Decorative paper for laminate panels

Abstract

The present disclosure relates to a decorative paper (10) for laminate panels, wherein the decorative paper comprises: a printed decorative layer (20) which is incorporated into the decorative paper via a surface (15) of the decorative paper; wherein the decorative layer has a decorative main layer (21) which comprises at least 80% of the printed dyes (26, 27) of the decorative layer; wherein the decorative main layer is incorporated into the decorative paper to such a depth that a bonding region (30) is formed between the decorative main layer and the surface, wherein the bonding region is configured for bonding resin, in particular amino resin; and wherein the decorative main layer has a distance from the surface of the decorative paper of at least 5 µm.

Description

[0001] Decorative paper for laminate panels

[0002] 1. Technical Field

[0003] The present disclosure relates to a decorative paper for laminate panels, wherein the decorative paper comprises a printed decorative layer having a decorative main layer which has a distance from the surface of the decorative paper. Furthermore, the present disclosure relates to a laminate panel with a corresponding decorative paper, a method for producing a decorative paper, and a method for producing a laminate panel.

[0004] 2. State of the Art

[0005] At present, a plurality of panels and laminates for walls, ceilings or floor coverings are known in the state of the art. In recent years, in particular laminate panels have experienced widespread use. Laminate panels are relatively inexpensive and can be further processed. They are usually based on a carrier board (carrier layer) made of MDF or HDF material, and on the upper side thereof a decorative paper impregnated with a resin is applied.

[0006] The decorative papers represent a decorative element and are usually printed with a pictorial representation of a wood or stone floor or other suitable floor elements in the form of a decorative layer. These reproductions of the reality have a comparatively real effect in view of the current state of the art, so that a difference from an original picture can only be recognized with difficulty. This applies in particular to reproductions of stone boards, tiles and also wooden floors.

[0007] Moreover, a so-called overlay layer / an overlay paper is usually applied over the decorative paper. In this way, the durability of the surface can be improved. The papers used are impregnated with resins, such as for example with amino resins, which cure by pressing under the action of heat and pressure. In order to increase the abrasion resistance of the surfaces, the resins are moreover often provided with abrasion-resistant particles, such as for example corundum. This surface consequently directly represents the wear layer of the laminate panel. However, it is also possible to laminate an additional wear-resistant wear layer onto the decorative layer. Such s become transparent in the course of the impregnation and the pressing. Pre-condensed resins liquefy as a result of the pressing and connect the individual layers to one another. Consequently, a chemical reaction takes place, in particular a polycondensation, as a result of which a wear-resistant matrix is produced. Owing to the transparency of the wear layer, the appearance of the surface is furthermore determined by the decorative layer.

[0008] There are likewise so-called directly printed panels in the state of the art of such laminate panels. In the case of these directly printed panels, generally no papers are used, in particular no decorative paper. Instead of such decorative papers, in the case of these directly printed panels, the decorative layer is printed directly onto the surface of the panel using dispersion inks by means of a gravure printing process (an intaglio printing process). Expediently, the panel is usually provided in advance with a suitable primer. For this purpose, the primer is usually applied via rollers. After drying of the decorative layer, a plurality of resin layers are subsequently applied and cured. The resin layers serve as protective layers and abrasion-resistant surfaces. In order to increase the abrasion resistance, here too abrasion-resistant particles, usually corundum, are often embedded in the resin layer.

[0009] The proposals made in the state of the art for the production of printed panels, in particular laminate panels, in recent years have already shown considerable progress with regard to the quality of the print. However, there is furthermore a need for improvement, this applies in particular to the digital printing of decorative papers for use for panels, in particular laminate panels. The state of the art specifically reveals drawbacks with regard to the compatibility of the print with subsequent melamine coatings of the overlay. This can cause bonding defects between the layers of the decorative paper and / or of the laminate panel. This becomes noticeable for example in subsequent process steps, in particular postforming, it being possible for bubbles to form between the layers under the action of high temperatures. With postforming, aesthetically attractive shapes can be formed, but the appearance of the panel is greatly impaired by local heating and the resulting bubbles between the layers. Furthermore, damage can also result after the production process of the panels and in the field of use: for example, bubbles and discolorations can occur as a result of great heat, caused by hot pots and / or hot drinks, which bubbles and discolorations damage the decorative layer and have a visually less attractive effect.

[0010] The present disclosure therefore has the object of improving the previously known state of the art. In particular, a decorative paper of the type described at the beginning is intended to be provided with a decorative layer, wherein the decorative layer is intended to be as durable as possible. In particular, the decorative layer is intended to be impaired and / or damaged as little as possible, even if the decorative paper is deformed in subsequent processing steps, for example by postforming under the action of elevated temperature.

[0011] 3. Summary of the invention

[0012] The above objects and further objects which result from the following description are achieved by the subject matter of the independent claims. Preferred embodiments are the subject matter of the dependent claims, and the person skilled in the art finds indications of other suitable embodiments of the present invention in the disclosure of the present application.

