UV protective film for outdoor use, methods for its manufacture, use of the film for coating and methods for the manufacture of building components

Abstract

UV protection film comprehensive: - a base film made of polyvinyl chloride or polyacrylate with a thickness of 120 to 250 µm, - a printed design and / or a coloring of the base film, - an abrasion-resistant polyurethane-based melt coating, and - a varnish and / or a polymer protective layer.

Description

[0001] The present invention relates to UV protective films for outdoor use, specifically for coating building elements such as floor coverings, in particular terrace decking, intended for outdoor use, as well as methods for producing the film, the use of the film for coating, and methods for producing building elements.

[0002] A key trend in recent years has been the use of high-quality building elements for outdoor spaces. More and more people are transforming their patios, balconies, and outdoor seating areas into additional living spaces. This includes not only suitable furniture but also attractive flooring, privacy screens, fences, planters, and much more. While the look of natural stone and wood remains largely preferred, there is a growing demand for easier-to-maintain surfaces.

[0003] These requirements can be met using plastics. Besides the use of solid plastics, and more recently so-called WPC (wood-plastic composite) materials, coating substrates has long been a known method. This has proven very successful for elements such as walls and fences. However, for floor coverings, the durability has so far been insufficient and / or other defects occur. For example, the laminating films commonly used for indoor furniture and flooring have problems in outdoor applications, such as the fact that decorative papers fade due to insufficient UV protection of the top layer(s), and the surface is often too smooth, thus failing to achieve the slip resistance required for outdoor flooring.

[0004] The task therefore remains to provide easy-care and durable surfaces with the desired appearance for outdoor areas.

[0005] For indoor use, DE 10 2012 022 461 A1 proposes a coating material for which a pressure-, temperature-, and dimensionally stable print substrate is provided with a wear layer comprising an inner, transparent, corundum-containing layer in contact with the print substrate and an outer layer comprising at least one plastic layer. Print substrates mentioned include paper, nonwoven fabric made of cellulose and / or synthetic fibers, and plastic films including PET, PP, and PA. Such coating materials are not suitable for outdoor use without modification.

[0006] Surprisingly, it has now been discovered that printed base films made of PVC or polyacrylate, coated with an abrasion-resistant polyurethane-based melt coating and varnished, offer effective UV protection, thus achieving the necessary durability of the printed design. Slip resistance is ensured by embossing combined with the abrasion-resistant PUR melt coating. In a preferred variant, embossing is particularly easily achieved by applying an embossed intermediate layer beneath the PUR melt coating.

[0007] The above task is thus solved by a UV protection film, which includes: - a base film made of PVC or polyacrylate with a thickness of 120 to 250 µm, - a printed design and / or coloring of the base film, - an abrasion-resistant polyurethane-based melt coating, and - a varnish and / or a polymer protective layer.

[0008] Furthermore, the problem is solved by a method for manufacturing coated components in which this UV protective film is laminated with a substrate, by using the UV protective film to coat substrates, and by a method for manufacturing UV protective films in which a base film made of PVC or polyacrylate with a thickness of 120 to 250 µm is printed with a design and / or colored, a polyurethane-based melt coating is applied, and a lacquer and / or a polymer protective layer is applied over it, with a layer being embossed below the lacquer.

[0009] The UV protection films according to the invention have a structure of at least three layers, preferably four. Additional layers are possible, e.g., a primer on the underside of the base film. The layers of the UV protection film can each consist of several independent layers. For example, thick layers can be obtained by repeatedly applying the material by knife coating, or a base film can be produced by coextrusion. The layers can be identical or different in composition.

[0010] Within the scope of the present invention, "bottom," "underside," "underside," etc., refers to the surface of a layer that faces the substrate or is closer to the substrate. "Top," "above," and "topside" denote a position facing away from or further away from the substrate; the uppermost surface of the UV protective film forms the functional surface of the component.

[0011] A printable base film is used as the bottom layer. This must, on the one hand, ensure sufficient adhesion to the substrate during lamination, and on the other hand, it provides the necessary mechanical properties to the UV protective film as a carrier during manufacturing and processing.

[0012] Suitable materials for the base film are PVC (polyvinyl chloride) and polyacrylates.

[0013] The bond to the substrate is typically achieved via adhesive lamination, for example, using polyurethane hot melt adhesive. To optimize adhesion, the underside of the base film can be primed. For instance, a primer based on vinyl chloride-vinyl acetate copolymer is well-suited for PVC, polyacrylate, and PVC-polyacrylate films. Alternatively or additionally, the base film can undergo plasma irradiation, corona treatment, or other surface treatments.

