Manufacturing of composite films and coating equipment

Abstract

The present invention relates to a method for producing a composite film having a polyurethane-based reactive hot melt layer using a coating installation, the method comprising the steps of a) optionally applying a primer onto a support material, b) applying a polyurethane-based reactive hot melt layer onto the primer or directly onto the support material, c) applying a lacquer layer onto the polyurethane-based reactive hot melt layer to produce a composite film on the support material, d) optionally embossing the composite film on the support material, and e) separating the composite film from the support material. The present invention further relates to a composite film obtainable by such a method and its uses.

Description

Technical Field

[0001] The present invention relates to a method for producing a composite film having a polyurethane-based reactive hot melt layer using a coating apparatus, and to a composite film obtained by such a method and its use.

Background Art

[0002] Plastic films produced on a large scale are usually produced by casting, calendering or extrusion, especially blow molding. The materials used in this case can vary. Examples are cellulose acetate, polyvinyl chloride or polyethylene. The plastic film may be produced in one layer or in multiple layers (laminated film). The mechanical devices used in the production, such as extruders, are configured for mass production and thus have a relatively expensive and complex design.

[0003] The trend towards customization often requires small batch sizes and minimal setup times in combination with the possibility of digital printing. To change the decoration or color, the conventional methods require long setup times and cause large losses of materials for the necessary make-up runs. Also, films with low thermal sensitivity and / or suitable for use in cladding are required.

[0004] In particular, considering the lack of such devices, there is a need for a method that avoids the procurement of such devices and related drawbacks and provides an economic form of deformation even for relatively small production volumes.

Summary of the Invention

Problems to be Solved by the Invention

[0005] Therefore, an object of the present invention is to provide such a method and a film produced thereby. ]>

Means for Solving the Problems

[0006] The objective is to achieve a composite film having a polyurethane-based reactive hot-melt layer by manufacturing it using a coating apparatus, and this method is a) A step of optionally applying a primer onto the support material, b) The step of applying a polyurethane-based reactive hot melt layer onto the primer or directly onto the support material, c) A step of applying a lacquer layer onto a polyurethane-based reactive hot melt layer in order to manufacture a composite film on a support material, d) A step of optionally embossing a composite film on a support material, e) A step of separating the composite film from the support material. Includes.

[0007] The objective is similarly achieved by a composite film (laminated film) that can be obtained by the method according to the present invention. The composite film according to the present invention is suitable, for example, as a cladding or lining material. Therefore, a further aspect of the present invention is the use of the composite film according to the present invention for cladding or lining.

[0008] Surprisingly, it has been found that by using reactive hot melts, composite films can be obtained that can be manufactured well and easily using coating equipment. Thermoplastic films exhibit certain thermal sensitivity during further processing, depending on their chemical basis and orientation. In particular, during coating or adhesive bonding processes such as hot coating, when the film is exposed to heat (hot melt, lamp, drying, etc.) and / or mechanical influences (winding process, roller compression, etc.), this can result in folding and dimensional changes.

[0009] At the same time, films are often used in cladding processes where maximum flexibility is required. Thermoplastic films with improved heat sensitivity often have low flexibility. Surprisingly, it has been found that these drawbacks can be avoided or at least reduced by the composite film according to the present invention, which has a reactive hot melt. This eliminates the need to handle highly heat-sensitive films. The manufactured composite film is not thermoplastic, but nevertheless exhibits maximum flexibility.

[0010] In step a) of the method according to the present invention, a primer is optionally applied to the support material. As a result of applying the primer to the support material, a primer layer is formed on the support material. This layer may consist of one or more layers. Therefore, the priming step a) itself may be performed in one or more steps.

[0011] However, such priming is not required. However, it is advantageous to provide a primer. Priming can be carried out by methods known to those skilled in the art. In this case, means known to those skilled in the art of coating apparatus, such as an applicator roller or slit die of a coating apparatus, are suitable. Therefore, a further aspect of the present invention is a method according to the present invention in which the application of the primer is carried out using an applicator roller or slit die of a coating apparatus.

[0012] If a primer is provided, it can be used as a separating agent. This allows for particularly direct separation of the composite film in step e).