[0013] Decorative paper

[0014] One aspect of the disclosure relates to a decorative paper for laminate panels, wherein the decorative paper comprises: a printed decorative layer which is incorporated into the decorative paper via a surface of the decorative paper; wherein the decorative layer has a decorative main layer which comprises at least 80% of the printed dyes of the decorative layer; wherein the decorative main layer is incorporated into the decorative paper to such a depth that a bonding region is formed between the decorative main layer and the surface, wherein the bonding region is configured for bonding resin, in particular amino resin; and wherein the decorative main layer has a distance from the surface of the decorative paper of at least 5 pm.

[0015] In the state of the art, the dye deposit of a decorative layer usually takes place in such a way that the dyes accumulate in a dye-receiving layer directly on the surface of the decorative paper. This has the effect that the dyes cannot penetrate sufficiently into the decorative paper. Consequently, a substantially closed layer is formed, as a result of which a bonding of resins (for example by an impregnation or an overlay layer) becomes more difficult. This leads to adhesion problems between the layers.

[0016] The applicants have now found that, according to the invention, the printed decorative paper can be processed particularly well in a further process step, in particular a deformation process, if the decorative main layer penetrates into the decorative paper to at least a certain depth. In this way, sufficient decorative paper is available to which resins can bond. These resins can be incorporated into the decorative paper for example by an impregnation after the application of the decorative layer, for example in the form of a resin-impregnated overlay layer.

[0017] The decorative paper can consist of fibers, preferably of cellulose fibers, to which the resins can bond. The decorative layer can then remain durable in the decorative paper and substantially no adhesion problems occur between the layers. In particular, the resin from an impregnated overlay layer can penetrate into the bonding region of the decorative paper and can offer a substantially firm bond of the layers.

[0018] At the same time, the decorative paper of the present invention can prevent excessively deep penetration of the dyes. Consequently, the decorative layer can furthermore be easily seen from the surface. The printed image is thus of high quality. According to the invention, a successful compromise owing to the distance from the surface can thus be made possible.

[0019] According to the present invention, the “dyes” are to be understood as meaning those color-imparting elements which remain in the product, that is to say the decorative paper and / or the laminate panel. Consequently, volatile components are not included. For example, inks can be used for printing, in which dyes can be dissolved in a solvent. During the dye deposit (dye application), the ink is thus moist or wet. After the application, the substantially dry dye remains in the decorative layer, in particular the decorative main layer.

[0020] In a preferred embodiment, the thickness of the decorative main layer is 5 to 50 pm, preferably 6 to 40 pm, more preferably 7 to 35 pm, more preferably 8 to 30 pm, more preferably 9 to 25 pm, most preferably 10 to 20 pm. In this case, the lower and / or upper limits can be combined with one another as desired in order to form new preferred regions for the thickness of the decorative main layer. This offers the advantage that a large part of the dyes which are introduced into the decorative layer are situated in a thickness specified herein, so that better bonding of the resin to the remaining regions of the decorative paper is made possible.

[0021] Preferably, the decorative main layer has a distance from the surface of the decorative paper of at least 6 pm, preferably at least 8 pm, more preferably at least 9 pm, more preferably at least io pm, more preferably at least 12 pm, more preferably at least 14 pm, more preferably at least 16 pm, more preferably at least 18 pm, and most preferably at least 20 pm.

[0022] This further contributes to better bonding of the resin to the decorative paper. Moreover, any pattern of the decorative main layer can furthermore be easily seen from outside the decorative paper. A high quality of the appearance can then be ensured.

[0023] A preferred embodiment relates to the decorative paper, wherein the decorative layer, in particular the decorative main layer, comprises individual substantially discrete decorative regions with dyes, and intermediate regions arranged therebetween substantially without dyes, wherein the intermediate regions are configured for bonding resins.

[0024] This further contributes to the fact that a better bonding of the resin to the decorative paper is made possible. In particular, a bonding region is provided in this way not only in the dimension of the thickness of the decorative paper, but now intermediate region within a plane parallel to the surface is also formed. A network of bonding possibilities for resin can thus be provided in a substantially three-dimensional region.

[0025] In one example, the decorative layer, in particular the decorative main layer, can constitute a non-continuous layer. In a further example, the intermediate regions could cover at least 10%, preferably at least 20%, preferably at least 30%, preferably at least 40%, preferably at least 50%, preferably at least 60%, preferably at least 70% of the surface. This has the advantage that a resin can be better bonded to the decorative paper. The “decorative regions” can constitute one or more print dots. In particular, the decorative regions can constitute an arrangement (connection, network, combination, or the like) of one or more dyes.

[0026] A preferred embodiment relates to the decorative paper, wherein the individual substantially discrete decorative regions cover at least io%, preferably at least 20%, more preferably at least 30%, more preferably at least 40%, more preferably at least 50%, more preferably at least 60%, most preferably at least 70% of the surface; and / or wherein the individual substantially discrete decorative regions cover at most 95%, preferably at most 90%, more preferably at most 85%, more preferably at most 80%, more preferably at most 75% of the surface.

[0027] This makes it possible for the decorative regions to cover the surface to an extent that is not too small and not too high. The covering of the surface can be understood as a projection of the decorative regions into the plane of the surface. The covering does not mean that the decorative regions have to be situated in the plane of the surface.

[0028] An accumulation of dyes in specific regions is consequently prevented. This further contributes to sufficient decorative paper material being provided for the bonding of resin.

