Method for manufacturing panels having a decorative surface

Patent metadata

Field	Value
Publication number	US-10471769-B2
Application number	US-201715689294-A
Country	US
Kind code	B2
Filing date	Aug 29, 2017
Priority date	Jan 10, 2014
Publication date	Nov 12, 2019
Grant date	Nov 12, 2019

Abstract

A method is provided for manufacturing panels having a decorative surface, wherein the panels at least include a plate shaped substrate and a top layer, and wherein the top layer includes a printed pattern. The method may involve providing the plate shaped substrate with at least a portion of the printed pattern. Providing the portion of the printed pattern may involve depositing water based inks using a digital inkjet printer. The plate shaped substrate may include one or more intermediate layers at the surface to be printed. And the intermediate layers may include an inkjet receiver coating, such that the inks are deposited on the inkjet receiver coating.

First claim

What is claimed is:

1. A method for manufacturing floor panels having a decorative surface, wherein the panels at least include a plate shaped substrate and a top layer, wherein the top layer includes a printed pattern, the method comprising:
providing the plate shaped substrate with at least a portion of the printed pattern;
wherein providing the portion of the printed pattern involves depositing water based inks using a digital inkjet printer;
wherein the water based inks are pigment containing inks;
wherein the dry weight of the total volume of the deposited pigment containing inks is lower than 9 grams per square meter;
wherein the plate shaped substrate includes one or more intermediate layers at the surface to be printed;
wherein the intermediate layers at least include an inkjet receiver coating, such that the inks are deposited on the inkjet receiver coating;
applying translucent or transparent resin above the printed pattern, wherein the translucent or transparent resin above the printed pattern includes hard particles;
wherein the inkjet receiver coating includes a pigment having a pore volume of 0.5 to 3 ml/g;
wherein the intermediate layers include a paper layer impregnated with a thermosetting resin, such that the portion of the printed pattern is provided on top of the thermosetting resin impregnated paper layer.

2. The method of claim 1 , wherein the inkjet receiver coating is provided on the thermosetting resin impregnated paper layer.

3. The method of claim 1 , wherein the translucent or transparent resin is liquidly applied in one or more coating steps.

4. The method of claim 1 , wherein the translucent or transparent resin is applied by means of a resin provided paper layer.

5. The method of claim 1 , wherein the method further comprises:
pressing the printed plate shaped substrate.

6. The method of claim 1 , wherein the inkjet receiver coating comprises a hydrophilic polymer and the pigment.

Assignees

• Unilin Bvba

Inventors

• Clement Benjamin

Classifications

• B44C5/0469

  comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper · CPC title

• B41M5/5236

  characterised by the use of natural gums, of proteins, e.g. gelatins, or of macromolecular carbohydrates, e.g. cellulose · CPC title

• B44C5/04 Primary

  Ornamental plaques, e.g. decorative panels, decorative veneers · CPC title

• B41M5/5254

  characterised by the use of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds, e.g. vinyl polymers · CPC title

• B41M5/5218 Primary

  characterised by inorganic additives, e.g. pigments, clays · CPC title