Dyeable thermoformed sheets, compositions, and methods of manufacture

Abstract

This disclosure describes a thermoformable sheet capable of retaining absorbent stains, pigmented sealers, or clear sealers. The unique resin binder formulation and product includes a porosity promoter that results in a resin binder with a stainable, porous surface while maintaining the favorable properties of traditional thermofoil products. The method of manufacturing the thermofill product of the present invention produces a thermofill product that can be dyed with a variety of stains and colorants to suit the preferences of the individual manufacturer or homeowner after the product is manufactured.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Application No. 62 / 832,802, filed April 11, 2019, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure relates to dyeable thermoformed sheets, resin binder formulations, and methods for making dyeable thermoformed sheets. The methods disclosed herein provide dyeable thermoformed sheets, including typical absorbent stains, pigmented sealers, or clear sealers. [Background technology]

[0003] Thermofoil is an inexpensive wood substitute. Typically, thermofoil is a plastic, vinyl, polyethylene terephthalate (PET), or paper substrate printed with either a wood grain or synthetic wood grain print. Thermofoil is mass-produced worldwide due to its wood-like appearance, and uses alternative resources to wood.

[0004] Traditionally, thermofoils are produced by extruding PVC or ABS into thin continuous sheets, for example, about 10 mm to 2500 mm wide, and then wound into rolls for secondary processing. Once the PVC or ABS is successfully extruded into rolls, it is then machined and unrolled and pre-treated for adhesion and uniform color development. It is then printed with ink, for example, gravure printing with UV-curable, solvent-based or water-based inks, or high-speed digital printing with UV-curable inks. After the substrate is printed with a wood grain or synthetic wood grain print, the resulting product is coated with one or more UV-curable topcoats to complete the product with its final properties. Once the foil is complete, it can be embossed to create a wood grain look or rewound into rolls and cut to size to customer specifications. The resulting product is wood-like, water-resistant, and has a range of sheens and durability. End products include edge banging, wrap moldings, furniture components, cabinet components, or cabinet doors that are obtained through various gluing processes.

[0005] While customers are willing to accept some flexibility in cost for existing processes, this is not the case for custom products or colors, resulting in huge order volumes for small quantities. Also, the product quality of Thermofoil products is not consistent worldwide. Therefore, there is a need to produce Thermofoil products that can be dyed to any color, for example with absorbent stains, colored sealers, or clear sealers, and then finished with a professional, high-quality coating to further enhance the appearance and durability of the overall surface. The products and methods disclosed herein are expected to reduce manufacturing and consumer costs and increase consumer acceptance. Summary of the Invention

[0006] The present invention relates to a dyeable thermoformed sheet. The dyeable thermoformed sheet includes: a thermofoil sheet; and a dyeable topcoat layer applied to the thermofoil sheet. The dyeable topcoat layer includes a resin binder formulation including a resin, an additive, and a porosity agent prior to curing. The dyeable topcoat layer preferably has at least 35 weight percent porosity agent prior to curing. In a non-limiting embodiment, the thermofoil sheet is a polyvinyl chloride (PVC) sheet, an acrylonitrile butadiene styrene (ABS) sheet, or a polyethylene terephthalate (PET) sheet.

[0007] The present invention also relates to a method of making a dyeable thermoformed sheet, the method comprising applying a dyeable topcoat layer having a resin binder formulation including a resin, an additive, and a porosity agent to a thermofoil sheet prior to curing. In a preferred embodiment, the dyeable topcoat layer has at least 35 weight percent porosity agent prior to curing. The particle size of the porosity agent in certain non-limiting embodiments is 0.4 to 70 μm.

[0008] Implementations are now described in conjunction with the accompanying drawings, in which like designations refer to like elements, and in which: FIG. Those skilled in the art will appreciate that the elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale, for example, the dimensions of some elements in the figures may be exaggerated relative to other elements to help improve understanding of the implementation. [Brief description of the drawings]

[0009] [Figure 1] 1 and 2 show perspective views of non-limiting examples of dyeable Thermofoil products having one dyeable topcoat layer. [Diagram 2] 1 and 2 show perspective views of non-limiting examples of dyeable Thermofoil products having one dyeable topcoat layer. [Diagram 3]3 and 4 show perspective views of non-limiting examples of dyeable Thermofoil products having two dyeable topcoat layers. [Figure 4] 3 and 4 show perspective views of non-limiting examples of dyeable Thermofoil products having two dyeable topcoat layers. [Diagram 5] 5 and 6 show cross-sectional views of non-limiting examples of dyeable Thermofoil products having one dyeable topcoat layer. [Figure 6] 5 and 6 show cross-sectional views of non-limiting examples of dyeable Thermofoil products having one dyeable topcoat layer. [Figure 7] 7 and 8 show cross-sectional views of non-limiting examples of dyeable Thermofoil products having two dyeable topcoat layers. [Figure 8] 7 and 8 show cross-sectional views of non-limiting examples of dyeable Thermofoil products having two dyeable topcoat layers. [Figure 9] 9 and 10 show an example of a process for making a dyeable thermofoil product. Additional steps in the process are also shown. [Figure 10] 9 and 10 show an example of a process for making a dyeable thermofoil product. Additional steps in the process are also shown. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] definition As used in this specification and claims, and in its conjugations, the verb "comprise" is used in an open-ended sense to mean that the items following the word are included, but not excluding items not specifically mentioned.