[0013] The primer layer is more preferably a colored layer or an opacity layer. When multiple primer layers are obtained by performing priming in multiple stages, it is preferable that at least one layer of the primer is a layer that produces such a colored layer or opacity. Thus, a further aspect of the present invention is that the application of the primer forms at least one colored layer or opacity layer. The primer is preferably a lacquer, particularly a UV-curable or aqueous lacquer, or both UV-curable and aqueous lacquer. Opacity is generally achieved by titanium dioxide. The primer can be optimized in its function as a base for decoration for various coloring methods, for example, with respect to ideal surface tension for pigment adhesion and wetting by printing inks.

[0014] However, the primer may also be configured to be semi-transparent. Similarly, if a composite film is used for cladding, for example, the primer can form the outer surface, and as a result the lacquer layer of step c) faces the surface of the object being cladded.

[0015] Therefore, it is equally possible for the primer to contain an embossed structure. This can be produced, for example, by printing a corresponding negative structure onto the surface of a support material with the help of digital 3D printing, and then this structure is transferred onto the primer by coating with the primer. Decorations to conform to the embossed structure may be further printed after step b) and before step c). This conformance can be performed, for example, by data synchronization ("digital synchronized 3D texture"). Generally, this type of embossing suitable for decoration is called "synchropore," or the term "EIR" (embossed in register) is also used. The term "true texture" is also used in the prior art.

[0016] If priming is performed, a reactivatable adhesive layer may be applied before its coating. Such an adhesive layer can then be applied to the support surface. In this case, the adhesive layer may also be used as a release agent, taking into consideration the release properties of the composite film.

[0017] Therefore, it is even more preferable to provide a reactivatable adhesive layer on the surface of the support material before applying the primer, or to use this adhesive layer as a primer. This is particularly preferable when the decorative layer is applied before step b).

[0018] The adhesive layer may be applied in one or more stages and therefore may itself consist of one or more layers. Similarly, the adhesive layer itself can be used as a primer. The adhesive layer may be a heat-reactivating dispersion, such as a polyurethane dispersion. Conventional thermoplastic hot-melt adhesives that are heat-reactivating in the lining process are preferably used. These may be, for example, hot-melt adhesives based on ethylene-vinyl acetate (EVA) copolymer, atactic polyalphaolefin (APAO), metallocene polyolefin (mPO), polyamide, or polyester. Reactive hot-melt adhesives based on polyurethane or polyolefin may also be used, which are heat-reactivating within a specified time window or protected from air moisture by a supporting material. Further alternatives are encapsulating adhesive systems or two-component systems that are activated by heat, pressure, or the application of further components in the lining process.

[0019] A decorative layer can be applied before step b) of the method according to the present invention. This can be manufactured, for example, by direct printing or digital printing, preferably by digital printing.

[0020] In step b), a polyurethane-based reactive hot melt layer is applied onto the primer or directly onto the support material. Thus, it is in direct contact with the surface of the primer layer or the support material (substrate). However, it is also possible to produce one or more additional layers by intermediate steps, with the result that this layer or these layers are located between the substrate surface and the reactive hot melt layer. For example, a decorative layer can be provided, for example, located between the reactive hot melt layer and the primer.

[0021] The reactive hot melt layer may be applied in one coat or multiple coats. Thus, the entire reactive hot melt layer may be a single layer or a multi-layer.

[0022] The reactive polyurethane hot melt is preferably produced from an isocyanate-reactive polymer and a polyisocyanate, and optionally additives.

[0023] The reactive polyurethane hot melt is solid at room temperature and is a product that does not contain emissions and solvents. The temperature at which the reactive hot melt is applied is in the range of 60°C to 150°C, preferably 100°C to 140°C, and the product has a Brookfield viscosity in the range of 1000 mPas to 30000 mPas, preferably 4000 mPas to 10000 mPas at 120°C. The density of the reactive hot melt is usually 1.1 g / m 2 is. Advantageously, the reactive hot melt layer itself has a certain residual elasticity in the cured state. In addition to physical curing, curing is carried out at least partially, particularly exclusively, by moisture curing, especially using air moisture. Complete curing may take several days. Thus, the reactive hot melt is applied in a high-temperature liquid state, and it is not necessary to perform complete curing before applying the lacquer layer.

[0024] Preferred isocyanate-reactive polymers are mainly linear polyesters, although branched polyesters are also possible, and in particular polyethylene glycols and polypropylene glycols which are bifunctional, although trifunctional ones are also possible, polytetrahydrofuran and polyamides and mixtures thereof. In this case, the corresponding copolymers, especially block copolymers, can also be used.