[0014] A PVC base film preferably contains, in addition to polyvinyl chloride, a stabilizer, processing aids, UV absorbers, an antistatic agent, and pigments. Modifiers, especially polyacrylate, and epoxidized soybean oil are also preferably included. Tin has proven particularly useful as a stabilizer; BaZn and CaZn are also suitable. Tin is preferably used in combination with phosphite as a co-stabilizer. Examples of processing aids include polymeric flow aids, e.g., based on MMA, BA, or styrene. PVC films with polymer plasticizers and copolymers—particularly based on vinyl chloride and acrylates—can also be used.

[0015] The PVC content is typically 70% to 85% by weight. The plasticizer content is usually up to 30% by weight, but can be wholly or partially replaced by suitable raw material additives or alternative raw materials such as copolymers. Recycled material can be a component of the formulation. The amount can be up to 20% by weight, preferably up to 5% by weight. The incorporated material can be of the same or a slightly modified formulation.

[0016] Polyacrylate base films can preferably be made of methyl methacrylate (MMA), butyl acrylate (BA), and / or ethyl acrylate (EA); in particular, copolymers of two, and especially preferably all three, of the aforementioned monomers are used. The base film also typically contains one or more UV absorbers, e.g., benzotriazole-based, antioxidants such as phenolic antioxidants, light stabilizers, preferably HALS, and pigments. Furthermore, processing aids based on polyacrylate may be included.

[0017] The thickness of the base film is from 120 to 250 µm, preferably from 120 to 200 µm, and particularly preferably from 120 to 160 µm. The base film is usually produced by calendering, but can also be extruded. Extrusion includes all processes, namely blown film, cast film, and cast film extrusion. Cast film extrusion is preferred. The melt is distributed through a slot die and cooled by a cooling roll. Single-screw and multi-screw extruders and variations thereof are conceivable tools. Production is preferably carried out using a single-screw extruder.

[0018] The desired design is printed onto the base film, unless the base film is dyed for solid colors. The base film can be dyed throughout, or in the case of multi-layer base films, the top layer can be dyed throughout. This is preferred for solid-colored designs. A base color can also be provided for printing by a dyed-through base film or top layer of the base film. The design can be printed using any known method. Particularly useful are gravure printing, particularly with solvent inks, and digital printing. Wood decor, natural stone and fantasy patterns are just as possible as designs as solid colors. The printing ink is applied to the base film using a series of printing rollers, for example. In digital printing, both single-pass and multi-pass print heads can be used for the design. The printed images are often composed of several printing inks and are characterized by their light stability.In addition to solvent-based printing inks, water-based inks are also conceivable.

[0019] The pigments used to color the base film or its top layer and to create solid colors can be organic or inorganic and can reflect or transmit the IR component in sunlight.

[0020] A polyurethane-based melt coating is applied above the print. In the context of the present invention, a polyurethane-based melt coating, also referred to as a PUR melt coating or simply a melt coating, is a reactive melt compound such as those described, for example, in WO 2006 / 056472 A1, WO 2012 / 084823 A1, WO 2006 / 106143 A1, or US 8,153,265 B2. The reactive melt compound can react and harden, for example, due to ambient humidity or irradiation with, for example, UV light. It can be a one- or two-component compound. It is important that the PUR melt coating is transparent so that the ink or print remains visible through the melt coating.

[0021] Preferably, one-component, atmospherically curing reactive melt compounds containing a polyurethane prepolymer are used. Upon heating, the prepolymer chains liquefy into an applicable liquid, which cures to form a polyurethane layer upon the addition of moisture.

[0022] To increase abrasion resistance, the reactive melt mass contains particles with appropriate hardness. Particles used as abrasives, such as corundum, zirconium carbide, boron nitride, diamond, or glass particles, are preferred. Corundum and glass particles are particularly favored due to their cost-effectiveness.

[0023] The PUR melt coating layer typically has a thickness of 10 to 150 µm, preferably 20 to 120 µm, and particularly 30 to 100 µm. It can be applied in a manner known per se by brushing, squeegeeing, roller application, etc.