[0011] The indefinite article "a" or "an" preceding an element does not exclude the possibility that a plurality of elements is present, unless the context clearly requires that there is only one of the element. Thus, the indefinite article "a" or "an" typically means "at least one." For example, a porous agent preceded by "a" or "the" refers to one porous agent or a combination of porous agents.

[0012] As used herein, the term "about" refers to a tolerance of plus or minus 20% (for example, "about 1" refers to 0.8 to 1.2, and "about 5" refers to 4 to 6). As used herein, the term "thermoformable sheet" or "thermofoil" refers to a plastic or paper material that can be thermoformed or applied to the contours of an underlying substrate (eg, an engineered wood core such as medium density fiberboard) and then finished with a surface.

[0013] As used herein, the term "dyeable" refers to the ability of a material surface to have absorptive properties such that it can be penetrated by a pigment or dye that produces a "dye" effect. As used herein, the term "absorbent stain" refers to a colorant, such as one or more dyes and / or pigments, suspended or dissolved in a pharmaceutical or solvent. Non-limiting examples include oil-based stains, varnish stains, water-based stains, solvent-based stains, gel stains, lacquer stains, water-soluble dye stains, ultraviolet (UV) light cured stains, and metal or composite (metallized) dye stains. Non-limiting examples of UV cured stains include sealants (e.g., tinted sealers), stains, and the like. Similar stains or colorants, existing or yet to be discovered, can also be used.

[0014] As used herein, the term "resin" refers to a solid or highly viscous substance, typically of plant origin or synthetic origin, that can be converted into a polymer. As used herein, the term "topcoat" or "topcoat layer" refers to a layer of resin and composition that covers an inner layer of thermofoil material. The topcoat provides a uniform, smooth or textured, durable, very attractive, stainable finish.

[0015] As used herein, the term "pigment volume concentration" or "PVC" refers to the volume percent of solid particles in the system after film formation and is calculated as follows: the volume of porosity agent divided by the volume of porosity agent plus the volume of solids in the resin. "Pigment volume concentration" allows one to determine if there is enough mineral in the resin system to actually ensure mineral uptake at the final surface.

[0016] As used herein, the term "additive" includes compounds that flow, level, dilute, reduce, react, and / or defoam the product, such as degassing agents, dispersing agents, catalysts, photoinitiators, wetting agents, etc. Thus, additives include surfactants, curing agents, etc.

[0017] As used herein, the term "photoinitiator" refers to a compound capable of converting the physical energy of light into suitable chemical energy in the form of reactive intermediates. Photoinitiators undergo a photoreaction upon absorption of light to produce reactive species that initiate or catalyze chemical reactions, resulting in the appropriate formulation solubility and dramatic changes in physical properties.

[0018] This disclosure relates to the discovery that certain porosity-promoting surface agents, incorporated into the resin binder (e.g., epoxy acrylate or acrylic) applied to the thermoformed sheet, provide a porous surface that can absorb stains, pigmented sealers, or clear sealers after the resin binder is applied to the thermoformed sheet. The degree of absorption of the dyeable topcoat layer can be controlled by the process of adding finely ground inorganics at high concentrations to the dyeable (e.g., UV-cured or air-cured) coating. By allowing the basic design to be modified after the manufacturing process, for example, the resulting surface can be altered with absorbing stains, pigments, or clear sealers after the thermoformed sheet is applied to a cabinet door, furniture component, etc., this disclosure allows for greater customer acceptance and manipulation at the customer side. Additional benefits include reduced cost and significantly improved water resistance when compared to wood counterparts.

[0019] In a first aspect of the present invention, a dyeable thermoformable sheet is provided comprising a thermofoil sheet and a dyeable topcoat layer applied to the thermofoil sheet, the dyeable topcoat layer including, prior to curing, a resin binder formulation including a resin, an additive, and at least 35 weight percent of a porosity agent.

[0020] In a second aspect of the invention, there is provided a method of making a dyeable thermoformed sheet comprising applying to a thermofoil sheet, prior to curing, a dyeable topcoat layer comprising a resin binder formulation comprising a resin, an additive, and at least 35 weight percent of a porosity agent.

[0021] In certain embodiments, the dyeable topcoat layer is flexible, easy to wrap around, and provides a variety of surface effects that are desirable when dyeing. Dyeable thermoformed sheets are formed by adding at least one porosity agent 150 and at least one additive to the resin binder layer 120 prior to curing the resin binder layer 120. In the present disclosure, dyeable resin binder layers 120 can be made using existing energy curable resin formulations with the addition of a porosity agent 150 as disclosed herein.

[0022] Thermoforming Sheet In some non-limiting embodiments, the dyeable thermoformed sheet 130 (FIG. 1) is a polyvinyl chloride (PVC) sheet, an acrylonitrile butadiene styrene (ABS) sheet, a polyethylene terephthalate (PET) sheet, or a cellulose paper. In other embodiments, the dyeable thermoformed sheet 130 (FIG. 1) is a polyvinyl chloride (PVC) sheet, an acrylonitrile butadiene styrene (ABS) sheet, or a polyethylene terephthalate (PET) sheet. In one embodiment, the dyeable thermoformed sheet 130 (FIG. 1) is not a cellulose paper. In one aspect, the dyeable thermoformed sheet 130 (FIG. 1) is a polyvinyl chloride (PVC) sheet. In another aspect, the dyeable thermoformed sheet 130 (FIG. 1) is an acrylonitrile butadiene styrene (ABS) sheet. In another aspect, the dyeable thermoformed sheet 130 (FIG. 1) is a polyethylene terephthalate (PET) sheet.