[0029] A preferred embodiment relates to the decorative paper, wherein the shortest distance of directly adjacent individual substantially discrete decorative regions is at least 10 pm, preferably at least 20 pm, more preferably at least 30 pm, more preferably at least 40 pm, more preferably at least 50 pm, more preferably at least 60 pm, more preferably at least 70 pm, more preferably at least 80 pm, more preferably at least 90 pm, more preferably at least too pm, more preferably at least 120 pm, more preferably at least 140 pm, most preferably at least 150 pm; and / or wherein the shortest distance of directly adjacent individual substantially discrete decorative regions is at most 400 pm, preferably at most 350 pm, more preferably at most 300 pm, more preferably at most 250 pm, more preferably at most 200 pm, most preferably at most 180 pm.

[0030] It can be ensured with this embodiment that sufficient regions are formed on the decorative paper to which resin can bond. In this way, improved stability with respect to (subsequent) deformation steps of the decorative paper, for example in the case of postforming, can be ensured.

[0031] The distance should not be too small to offer sufficient bonding regions for the resin. The distance should not be too large, for example if a specific print pattern is intended to be produced by the decorative regions.

[0032] In the case of a plurality of directly adjacent decorative regions, the shortest distance can be understood as the one which is the shortest of all possible distances.

[0033] A preferred embodiment relates to the decorative paper, wherein the individual substantially discrete decorative regions have a largest dimension of at most 200 pm, preferably at most 150 pm, further preferably at most 120 pm, further preferably at most 100 pm, further preferably at most 80 pm, further preferably at most 60 pm, further preferably at most 40 pm, most preferably at most 30 pm.

[0034] This makes it possible for the decorative regions to be formed not too large. An accumulation of dyes in one region is consequently prevented. This contributes to sufficient decorative paper material being provided for the bonding of resin.

[0035] A preferred embodiment relates to the decorative paper, wherein of the printed dyes black is incorporated into the decorative paper first as part of the decorative layer, in particular the decorative main layer, wherein preferably the decorative layer, in particular the decorative main layer, has one or more of the colors black, magenta, yellow, cyan.

[0036] It has been found that, if the application of the color black takes place first, a saving of the quantity of ink for the application of the dyes can be achieved. At the same time, a visually attractive decorative layer, in particular decorative main layer, can furthermore be provided.

[0037] The person skilled in the art understands that such an application is reflected in the decorative paper and consequently leads to a recognizably different nature of the decorative paper, compared with decorative papers in which the color black is not applied first.

[0038] In order to apply the color black first, for example, corresponding print rows can be arranged in a printing direction along the decorative paper, which print rows apply the color black first. In downstream print rows of the first print row, for example, the dye deposit of a different color can take place. It is also possible to apply the color black in print rows downstream. In a preferred embodiment, six print rows can be arranged. An excessively dense dye deposit can thus advantageously be prevented according to the invention. In conventional devices, only four print rows are generally provided.

[0039] A preferred embodiment relates to the decorative paper, wherein the decorative main layer comprises at least 85%, preferably at least 90%, further preferably at least 94%, further preferably at least 96%, most preferably at least 98% of the printed dyes.

[0040] This has the advantage that the decorative main layer comprises the large part of the dyes. The formation of the bonding region for resins can consequently be provided in an improved manner. In particular, it can thus be prevented, in one example, that relatively large dye residues are situated outside the decorative main layer between the decorative main layer and the surface.

[0041] The decorative paper is preferably substantially non-opaque.

[0042] This contributes to the decorative paper serving substantially as dye carrier, in particular ink carrier. This ensures that dye droplets, in particular ink droplets, do not remain on the surface during the printing / application. A closed layer which would make a bonding of resin more difficult is then not formed. Rather, the decorative paper ensures that the dyes penetrate to a defined depth.

[0043] The decorative paper preferably has a grammage of at most 80 g / m2, preferably at most 70 g / m2, preferably at most 60 g / m2, preferably at most 50 g / m2, most preferably at most 45 g / m2. The decorative paper preferably has a grammage of at least 10 g / m2, preferably at least 20 g / m2, preferably at least 30 g / m2, preferably at least 40 g / m2, most preferably at least 45 g / m2.

[0044] Decorative papers which have a relatively high grammage (corresponding to a high basis weight) are usually used. According to the invention, this grammage can be reduced, wherein the advantageous effects of an increased grammage can substantially be maintained. Moreover, the penetration of the decorative main layer into the decorative paper can be controlled in an improved manner in this way. Further, decorative paper material can be saved. Moreover, resin for impregnation can also be saved. The amount of resin required for impregnation usually correlates approximately with the amount of decorative paper.

[0045] A preferred embodiment relates to the decorative paper, wherein the decorative layer, in particular the decorative main layer, has a dye deposit of at most 40 g / m2, preferably at most 30 g / m2, more preferably at most 20 g / m2, more preferably at most 15 g / m2, more preferably at most 12 g / m2, more preferably at most 10 g / m2, more preferably at most 8 g / m2, most preferably at most 6 g / m2.

[0046] The reduction of the dye deposit has the advantage that sufficient uncovered points can be formed to which an overlay layer can be better bonded. For example, this can be achieved by a corresponding control of a quantity of ink, which comprises the dyes, per print dot.

[0047] The decorative layer is preferably applied by digital printing.