[0025] Particularly preferred are polyester polyols, which may be liquid, glassy amorphous or crystalline and have a number average molecular weight of from 400 to 25,000 g / mol, in particular from 1000 to 10,000 g / mol, particularly preferably from 2000 to 6000 g / mol. Such particularly suitable polyester polyols are available, for example, as commercial products under the name Dynacoll® from Degussa AG. Further suitable polyester polyols are polycaprolactone polyesters, polycarbonate polyesters and polyester polyols based on fatty acids.

[0026] Further preferred isocyanate-reactive polymers are mainly linear or slightly branched polyalkylene oxides, in particular polyethylene oxide, polypropylene oxide or polytetrahydrofuran (polyoxytetramethylene oxide) having a number average molecular weight of from 250 to 12,000 g / mol, preferably from 500 to 4000 g / mol.

[0027] The polyisocyanate is preferably a substance or a mixture of substances selected from aromatic, aliphatic or cycloaliphatic polyisocyanates having an isocyanate functionality of from 1 to 4, preferably from 1.8 to 2.2, particularly preferably having an isocyanate functionality of 2.

[0028] Polyisocyanates with a molecular weight < 500 are particularly preferably substances or mixtures of substances from the following list: methylenediphenyl diisocyanate (MDI), especially 4,4'-methylenediphenyl diisocyanate and 2,4'-methylenediphenyl diisocyanate, and mixtures of different methylenediphenyl diisocyanates; hydrogenated 4,4'-MDI bis(4-isocyanatocyclohexyl)methane and hydrogenated 2,4'-MDI tetramethylxylylene diisocyanate (TMXDI); xylylene diisocyanate (XDI); 1,5-naphthalene diisocyanate (NDI); toluene diisocyanate (TDI), especially 2,4-toluene diisocyanate, and TDI-uretdione, especially the dimer 1-methyl-2,4-phenylenediisocyanate (TDI-U) and TDI-urea; 1-isocyanate-3 -Isocyanatomethyl-3,5,5-trimethylcyclohexane (IPDI) and its isomers and derivatives, particularly dimers, trimers and polymers, as well as IPDI-isocyanurate (IPDI-T); 3,3'-dimethylbiphenyl-4,4'-diisocyanate (TODI); 3,3'-diisocyanato-4,4'-dimethyl-N,N'-diphenylurea (TDIH); hexamethylene-1,6-diisocyanate (HDI) and methylene-bis-(4-isocyanatocyclohexane) (H 12 MDI).

[0029] Preferably, a light-resistant aliphatic polyisocyanate is used. Isocyanate-terminated prepolymers having a low residual monomer content are preferably used as polyisocyanates, especially when aliphatic isocyanate-based prepolymers are used. Assuming low monomer content, i.e., their residual monomer content is 0.5% by weight or less, preferably less than 0.3% by weight, and particularly preferably less than 0.1% by weight. In particular, polyether polyols, preferably polypropylene glycol, and polyester polyols and polyisocyanates, especially methylenediphenyl diisocyanate, toluene diisocyanate, hexane diisocyanate, 3-isocyanatomethyl-3,5,5-trimethylcyclohexyl isocyanate (IPDI), hexamethylene-1,6-diisocyanate (HDI) and / or H 12 Reaction products with MDI, as well as derivatives of these isocyanates, are suitable. In this case, prepolymers based on aliphatic isocyanates such as HDI and IPDI are particularly preferred.

[0030] Such low-monomer isocyanate-terminated prepolymers are produced by reacting a polyether polyol with an excess of polyisocyanate. After the reaction, any remaining monomeric isocyanate is optionally removed by thin-film evaporator.

[0031] Reactive polyurethane hot melt may also be produced by a two-step process according to patent specification EP1831277B2. For this purpose, an isocyanate reactive polymer is reacted in a first step with a quasi-stoichiometric molar amount of polyisocyanate having a molecular weight <500 g / mol, and then in a second step, the prepolymer from the first step is reacted in a molar excess with the isocyanate-terminated prepolymer.

[0032] In one advantageous procedure, to produce thermoplastic polyurethane, in a first method step, water is removed from the isocyanate-reactive polymer or mixture of isocyanate-reactive polymers at 120°C under vacuum. This is then reacted with polyisocyanate at 80-140°C, preferably 100-120°C.