[0023] Thermoformed sheets made of PVC, ABS, or PET cannot be wetted with resin system compositions (e.g., urea-formaldehyde or melamine formaldehyde resins) due to several factors: 1) there is no chemical compatibility; 2) PVC, ABS, and PET sheets cannot withstand the amount of heat and pressure required to create a laminate surface; and 3) while a melamine resin system can be made to bond to the surface of a PVC, ABS, or PET sheet in a short time, the resin system loses adhesion over time due to a large difference in elongation modulus (i.e., the difference in the amount of displacement of the substrate (PVC, ABS, or PET) and the amount of displacement of the coating (melamine resin system) over time and tension). The last factor is particularly important because the process of making thermofoil sheet requires that the sheet be wrapped around a mold, door center panel, etc. The thermofoil sheet must be pliable and wrapable. The present application system should also possess these characteristics. The present invention provides such an application system that applies a truly flexible, wrappable, dyeable topcoat layer onto a thermoformed sheet, as opposed to other systems and methods that use a resin system to provide a moist or embedded dyeable sheet.

[0024] When the thermoformed sheet is impregnated with the above resin system, it performs differently than when a resin system is applied to the thermoformed sheet. When the paper sheet is moistened with the resin system, it provides excellent adhesion to the substrate and uniform dyeability. Having the resin system on the surface as provided by the present invention provides a variety of surface effects required for dyeing. In other words, applying the resin system locally allows for more creative dye patterns that cannot be achieved by the impregnation process.

[0025] In one non-limiting embodiment, the dyeable thermoformable sheet 130 is thermoformed or applied onto an underlying substrate 110 (FIG. 2). Non-limiting examples of the substrate 110 include edge finishes, buntings, wrap molds, furniture components, cabinet components, or finished cabinet doors. In these implementations, no additional sealer or topcoat is applied to the thermoformable sheet 130 prior to application of the dyeable topcoat layer 120.

[0026] In a non-limiting implementation of the first embodiment, the dyeable thermoformable sheet includes a wood grain design 132 (FIG. 5). In a non-limiting implementation of the second aspect, the method further includes generating a wood grain print on the thermofoil sheet using an ink selected from the group consisting of a solvent-reduced ink, a water-reduced ink, and a UV-curable ink prior to applying the dyeable topcoat layer. In some implementations, the method further includes applying a seal coat agent between generating the wood grain print and applying the dyeable topcoat layer.

[0027] Resin binder layer In some non-limiting embodiments, the resin binder layer (total coat weight) is in grams per square meter (gsm) of one layer of thermofoil sheet in an amount of 5 to 190 gsm, or any range of values ​​therebetween, such as 5 to 175 gsm, 5 to 160 gsm, 5 to 145 gsm, 5 to 130 gsm, 5 to 115 gsm, 5 to 100 gsm, 5 to 85 gsm, 5 to 70 gsm, 10 to 190 gsm, 10 to 175 gsm, 10 to 160 gsm, 10 to 145 gsm, 10 to 130 gsm, 10 to 115 gsm, 10 to 100 gsm, 10 to 85 gsm, 10 to 70 gsm, 15 to 190 gsm, m, 15~175gsm, 15~160gsm, 15~145gsm, 15~130gsm, 15~115gsm, 15~100gsm, 15~85gsm, 15~70gsm, 20~190gsm, 20~175gsm, 20~160gsm, 20~145gsm, 20~130gsm, 20~115gsm, 20~100gsm, 20~85gsm, 20~70gsm, 25~190gsm, 25~175gsm, 25~160gsm, 25~145gsm, 25~130gsm, 25~115gsm, 25~100gsm, 25~85gsm, and 25~70gsm, etc.

[0028] resin In some non-limiting embodiments, the resin is an energy curable resin. Non-limiting examples of energy curable resins include ultraviolet (UV) curable resins, electron beam (EB) curable resins, or conventional heat curable (non-UV / EB) resins. In these embodiments, the resin binder formulation includes a photoinitiator.

[0029] In certain non-limiting embodiments, the resin requires a catalyst for film formation (catalyst system). In other non-limiting embodiments, the resin forms a film without the need for additional catalysis (non-catalyzed systems). In these embodiments, the resin binder formulation does not require a catalyst. In some non-limiting embodiments, non-catalyzed systems form a film by air drying due to a relatively low (e.g., lower than room temperature) glass transition temperature (Tg). In other non-limiting implementations, non-catalyzed systems may use a solvent to reduce the Tg and allow the resin to form a film by evaporation.

[0030] In some non-limiting embodiments, the energy curable resin is selected from the group consisting of urethane acrylates, polyester acrylates, epoxy acrylates, acrylics, and combinations thereof. In other non-limiting embodiments, the energy curable resin is selected from the group consisting of epoxy acrylates, acrylics, and combinations thereof.