[0024] In a preferred embodiment, an embossed intermediate layer is arranged beneath the PUR hot-melt coating. This intermediate layer is also formed from a polyurethane-based reactive hot-melt compound, but contains no or significantly less filler than the PUR hot-melt coating. The intermediate layer must also be transparent. The intermediate layer makes it particularly easy to obtain a bubble-free and thus highly transparent PUR hot-melt coating. Without a filler-free intermediate layer, gas bubbles can be introduced during the application of the PUR hot-melt coating, impairing transparency.

[0025] The thickness of the intermediate layer depends on the desired embossing depth and the thickness of the PUR melt coating layer and is generally from 10 to 100 µm, preferably from 20 to 80 µm, particularly preferably from 30 to 60 µm.

[0026] The intermediate layer can be applied in the same way as the PUR melt coating, whereby the same or different methods can be used for coating a single film. In a preferred embodiment, the intermediate layer is applied using a slot die, with or without a roller, and the PUR melt coating layer is applied by roller application. Advantageously, the same reactive melt compound is used for the intermediate layer as for the PUR melt coating, but without particles. It is also possible to use a different reactive melt compound, e.g., a radiation-curable compound for the intermediate layer and a moisture-curing compound for the melt coating. The intermediate layer can also be supplied as a film, e.g., as an embossed film. The intermediate layer significantly improves UV protection because it contains few or no particles.Without the intermediate layer, particles in the PUR melt coating could reach the base film and thus allow light to pass directly onto the printed design.

[0027] Unless an embossed intermediate layer made of a polyurethane-based reactive melt compound is used, either the base film or, preferably, the PUR melt coating layer is embossed. The embossing of the base film and / or the intermediate layer and / or the PUR melt coating is carried out in a manner known per se, e.g., using a pair of rollers. As is also known, the embossing pattern can be tailored to and correspond with the printed design. For example, it is common for the embossing to follow the grain of the printed wood structure or, in the case of a tile look, to simulate grout lines. Typical embossing depths range from 5 to 30 µm, preferably from 10 to 20 µm. This, in combination with the particles in the PUR melt coating layer, ensures sufficient slip resistance. Slip resistance values ​​of at least R10 to R12 according to DIN 51130 or ASR A1.5 / 1.2 are typically achieved, preferably at least R11.

[0028] The upper layer is formed by a transparent varnish and / or a removable polymer protective layer. Due to the PUR hot melt coating layer, the film has a very rough surface. This is also desired to achieve high slip resistance when wet. However, a very rough and very hard, abrasion-resistant surface has the disadvantage that the pressure rollers of wrapping or coating systems wear out very quickly and the process becomes unstable. Complaints due to defective coating are the result. Therefore, the surface of the protective film according to the invention is formed by the varnish or the polymer protective layer. The application of a varnish or a polymer protective layer is also necessary to be able to immediately wind up the film with the PUR hot melt coating. Otherwise, the film roll will block, as it normally takes some time for the applied hot melt coating(s) to cure to a blocking-resistant level.If the polymer protective layer does not exhibit excessive adhesion to the PUR melt compound, the lacquer layer can be omitted, and the material can be wound through the protective layer. An additional advantage of the protective layer is that it protects the surface of the component from scratches, for example, from the anti-slip PUR melt coating of other components. A lacquer remains part of the protective film according to the invention; the polymer protective layer is removed after the component is manufactured or directly before or after its installation.

[0029] Acrylic and polyurethane lacquers are preferred as coatings, especially radiation-curable lacquers. The crosslinking of the lacquer is preferably carried out by UV or LED lamps. This can be done by a single or multiple sources. The energy output is, for example, 30 W to 200 W, preferably 50 W to 180 W, and particularly 90 W to 150 W.

[0030] The lacquer is expediently applied by roller or spray application and, if necessary, cured by irradiation. Thicknesses of 1 to 50 µm, preferably 3 to 15 µm, and particularly preferably 5 to 10 µm, have proven effective. The lacquer improves UV protection and also provides an anti-blocking effect, allowing the UV protective film to be wound and, more importantly, unwound without difficulty. The lacquer typically has a low gloss level of 4 to 20 gloss points, preferably up to 15 gloss points, according to ISO 2813. The gloss level is measured using a goniophometer. The measuring angle can be 20°, 35°, 60° (preferred), 80°, or 85°.