[0048] The use of this printing technology contributes to increasing the quality of the print, for example of any pattern of the decorative layer, in particular of the decorative main layer. In particular, the digital printing facilitates the application of the decorative layer in a substantially contactless manner.

[0049] A preferred embodiment relates to the decorative paper, wherein the bonding region of the decorative paper is configured such that substantially no boundary layer is formed between the decorative main layer and a resin, in particular amino resin.

[0050] A boundary layer is usually formed in the case of printed decorative papers of the state of the art, as a result of which an adhesion of an overlay layer to the decorative paper is disadvantageously prevented. According to the invention, this disadvantage can be counteracted, so that an overall better appearance is provided.

[0051] A preferred embodiment relates to the decorative paper, wherein the decorative layer has been heat-treated with radiation, preferably UV radiation, wherein preferably UV radiation with a power of 200 - 800 W / cm, preferably 300 - 700 W / cm, more preferably 360 - 600 W / cm, more preferably 400 - 500 W / cm, most preferably 420 - 460 W / cm has been used. This offers the advantage that the decorative layer, in particular the decorative main layer, dries sufficiently in the decorative paper. This can also be understood as curing.

[0052] A preferred embodiment relates to the decorative paper, wherein the decorative paper has a thickness of at least 20 pm, preferably at least 30 pm, more preferably at least 35 pm, more preferably at least 40 pm, more preferably at least 45 pm, more preferably at least 50 pm, more preferably at least 55 pm, more preferably at least 60 pm, most preferably at least 65 pm; and / or wherein the decorative paper has a thickness of at most 150 pm, preferably at most 130 pm, more preferably at most 110 pm, more preferably at most too pm, more preferably at most 90 pm, more preferably at most 80 pm, more preferably at most 75 pm, most preferably at most 70 pm.

[0053] These thicknesses of the decorative paper have, on the one hand, proven to be advantageous in order to provide sufficient strength and in order to ensure sufficient penetration into the decorative paper and to make possible a distance of the decorative main layer from a rear side situated opposite the surface. On the other hand, the use of material can be kept at a moderate level.

[0054] Laminate panel

[0055] A further aspect relates to a laminate panel, in particular a wall, ceiling, furniture or floor panel, wherein the laminate panel comprises: a decorative paper as described herein; a carrier board, such as a medium density fiber (MDF) board, a high density fiber (HDF) board or a particle board.

[0056] The corresponding advantages mentioned with respect to the decorative paper apply to the laminate panel as well.

[0057] A “laminate panel” is to be understood herein as meaning a material or a product which consists of two or more layers adhesively bonded to one another substantially in a planar manner. In one example, these layers can consist of identical or different materials.

[0058] The carrier board can comprise wood, in particular wood-based materials. The carrier board can consist of wood, in particular of wood-based materials. The wood-based materials can comprise fibers, in particular wood fibers. The wood fibers can be, for example, medium density wood fibers, MDF, or high density wood fibers, HDF. The carrier board can furthermore consist of plastic or comprise plastic.

[0059] The decorative paper is configured to be applied onto the carrier board, preferably with the rear side of the decorative paper situated opposite the surface.

[0060] The laminate panel can furthermore comprise a resin coating, preferably a melamine resin coating, wherein the resin coating is formed substantially in the bonding region of the decorative paper between the decorative main layer and the surface of the decorative paper.

[0061] The laminate panel can furthermore comprise a substantially transparent, preferably wear-resistant, cover layer, wherein the cover layer is provided with melamine resin.

[0062] The cover layer is preferably a wear layer. This increases the protection of the laminate panel. In particular, the cover layer / wear layer can protect the decorative layer, in particular the decorative main layer, from harmful influences of the environment.

[0063] Preferably, the laminate panel has a thickness of o.i to 2.0 mm, preferably of 0.2 to 1.5 mm, more preferably of 0.3 to 1.2 mm, more preferably of 0.4 to 1.0 mm, most preferably of 0.5 to 0.8 mm.

[0064] These thicknesses of the laminate panel have proven to be advantageous, in particular for any deformation steps, for example postforming. The laminate panel thus has sufficient stability, wherein the use of material can be kept at a moderate level.

[0065] Method

[0066] While the description of the decorative paper and / or of the laminate panel is directed to the product, wherein the described properties and features are usually to be found in the dried state of the product, the description of the method for producing the decorative paper and / or the laminate panel sometimes relates to active steps. It may consequently be the case that, for example during the incorporation / application / printing of layers in the method, the layers are at least partially liquid / viscous. However, it goes without saying that substantially the same advantages and features mentioned with respect to the decorative paper and / or to the laminate panel apply equally to the method for producing the decorative paper and / or the laminate panel. Furthermore, the features can thus also be applied in a combined and / or exchangeable manner to embodiments of the decorative paper, of the laminate panel or of the respective methods.

[0067] Method for decorative paper

[0068] A further aspect relates to a method for producing a decorative paper having a decorative layer for laminate panels, wherein the method comprises: providing a decorative paper; incorporating and / or printing a decorative layer into the decorative paper via a surface of the decorative paper; wherein the decorative layer has a decorative main layer which comprises at least 8o% of the printed dyes of the decorative layer; wherein the decorative main layer is incorporated into the decorative paper to such a depth that a bonding region is formed between the decorative main layer and the surface, wherein the bonding region is configured for bonding resins, in particular amino resins; and wherein the decorative main layer has a distance from the surface of the decorative paper of at least 5 pm.