[0031] Epoxy acrylates are commercially available from manufacturers such as Sartomer, BASF, or Miller-Stephenson. Non-limiting examples of epoxy acrylates are described in more detail in the following patents and references, the entire contents of which are incorporated herein by reference: U.S. Patent No. 3,989,610; U.S. Patent No. 4,472,019; U.S. Patent No. 4,789,620; U.S. Patent No. 5,086,088 U.S. Patent No. 5,356,949; U.S. Patent No. 6,844,034; European Patent No. 1,295,900; and Chattopadhyay et al, “Thermal and mechanical properties of epoxy acrylate / methacrylates UV cured coatings”, Progress in Organic Coatings 54 (1), 2005,; Habib et al, “UV Curable Heat Resistant Epoxy Acrylate Coatings (UV-curable heat-resistant epoxy acrylate coating film),” Chemistry & Chemical Technology 4(3), 2010; and Konuray et al., “State of the Art in Dual-Curing Acrylate. "The Frontline of Dual-Cure Acrylate Systems," Polymers, 10, 2018.

[0032] Acrylics are commercially available from manufacturers such as Advanced Plastiform, Inc. Non-limiting examples of acrylics are described in more detail in the following patents, the contents of which are incorporated herein by reference in their entirety: U.S. Pat. No. 5,242,968; U.S. Pat. No. 5,686,186; U.S. Pat. No. 7,252,786; Chinese Patent No. 101044023; and German Patent No. 69725,422.

[0033] In some non-limiting embodiments, the resin binder formulation comprises 15-45 weight percent of resin (e.g., epoxy acrylates or acrylics) prior to curing, or any percentage range therebetween, such as 15-43%, 15-40%, 15-38%, 15-35%, 16-45%, 16-43%, 16-40%, 16-38%, 16-45 ... Includes 6~35%, 17~45%, 17~43%, 17~40%, 17~38%, 17~35%, 18~45%, 18~43%, 18~40%, 18~38%, 18~35%, 19~45%, 19~43%, 19~40%, 19~38%, 19~35%, 20~45%, 20~43%, 20~40%, 20~38%, or 20~35%.

[0034] In certain non-limiting implementations, the resin binder formulation, after curing, comprises 5-45 weight percent of resin (e.g., epoxy acrylates or acrylics), or any percentage range therebetween, such as, for example, 5-40%, 5-35%, 5-30%, 5-25%, 6-45%, 6-40%, 6-35%, 6-30%, 6-25%, 7-45%, 7-40%, 7-35%, 7-30%, 7-25%, 8-45%, 8-40%, 8-35%, 8-30%, 8-25%, 9-45%, 9-40%, 9-35%, 9-30%, 9-25%, 10-45%, 10-40%, 10-35%, 10-30%, or 10-25%, etc.

[0035] The coating weight of the resin binder is from 2 to 100 gsm, or any number of ranges therebetween, such as, for example, 2 to 95 gsm, 2 to 90 gsm, 2 to 85 gsm, 2 to 80 gsm, 2 to 75 gsm, 2 to 70 gsm, 2 to 65 gsm, 2 to 60 gsm, 2 to 55 gsm, and 2 to 50 gsm, per layer of resin binder on the thermofoil sheet.

[0036] In other non-limiting embodiments, the resinous binder formulation further includes a urea-formaldehyde resin, a melamine formaldehyde resin, or both.

[0037] Porous Material In some embodiments, the porosity agent comprises one or more multiple inorganics (eg, two, three, four, etc.) to allow for dyeing of the thermoformed sheet.

[0038] In non-limiting embodiments, the particle size of the porosity agent 150 is typically in the range of 0.4 μm to 80 μm, or any other number of ranges therebetween, such as 0.4 to 70 μm, 0.5 to 70 μm, 0.5 to 60 μm, 0.6 to 60 μm, 0.6 to 50 μm, 0.7 to 50 μm, 0.7 to 40 μm, 0.8 to 40 μm, 0.8 to 30 μm, 0.9 to 30 μm, 0.9 to 20 μm, 0.9 to 15 μm, 0.4 to 60 μm, 0.4 to 45 μm, 0.4 to 30 μm, or 0.4 to 15 μm.

[0039] In a non-limiting embodiment, the density of the porous material 150 (FIGS. 3 and 4) is typically 0.5 g / cm 3 ~4.5g / cm 3 or any other number range therebetween, for example, 0.5 to 4.2 g / cm 3 , 0.6~4.2g / cm 3 , 0.6-4.0g / cm 3 , 0.7~4.0g / cm 3 , 0.7~3.8g / cm 3 , 0.8~3.8g / cm 3 , 0.8~3.6g / cm 3 , 0.9~3.6g / cm 3 , 0.9~3.5g / cm 3 , 1~3.5g / cm 3 , 1~3.4g / cm 3 , 1.1~3.4g / cm 3 , 1.1~3.3g / cm 3 , 1.1~3.2g / cm 3 , 1.2~3.2g / cm 3 , 1.4~3.2g / cm 3 , 1.4~3.1g / cm 3 , 1.6~3.1g / cm 3 , 1.6~3.0g / cm 3 , 1.8~3.0g / cm 3 , or 1.8 to 2.9 g / cm 3 And so on.

[0040] Non-limiting examples of porosity agents 150 include calcium carbonate (e.g., precipitated calcium carbonate), crystalline silica (e.g., microcrystalline silica, silica, and silicate minerals), kaolin clay, talc, other minerals commonly used in the manufacture of paints and coatings, other agents that allow the stain to penetrate the resin binder layer 120 to impart porous properties to the cured resin binder surface, or combinations thereof. Silica includes untreated silica, treated silica, or both.