[0033] The reactions in step 1 and / or 2 of the method are preferably carried out at a temperature in the range of 80 to 140°C, particularly 100 to 120°C.

[0034] Preferably, the reactive polyurethane composition produced in this manner is then placed in a water vapor impermeable container.

[0035] According to International Publication No. 2012 / 084823A1, reactive polyurethane hot melts may also contain abrasion-resistant fillers if it is necessary to increase abrasion resistance during use, as is often the case in the flooring sector. Thus, the hot melt may contain an inorganic filler component, the filler component containing particles of at least one filler having a Mohs hardness of at least 6, preferably at least 7. The particles of at least one filler preferably have a nanoparticle range (<1 μm) or an average particle size in the range of 3.5 μm to 56 μm. The at least one filler may be, for example, a metal oxide, silicon dioxide, metal carbide, silicon carbide, metal nitride, silicon nitride, or boron nitride. Suitable materials are corundum, emery, spinel, and / or zirconium oxide.

[0036] According to International Publication No. 2006 / 106143A1, reactive hot melts may also consist of hot melts that cure with both moisture and UV light.

[0037] In particular, reactive polyurethane compositions may also contain auxiliary agents, especially fillers, non-reactive polymers, tackifying resins, waxes, plasticizers, additives, light stabilizers, flow regulators, accelerators, adhesion promoters, pigments, catalysts, stabilizers, and / or solvents.

[0038] The non-reactive polymer may preferably be a polyolefin, polyacrylate, or a polymer or polyacrylate based on ethylene and vinyl acetate having a vinyl acetate content of 0 to 80% by weight, preferably 0.1 to 801% by weight, or a mixture thereof.

[0039] The reactive polyurethane composition produced in this manner preferably has a viscosity of 2,000 mPas to 100,000 mPas at 120°C, and more preferably 5,000 to 50,000 mPas at 120°C.

[0040] In addition to reactive polyurethane hot melt, polyolefin-based reactive hot melt may also be used. The latter hardens through a reaction between silane groups and moisture in the air.

[0041] Preferably, the reactive hot melt layer is a moisture-curing layer. More preferably, it is a reactive polyurethane hot melt (PUR-SK), which can be obtained from an isocyanate-reactive polymer and a polyisocyanate, and optionally from additives. In particular, light-resistant PUR-SK as described above is preferred.

[0042] As described above, the reactive hot melt may contain additives, such as fillers, particularly wear-resistant fillers. The inorganic filler component preferably comprises a proportion ranging from 5% to 60% by weight, based on the total weight of the reactive hot melt. More preferably, this proportion is in the range of 10% to 50% by weight, and even more preferably in the range of 15% to 30% by weight.

[0043] Preferably, the reactive hot melt layer has a thickness in the range of 20 μm to 150 μm. The reactive hot melt layer can be applied by methods known to those skilled in the art. Means of coating apparatus suitable for producing the reactive hot melt layer are known. Preferably, the reactive hot melt layer is applied using an applicator roller with or without a smoothing roller, or a slit die with or without a roll bar of a coating apparatus.

[0044] In step c) of the method according to the present invention, a lacquer layer is applied. By applying a lacquer layer on a polyurethane-based reactive hot melt layer, a composite film can be manufactured on a support material. The lacquer layer may be applied in one or more steps. Therefore, a single-layer or multi-layer structure of the lacquer layer is possible. However, preferably, the lacquer layer is applied as a single coat. In particular, it is preferable that the hot melt layer and the lacquer layer each be applied as a single coat.

[0045] Preferably, the lacquer layer has a thickness of 5 μm to 25 μm. The lacquer possesses the necessary flexibility for the roll material. It can significantly determine the gloss level of the composite film. This can be optimized for physical matte (excimer) finishes, including explicit high-gloss properties (flow properties, compatibility with inert calendering (ICC)). Simultaneously, embossing of the lacquer layer or the entire composite film can be performed using ICC technology.

[0046] Lacquers can be adapted to have chemical and physical properties that are appropriate for the application area of ​​the composite film (e.g., scratch resistance, outdoor weather resistance). Such lacquers are known in the prior art.

[0047] The lacquer is preferably a lacquer that can be crosslinked by electron beams or UV rays.

[0048] In this case, any compound containing one or more functional groups that can be polymerized by electron beams and / or UV rays can be used as the polymerizable component by irradiation. Preferably, a compound having an olefinic unsaturated functional group is used in this case.