[0069] The respective advantages in this regard are described in particular with respect to the decorative paper.

[0070] The method preferably further comprises the step of heat-treating the decorative layer in the decorative paper with radiation, preferably UV radiation, wherein preferably UV radiation with a power of 200 - 800 W / cm, preferably 300 - 700 W / cm, more preferably 360 - 600 W / cm, more preferably 400 - 500 W / cm, more preferably 420 - 460 W / cm is used.

[0071] One or more, most preferably two UV emitters with a power of in each case too - 400 W / cm, preferably 150 - 350 W / cm, more preferably 180 - 300 W / cm, more preferably 200 - 250 W / cm, more preferably 210 - 230 W / cm are used.

[0072] The respective advantages in this regard are described in particular with respect to the decorative paper.

[0073] In a preferred embodiment of the method, the decorative layer is applied by digital printing. The respective advantages in this regard are described in particular with respect to the decorative paper.

[0074] In the method, of the printed dyes the dye black is preferably incorporated into the decorative paper first as part of the decorative layer, in particular the decorative main layer, wherein preferably the decorative layer, in particular the decorative main layer, has one or more of the colors black, magenta, yellow, cyan.

[0075] The respective advantages in this regard are described in particular with respect to the decorative paper.

[0076] In the method, the following colors are preferably incorporated into the decorative paper as part of the decorative layer, in particular the decorative main layer, in the following sequence: black, magenta, yellow, magenta, cyan, black.

[0077] It has proven to be advantageous to apply the color black first and last. A reduction of the quantity of dye can thus be achieved, wherein the decorative layer can furthermore be configured to be visually attractive. Further advantages in this regard are described with respect to the decorative paper.

[0078] In the method, the decorative layer, in particular the decorative main layer, is preferably incorporated into the decorative paper by a dye deposit of at most 40 g / m2, preferably at most 30 g / m2, more preferably at most 20 g / m2, more preferably at most 15 g / m2, more preferably at most 12 g / m2, more preferably at most 10 g / m2, more preferably at most 8 g / m2, most preferably at most 6 g / m2.

[0079] The respective advantages in this regard are described in particular with respect to the decorative paper.

[0080] Method for laminate panel

[0081] A further aspect relates to a method for producing a laminate panel, in particular a wall, ceiling, furniture or floor panel, wherein the method comprises: carrying out the method for producing a decorative paper with a printed decorative layer for laminate panels or providing a decorative paper as described herein; providing a carrier board, such as a medium density fiber (MDF) board, a high density fiber (HDF) board or a particle board; applying the decorative paper with the printed decorative layer onto the carrier board. Preferably, the method comprises the step of applying a resin coating, preferably a melamine resin coating, wherein the resin coating is formed substantially in the bonding region of the decorative paper between the decorative main layer and the surface of the decorative paper.

[0082] The resins addressed herein can comprise all resins usually used, for example synthetic resins or natural resins. In particular, formaldehyde-containing synthetic resins such as melamine resin, phenol-formaldehyde resin and urea resin can be used. Brief Description of the Figures

[0083] Preferred embodiments are described below only by way of example. Reference is made to the following accompanying figures:

[0084] FIG. 1 shows a decorative paper according to an embodiment of the present invention in a side view;

[0085] FIG. 2 shows a laminate panel according to an embodiment of the present invention in a side view;

[0086] FIG. 3 shows a decorative paper according to an embodiment of the present invention in a side view;

[0087] FIG. 4 shows a detailed view to scale of a decorative paper according to an embodiment of the present invention in a plan view;

[0088] FIG. 5 shows a further detailed view to scale of a decorative paper according to an embodiment of the present invention in a plan view;

[0089] FIG. 6 shows a flow chart of a method for producing a decorative paper according to an embodiment of the present invention;

[0090] FIG. 7 shows a flow chart of a method for producing a laminate panel according to an embodiment of the present invention. Detailed Description of the Figures

[0091] Only a few possible embodiments of the invention are described in detail below. However, the present invention is not limited thereto, and a multiplicity of other embodiments maybe applied without departing from the scope of the invention. The embodiments presented can be modified and combined with one another in many ways whenever they are compatible, and specific features can be omitted insofar as they appear dispensable. In particular, the disclosed embodiments can be modified by combining specific features of one embodiment with one or more features of another embodiment.

[0092] Throughout the present figures and the description, the same reference signs refer to the same elements. The figures are not to scale (unless explicitly indicated otherwise), and the relative size, proportions and representation of elements in the figures may be exaggerated for clarity, illustration and convenience.