[0041] In some embodiments, at least one of the porosity agents 150 is selected from the group consisting of calcium carbonate, kaolin clay, silica, and talc. In other embodiments, at least one of the porosity agents 150 is selected from the group consisting of kaolin clay, silica, and talc. In yet other embodiments, the porosity agent 150 is selected from the group consisting of kaolin clay and talc.

[0042] In another embodiment, the porosity agent 150 is calcium carbonate. In one aspect, the calcium carbonate is ground (natural) calcium carbonate (GCC). In another aspect, the particle size of the calcium carbonate is between about 0.5 μm and about 500 μm, between about 0.5 μm and about 400 μm, between about 0.5 μm and about 300 μm, between about 0.5 μm and about 200 μm, between about 0.5 μm and about 100 μm, between about 0.5 μm and about 90 μm, between about 0.5 μm and about 80 μm, between about 0.5 μm and about 70 μm, between about 0.5 μm and about 60 μm, between about 0.5 μm and about 50 μm, between about 0.5 μm and about 40 μm, between about 0.5 μm and about 30 μm, between about 0.5 μm and about 20 μm, or between about 0.5 μm and about 10 μm. In one embodiment, the particle size of the calcium carbonate is between about 0.5 μm and about 100 μm, in another embodiment, the particle size of the calcium carbonate is between about 0.5 μm and about 50 μm.

[0043] In one embodiment, the porosity agent 150 is not silica. In certain aspects, silica may adversely affect the ability of the final surface to absorb staining agents. In certain preferred embodiments, the porosity agent 150 includes kaolin clay, silica, and talc in a ratio of about 3 to 2 to 1 by weight (i.e., a formulation including 600 grams of minerals includes about 300 grams of kaolin clay, about 200 grams of silica, and about 100 grams of talc.) In other preferred embodiments, the porosity agent 150 includes kaolin clay, silica, and talc in a ratio of about 2.5-3.5 to 1.5-2.5 to 1 by weight, or any ratio range therebetween, such as 2.6-3.4 to 1.6-2.4 to 1, 2.7-3.3 to 1.7-2.3 to 1, 2.8-3.2 to 1.8-2.2 to 1, 2.9-3.1 to 1.9-2.1 to 1, etc.

[0044] In a non-limiting embodiment, a typical amount of the one or more porosity agents 150 per layer of the resin binder is at least 2 gsm of thermofoil sheet, e.g., at least 2.5 gsm, at least 3 gsm, at least 3.5 gsm, or 4 gsm of thermofoil sheet. In other non-limiting embodiments, a typical amount of the one or more porosity agents 150 per layer of the resin binder is, in grams per square meter (gsm) of thermofoil sheet, from 2 to 100 gsm, or any number of ranges therebetween, e.g., from 3 to 70 gsm, from 3 to 65 gsm, from 3 to 60 gsm, from 3 to 55 gsm, from 3 to 50 gsm, from 3 to 45 gsm, from 3 to 40 gsm, from 3 to 35 gsm, from 3 to 30 gsm, from 3 to 25 gsm, from 3 to 20 gsm, from 3.5 to 70 gsm. m, 3.5~65gsm, 3.5~60gsm, 3.5~55gsm, 3.5~50gsm, 3.5~45gsm, 3.5~40gsm, 3.5~35gsm, 3.5~30gsm, 3.5~25gsm, 3.5~20gsm, 4~70gsm, 4~65gsm, 4~60gsm, 4~55gsm, 4~50gsm, 4~45gsm, 4~40gsm, 4~35gsm, 4~30gsm, 4~25gsm, or 4~20gsm, etc.

[0045] In non-limiting embodiments, the resin binder formulation 124 includes at least 35 weight percent porosity agent prior to curing, e.g., at least 40 weight percent, at least 45 weight percent, at least 50 weight percent, at least 55 weight percent, or at least 60 weight percent of porosity agent.

[0046] In other non-limiting embodiments, the resin binder formulation 124 contains 30%-70% porosity agent prior to curing, or any percentage range therebetween, such as between 30%-68%, 35-68%, 35-65%, 36-65%, 36-63%, 37-63%, 37-60%, 38-60%, or 40-60% porosity agent.

[0047] The pigment volume concentration (PVC) is very important for the overall system to have an absorbent function. In a non-limiting embodiment, the pigment volume concentration (PVC) is 25% to 80%, or any percentage range therebetween, such as 25% to 70%, 25% to 65%, 25% to 60%, 25% to 55%, 30% to 80%, 30% to 75%, 30% to 70%, 30% to 65%, 30% to 60%, 30% to 55%, 35% to 80%, The percentage range between is 35%-75%, 35%-70%, 35%-65%, 35%-60%, 35%-55%, 40%-80%, 40%-75%, 40%-70%, 40%-65%, 40%-60%, 45%-80%, 45%-75%, 45%-70%, 48%-80%, 48%-75%, or 48%-70%, etc.

[0048] Additives In some embodiments, the resin binder further comprises an additive, wherein the at least one additive is selected from the group consisting of a degassing agent, a dispersing agent, a wetting agent, a photoinitiator, a catalyst, and combinations thereof.

