Method for producing a matt support material provided with an anti-fingerprint coating

Patent metadata

Field	Value
Publication number	US-11612911-B2
Application number	US-202017610872-A
Country	US
Kind code	B2
Filing date	May 6, 2020
Priority date	May 13, 2019
Publication date	Mar 28, 2023
Grant date	Mar 28, 2023

Abstract

It is provided a method for producing a support material provided with at least one anti-fingerprint coating including the steps of: applying at least one layer of at least one powdered resin to at least one side of the support material; melting on the at least one applied layer of the one powdered resin; applying at least one acrylate-containing dispersion to the melted-on resin layer; and drying and curing the layered structure.

First claim

The invention claimed is:

1. A method of producing a support material having anti-fingerprint properties comprising the steps of:
applying at least one layer of at least one powdered resin to at least one side of a substrate;
melting-on the at least one applied layer of the at least one powdered resin;
applying at least one acrylate-containing dispersion to the melted-on resin layer; and
drying and hardening the layered structure.

2. The method according to claim 1 , wherein the substrate is at least one paper layer.

3. The method according to claim 1 , wherein the substrate is a wood-based panel.

4. The method according to claim 1 , wherein the at least one powdered resin is a powdered formaldehyde resin.

5. The method according to claim 1 , wherein after applying and melting-on at least one first resin layer of at least one powdered resin and before applying the at least one acrylate-containing dispersion, the method further comprises:
applying at least one decorative layer to the at least one melted-on first resin layer by a direct printing method;
applying the at least one second resin layer of the at least one powdered resin to the at least one decorative layer; and
melting-on the applied at least one second resin layer resin applied to the decorative layer.

6. The method according to claim 5 , wherein at least one undercoat is applied to the melted-on at least one first resin layer before applying the at least one decorative layer.

7. The method of claim 6 , wherein the at least one undercoat comprises casein, corn starch or soy protein.

8. The method according to claim 6 , wherein at least one primer layer is applied to the melted-on at least one first resin layer before applying the at least one undercoat.

9. The method according to claim 5 , wherein at least one primer layer is applied to the melted-on at least one first resin layer before applying the at least one decorative layer.

10. The method according to claim 5 , wherein abrasion-resistant particles are scattered on the decorative layer or on the melted-on at least one first resin layer and/or at least one second resin layer.

11. The method according to claim 10 , wherein at least one third resin layer of at least one powdered resin is applied and melted-on after scattering of the abrasion-resistant particles.

12. The method according to claim 11 , wherein glass beads are scattered on the at least one third resin layer.

13. The method according to claim 12 , wherein at least one fourth resin layer of at least one powdered resin is applied to the layer of glass beads.

14. The method of claim 5 , wherein the substrate is a wood-based panel.

15. The method according to claim 1 , wherein the at least one acrylate-containing dispersion comprises a radiation-curable acrylate-containing varnish.

16. The method according to claim 1 , wherein the at least one acrylate-containing dispersion is cured after application using a UV lamp at wavelengths between 120 and 350 nm under inert gas.

17. The method according to claim 1 , wherein the dried and hardened layered structure is pressed in a short-cycle press.

18. The method of according to claim 1 , wherein after applying and melting-on at least one first resin layer of at least one powdered resin and before applying the at least one acrylate-containing dispersion, the method further comprises:
applying at least one undercoat to the melted-on at least one first resin layer;
applying at least one primer layer on top of the at least one undercoat;
applying at least one decorative layer by means of a direct printing process to the undercoat layer;
applying at least one second resin layer of at least one powdered resin to the at least one decorative layer, and melting-on the at least one second resin layer applied to the at least one decorative layer;
scattering at least one layer of abrasion-resistant particles on the second resin layer;
applying at least one third resin layer of at least one powdered resin to the at least one layer of abrasion-resistant particles, and melting-on the applied third resin layer;
scattering of a layer of glass beads on the at least one third resin layer;
applying at least one fourth resin layer of at least one powdered resin to the layer of glass beads and melting-on the applied at least one fourth resin layer;
applying at least one acrylate-containing dispersion to the fourth resin layer; and
wherein after drying and hardening the at least one acrylate-containing dispersion, pressing the layered structure.

19. The method according to claim 1 , wherein the substrate is a decorative paper layer or an overlay paper layer.

20. The method according to claim 1 , wherein the substrate is a medium-density fiber (MDF), high-density fiber (HDF) or rough particleboard (OSB), a plywood panel, or a wood-plastic composite (WPC) panel.

21. The method according to claim 1 , wherein the at least one powdered resin is applied to the substrate by electrostatic charging.

22. The method according to claim 1 , wherein the powdered formaldehyde resin comprises pigments, conductive substances, and/or cellulose.

23. The method according to claim 1 , wherein the at least one powdered resin is a urea resin, a melamine resin, or a phenolic resin.

24. The method according to claim 1 , wherein the at least one powdered resin is a melamine-formaldehyde resin.

25. The method according to claim 1 , wherein the at least one acrylate-containing dispersion is polyether (meth)acrylates, polyether (meth)acrylates, epoxy (meth)acrylates, or urethane (meth)acrylates.

26. The method according to claim 1 , wherein the at least one acrylate-containing dispersion is cured after application using a UV lamp at wavelengths between 150 and 250 nm under inert gas.

27. The method according to claim 1 , wherein the at least one acrylate-containing dispersion is cured after application using a UV lamp at wavelengths between 170 and 200 nm under inert gas.

Assignees

• Flooring Technologies Ltd

Inventors

• Kalwa Norbert
• Hasch Joachim
• Stiewe Bernd

Classifications

• B32B37/24

  with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate (B32B37/15 takes precedence) · CPC title

• B41M5/0064

  on plastics, horn, rubber, or other organic polymers · CPC title

• B32B2255/10

  on synthetic resin layer or on natural or synthetic rubber layer · CPC title

• B05D7/576

  each layer being cured, at least partially, separately · CPC title

• B05D3/0263

  with IR heaters · CPC title