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EP-4739513-A1 - DIGITALLY EMBOSSED DECORATIVE SURFACE COVERINGS

EP4739513A1EP 4739513 A1EP4739513 A1EP 4739513A1EP-4739513-A1

Abstract

A method for producing a decorative surface covering, e.g., a floor covering or a wallcovering, is proposed. The method comprises forming an embossed layer by the following steps: applying a crosslinkable resin composition in a continuous layer (20) on a face of a surface covering substructure (10) comprising one or more core layers (10a, 10b), the one or more core layers comprising one or more linoleum layers, the face of the surface covering substructure having a printed decorative motif (18), the crosslinkable resin composition being applied on the printed decorative motif, and generating a three-dimensional surface relief (30) by digitally embossing the crosslinkable resin composition, the digitally embossing comprising at least partially curing the crosslinkable resin composition. The digital embossing is preferably executed in register with the printed decorative motif.

Inventors

  • BODY, Jean-François

Assignees

  • Tarkett GDL

Dates

Publication Date
20260513
Application Date
20240614

Claims (20)

  1. 1 . A method for producing a decorative surface covering, e.g., a floor covering or a wallcovering, comprising: applying at least one crosslinkable resin composition in a continuous layer on a face of a surface covering substructure comprising one or more core layers, the one or more core layers comprising one or more linoleum layers, the face of the surface covering substructure having a printed decorative motif, the at least one crosslinkable resin composition being applied on, the printed decorative motif; generating a three-dimensional surface relief by digitally embossing the at least one crosslinkable resin composition, the digitally embossing comprising at least partially curing the at least one crosslinkable resin composition.
  2. 2. The method as claimed in claim 1 , wherein the surface covering substructure is substantially PVC-free.
  3. 3. The method as claimed in claim 1 or 2, wherein the decorative surface covering is PVC-free.
  4. 4. The method as claimed in any one of claims 1 to 3, wherein the digital embossing is executed in register with the printed decorative motif.
  5. 5. The method as claimed in any one of claims 1 to 4, wherein the surface covering substructure comprises a decor layer including a printing substrate and the decorative motif printed on the printing substrate, the decor layer being assembled with the one or more core layers.
  6. 6. The method as claimed in any one of claims 1 to 5, wherein the decorative motif is digitally printed one a printing substrate or directly on one of the one or more core layers.
  7. 7. The method as claimed in any one of claims 1 to 6, wherein the digital embossing of the crosslinkable resin composition comprises digitally printing a pattern of a crosslinking blocking agent onto the crosslinkable resin composition, curing the crosslinkable resin composition with the pattern in place, and removing the crosslinking blocking agent and, possibly, uncured crosslinkable resin composition.
  8. 8. The method as claimed in any one of claims 1 to 7, wherein the digital embossing of the crosslinkable resin composition comprises digitally printing a pattern of a repelling agent onto the crosslinkable resin composition, curing the crosslinkable resin composition with the pattern in place, and removing the repelling agent and, possibly, uncured crosslinkable resin composition.
  9. 9. The method as claimed in any one of claims 1 to 8, wherein the digital embossing of the crosslinkable resin composition comprises additive manufacturing, the additive manufacturing including digitally printing plural patterned layers of the crosslinkable resin composition onto the continuous layer.
  10. 10. The method as claimed in any one of claims 1 to 9, wherein the crosslinkable resin composition is a radiation-curable resin composition, e.g., a UV-curable resin composition or an electron-beam-curable resin composition.
  11. 11 . The method as claimed in claim 10, wherein the crosslinkable resin composition comprises at least one of urethane (meth)acrylate, epoxy (meth)acrylate, polyester (meth)acrylate, polyether (meth)acrylate, amino (meth)acrylate, silicone (meth)acrylate, polyether urethane (meth)acrylate and/or any mixtures thereof.
  12. 12. The method as claimed in claim 10 or 11 , wherein the at least partial curing of the crosslinkable resin composition is effected with UV light.
  13. 13. The method as claimed in claim 12, wherein the UV light is produced with at least one of a mercury lamp, a gallium lamp, a UV-LED, and an excimer lamp.
  14. 14. The method as claimed in claim 12 or 13, wherein the at least partial curing of the crosslinkable resin composition comprises generating a microfolded skin layer in the crosslinkable resin composition by exposing the crosslinkable resin composition to V-UV light.
  15. 15. The method as claimed in any one of claims 1 to 14, comprising applying a continuous topcoat over the at least partially cured crosslinkable resin composition.
  16. 16. The method as claimed in claim 15, wherein the topcoat is UV-curable and wherein applying the continuous topcoat comprises generating a microfolded skin layer in the topcoat by exposing the UV-curable topcoat to V-lIV light and then curing the topcoat in depth.
  17. 17. The method as claimed in claims 11 and 16, taken in combination.
  18. 18. The method as claimed in any one of claims 1 to 17, wherein the at least one crosslinkable resin composition has: - a glass transition temperature (Tg) in the range from 10°C to 30°C, preferably in the range from 15°C to 25°C, and/or - a crosslink density in the range from 1 mol/m 3 to 10 mol/m 3 , preferably in the range from 2 mol/m 3 to 5 mol/m 3 .
  19. 19. The method as claimed in any one of claims 1 to 18, wherein the thickness of the layer of the at least one crosslinkable resin composition is between 50 pm and 220 pm, more preferably between 120 pm and 180 pm.
  20. 20. A decorative surface covering, e.g., a floor covering or a wallcovering, obtained by the method as claimed in any one of claims 1 to 19.

