist of, a combination of (meth)acrylate monomers with a (meth)acrylate functionality of 1, (meth)acrylate monomers with a (meth)acrylate functionality of 2, and (meth)acrylate monomers with a (meth)acrylate functionality of 3.

4. The UV-curable acrylic paint composition according to any one of the preceding claims, characterized in that, The (meth)acrylate monomer has a molecular weight between 200 g / mol and 750 g / mol, and preferably less than 600 g / mol.

5. The UV-curable acrylic paint composition according to any one of the preceding claims, characterized in that, The (meth)acrylate oligomer is selected from polyurethane (meth)acrylate oligomers, epoxy (meth)acrylate oligomers, polyester (meth)acrylate oligomers, unsaturated polyester (meth)acrylates, polyether (meth)acrylate oligomers, or combinations thereof.

6. The UV-curable acrylic paint composition according to any one of the preceding claims, characterized in that, The UV-curable acrylic paint composition includes unsaturated polyester oligomers, preferably non-(meth)acrylate unsaturated polyester oligomers.

7. The UV-curable acrylic paint composition according to any one of the preceding claims, characterized in that, The UV-curable acrylic paint composition includes thermoplastic beads, preferably wherein... The thermoplastic beads are selected from thermoplastic (meth)acrylate beads, styrene / acrylate copolymer beads, acrylate copolymer beads, thermoplastic polyurethane beads, thermoplastic polyvinylpyrrolidone beads, polymethyl methacrylate (PMMA) beads, polyvinyl chloride beads, polyvinyl butyral beads, or combinations thereof.

8. The UV-curable acrylic paint composition according to any one of the preceding claims, characterized in that, The UV-curable acrylic paint composition comprises a thermoplastic resin, preferably wherein... The thermoplastic resin is selected from thermoplastic (meth)acrylates, thermoplastic polyurethane resins, polyvinyl chloride resins, polyvinyl butyral resins, or combinations thereof.

9. The UV-curable acrylic paint composition according to any one of the preceding claims, characterized in that, The UV-curable acrylic paint composition includes thermoplastic beads, wherein the thermoplastic beads have a D50 particle size between 5 micrometers and 250 micrometers (and preferably greater than 10 micrometers, more preferably greater than 50 micrometers, more preferably greater than 100 micrometers); wherein the D50 particle size determined by cumulative particle size distribution by volume as measured by laser diffraction is the particle size at which 50% of the particles are smaller than the D50 particle size.

10. The UV-curable acrylic paint composition according to any one of the preceding claims, characterized in that, The UV-curable acrylic paint composition includes thermoplastic beads, wherein the thermoplastic beads comprise, or are composed of, thermoplastic microspheres containing encapsulated gas or expandable liquid.

11. A method for producing decorative panels, wherein, The method includes the following steps: - Provide substrate; - Apply the UV-curable paint composition of any one of claims 1-10 to the substrate to obtain a coating on the substrate; - The coating is at least partially cured and optionally fully cured by UV radiation curing, or by UV-LED radiation curing, or by electron beam curing; - Mechanically emboss the coating to provide texture to the coating and optionally to at least the upper part of the substrate; Optionally, the coating is thermally cured during the mechanical embossing operation, or alternatively, the coating is not thermally cured during the mechanical embossing operation.

12. The method according to claim 11, characterized in that, The mechanical embossing step of the coating is performed at a temperature higher than the glass transition temperature of the thermoplastic beads in the UV-curable paint composition, and / or higher than the glass transition temperature of the thermoplastic resin in the UV-curable paint composition.

13. The method according to any one of claims 11-12, characterized in that, After mechanically embossing the coating, the coating is post-cured by UV radiation, UV-LED radiation, or electron beam curing.

14. The method according to any one of claims 11-13, characterized in that, The UV-curable paint composition is applied at a concentration between 20 g / m² and 300 g / m², and preferably between 20 g / m² and 200 g / m².