[0093] FIG. i shows a decorative paper io according to an embodiment of the present invention in a side view. The decorative paper io is suitable for laminate panels 50. The decorative paper io has a printed decorative layer 20 which is incorporated into the decorative paper 10 via a surface 15 of the decorative paper 10. The decorative layer 20 has a decorative main layer 21 which comprises at least 80% of the printed dyes 26, 27 of the decorative layer 20. The decorative main layer 21 is incorporated into the decorative paper 10 to such a depth that a bonding region 30 is formed between the decorative main layer 21 and the surface 15, wherein the bonding region 30 is configured for bonding resin, in particular amino resin. The decorative main layer 21 has a distance from the surface 15 of the decorative paper 10 of at least 5 pm. The decorative layer 20, in particular the decorative main layer 21, comprises individual substantially discrete decorative regions 26, 27 with dyes 26, 27 and intermediate regions arranged therebetween substantially without dyes. The intermediate regions are configured for bonding resins. For the sake of clarity and / or brevity, not all decorative regions / dyes are provided with reference signs.

[0094] FIG. 2 shows a laminate panel 50 according to an embodiment of the present invention in a side view. The laminate panel 50 can be in particular a wall, ceiling, furniture or floor panel. The laminate panel 50 comprises the following: a decorative paper 10 as described herein, and a carrier board 60, such as a medium density fiber (MDF) board, a high-density fiber (HDF) board or a particle board. The decorative paper 10 can be applied onto the carrier board 60 by common methods. Furthermore, a connecting structure 65 is shown. The connecting structure 65 makes it possible for the side face of the laminate panel 50 to be brought into engagement with a side face of another laminate panel. The connecting structure 65 can be provided by profiling.

[0095] FIG. 3 shows a decorative paper 10 according to an embodiment of the present invention in a side view. The decorative paper 10 substantially corresponds to that of the embodiment from FIG. 1. Furthermore, it can be seen that of all printed dyes 26, 27, the dye black 26 is incorporated into the decorative paper 10 first as part of the decorative layer 20, in particular the decorative main layer 21. For reasons of clarity, not all decorative regions / dyes 26, 27 are provided with reference signs. The dye black 26 is situated closer to the rear side 16 than the remaining dyes 27. The decorative layer 20 can have one or more of the colors black, magenta, yellow, cyan.

[0096] FIG. 4 shows a detailed view to scale of a decorative paper 10 according to an embodiment of the present invention in a top view. The scale is illustrated in the lower right corner of the figure. The dyes black 26 and any desired further dye 27 are illustrated. For reasons of clarity, not all decorative regions / dyes are provided with reference signs. The distance of directly adjacent individual substantially discrete decorative regions is illustrated in FIG. 4 by, for example, 144 pm, 230 pm, and 250 pm. The shortest distance of directly adjacent individual substantially discrete decorative regions is smaller, as illustrated in FIG. 4.

[0097] FIG. 5 shows a further detailed view to scale of a decorative paper 10 according to an embodiment of the present invention in a top view. The individual substantially discrete decorative regions have a largest dimension of at most 200 pm, 150 pm, 120 pm, too pm, or 80 pm. Dimensions of 56 pm, 69 pm, and 75 pm are illustrated byway of example in Fig. 5. For reasons of clarity, not all decorative regions / dyes are provided with reference signs.

[0098] FIG. 6 shows a flow chart of a method too for producing a decorative paper according to an embodiment of the present invention. The method too comprises: providing 110 a decorative paper and incorporating and / or printing 120 a decorative layer into the decorative paper via a surface of the decorative paper; wherein the decorative layer has a decorative main layer which comprises at least 80% of the printed dyes of the decorative layer; wherein the decorative main layer is incorporated into the decorative paper to such a depth that a bonding region is formed between the decorative main layer and the surface, wherein the bonding region is configured for bonding resins, in particular amino resins; and wherein the decorative main layer has a distance from the surface of the decorative paper of at least 5 pm.

[0099] FIG. 7 shows a flow chart of a method 200 for producing a laminate panel according to an embodiment of the present invention. The method 200 comprises: carrying out the method 100 for producing a decorative paper with a printed decorative layer for laminate panels or providing a decorative paper; providing 210 a carrier board, such as a medium density fiber (MDF) board, a high density fiber (HDF) board or a particle board; applying 220 the decorative paper with the printed decorative layer onto the carrier board.

[0100] The “dyes” described herein are used for example in inks for printing. In this case, both inks with soluble and insoluble dyes are comprised. In the case of inks with soluble dyes, the dyes can be present in a chemically dissolved manner with a medium or be bound as a complex. Water-soluble inks and solvent-based inks are comprised. Examples of solvents are alcohol, ethyl acetate, toluene (toluol) and xylene (xylol). These solvents can be volatile and evaporate, for example. After the application, the dye is therefore usually present as a substantially dry dye.

[0101] Preferred embodiments of the invention, in particular of the laminate panel, can be postformed as desired and are also durable after any further processing steps. Furthermore, preferred embodiments of the invention achieve very good values in the surface test according to EN 438. These values relate, of course, to the finished panel, in particular laminate panel, when all layers are cured. The person skilled in the art understands that the values of the surface properties can depend on at least the following criteria: water vapour resistance, dry heat, moist heat, impact stress by means of a small ball, impact stress by means of a large ball, stains and / or light fastness (light authenticity), and / or abrasion.

[0102] The European standard EN 438 (surface test) defines material, requirements and properties of high-pressure laminate (HPL). Similar standards are found for further types of laminates. The standard EN 438 comprises some test criteria, inter alia the assessment of the appearance of the laminate, the resistance to surface abrasion, the dimensional stability at elevated temperature, and also the resistance to impact stress. Example of a decorative paper according to the present invention. In one example, the decorative paper has a grammage of 43-47 g / m2. The longitudinal dry fracture is at least 19 N / 15 mm. The porosity (Gurley value) is 15 - 21 s. The smoothness (Bekk value) is 80 - 120 s. The ash content is at least 15%. The pH value is 8 - 9.