[0049] In some embodiments, the resin binder formulation, prior to curing, includes 0.01 to 1 weight percent of the degassing agent, or any percentage range therebetween, such as, for example, 0.01 to 0.9 weight percent, 0.01 to 0.8 weight percent, 0.01 to 0.7 weight percent, 0.01 to 0.6 weight percent, 0.01 to 0.5 weight percent, 0.015 to 1 weight percent, 0.015 to 0.9 weight percent, 0.015 to 0.8 weight percent, 0.015 to 0.7 weight percent, 0.015 to 0.6 weight percent, 0.015 to 0.5 weight percent, 0.02 to 1 weight percent, 0.02 to 0.9 weight percent, 0.02 to 0.8 weight percent, 0.02 to 0.7 weight percent, 0.02 to 0.6 weight percent, or 0.02 to 0.5 weight percent.

[0050] In some embodiments, the resinous binder formulation, prior to curing, includes 0.01 to 1 weight percent of a dispersant, or any percentage range therebetween, such as, for example, 0.01 to 0.9 weight percent, 0.01 to 0.8 weight percent, 0.01 to 0.7 weight percent, 0.01 to 0.6 weight percent, 0.01 to 0.5 weight percent, 0.015 to 1 weight percent, 0.015 to 0.9 weight percent, 0.015 to 0.8 weight percent, 0.015 to 0.7 weight percent, 0.015 to 0.6 weight percent, 0.015 to 0.5 weight percent, 0.02 to 1 weight percent, 0.02 to 0.9 weight percent, 0.02 to 0.8 weight percent, 0.02 to 0.7 weight percent, 0.02 to 0.6 weight percent, or 0.02 to 0.5 weight percent.

[0051] In some implementations, the resin is ultraviolet (UV) curable, electron beam (EB) curable, or both, and the resin binder formulation, prior to curing, includes 0.4-5 weight percent of a photoinitiator, or any percentage range, such as, for example, 0.4-4.5 weight percent, 0.4-4 weight percent, 0.5-5 weight percent, 0.5-4.5 weight percent, 0.5-4 weight percent, 0.8-5 weight percent, 0.8-4.5 weight percent, 0.8-4 weight percent, 1-5 weight percent, 1-4.5 weight percent, 1-4 weight percent, 1.5-5 weight percent, 1.5-4.5 weight percent, 1.5-4 weight percent, 2-5 weight percent, 2-4.5 weight percent, or 2-4 weight percent of the photoinitiator.

[0052] In other embodiments, the resinous binder formulation, prior to curing, includes 0.4-5 weight percent of catalyst, or any percentage range therebetween, such as, for example, 0.4-4.5 weight percent, 0.4-4 weight percent, 0.5-5 weight percent, 0.5-4.5 weight percent, 0.5-4 weight percent, 0.8-5 weight percent, 0.8-4.5 weight percent, 0.8-4 weight percent, 1-5 weight percent, 1-4.5 weight percent, 1-4 weight percent, 1.5-5 weight percent, 1.5-4.5 weight percent, 1.5-4 weight percent, 2-5 weight percent, 2-4.5 weight percent, or 2-4 weight percent.

[0053] In some non-limiting embodiments, the resinous binder layer is 90-100% cured, or any percentage range therebetween, such as 90-99%, 90-98%, 90-97%, 90-96%, 92-100%, 92-99%, 92-98%, 92-97%, 92-96%, 94-100%, 94-99%, 94-98%, 94-97%, 94-96%, 95-100%, 95-99%, 95-98%, 95-97%, 95-96%, 100% cured.

[0054] In some non-limiting embodiments, two or more dyeable topcoat layers are applied to the thermofoil sheet. In these embodiments, the first dyeable topcoat layer is the top layer, and the amount of porosity agent is greater in the first dyeable topcoat layer than in the second dyeable topcoat layer. In some non-limiting implementations, a printing cylinder is used to apply a pattern to the first dyeable topcoat layer to create a pattern on the final surface, but the second dyeable topcoat layer is not.

[0055] In some non-limiting embodiments, the resin binder formulation of the first dyeable topcoat layer includes about 50 weight percent of the porosity agent prior to curing. In other non-limiting implementations, the resin binder formulation of the first dyeable topcoat layer includes 40-60 weight percent of the first porosity agent prior to curing, or any percentage value therebetween, such as, for example, 41-59%, 42-58%, 43-57%, 44-56%, or 45-55%.

[0056] In some non-limiting implementations, the resinous binder formulation of the second dyeable topcoat layer, prior to curing, comprises 15-40 weight percent of the second porosity agent, or any percentage value therebetween, such as, for example, 15-35%, 15-30%, 15-25%, 20-40%, 20-35%, 20-30%, 25-40%, 25-35%, 25-30%, or 30-40%.

[0057] Non-limiting examples of the first and / or second porosity agents 150 include calcium carbonate (e.g., precipitated calcium carbonate), crystalline silica (e.g., microcrystalline silica, silica, and silicate minerals), kaolin clay, talc, other minerals commonly used in the manufacture of paints and coatings, another agent that allows the stain to penetrate the resin binder layer 120 to impart porous properties to the cured resin binder surface, or combinations thereof. Silica includes untreated silica, treated silica, or both.

[0058] In some embodiments, at least one of the first and / or second porosity agents 150 is selected from the group consisting of calcium carbonate, kaolin clay, silica, and talc. In other embodiments, at least one of the first and / or second porosity agents 150 is selected from the group consisting of kaolin clay, silica, and talc. In yet other embodiments, the first and / or second porosity agents 150 are selected from the group consisting of kaolin clay and talc.

[0059] In some non-limiting embodiments, a stain is applied to the dyeable thermoformed sheet. In further non-limiting embodiments, one or more additional coatings are applied after the stain. Non-limiting examples of additional coatings applied after the stain include resins, clear sealers, etc. (Once a sealer is applied over the dyeable topcoat layer, the thermoformed sheet cannot be dyed).