[0049] Examples of such compounds include vinyl ethers of styrene, 1-methylstyrene, vinyl acetate, vinyl chloride, conjugated dienes such as butadiene and isoprene, and C1-C20 alkanols, as well as aryl nitriles, vinyl caprolactam, n-vinylformamide, C1-C4 acrylates and methyl (meth)acrylates, ethyl (meth)acrylate, n-propyl (meth)acrylate, and isobornyl acrylate (IBOA). Highly functional group components such as trimethylol triacrylate (TMTPA), ethoxylated trimethylol triacrylate, propoxylated glycerol diacrylate, butanediol diacrylate (BDDA), hexanediol diarylate (HDDA), tripropylene glycol diacrylate (TPGDA), dipropylene glycol diacrylate (DPGDA), pentaerythritol triacrylate (PETIA), and pentaerythritol tetraacrylate (PETTA) may also be used.

[0050] In addition to these, so-called oligomers may also be used. By oligomer, we mean, for example, aliphatic and aromatic epoxy acrylates, aliphatic and aromatic urethane acrylates, polyester acrylates, polyether acrylates, amine-functionalized polyether acrylates, and unsaturated polyester resins.

[0051] These oligomers are known from prior art and are available, for example, from Rahn under the trade name Genomer®, from Allnex under the trade name Ebecryl®, from Miwon under the trade name Miramer®, from Sartomer under the CN series, or from BASF under the trade name Laromer 1®.

[0052] Preferably, as photoinitiators for radical reactions, substances and mixtures of substances that can initiate radical polymerization of olefinic unsaturated double bonds when irradiated with light having a wavelength of about 240 to about 480 nm can be used. Suitable photoinitiators are described, for example, in Advances in Polymer Science, Vol. 14, Springer Berlin 1974.

[0053] For example, these are all Norrish type I fragmentation materials. Examples include benzophenone, camphorquinone, Quantacure (manufacturer: International Bio-Synthetics), the Omnirad® series (IGM), the Genocure® series (Rahn), and the Speedcure™ series (Lambson) as photoinitiators.

[0054] Particularly suitable photoinitiators are those of the benzoin, phenylhydroxyalconone, α-hydroxyketone, α-aminoketone, phenylglyoxylate, monoacylphosphine (MAPO), and bisacylphosphine (BAPO) classes.

[0055] Particularly suitable examples of photoinitiators are Speedcore 73, Ominirad 819, Speedcure MBF, and Ominirad TPO.

[0056] Polymerizable photoinitiators are also particularly suitable, and are available, for example, from Rahn under the trademark name Genopol®.

[0057] The lacquer may be transparent or colored. If the lacquer is colored, it is preferable that it contains titanium dioxide as a filler. However, the lacquer may also contain other fillers, such as chalk, talc, and fillers that enhance scratch and micro-scratch resistance, such as glass beads or nanoparticles. Furthermore, the lacquer may contain coloring pigments.

[0058] The lacquer may further contain conventional additives for lacquers known to those skilled in the art, such as defoamers, degassing agents, surfactants, dispersants, flow regulators, antioxidants, and UV stabilizers.

[0059] The lacquer preferably has a Brookfield viscosity (at 20°C) of 200 mPas to 20,000 mPas, and more preferably 500 mPas to 10,000 mPas.

[0060] If priming (step a) is performed and lacquer is used for this, it may similarly possess the characteristics described above.

[0061] The support material may be metal foil, CPL laminate (continuous pressure laminate), melamine paper, separation paper, silicone coated mesh material, plastic film, etc., and may contain at least one or more of these. Plastic film is particularly preferred. High dimensional stability and mechanical strength under thermal load are advantageous in selecting the support material. Separability of the primer or reactive hot melt layer may also be considered in selecting the support material.

[0062] Preferably, the support material has a thickness of 30 μm to 400 μm. However, the support material can also be a conveyor belt of a coating apparatus.

[0063] The support material may also be a support for the printing ink that is simultaneously introduced into the reactive hot-melt layer by a transfer printing method (sublimation).

[0064] Furthermore, embossing of the composite film on the support material may be provided as step d). However, such a step may also be omitted. Embossing may be performed by an embossing roller of a coating apparatus or by pressing the structured web material.