[0103] The scope of protection is determined by the claims and is not limited by the exemplary embodiments. List of reference signs

[0104] 10 decorative paper

[0105] 15 surface

[0106] 16 rear side

[0107] 20 decorative layer

[0108] 21 decorative main layer

[0109] 26 black dye / decorative region

[0110] 27 magenta / yellow / cyan / decorative region

[0111] 30 bonding region

[0112] 50 laminate panel

[0113] 60 carrier board

[0114] 65 connecting elements

[0115] 66 rear side of the carrier board

[0116] 100 method for producing a decorative paper

[0117] 110 method step: providing

[0118] 120 method step: incorporating

[0119] 200 method for producing a laminate panel

[0120] 210 method step: providing

[0121] 220 method step: applying

Claims

Claims1. A decorative paper (io) for laminate panels (50), wherein the decorative paper (10) comprises: a printed decorative layer (20) which is incorporated into the decorative paper (10) via a surface (15) of the decorative paper (10); wherein the decorative layer (20) has a decorative main layer (21) which comprises at least 80% of the printed dyes of the decorative layer (20); wherein the decorative main layer (21) is incorporated into the decorative paper (10) to such a depth that a bonding region (30) is formed between the decorative main layer (21) and the surface (15), wherein the bonding region (30) is configured for bonding resin, in particular amino resin; and wherein the decorative main layer (21) has a distance from the surface (15) of the decorative paper (10) of at least 5 pm.

2. The decorative paper (10) according to the preceding claim, wherein the thickness of the decorative main layer (21) is 5 to 50 pm, preferably 6 to 40 pm, more preferably 7 to 35 pm, more preferably 8 to 30 pm, more preferably 9 to 25 pm, most preferably 10 to 20 pm.

3. The decorative paper (10) according to one of the preceding claims, wherein the decorative main layer (21) has a distance from the surface (15) of the decorative paper (10) of at least 6 pm, preferably at least 8 pm, more preferably at least 10 pm, more preferably at least 15 pm, and most preferably at least 20 pm.

4. The decorative paper (10) according to one of the preceding claims, wherein the decorative layer (20), in particular the decorative main layer (21), comprises individual substantially discrete decorative regions (26, 27) with dyes, and intermediate regions arranged therebetween substantially without dyes, wherein the intermediate regions are configured for bonding resins.

5. The decorative paper (io) according to the preceding claim, wherein the individual substantially discrete decorative regions (26, 27) cover at least 10%, preferably at least 20%, more preferably at least 30%, more preferably at least 40%, more preferably at least 50%, more preferably at least 60%, most preferably at least 70% of the surface (15); and / or cover at most 95%, preferably at most 90%, more preferably at most 85%, more preferably at most 80%, more preferably at most 75% of the surface (15)-6. The decorative paper (10) according to one of claims 4 or 5, wherein the shortest distance of directly adjacent individual substantially discrete decorative regions (26, 27) is at least 10 pm, preferably at least 20 pm, more preferably at least 40 pm, more preferably at least 60 pm, more preferably at least 80 pm, more preferably at least 120 pm, most preferably at least 150 pm; and / or is at most 400 pm, preferably at most 350 pm, more preferably at most 300 pm, more preferably at most 250 pm, more preferably at most 200 pm, most preferably at most 180 pm.

7. The decorative paper (10) according to one of claims 4 to 6, wherein the individual substantially discrete decorative regions (26, 27) have a largest dimension of at most too pm, preferably at most 80 pm, preferably at most 60 pm, preferably at most 40 pm, most preferably at most 30 pm.

8. The decorative paper (10) according to one of the preceding claims, wherein of the printed dyes black is incorporated into the decorative paper (10) first as part of the decorative layer (20), in particular the decorative main layer (21), wherein preferably the decorative layer (20), in particular the decorative main layer (21), has one or more of the colors black, magenta, yellow, cyan.

9. The decorative paper (10) according to one of the preceding claims, wherein the decorative main layer (21) comprises at least 85%, preferably at least 90%, more preferably at least 94%, more preferably at least 96%, most preferably at least 98% of the printed dyes.io. The decorative paper (io) according to one of the preceding claims, wherein the decorative paper (io) is substantially non-opaque. n. The decorative paper (io) according to one of the preceding claims, wherein the decorative paper (io) has a grammage of at most 8o g / m2, preferably at most 70 g / m2, preferably at most 6o g / m2, preferably at most 50 g / m2, most preferably at most 45 g / m2; and / or wherein the decorative paper (10) has a grammage of at least 10 g / m2, preferably at least 20 g / m2, preferably at least 30 g / m2, preferably at least 40 g / m2, most preferably at least 45 g / m2.

12. The decorative paper (10) according to one of the preceding claims, wherein the decorative layer (20), in particular the decorative main layer (21), has a dye deposit of at most 40 g / m2, preferably at most 30 g / m2, more preferably at most 20 g / m2, more preferably at most 15 g / m2, more preferably at most 12 g / m2, more preferably at most 10 g / m2, more preferably at most 8 g / m2, most preferably at most 6 g / m2.