Description

DIGITALLY EMBOSSED DECORATIVE SURFACE COVERINGS Background of the Invention [0001 ] The invention generally relates to the field of finishing materials for constructions, in particular to decorative surface coverings such as, for instance, floorings, wallcoverings or ceiling coverings. [0002] Decorative surface coverings such as flooring, wallcovering or ceiling covering, may be of the so-called homogeneous or heterogeneous types. A homogeneous surface covering has essentially the same composition throughout its thickness (except, maybe, for a topcoat and/or a textile backing), whereas a heterogeneous surface covering comprises a stack of layers which differ in their functions and compositions. A typical layer structure of a heterogeneous surface covering comprises a backing layer, one or more core layers, a decor layer, a protective wear layer and a topcoat. [0003] The decor layer may be a thin layer of a natural material, e.g., cork or wood, but may also comprise a printed decor, imitating or not a natural material. In order to improve the realism of a printed decor imitating a natural material, such as wood, cork, stone, etc., the surface covering may be given a surface structure by embossing. Mechanical embossing involves pressing an embossing plate or cylinder against the surface covering under high temperature so as to transfer the three-dimensional pattern of the embossing plate or cylinder into the surface covering. In high-quality surface coverings, the embossing is carried out in register with the printed decor. [0004] WO 2017/046309 A1 discloses a base panel suitable to be processed into a covering panel, consisting of: (i) a substrate having a top surface, (ii) a resilient layer having a top surface and a bottom surface, the bottom surface being connected to the top surface of the substrate, and (iii) optionally, a contact layer between the bottom surface of the resilient layer and the top surface of the substrate. The covering panel comprises a digitally printed decor on the top surface of the resilient layer of the base panel. The covering panel may further be provided with an embossing pattern, which may be applied in register with the print, so as to accentuate the appearance of the decor. [0005] Digitally printed decors are gaining in importance, in particular (but not only) due to the fact that designs can be changed more quickly and at much lower costs than with conventional printing techniques, such as, e.g. heliogravure printing. This allows the industry to react more flexibly to changing market demands and to reduce product development costs. Likewise, digital embossing techniques have been developed to replace the conventional embossing cylinders. [0006] WO2017067978A1 relates to a method for manufacturing embossed decorative substrates, e.g., panels and boards, in particular based on wood fibers such as MDF (Medium Density Fiberboard) or HDF (High Density Fiberboard) substrates on which a decor is formed by digital printing. The method comprises the steps of: a) mechanical embossing a substrate so as to form an embossed surface; b) applying a primer on the embossed surface of the substrate; c) drying or curing the primer coated on the embossed surface so as to form a base layer; d) digitally printing a decor onto the base layer using a liquid ink; and e) drying or curing the liquid ink forming the digitally printed decor. [0007] US2020346246A1 relates to a method for manufacturing a structure on a surface of a workpiece. The method comprises the following steps: applying a liquid base layer onto the surface of the workpiece; jetting droplets into the not yet solidified base layer, wherein the droplets at least partially penetrate into the base layer; indurating the base layer; and removing the droplets. [0008] EP3109056A1 discloses a method for producing a structure on a surface. A liquid layer is applied onto a workpiece. Subsequently, a manipulation medium in the form of droplets is sprayed onto the liquid layer, whereby a displacement of the liquid layer occurs by the droplets so that recesses together forming a structure in the liquid layer are formed therein. Subsequently, this layer is solidified. [0009] US2020368777A1 discloses a method for producing a decorative surface on a workpiece. The method comprises: feeding of the workpiece coated with a liquid layer to a digital printing station; application of an agent capable of at least partially absorbing electromagnetic radiation, at least on a partial area of the surface of the liquid layer, or which, in contact with the surface, produces a reaction product which is capable of at least partially absorbing electromagnetic radiation; irradiation of the surface of the liquid layer and of the agent with electromagnetic radiation having a wavelength of less than 300 nm. Irradiation of the surface of the liquid layer causes polymerization of the liquid layer and leads to micro-folding, thereby forming a microstructure. [0010] US2