Manufacturing of decorative surfaces by inkjet

Patent metadata

Field	Value
Publication number	US-10022956-B2
Application number	US-201414917042-A
Country	US
Kind code	B2
Filing date	Feb 27, 2014
Priority date	Oct 22, 2013
Publication date	Jul 17, 2018
Grant date	Jul 17, 2018

Abstract

A method for manufacturing decorative surfaces includes the steps of inkjet printing a color pattern with one or more aqueous inkjet inks including a polyurethane based latex binder; impregnating a paper substrate with a thermosetting resin; and heat pressing the thermosetting resin impregnated paper substrate carrying the inkjet printed color pattern into a decorative surface.

First claim

The invention claimed is:

1. A method for manufacturing decorative surfaces, the method comprising the steps of:
a) inkjet printing a color pattern with one or more pigmented aqueous inkjet inks including a polyurethane based latex binder;
b) impregnating a paper substrate with a thermosetting resin; and
c) heat pressing the thermosetting resin impregnated paper substrate including the inkjet printed color pattern into a decorative surface; wherein
the one or more pigmented aqueous inkjet inks includes a red pigmented aqueous inkjet ink including a color pigment selected from the group consisting of C.I. Pigment Red 254, C.I. Pigment Red 122, and mixed crystals thereof.

2. The method according to claim 1 , wherein the steps are performed in order of a), then b), and then c).

3. The method according to claim 1 , wherein the steps are performed in order of b), then a), and then c).

4. The method according to claim 1 , wherein the step of heat pressing includes heat pressing the thermosetting resin impregnated paper substrate including the inkjet printed color pattern between a protective layer including a thermosetting resin and a core layer, wherein the color pattern faces the protective layer.

5. The method according to claim 1 , wherein the step of heat pressing includes heat pressing the thermosetting resin impregnated paper substrate including the color pattern as a protective layer into a decorative surface, wherein the color pattern faces a core layer of the decorative surface.

6. The method according to claim 5 , wherein the color pattern includes a white ink layer as an outermost ink layer.

7. The method according to claim 5 , wherein the protective layer includes particles in an amount between 1 g/m 2 and 100 g/m 2 .

8. The method according to claim 5 , wherein the protective layer is embossed with a relief corresponding to the color pattern.

9. The method according to claim 1 , wherein the one or more pigmented aqueous inkjet inks define an aqueous inkjet ink set including:
a cyan pigmented aqueous inkjet ink including a copper phthalocyanine pigment;
the red pigmented aqueous inkjet ink;
a yellow pigmented aqueous inkjet ink including a color pigment selected from the group consisting of C.I. Pigment Yellow 151, C.I. Pigment Yellow 74, and mixed crystals thereof; and
a black pigmented aqueous inkjet ink including carbon black pigment.

10. The method according to claim 1 , wherein the thermosetting resin is a melamine based resin.

11. The method according to claim 1 , wherein the inkjet printing is performed using a single pass printing inkjet printing process.

12. A decorative panel obtained by the method according to claim 1 , wherein the decorative panel is selected from the group consisting of flooring, kitchen, furniture, and wall panels.

13. The decorative panel according to claim 12 , wherein the decorative panel includes a tongue and a groove mechanical joint that requires no glue.

Assignees

• Agfa Graphics Nv
• Unilin Bvba
• Agfa Nv

Inventors

• De Mondt Roel
• Meersseman Laurent

Classifications

• B41M7/0045

  using protective coatings or film forming compositions cured by mechanical wave energy, e.g. ultrasonics, cured by electromagnetic radiation or waves, e.g. ultraviolet radiation, electron beams, or cured by magnetic or electric fields, e.g. electric discharge, plasma · CPC title

• B41M5/5263

  characterised by the use of polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds · CPC title

• B32B2260/028

  Paper layer · CPC title

• E04B1/6125

  with protrusions on the one frontal surface co-operating with recesses in the other frontal surface · CPC title

• B41M7/0054

  using protective coatings or film forming compositions cured by thermal means, e.g. infrared radiation, heat · CPC title