[0065] In step e), the composite film is separated from the support material. Separation of the composite film from the support material is preferably carried out by peeling after the crystallization or complete reaction of the reactive hot melt layer. Preferably, after separation in step e), the support material may be optionally washed and reused in the method according to the present invention. Therefore, it is preferable that the support material be reused for the method according to the present invention.

[0066] Preferably, the coating apparatus is a roll-to-roll apparatus. The term "roll-to-roll apparatus" should be understood as an apparatus in which a roll material, which is a support material within the scope of the present invention, is supplied to the apparatus, and a desired product, i.e., a composite film within the scope of the present invention, is obtained as a processed roll.

[0067] The composite film and support material are preferably obtained in roll form. The material can be precisely wound onto a replaceable sleeve by edge control, and as a result, can be further processed by a commercially available conventional holder lining process.

[0068] Therefore, in a preferred embodiment, after separation in step e) of the method according to the present invention, the composite film according to the present invention is obtained as a roll that can be obtained by winding. Similarly, the support is preferably in the form of a roll before step a) which it is unwound for processing in a coating apparatus.

[0069] The method according to the present invention may include further steps. For example, smoothing of the reactive hot melt layer is possible after step b) and before step c). At least one of the following steps is also possible.

[0070] • Physical matting of lacquer (excimer lamp) • Smoothing and curing of lacquer using the inert calendering method. The resulting composite film can be divided into different widths using a downstream cutting device (e.g., a roll blade).

[0071] • To create a "non-slip" surface, a reactive hot-melt layer is applied, followed by sprinkling of particles.

[0072] The composite film according to the present invention can be used, for example, for cladding or lining. In this case, the composite film may have an adhesive layer pre-applied to it. Suitable adhesives include, for example, thermoplastic or reactive hot-melt adhesives, particularly PUR-SK, dispersions, and hot-melt pressure-sensitive adhesives. Application can be done, for example, by roller or slit die.

[0073] The manufactured composite film can be used as a replacement for conventional films. Possible applications include flooring. In this case, it can replace TPU, PET, or PVC films in particular.

[0074] Outdoor applications are also conceivable, particularly as a substitute for PMMA film, for example, as window film, on the front or contoured surfaces. Further potential applications include patio surfaces and furniture, especially for creating a soft feel and texture. [Brief explanation of the drawing]

[0075] [Figure 1] This figure shows a coating apparatus for manufacturing a composite film according to the present invention. [Modes for carrying out the invention]

[0076] The present invention will be described in more detail with reference to the following figures and examples, but the present invention is not limited thereto. [Examples]

[0077] Example 1 Flooring film: High abrasion resistance, shatter resistance, adhesive bonding, and embossing through reactivation. An exemplary composite film according to the present invention has the following layer structure.

[0078] 1. Heat-reactive adhesive, opaque (e.g., EVA SK Kleiberit 743.6) 2. Primer: Opaque, white, UV curing (e.g., UV lacquer Kleiberit 653.1.33) 3. Digital Printing: UV-curing printing ink, applied using a single-pass printer. 4. Corundum-containing polyurethane reactive hot melt layer (e.g., PUR HotCoating Kleiberit 717.6) 5. UV-cured acrylic lacquer: scratch-resistant, optionally physically matte (e.g., UV lacquer Kleiberit 659.0.04) Further processing can be performed, such as short-cycle presses or lining devices equipped with heated calender rollers, or the introduction of texture by press plates / matrices or embossing rollers.

[0079] Example 2: Patio floor film: High abrasion resistance, shatter resistance, weather resistance An exemplary composite film according to the present invention has the following layer structure.

[0080] 1. Primer: Opaque, white, UV curing, optimized wetting behavior (e.g., UV lacquer Kleiberit 653.1.33) 2. Digital Printing: UV-curing printing ink, applied using a single-pass printer. 3. A polyurethane-based reactive hot melt layer containing corundum with a UV absorber (e.g., PUR HotCoating Kleiberit 9383 / 627) 4. UV-cured acrylic lacquer: scratch-resistant, weather-resistant, and flexible (e.g., UV lacquer Kleiberit 659.2.22) 5. Embossed / Anti-slip surface Further processing can be performed. Cladding apparatus with PUR hot melt adhesive.