[0031] The polymer protective layer is preferably a melt compound made of polyethylene (PE, preferably HDPE) or PE (preferably LDPE blended with linear low-density polyethylene, LLDPE) and ethylene-vinyl acetate (EVA). EVA typically has a vinyl acetate content in the range of 15 to 25 wt.%. The polymer protective layer can contain additives such as thermal stabilizers, HALS, UV stabilizers, and optionally fillers. In a preferred embodiment, no additives are included or only UV stabilizers are present in a smaller than usual amount.

[0032] The polymer protective layer material exhibits the desired adhesion to the PUR melt layer or the coating by selecting the correct weight ratio of PE to EVA. The adhesion should be sufficient to prevent the polymer protective layer from detaching significantly until the completion of component manufacturing. It must be weak enough to allow the protective layer to be peeled off. The mixing ratios depend on the desired surface roughness and, if applicable, also on the desired adhesion to the coating. The PE:EVA mixing ratio, based on mass, can range from 1:5 to 5:1, preferably from 1:1 to 3:1, depending on the desired adhesion. Adhesion can also be influenced by mixing different PEs; for example, adding LLDPE leads to increased adhesion and simultaneously improved tear resistance, which facilitates peeling.Other melting compounds that create the desired adhesion with the PUR melt coating layer or the paint are also possible, e.g. compounds that are known as protection for PVC-laminated sheets.

[0033] The polymer protective layer can be applied to the rough surface after PUR melt coating or painting using a casting, doctor blade, or rolling process. The casting process into a cooled roller gap is preferred. In this process, the melt flows into the valleys and mitigates the abrasive effect. The side facing the coating pressure rollers is designed to be smooth.

[0034] The application quantity depends on the structure of the anti-slip PUR melt coating and ranges from 20 g / m². 2 up to 200 g / m 2 , preferably 100 g / m² 2 and 150 g / m 2 .

[0035] The total thickness of the UV protection film without polymer protective layer is usually from 10 to 150 µm, preferably from 40 to 100 µm and particularly preferably from 50 to 80 µm.

[0036] The UV protection film according to the invention preferably has at least one of the following properties: - Scratch resistance ≥ 3 N, preferably ≥ 4 N, according to DIN 15186, or at least class A3 according to DIN EN 16094:2012-04 and B3 according to DIN CEN / TS 16611:2014, and / or - Abrasion and wear resistance ≥ 3,000 revolutions, preferably ≥ 4,000 revolutions according to DIN EN 13329 or ≥ 8,000 revolutions, preferably 10,000 revolutions according to EN 14354:2017-11, and / or - Weather resistance with at least 10,000, preferably at least 15,000, test hours according to EN 513 (Method 1 (M)) and a minimum colour stability of grey scale 3, assessed according to EN 20105-A02 and / or - Slip resistance reaches at least class R10, which according to DIN 51130:2014 corresponds to a minimum slope of 10°, preferably R11.

[0037] Suitable substrates include wood, metal, plastic, and composite materials. The substrate provides the necessary mechanical properties for the component. Coating with the UV protective film achieves the desired visual appearance while simultaneously protecting the substrate from the elements. Plastics do not age due to UV light, metals do not corrode, and wood remains dry and is also protected from UV light. The surface is easy to clean and thus remains visually appealing for significantly longer with much less effort.

[0038] Typical building elements include floorboards and slabs for terraces, balconies, paths, etc., panels, fence posts and elements, privacy screens, and planters. According to the invention, floor coverings are of particular interest, as they place high demands on slip resistance, become soiled particularly quickly, and are subject to high UV and mechanical stress. Previous products often failed to meet slip resistance requirements, deteriorated too quickly in appearance due to UV light, and / or were unable to withstand mechanical stress. Delamination, especially at corners and edges, was common.

[0039] In contrast, the components manufactured according to the invention offer improved UV protection, particularly when the intermediate layer is present, and do not compromise on slip resistance. Mechanical strength is also improved, as the adhesion of the base film to the substrate and of the film layers to each other is optimized by the measures described.

[0040] Elesgo paper-based films are well-known for outdoor use. These films consist of a printed paper film impregnated with acrylate and coated with a thick, corundum-containing acrylic lacquer. The surface texture is created by a textured film, but only slip resistance around R10 is achieved. This is a low value for safe walking in wet conditions. Plastic-based versions of this film with improved internal strength have the same poor slip resistance due to the identical coating manufacturing technology. The process is shown at https: / / laminate.de / index.php / de / technologie2 / prozess.

