Method of producing a building panel

Patent metadata

Field	Value
Publication number	US-9409382-B2
Application number	US-201314091957-A
Country	US
Kind code	B2
Filing date	Nov 27, 2013
Priority date	Nov 28, 2012
Publication date	Aug 9, 2016
Grant date	Aug 9, 2016

Abstract

A method of producing a floor panel ( 1 ), including providing a carrier ( 3 ) including a thermoplastic material, applying a primer comprising at least one salt, preferably a metal salt, on a first surface of the carrier ( 3 ), printing by means of digital printing a first print ( 10 ) on said first surface of the carrier ( 3 ) with an aqueous pigment ink composition, and applying a protective layer ( 4 ) on said first surface of the carrier ( 3 ) and applying the carrier ( 3 ) on a core ( 2 ) and pressing by applying heat and pressure the protective layer ( 4 ), the carrier ( 3 ) and the core ( 2 ) together to form a floor panel ( 1 ). Also, a method for forming a decorative substrate.

First claim

The invention claimed is:

1. Method of producing a building panel, comprising
providing a carrier comprising a thermoplastic material,
applying a primer comprising at least one salt on a first surface of the carrier,
printing by means of digital printing a first print on said first surface of the carrier with an aqueous pigment ink composition, and
applying a protective layer on said first surface of the carrier and applying the carrier on a core, and
pressing, by applying heat and pressure, the protective layer, the carrier, and the core together to form a building panel,
wherein the primer possesses a salt concentration of at least 50 % of a saturation point of the salt.

2. Method according to claim 1 , wherein the primer is an aqueous solution comprising said salt.

3. Method according to claim 1 , wherein the primer further comprises a wetting agent.

4. Method according to claim 1 , wherein the primer is applied by means of digital printing.

5. Method according to claim 1 , further comprising drying the primer applied on the first surface of the carrier prior to printing said first print.

6. Method according to claim 1 , wherein the aqueous pigment ink composition is a heat activated curing ink.

7. Method according to claim 1 , wherein the aqueous pigment ink composition comprises a binder, water and a pigment.

8. Method according to claim 1 , further comprising applying heat to the print.

9. Method according to claim 1 , wherein the printing is made by an inkjet printer.

10. Method according to claim 1 , wherein the thermoplastic material of the carrier is polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PUR), or polyethylene terephthalate (PET).

11. Method according to claim 1 , wherein the protective layer comprises a thermoplastic material.

12. Method for forming a decorative substrate, comprising
providing a carrier comprising a thermoplastic material,
applying a primer comprising at least one salt on a first surface of the carrier,
printing by means of digital printing a first print on said first surface of the carrier with an aqueous pigment ink composition,
applying a protective layer comprising a thermoplastic material on the first surface of the carrier,
pressing, by applying heat and pressure, the protective layer and the carrier together to form a decorative substrate,
wherein the primer possesses a salt concentration of at least 50% of a saturation point of the salt.

13. Method according to claim 12 , wherein the primer is an aqueous solution comprising said salt.

14. Method according to claim 12 , further comprising a wetting agent.

15. Method according to claim 12 , wherein the primer is applied by means of digital printing.

16. Method according to claim 12 , further comprising drying the primer applied on the first surface of the carrier prior to printing said first print.

17. Method according to claim 12 , wherein the aqueous pigment ink composition is a heat activated curing ink.

18. Method according to claim 12 , wherein the aqueous pigment ink composition comprises a binder, water and a pigment.

19. Method according to claim 12 , further comprising applying heat to the print.

20. Method according to claim 12 , wherein the printing is made by an inkjet printer.

21. Method according to claim 12 , wherein thermoplastic material of the carrier is polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PUR), or polyethylene terephthalate (PET).

22. Method according to claim 12 , wherein the thermoplastic material of the protective layer is polyvinyl chloride (PVC), polyester, polypropylene (PP), polyethylene (PE), polystyrene (PS), polyurethane (PUR), or polyethylene terephthalate (PET).

23. Method of producing a building panel, comprising
providing a carrier comprising a thermoplastic material,
applying a primer comprising at least one salt on a first surface of the carrier,
printing by means of digital printing a first print on said first surface of the carrier with an aqueous pigment ink composition, and
applying a protective layer on said first surface of the carrier and applying the carrier on a core, and
pressing, by applying heat and pressure, the protective layer, the carrier, and the core together to form a building panel,
wherein the salt is applied to the first surface of the carrier in solid form.

24. The method according to claim 1 , wherein the primer is applied on the first surface of the carrier with a contact angle of less than 50°.

25. The method according to claim 1 , wherein the salt is a monovalent metallic salt or a polyvalent metallic salt.

26. The method according to claim 1 , wherein the salt is applied onto the first surface of the carrier by a scattering device.

27. Method for forming a decorative substrate, comprising
providing a carrier comprising a thermoplastic material,
applying a primer comprising at least one salt on a first surface of the carrier,
printing by means of digital printing a first print on said first surface of the carrier with an aqueous pigment ink composition,
applying a protective layer comprising a thermoplastic material on the first surface of the carrier,
pressing, by applying heat and pressure, the protective layer and the carrier together to form a decorative substrate,
wherein the salt is applied to the first surface of the carrier in solid form.

28. The method according to claim 12 , wherein the primer is applied on the first surface of the carrier with a contact angle of less than 50°.

29. The method according to claim 12 , wherein the salt is a monovalent metallic salt or a polyvalent metallic salt.

30. The method according to claim 12 , wherein the salt is applied onto the first surface of the carrier by a scattering device.

Assignees

• Ceraloc Innovation Ab
• Valinge Innovation Ab

Inventors

• Hakansson Niclas
• Jacobsson Jan
• Bergelin Marcus
• Rittinge Rickard
• Ryberg Melker
• Ziegler Goran

Classifications

• B32B38/145 Primary

  Printing · CPC title

• B32B2607/00

  Walls, panels · CPC title

• B32B2471/00

  Floor coverings (B32B2419/04 takes precedence) · CPC title

• 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

• B32B37/14

  characterised by the properties of the layers · CPC title