15. The method according to any one of claims 11-14, characterized in that, The step of applying the UV-curable paint composition is carried out in a first step and a second step, wherein in the first step a first UV-curable paint composition of any one of claims 1-10 is applied; and in the second step a second UV-curable paint composition of any one of claims 1-10 is applied.

16. The method according to claim 15, characterized in that, The amount of the first UV-curable paint composition applied is greater than the amount of the second UV-curable paint composition applied, and the amount of the first UV-curable paint composition applied is preferably at least two times, and more preferably at least three times, the amount of the second UV-curable paint composition applied.

17. The method according to any one of claims 15-16, characterized in that, The first UV-curable paint composition includes thermoplastic beads, and the second UV-curable paint composition includes thermoplastic beads, wherein the glass transition temperature of the thermoplastic beads in the second UV-curable paint composition is higher than the glass transition temperature of the thermoplastic beads in the first UV-curable paint composition.

18. The method according to any one of claims 15-17, characterized in that, The second UV-curable paint composition includes abrasion-resistant reinforcing particles, such as corundum particles; preferably wherein, The wear-resistant particles have a particle size between 5 micrometers and 25 micrometers.

19. The method according to claim 18, characterized in that, The first UV-curable paint composition includes abrasion-resistant reinforcing particles, such as corundum particles, preferably wherein... The size of the abrasion-resistant reinforcing particles in the first UV-curable paint composition is larger than the size of the abrasion-resistant reinforcing particles in the second UV-curable paint composition; and / or wherein the abrasion-resistant reinforcing particles in the first UV-curable paint composition have a D50 particle size between 20 micrometers and 80 micrometers.

20. The method according to any one of claims 11-19, characterized in that, In the step of mechanically embossing the coating, the temperature of the coating is at least 35°C; and preferably higher than the glass transition temperature of the thermoplastic beads in the UV-curable paint composition and / or higher than the glass transition temperature of the thermoplastic resin in the UV-curable paint composition.

21. The method according to any one of claims 11-20, characterized in that, The substrate includes printed decorations.

22. The method according to claim 21, characterized in that, The step of mechanically embossing the coating to provide texture to the coating and optionally to at least the upper part of the substrate is performed, such that the texture is obtained in a manner that aligns with the printed decoration.

23. The method according to any one of claims 11-22, characterized in that, The substrate is selected from printing plates, preferably digital printing plates (e.g., polypropylene-based plates, polyethylene-based plates, polyester-based plates, magnesium oxide-based plates, wood fiberboard or wood chipboard); printing films (e.g., printed PVC films, printed PP films or printed PET films, or printed polyurethane films); transparent thermoplastic films (e.g., PVC films, PP films or PET films); or printed paper, preferably resin-impregnated printed paper.

24. The method according to any one of claims 11-23, characterized in that, The method includes a step of applying an adhesion layer to the substrate prior to the step of applying the UV-curable paint composition; preferably wherein... The adhesive layer is a polyurethane adhesive layer, more preferably applied as a radiation-curable waterborne polyurethane dispersion.

25. The method according to any one of claims 11-24, characterized in that, The method includes the step of applying a polyurethane layer onto the coating provided by the UV-curable paint composition; preferably wherein... The polyurethane layer is applied using a radiation-curable waterborne polyurethane dispersion.

26. The method according to any one of claims 11-25, characterized in that, The UV-curable acrylic paint composition includes thermoplastic beads, wherein the thermoplastic beads comprise thermoplastic microspheres encapsulating gas or expandable liquid, or are composed of thermoplastic microspheres encapsulating gas or expandable liquid; preferably, heat is applied during the mechanical embossing step of the coating, causing the gas or expandable liquid to expand while the shell of the microspheres softens.