[0041] HPL compact panels are also known, which are produced using melamine or phenolic resin-impregnated paper. Many of these products have low lightfastness due to the printing process. The slip resistance of these products is achieved using press plates, which reduces the effectiveness of corundum embedded in the top paper layer. While this achieves good abrasion resistance, the slip resistance is rather low, as the press plates would otherwise wear out quickly due to the process.

[0042] Current technology offers no high-quality decorative finishes for horizontal exterior applications comparable to those made possible by this invention. Existing systems fail to meet these high standards after only a few years. Common problems include layer separation, layer cracking, fading and color changes due to the use of unsuitable UV protection layers, difficult processing due to excessive stiffness, increased water absorption and resulting swelling, and insufficient adhesion to the substrate.

[0043] Embodiments of the inventive method for producing the UV protective film are described in Fig. 1 to 7. For identical process sequences, identical reference numerals are used for the devices shown in the figures. In all of the illustrated processes, a base film 1 is produced in a manner known per se (not shown), e.g. by calendering. This base film 1 is printed in an equally known manner (unless it is a colored film for single-color components) and, if necessary, provided with a primer 5 on the underside (underside means facing the substrate) and / or irradiated. The base film 1 is usually rolled up and stored. In the next step, the printed (or colored) base film 1 is unrolled and a reactive melt is applied to the base film 1 or the print D.

[0044] In the Fig. 1, Fig. 2, Fig. 4 and Fig. In the embodiments shown in Figure 6, an intermediate layer 2 without particles is first applied using a slot nozzle a. The intermediate layer 2 on the base film 1 is embossed with a pair of rollers b, b'.

[0045] In all figures, an abrasion-resistant polyurethane-based melt coating with particles is applied as a second or third layer 3 using rollers c, c'. The heated polyurethane melt coating 3 cures after application through contact with atmospheric moisture. Alternatively, radiation curing can be provided for radiation-curing reactive melts.

[0046] Then in Fig. 1, Fig. 2, Fig. 4 and Fig. 6. The lacquer 4, here a UV-curing acrylic lacquer, is applied by rollers d, d'. The lacquer 4 is cured by UV radiation from the radiation source. The curing of the lacquer is carried out, for example, by UV lamps or LED spotlights; an excimer laser or excimer UV spotlight may also be used to achieve a matting effect and improved scratch resistance of the surface.

[0047] According to Fig. 2, a polymer protective layer 6 is poured onto the paint, according to Fig. 4 squeegeed and according to Fig. 6 rolled out. In Fig. 3, the polymer protective layer 6 is poured directly onto the PUR melt coating 3, in Fig. 5 scooped up and in Fig. 7 rolled up.

[0048] The finished UV protection film is wound up and is ready for coating substrates after the melt coating(s) have cured. It includes Fig. 1, Fig. 2, Fig. 4, and Fig. 6 an intermediate layer and a varnish, as well as in the Fig. 2 to 7 a polymer protective layer. Fig. 3, Fig. 5 and Fig. 7. The varnish and intermediate layer are missing. Fig. 1 a polymer protective layer.

[0049] The Fig. 8a and Fig. Figure 8b schematically shows the layers of a first preferred UV protective film separated and combined. It can be seen how the embossing of the intermediate layer 2 determines the surface structure of the UV protective film. The PUR melt coating 3 and the lacquer 4 follow the structure of the intermediate layer 2.

[0050] The Fig. 9a and Fig. Figure 9b schematically shows the layers of a second preferred UV protective film, separated and combined. It can be seen how the embossing of the intermediate layer 2 determines the surface structure of the UV protective film. The PUR melt coating 3, lacquer 4, and polymer protective layer 6 follow the structure of the intermediate layer 2.

[0051] The Fig. 10a and Fig. Figure 10b schematically shows the layers of a third preferred UV protective film, separated and combined. It can be seen how the embossing of the intermediate layer 2 determines the surface structure of the UV protective film. The PUR melt coating 3 and the polymer protective layer 6 follow the structure of the intermediate layer 2.