[0081] In the coating apparatus 1, a support film 2, as a support material, is supplied from the roll unit 3 to the priming unit 4, where the support film 2 is primed and a reactive adhesive is provided on the surface of the support film as needed. The support film 2 then passes through the printing unit 5, which allows printing on the primed support film surface. The support film surface is then coated with a polyurethane-based reactive hot melt in the subsequent coating unit 6. Next, a UV lacquer layer is applied in the lacquer unit 7. A curing unit 8 in the form of a UV lamp cures the UV lacquer. Subsequently, embossing is performed in the embossing unit 9, followed by separation and winding of the support film 2 and the composite film 10 according to the present invention. [Explanation of symbols]

[0082] 1 Coating apparatus 2. Support film 3 Roll Unit 4 priming units 5 Printing Units 6 Coating Unit 7 Lacquer Units 8. Curing Unit 9 Embossing Unit 10 Composite film

Claims

1. A method for producing a composite film having a polyurethane-based reactive hot melt layer using a coating apparatus, a) A step of optionally applying a primer onto the support material, b) The step of applying the polyurethane-based reactive hot melt layer onto the primer or directly onto the support material, c) A step of applying a lacquer layer onto the polyurethane-based reactive hot melt layer in order to manufacture the composite film on the support material, d) The step of optionally embossing the composite film on the support material, e) The step of separating the composite film from the support material A method that includes this.

2. The method according to claim 1, characterized in that the primer is provided.

3. The method according to claim 1 or 2, characterized in that the primer is used as a separating agent.

4. The method according to any one of claims 1 to 3, characterized in that the polyurethane-based reactive hot melt layer and the lacquer layer are each applied in one coat.

5. The method according to any one of claims 1 to 4, characterized in that the polyurethane-based reactive hot melt layer has a thickness in the range of 20 μm to 150 μm.

6. The method according to any one of claims 1 to 5, characterized in that the lacquer layer has a thickness in the range of 5 μm to 25 μm.

7. The method according to any one of claims 1 to 6, characterized in that the application of the primer forms at least one colored layer or opacity layer.

8. The method according to any one of claims 1 to 7, characterized in that an adhesive layer that can be reactivated before the application of the primer is provided on the surface of the support material, or the adhesive layer is used as the primer.

9. The method according to any one of claims 1 to 8, characterized in that the decorative layer is manufactured before step b).

10. The method according to any one of claims 1 to 7, characterized in that the application of the primer is performed using an applicator roller or a slit die of the coating apparatus.

11. The method according to any one of claims 1 to 10, characterized in that the primer comprises an embossed structure.

12. The method according to any one of claims 1 to 11, characterized in that the support material is a metal foil, a CPL laminate, melamine paper, a separator paper, a silicone-coated web material, or a plastic film, particularly a plastic film, or comprises at least these.

13. The method according to any one of claims 1 to 12, characterized in that the support material has a thickness of 30 μm to 400 μm.

14. The method according to any one of claims 1 to 13, characterized in that the support material is a conveyor belt of the coating apparatus.

15. The method according to any one of claims 1 to 14, characterized in that the application of the polyurethane-based reactive hot melt layer is carried out using an applicator roller with or without a smoothing roller, or a slit die with or without a roll bar of the coating apparatus.

16. The method according to any one of claims 1 to 15, characterized in that the polyurethane-based reactive hot melt layer is a moisture-curing layer.

17. The method according to any one of claims 1 to 16, characterized in that the polyurethane-based reactive hot melt layer is a reactive polyurethane hot melt that can be obtained from an isocyanate-reactive polymer and a polyisocyanate, and optionally from an additive.

18. The method according to any one of claims 1 to 17, characterized in that the embossing of the composite film is provided.

19. The method according to any one of claims 1 to 18, characterized in that the embossing is performed using an embossing roller of the coating apparatus.

20. The method according to any one of claims 1 to 19, characterized in that the separation of the composite film from the support material is carried out by peeling off the polyurethane-based reactive hot melt layer after crystallization or after complete reaction.

21. The method according to any one of claims 1 to 20, characterized in that the polyurethane-based reactive hot melt layer contains at least one filler, particularly an abrasion-resistant filler.

22. The method according to any one of claims 1 to 21, characterized in that the coating apparatus is a roll-to-roll apparatus.

23. The method according to any one of claims 1 to 22, characterized in that the lacquer in the lacquer layer in step c) can be crosslinked by electron emission or UV emission.

24. The method according to any one of claims 1 to 23, characterized in that the support material is reused for the method.

25. A method of using a composite film, comprising the steps of: manufacturing a composite film by the method of any one of claims 1 to 24; and using the composite film for cladding or lining.

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