[0060] The present invention is illustrated by the following figures and claims, which should not be construed as further limiting. The contents of all references, patents, and published patent applications cited throughout this application, as well as the figures, are hereby incorporated by reference in their entirety for all purposes.

[0061] Working Example Figures 1-4 show a non-limiting example of a dyeable thermofoil product 100. The exemplary dyeable thermofoil product 100 includes a thermofoil sheet 130 and one or more dyeable resin binder layers 120 applied to a surface of the thermofoil sheet 130. In an embodiment, there is one dyeable resin binder layer 120 (Figures 1 and 2). In another non-limiting embodiment, there are two dyeable resin binder layers (Figures 3 and 4). In yet another non-limiting embodiment, there are three or more dyeable resin binder layers (not shown).

[0062] In some non-limiting embodiments, the dyeable thermofoil product 100 further includes a substrate 110 (FIGS. 2 and 4). A thermofoil sheet 130 is applied onto the substrate 110, for example, by thermoforming or via a hot melt adhesive. In many non-limiting embodiments, the thermofoil sheet 130 is a polyvinyl chloride (PVC) sheet, an acrylonitrile butadiene styrene (ABS) sheet, a polyethylene terephthalate (PET) sheet, or a cellulose paper.

[0063] A "complete" thermofoil product available on the market is intended to be a finished product that, prior to disclosure by applicant, was not designed to retain a dye and / or clear finish. However, the present dyeable thermofoil product has an open, porous surface that allows it to retain a dye and / or clear finish. Without wishing to be bound by any particular theory, the open, porous surface is created by applying a resin binder layer 120 containing inorganics and additives to the thermofoil during the manufacturing process. Furthermore, the porous surface is physically hardened, allowing the final layer to be sanded off without affecting the underlying print.

[0064] The thermofoil sheet 130 is adhered to the substrate 110 by a hot melt adhesive applied to the backside of the foil, or by actually applying an adhesive to the backside and / or portions of the foil and attaching it to the substrate. A layer of inorganic resin binder can be applied to the surface of the thermofoil, and then the foil can be wrapped around the surface of a pre-formed and pre-cut contour. Dyeable thermofoil can be applied to the substrate in both hot press and cold press processes.

[0065] 5-8 show non-limiting examples of dyeable resin binder layer 120. In some non-limiting embodiments, dyeable resin binder layer 120 includes only one porosity agent 150 (150, 151 in Figs. 5 and 7). In other non-limiting embodiments, dyeable resin binder layer 120 includes two porosity agents 150 (150, 151 and 150, 152 in Fig. 6 and the first dyeable topcoat layer in Fig. 8). In further non-limiting embodiments, dyeable resin binder layer 120 includes three or more porosity agents 150 (not shown). In some non-limiting embodiments, resin binder layer 120 is the final, top layer. In other non-limiting embodiments, resin binder layer 120 includes two or more layers.

[0066] In some embodiments, the dyeable thermofoil product 100 includes a dyeable resin binder layer 120 that is formed by applying an energy curable resin 124 that includes at least one porosity agent 150 to a surface of a thermofoil sheet.

[0067] The dyeable topcoat layer 120 contains enough porosity 150 to absorb both the energy curable resin 124 and subsequent stains applied after curing. The thermoformable sheet 130 is a polyvinyl chloride (PVC) sheet, an acrylonitrile butadiene styrene (ABS) sheet, a polyethylene terephthalate (PET) sheet, or a cellulose paper. PVC and ABS sheets are plastics and therefore do not absorb stains. Cellulose paper absorbs stains, but not uniformly, resulting in distorted images printed on the paper surface. Without wishing to be bound by a particular theory, it is believed that when one or more porosity agents 150 (inorganic additives) are added to the point of reaching CPVC, the one or more porosity agents 150 are not fully wetted by the resin. As a result, the surface remains "open" even after application of the dyeable resin binder layer 120, and is therefore able to absorb stains. The amount and location of absorption can be controlled by applying a dyeable topcoat layer 120 containing a large amount of porosity agent 150 (e.g., based on printing one of the dyeable topcoats), allowing for highly reproducible, real substrates to be mass-produced for industry.

[0068] In some non-limiting embodiments, a porosity-free sealer is applied underneath the dyeable topcoat layer. Because the substrate is sealed, the dye cannot get past the sealer to the thermofoil sheet 130. In a further non-limiting implementation, the dyeable topcoat layer 120 is printed as a pattern onto the thermofoil sheet 130.

[0069] In creating a dyeable thermofoil product 100, the porosity agent 150 can be contributed in a variety of different ways. The dye is dispersed throughout the resin binder layer 120, and the dye-impregnated porosity agent 150 provides a path for the dye to eventually reach the sheet 130, which impregnates, disperses, and holds the dye. The porosity agent 150 itself then absorbs the dye, allowing more color to be added throughout the resin binder layer 120. Experimentation has shown that deep and uniform dye penetration often occurs when the pigment volume concentration of the porosity agent 150 relative to the energy curable resin 124 reaches or exceeds the critical pigment volume concentration of the energy curable resin 124. The critical pigment volume concentration of the thermosetting polymer resin 124 often depends on the physical and chemical properties of the porosity agent 150 and how these properties interact with the energy curable resin 124. Thus, it is understood that the critical pigment volume concentration of the energy curable resin 124 varies between different porosity agents 150 .