[0052] The invention also relates to all combinations of preferred embodiments, provided these are not mutually exclusive. The terms "approximately" or "about" in conjunction with a numerical value mean that values ​​at least 10% higher or lower, or 5% higher or lower, and in any case values ​​1% higher or lower, are included. Unless otherwise specified or the context necessarily implies otherwise, percentages refer to weight, or, if in doubt, to the total weight of the mixture. List of reference symbols 1 base film 2 Intermediate layer 3 PUR melt coating based on polyurethane 4 varnish 5 primers 6 Polymer protective layer D pressure a slot nozzle with or without roller bar b, b' embossing roller pair c, c' Roller application of PUR melt coating d, d' roller application paint a radiation source f Pouring (direct extrusion) polymer protective layer g Squeegee application of polymer protective layer h Roller application of polymer protective layer

Claims

[1] UV protective film including: - a base film made of polyvinyl chloride or polyacrylate with a thickness of 120 to 250 µm, - a printed design and / or coloring of the base film, - an abrasion-resistant polyurethane-based melt coating, and - a varnish and / or a polymer protective layer. [2] UV protective film according to claim 1, characterized by that an embossed intermediate layer comprising a reactive melt mass is arranged under the abrasion-resistant melt coating based on polyurethane, which contains no or fewer particles than the abrasion-resistant melt coating based on polyurethane. [3] UV protective film according to claim 2, characterized by that the thickness of the intermediate layer is from 10 to 100 µm, preferably from 20 to 80 µm, particularly preferably 30 to 60 µm. [4] UV protective film according to one of claims 1 to 3, characterized bythat the base film has a primer on the underside and / or has been subjected to plasma radiation or corona treatment. [5] UV protective film according to one of claims 1 to 4, characterized by that the base film has a thickness of 120 to 200 µm and preferably 120 to 160 µm. [6] UV protective film according to one of claims 1 to 5, characterized by that the abrasion-resistant melt coating contains particles selected from, among others, glass particles, particles used as abrasives and mixtures thereof, preferably corundum. [7] UV protective film according to one of claims 1 to 6, characterized by that the abrasion-resistant melt coating has a thickness of 10 to 150 µm, preferably 20 to 120 µm and in particular 30 to 100 µm. [8] UV protective film according to one of claims 1 to 7, characterized bythat the varnish is an acrylate varnish or a polyurethane varnish, preferably a radiation-curable acrylate or polyurethane varnish. [9] UV protective film according to one of claims 1 to 8, characterized by that the lacquer has a thickness of 1 to 50 µm, preferably 3 to 15 µm, particularly preferably 5 to 10 µm. [10] UV protective film according to one of claims 1 to 9, characterized by that the polymer protective layer is made of polyethylene or of a mixture of polyethylene and ethylene vinyl acetate, preferably in a weight ratio of 1:5 to 5:1, and / or in an amount of 20 to 200 g / m 2 is applied. [11] Process for the production of coated components, characterized by that a UV protective film according to one of claims 1 to 10 is laminated with a substrate. [12] Method according to claim 11, characterized bythat the UV protective film is laminated to the substrate by heat lamination or adhesive lamination, e.g. using polyurethane hot melt adhesive. [13] Method according to claim 11 or 12, characterized in that the substrate is made of wood, metal, plastic or composite material. [14] Use of a UV protective film according to one of claims 1 to 10 for coating substrates for the production of components. [15] Use according to claim 14, characterized by that the building element is selected from floorboards and panels, panels, fence posts and elements, privacy screens, and plant boxes. [16] A process for producing UV protective films according to any one of claims 1 to 10, comprising - Production of a base film made of PVC or polyacrylate with a thickness of 120 to 250 µm and printing the base film with a design or production of a dyed base film made of PVC or polyacrylate with a thickness of 120 to 250 µm - Applying a polyurethane-based hot melt coating to the base film or print - Applying a varnish and / or a polymer protective layer, whereby the base film and / or an intermediate layer under the melt coating and / or the melt coating is embossed. [17] Method according to claim 16, characterized by that the base film is printed using gravure printing, particularly with solvent inks, or digital printing. [18] Method according to claim 16 or 17, characterized by that the abrasion-resistant melt coating is applied by brushing, doctoring or roller application. [19] Method according to one of claims 16 to 18, characterized bythat an embossed polyurethane-based intermediate layer containing no or substantially less filler than the melt coating is introduced beneath the melt coating, preferably using a slot die. [20] Method according to one of claims 16 to 19, characterized by that an embossed pattern is matched to the printed design. [21] Method according to one of claims 16 to 20, characterized by that the embossing depths are from 5 to 30 µm, preferably from 10 to 20 µm. [22] Method according to one of claims 16 to 21, characterized by that the varnish is cured by radiation and / or the polymer protective layer is applied by pouring, doctoring or roller application.

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