27. A decorative panel, characterized in that, The decorative panel includes a board, printed decoration, and a wear-resistant layer, wherein the wear-resistant layer includes a coating and preferably consists of a coating; wherein the coating is an acrylic coating comprising thermoplastic beads and / or thermoplastic resin, preferably wherein the acrylic coating comprises thermoplastic beads and / or thermoplastic resin, preferably, the total amount of thermoplastic beads and / or thermoplastic resin relative to the weight of the acrylic coating is at least 0.3 wt% and preferably less than 40 wt%, more preferably less than 25 wt%; and wherein the acrylic coating optionally includes additives, such as wear-resistant particles.

28. The decorative panel according to claim 27, characterized in that, The acrylate coating is a UV-cured acrylate coating or an electron beam-cured acrylate coating.

29. The decorative panel according to any one of claims 27-28, characterized in that, The acrylate coating comprises at least one (meth)acrylate obtained from oligomers selected from: polyurethane (meth)acrylate, epoxy (meth)acrylate, polyester (meth)acrylate oligomer, unsaturated polyester (meth)acrylate oligomer, polyether (meth)acrylate, or combinations thereof.

30. The decorative panel according to any one of claims 27-29, characterized in that, The acrylate coating is obtained from a paint composition comprising at least an unsaturated polyester oligomer, preferably a non-(meth)acrylate unsaturated polyester oligomer.

31. The decorative panel according to any one of claims 27-30, characterized in that, The acrylate coating includes thermoplastic beads, wherein the thermoplastic beads are selected from thermoplastic (meth)acrylate beads, thermoplastic polyurethane beads, styrene / acrylate copolymer beads, acrylate copolymer beads, thermoplastic polyvinylpyrrolidone beads, polymethyl methacrylate (PMMA) beads, polyvinyl chloride beads, polyvinyl butyral beads, or combinations thereof.

32. The decorative panel according to any one of claims 27-31, characterized in that, The acrylate coating includes thermoplastic beads, wherein the thermoplastic beads comprise, or are composed of, thermoplastic microspheres encapsulating gas or expandable liquid.

33. The decorative panel according to any one of claims 27-32, characterized in that, The acrylate coating comprises a thermoplastic resin, wherein the thermoplastic resin is selected from thermoplastic (meth)acrylates, thermoplastic polyurethane resins, polyvinyl chloride resins, polyvinyl butyral resins, or combinations thereof.

34. The decorative panel according to any one of claims 27-33, characterized in that, The coating comprises thermoplastic beads, wherein the thermoplastic beads have a D50 particle size between 5 micrometers and 250 micrometers (and preferably above 100 micrometers); wherein the D50 particle size, determined by cumulative particle size distribution by volume as measured by laser diffraction, is the particle size at which 50% of the particles are smaller than the D50 particle size.

35. The decorative panel according to any one of claims 27-34, characterized in that, The coating comprises thermoplastic beads, wherein the glass transition temperature of the thermoplastic beads in the coating is higher than the glass transition temperature of the resin in the coating.

36. The decorative panel according to any one of claims 27-35, characterized in that, The coating is obtained from the UV-curable paint composition of any one of claims 1-10, and / or wherein the decorative panel is obtained according to the method of any one of claims 11-26; wherein the coating includes a texture.

37. The decorative panel according to any one of claims 27-36, characterized in that, The substrate includes a board, wherein the printed decoration is digitally printed on the board, preferably wherein the board is selected from polypropylene-based boards, polyethylene-based boards, polyester-based boards, magnesium oxide-based boards, wood fiberboard, or wood chipboard; optionally wherein the wear-resistant layer includes a transparent thermoplastic film (e.g., PVC film, PP film, or PET film) between the board and the coating.

38. The decorative panel according to any one of claims 27-37, characterized in that, The printed decoration is provided by printed decoration on paper, preferably by printed decoration on resin-impregnated paper.

39. The decorative panel according to claim 38, characterized in that, The paper, including the printed decoration, is laminated onto the board, preferably wherein, The board is selected from polypropylene-based boards, polyethylene-based boards, polyester-based boards, magnesium oxide-based boards, wood fiberboard, or wood chipboard.