[0070] 9-10 show non-limiting examples of producing a dyeable thermofoil product. In some non-limiting embodiments, the method includes applying a dyeable topcoat layer containing a porosity agent 150 (960) to a surface of a thermofoil sheet, followed by curing the thermofoil sheet (970).

[0071] In other non-limiting embodiments, the process begins with an extrusion process, for example, extruding PVC or ABS into a thin continuous sheet (910). In some non-limiting implementations, the sheet width is between 10 mm and 2500 mm. The sheet is then wound into a roll for secondary processing (920). Once the PVC or ABS is successfully extruded and wound, the roll is machined and unrolled (930) and pre-treated for adhesion and uniform color (940). Ink is then applied to the sheet (950). In certain non-limiting implementations, the ink is applied via gravure printing using UV-curable, solvent-based or water-based inks, or in other non-limiting implementations, the ink is applied via high-speed digital printing using UV-curable inks. After printing the wood grain or synthetic wood grain print look, the product is coated with one or more topcoats (960). In certain non-limiting implementations, UV-curable or air-curable topcoats are used. The sheet is then cured (970). Once all layers of the foil are complete, the product can be embossed to give it a wood grain look or rewound into a roll and cut to size to customer specifications.

[0072] In some non-limiting embodiments, the processable sheet is processed onto a substrate prior to application of a dyeable topcoat layer. See, for example, FIG.

Claims

1. Thermofoil sheet, and a dyeable topcoat layer applied to said thermofoil sheet; Including, the dyeable topcoat layer comprises a resin binder formulation comprising a resin, an additive, and a porosity agent; wherein the porosity agent is at least 35 weight percent of the resin binder formulation prior to curing, and / or the porosity agent is present in an amount of at least 3 grams per square meter (gsm) of the thermofoil sheet; wherein both the thermofoil sheet and the dyeable topcoat layer are flexible and easy to wrap so that they can be wrapped around a mold, a door center panel, etc.; wherein the thermofoil sheet comprises a polyvinyl chloride (PVC) sheet, an acrylonitrile butadiene styrene (ABS) sheet, a polyethylene terephthalate (PET) sheet, or a cellulose paper; Dyeable thermoformable sheet.

2. applying a dyeable topcoat layer to the thermofoil sheet prior to curing, the topcoat layer comprising a resin binder formulation comprising a resin, an additive, and at least 35 weight percent of a porosity agent; and / or the porosity agent is applied to the thermofoil sheet in an amount of at least 3 grams per square meter (gsm); wherein both the thermofoil sheet and the dyeable topcoat layer are flexible and easy to wrap so that they can be wrapped around a mold, a door center panel, etc.; wherein the thermofoil sheet comprises a polyvinyl chloride (PVC) sheet, an acrylonitrile butadiene styrene (ABS) sheet, or a polyethylene terephthalate (PET) sheet; A method for producing dyeable thermoformed sheet.

3. 10. The dyeable thermoformable sheet of claim 1, wherein the gsm of the thermofoil sheet of the porosity agent is at least 3.5 gsm.

4. 10. The dyeable thermoformable sheet of claim 1, wherein said resinous binder formulation, prior to curing, comprises from 35 to 65 weight percent of said porosity agent.

5. 10. The dyeable thermoformable sheet of claim 1, wherein the grams per square meter (gsm) of the porosity agent per dyeable topcoat layer is from 3 to 60 gsm of the Thermofoil sheet.

6. The porosity agent includes an inorganic material capable of dyeing the thermoformed sheet, and the inorganic material has a density of 1.8 to 2.9 g / cm ３ 2. The dyeable thermoformable sheet of claim 1 having a density of

7. 7. The dyeable thermoformable sheet of claim 6, wherein said inorganic matter has a particle size of 0.9 to 15 microns.

8. 7. The dyeable thermoformable sheet of claim 6, wherein the at least one mineral is selected from the group consisting of calcium carbonate, kaolin clay, silica, and talc.

9. 9. The dyeable thermoformable sheet of claim 8, wherein the minerals consist of kaolin clay, silica, and talc in a weight ratio of about 3:2:

1.

10. 9. The dyeable thermoformable sheet of claim 8, wherein the mineral is calcium carbonate having a particle size of about 0.5 microns to about 100 microns.

11. 10. The dyeable thermoformable sheet of claim 1, wherein said thermofoil sheet includes a wood grain design.

12. 10. The dyeable thermoformable sheet of claim 1, wherein the porosity agent comprises calcium carbonate and talc, and the gsm of the porosity agent of the Thermofoil sheet is at least 4 gsm.

13. 10. The dyeable thermoformable sheet of claim 1, wherein the resin is selected from the group consisting of urethane acrylates, polyester acrylates, epoxy acrylates, acrylics, and combinations thereof.

14. 10. The dyeable thermoformable sheet of claim 1, wherein the resinous binder formulation comprises 15 to 45 weight percent of the resin before curing, or the resinous binder formulation comprises 5 to 45 weight percent of the resin after curing.

15. 2. The dyeable thermoformable sheet of claim 1, wherein the resinous binder formulation comprises urea-formaldehyde resins, melamine formaldehyde resins, or both, and the resinous binder portion of the coat weight per dyeable topcoat layer is in the amount of 5 to 190 gsm of the Thermofoil sheet.

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