13. The decorative paper (10) according to one of the preceding claims, wherein the decorative layer (20) has been applied by digital printing.

14. The decorative paper (10) according to one of the preceding claims, wherein the bonding region (30) of the decorative paper (10) is configured such that substantially no boundary layer is formed between the decorative main layer (21) and a resin, in particular amino resin.

15. The decorative paper (10) according to one of the preceding claims, wherein the decorative layer (20) has been heat-treated with radiation, preferably UV radiation, wherein preferably UV radiation with a power of 200 - 800 W / cm, preferably 300 - 700 W / cm, more preferably 360 - 600 W / cm, more preferably 400 - 500 W / cm, most preferably 420-460 W / cm has been used.

16. The decorative paper (io) according to one of the preceding claims, wherein the decorative paper (io) has a thickness of at least 40 pm, preferably at least 55 pm, most preferably at least 65 pm; and / or wherein the decorative paper (10) has a thickness of at most 150 pm, preferably at most 100 pm, most preferably at most 70 pm.

17. A laminate panel (50), in particular a wall, ceiling, furniture or floor panel, wherein the laminate panel (50) comprises: a decorative paper (10) according to one of the preceding claims; a carrier board (60), such as a medium density fiber (MDF) board, a high density fiber (HDF) board or a particle board.

18. The laminate panel (50) according to the preceding claim, further comprising a resin coating, preferably a melamine resin coating, wherein the resin coating is formed substantially in the bonding region (30) of the decorative paper (10) between the decorative main layer (21) and the surface (15) of the decorative paper (10).

19. The laminate panel (50) according to one of the preceding claims relating to the laminate panel (50), further comprising a substantially transparent, preferably wear-resistant, cover layer, wherein the cover layer is provided with melamine resin.

20. The laminate panel (50) according to one of the preceding claims relating to the laminate panel (50), wherein the laminate panel (50) has a thickness of 0.1 to 2.0 mm, preferably of 0.2 to 1.5 mm, more preferably of 0.3 to 1.2 mm, more preferably of 0.4 to 1.0 mm, most preferably of 0.5 to 0.8 mm.

21. A method (too) for producing a decorative paper (10) with a decorative layer (20) for laminate panels (50), wherein the method (too) comprises: providing (110) a decorative paper (10); incorporating and / or printing (120) a decorative layer (20) into the decorative paper (10) via a surface (15) of the decorative paper (10);wherein the decorative layer (20) has a decorative main layer (21) which comprises at least 80% of the printed dyes of the decorative layer (20); wherein the decorative main layer (21) is incorporated into the decorative paper (10) to such a depth that a bonding region (30) is formed between the decorative main layer (21) and the surface (15), wherein the bonding region (30) is configured for bonding resins, in particular amino resins; and wherein the decorative main layer (21) has a distance from the surface (15) of the decorative paper (10) of at least 5 pm.

22. The method (100) according to the preceding method claim, further comprising the step of heat-treating the decorative layer (20) in the decorative paper (10) with radiation, preferably UV radiation, wherein preferably UV radiation with a power of 200 - 800 W / cm, preferably 300 - 700 W / cm, more preferably 360 - 600 W / cm, more preferably 400 - 500 W / cm, more preferably 420 - 460 W / cm is used.

23. The method (100) according to one of the preceding method claims, wherein the decorative layer (20) is applied by digital printing.

24. The method (100) according to one of the preceding method claims, wherein of the printed dyes black is incorporated into the decorative paper (10) first as part of the decorative layer (20), in particular the decorative main layer (21), wherein preferably the decorative layer (20), in particular the decorative main layer (21), has one or more of the colors black, magenta, yellow, cyan.

25. The method (too) according to one of the preceding method claims, wherein the following colors are incorporated into the decorative paper (10) as part of the decorative layer (20), in particular the decorative main layer (21), in the following sequence: black, magenta, yellow, magenta, cyan, black.

26. The method (too) according to one of the preceding method claims, wherein the decorative layer (20), in particular the decorative main layer (21), is incorporated into the decorative paper (10) by a dye deposit of at most 40 g / m2,preferably at most 30 g / m2, more preferably at most 20 g / m2, more preferably at most 15 g / m2, more preferably at most 12 g / m2, more preferably at most 10 g / m2, more preferably at most 8 g / m2, most preferably at most 6 g / m2.

27. A method (200) for producing a laminate panel (50), in particular a wall, ceiling, furniture or floor panel, wherein the method (200) comprises: carrying out the method (100) for producing a decorative paper (10) with a printed decorative layer (20) for laminate panels (50) according to one of claims 21 - 26 or providing a decorative paper (10) according to one of claims 1 - 16; providing (210) a carrier board (60), such as a medium density fiber (MDF) board, a high density fiber (HDF) board or a particle board; applying (220) the decorative paper (10) with the printed decorative layer (20) onto the carrier board (60).

28. The method (200) according to the preceding method claim, further comprising the step of applying a resin coating, preferably a melamine resin coating, wherein the resin coating is formed substantially in the bonding region (30) of the decorative paper (10) between the decorative main layer (21) and the surface

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