40. The decorative panel according to any one of claims 27-39, characterized in that, The printed decoration is provided by printing decoration on a thermoplastic film, preferably by printing decoration on a PVC film, PP film or PET film.

41. The decorative panel according to claim 40, characterized in that, The thermoplastic film including the printed decoration is laminated onto the plate, preferably wherein, The board is selected from polypropylene-based boards, polyethylene-based boards, polyester-based boards, magnesium oxide-based boards, wood fiberboard, or wood chipboard.

42. The decorative panel according to claim 41, characterized in that, The decorative panel includes a transparent thermoplastic film disposed between the printed thermoplastic film and the coating.

43. The decorative panel according to any one of claims 27-42, characterized in that, The wear-resistant layer includes an additional coating on top of the coating, wherein the glass transition temperature of the additional coating is higher than that of the coating.

44. The decorative panel according to any one of claims 27-43, characterized in that, The wear-resistant layer includes an additional coating on top of the coating, wherein the additional coating is an acrylic coating comprising thermoplastic beads, wherein the coating comprises thermoplastic beads, and wherein the glass transition temperature of the thermoplastic beads in the additional coating is higher than the glass transition temperature of the thermoplastic beads in the coating.

45. The decorative panel according to any one of claims 27-44, characterized in that, The wear-resistant layer includes an additional coating on top of the coating, wherein the additional coating does not include thermoplastic beads, and preferably does not include thermoplastic resin.

46. ​​The decorative panel according to any one of claims 43-45, characterized in that, The thickness of the additional coating is less than 25% of the thickness of the original coating.

47. The decorative panel according to any one of claims 27-46, characterized in that, An adhesive layer is disposed between the coating and the plate, preferably wherein the adhesive layer is a polyurethane adhesive layer, more preferably applied as a radiation-curable waterborne polyurethane dispersion.

48. The decorative panel according to any one of claims 27-47, characterized in that, The decorative layer includes a polyurethane layer, wherein the polyurethane layer is disposed on the printed decoration and preferably in contact with the printed decoration; preferably, the polyurethane layer is applied with a radiation-curable waterborne polyurethane dispersion.

49. The decorative panel according to any one of claims 27-48, characterized in that, The decorative panel includes a top layer, wherein the top layer is in contact with the coating; preferably, the top layer is a polyurethane layer; more preferably, the polyurethane layer is applied with a UV-curable waterborne polyurethane dispersion.

50. The decorative panel according to any one of claims 27-49, characterized in that, The wear-resistant layer is textured, preferably the texture being aligned with the printed decoration.

51. The decorative panel according to any one of claims 27-50, characterized in that, The decorative panel includes coupling members at at least two opposite edges for coupling the decorative panel to a second such decorative panel at their respective side edges; wherein, in the coupled state, a locking mechanism is provided in a direction perpendicular to the surface of the coupled decorative panel, and also in a direction perpendicular to the coupled side edges and parallel to the surface of the coupled decorative panel; wherein the coupling member includes a male coupling member at one of the two opposite edges; and wherein the coupling member includes a female coupling member at the other of the two opposite edges.

52. The decorative panel according to claim 51, characterized in that, The coupling member is constructed as a tenon on one hand and a mortise and tenon groove formed by an upper lip and a lower lip on the other hand; wherein, in the coupled state, the tenon and the mortise and tenon groove provide locking in a direction perpendicular to the surface of the coupled decorative panel; wherein, the tenon and the female coupling member include a locking member, wherein, in the coupled state, the locking member provides locking in a direction perpendicular to the side edge of the coupling and parallel to the surface of the coupled decorative panel; preferably, the locking member includes a protrusion at the lower lip and a corresponding recess at the bottom of the tenon; preferably, the lower lip extends further than the upper lip.

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