Method for manufacturing panels having a decorative surface

Patent metadata

Field	Value
Publication number	US-9770937-B2
Application number	US-201515110582-A
Country	US
Kind code	B2
Filing date	Jan 6, 2015
Priority date	Jan 10, 2014
Publication date	Sep 26, 2017
Grant date	Sep 26, 2017

Abstract

Method for manufacturing panels having a decorative surface, wherein the panels at least comprise a substrate and a top layer, wherein the top layer comprises a paper layer having a printed pattern, and wherein the method at least comprises the step of providing the paper layer with thermosetting resin and the step of providing the resin provided paper layer with at least a portion of the printed pattern, wherein for providing the portion of the printed pattern use is made of pigment containing inks deposited on the paper layer by means of a digital inkjet printer, and wherein the dry weight of the total volume of the pigment containing inks deposited on the paper layer is lower than 9 grams per square meter, wherein for the pigment containing ink use is made of a water-based ink.

First claim

The invention claimed is:

1. A method for manufacturing panels having a decorative surface, wherein the panels at least include a substrate and a top layer, wherein the top layer includes a paper layer having a printed pattern, the method comprising:
providing the paper layer with thermosetting resin; and
providing the resin provided paper layer with at least a portion of the printed pattern;
wherein providing the portion of the printed pattern involves depositing pigment containing inks on the paper layer using a digital inkjet printer;
wherein the dry weight of the total volume of the pigment containing inks deposited on the paper layer is lower than 9 grams per square meter;
wherein the pigment containing ink is a water based ink;
wherein the paper layer, prior to providing the printed pattern, is provided with an inkjet receiver coating; and
wherein the inkjet receiver coating is preferably free from the thermosetting resin upon printing or comprises less than 20 percent by weight of the thermosetting resin based upon the total weight of the inkjet receiver coating.

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

3. The method of claim 2 , wherein the pigments have a mean particle size of 0.1 to 40 micrometer, and/or a pore volume of 0.5 to 3 ml/g.

4. The method of claim 1 , wherein the inkjet receiver coating comprises polyvinylalcohol and silica pigments.

5. The method of claim 1 , wherein the inkjet receiver coating at least comprises a binder and a pigment; and
wherein the pigment to binder ratio is between 10:90 and 90:10.

6. The method of claim 1 , wherein the inkjet receiver coating is obtained from a liquid substance comprising a content of dry solids of between 1 to 20 percent by weight and/or having a viscosity of 10 to 75 seconds Din cup 4 at 20° C.

7. The method of claim 1 , wherein the inkjet receiver coating is obtained from a liquid substance which next to a binder and/or pigments further comprises at least a levelling agent, a preservative, an antifoaming agent, a dispersing agents and/or a thickener.

8. The method of claim 1 , wherein the dry weight of the total volume of the pigment containing inks is 5 grams per square meter or less.

9. The method of claim 1 , wherein the total volume is less than 15 milliliter.

10. The method of claim 1 , wherein the paper layer has a paper weight of between 50 and 100 grams per square meter and an air resistance of below 25 seconds according to the Gurley method.

11. The method of claim 1 , wherein the paper layer is provided with an amount of thermosetting resin equaling 40 to 250% dry weight of resin as compared to weight of the paper.

12. The method of claim 1 , wherein the inkjet receiver coating is obtained by coating a liquid substance on the surface of the resin provided paper layer;
wherein the resin provided paper layer is in a state having a residual humidity lower than 10%; and
wherein the paper layer is further dried after application of the liquid substance.

13. The method of claim 1 , wherein the paper layer is provided with such an amount of thermosetting resin, that at least the paper core is satisfied with the resin.

14. A method for manufacturing panels having a decorative surface, wherein the panels at least include a substrate and a top layer, wherein the top layer includes a paper layer having a printed pattern, the method comprising:
providing the paper layer with thermosetting resin; and
providing the resin provided paper layer with at least a portion of the printed pattern;
wherein providing the portion of the printed pattern involves depositing pigment containing inks on the paper layer using a digital inkjet printer;
wherein the dry weight of the total volume of the pigment containing inks deposited on the paper layer is 5 grams per square meter or less; and
wherein the pigment containing ink is a water based ink.

15. The method of claim 14 , wherein the paper layer, prior to providing the printed pattern, is provided with an inkjet receiver coating; and
wherein the inkjet receiver coating is preferably free from the thermosetting resin upon printing or comprises less than 20 percent by weight of the thermosetting resin based upon the total weight of the inkjet receiver coating.

16. The method of claim 15 , wherein the inkjet receiver coating comprises a hydrophilic polymer and a pigment.

17. The method of claim 16 , wherein the pigments have a mean particle size of 0.1 to 40 micrometer, and/or a pore volume of 0.5 to 3 ml/g.

18. The method of claim 15 , wherein the inkjet receiver coating comprises polyvinylalcohol and silica pigments.

19. The method of claim 15 , wherein the inkjet receiver coating at least comprises a binder and a pigment; and
wherein the pigment to binder ratio is between 10:90 and 90:10.

20. The method of claim 15 , wherein the inkjet receiver coating is obtained from a liquid substance comprising a content of dry solids of between 1 to 20 percent by weight and/or having a viscosity of 10 to 75 seconds Din cup 4 at 20° C.

21. The method of claim 15 , wherein the inkjet receiver coating is obtained from a liquid substance which next to a binder and/or pigments further comprises at least a levelling agent, a preservative, an antifoaming agent, a dispersing agents and/or a thickener.

22. The method of claim 14 , wherein the total volume is less than 15 milliliter.

23. The method of claim 14 , wherein the paper layer has a paper weight of between 50 and 100 grams per square meter and an air resistance of below 25 seconds according to the Gurley method.

24. The method of claim 14 , wherein the paper layer is provided with an amount of thermosetting resin equaling 40 to 250% dry weight of resin as compared to weight of the paper.

25. The method of claim 14 , wherein an inkjet receiver coating is obtained by coating a liquid substance on the surface of the resin provided paper layer;
wherein the resin provided paper layer is in a state having a residual humidity lower than 10%; and
wherein the paper layer is further dried after application of the liquid substance.

26. The method of claim 14 , wherein the paper layer is provided with such an amount of thermosetting resin, that at least the paper core is satisfied with the resin.

27. A method for manufacturing panels having a decorative surface, wherein the panels at least include a substrate and a top layer, wherein the top layer includes a paper layer having a printed pattern, the method comprising:
providing the paper layer with thermosetting resin; and
providing the resin provided paper layer with at least a portion of the printed pattern;
wherein providing the portion of the printed pattern involves depositing pigment containing inks on the paper layer using a digital inkjet printer;
wherein the dry weight of the total volume of the pigment containing inks deposited on the paper layer is lower than 9 grams per square meter;
wherein the pigment containing ink is a water based ink;
wherein an inkjet receiver coating is obtained by coating a liquid substance on the surface of the resin provided paper layer;
wherein the resin provided paper layer is in a state having a residual humidity lower than 10%; and
wherein the paper layer is further dried after application of the liquid substance.

28. The method of claim

Assignees

• Unilin Bvba

Inventors

• Clement Benjamin

Classifications

• B41M5/5236

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

• B44C5/0469

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

• B44C5/04 Primary

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

• B41J2/01

  Ink jet · CPC title

• B41M5/5218 Primary

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