# US 10,308,056 B2 · Manufacturing of decorative surfaces by inkjet

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- Number: US 10,308,056 B2
- Document ID: US10308056B2
- Status: Granted
- Kind: B2
- Application number: 15/575,986
- Filed: 2016-05-11
- Published: 2018-05-31
- Granted: 2019-06-04
- Earliest claimed: 2015-05-22
- Assignees: Agfa NV; Unilin, Bvba
- Applicants: Agfa NV; Unilin BvbA
- Inventors: Roel De Mondt; Nadine Willems
- Web page: https://patentgrep.com/patent/US10308056B2

## CPC

- B41M 5/0047: {by ink-jet printing}
- B32B 27/08: of synthetic resin
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 37/06: characterised by the heating method
- B32B 37/10: characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- B32B 38/0004: {Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence)}
- B32B 38/145: {Printing}
- B41M 5/0064: {on plastics, horn, rubber, or other organic polymers}
- B41M 7/0027: {using protective coatings or layers by lamination or by fusion of the coatings or layers}
- B41M 7/0081: {using electromagnetic radiation or waves, e.g. ultraviolet radiation, electron beams}
- B44C 5/04: Ornamental plaques, e.g. decorative panels, decorative veneers
- C09D 11/101: Inks specially adapted for printing processes involving curing by wave energy or particle radiation, e.g. with UV-curing following the printing
- C09D 11/322: Pigment inks
- E04F 15/02188: {for use in wet rooms}
- E04F 15/107: {composed of several layers, e.g. sandwich panels (layered products in general B32B; producing decorative panels or veneers B44C5/04)}
- B32B 2255/26: Polymeric coating
- B32B 2262/101: Glass fibres
- B32B 2305/08: Reinforcements
- B32B 2305/30: Fillers, e.g. particles, powders, beads, flakes, spheres, chips
- B32B 2307/41: Opaque
- B32B 2307/412: Transparent
- B32B 2327/06: PVC, i.e. polyvinylchloride
- B32B 2419/04: Tiles for floors or walls
- B44F 9/02: wood grain effects
- B44F 9/04: of stone surfaces, e.g. marble
- E04F 15/02038: {characterised by tongue and groove connections between neighbouring flooring elements}
- E04F 15/102: {of fibrous or chipped materials, e.g. bonded with synthetic resins}
- E04F 2201/0153: by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
- B41M: PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING, (correction of typographical errors B41J; processes for applying transfer pictures or the like B44C1/16; fluid media for correction of typographical errors by coating C09D10/00; printing textiles D06P)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B44C: PRODUCING DECORATIVE EFFECTS (processes for applying liquids or other fluent materials to surfaces, in general B05D; shaping of plastics or substances in a plastic state B29C; printing processes to produce transfer pictures B41M3/12; thermographic duplication or marking methods B41M5/00); MOSAICS; TARSIA WORK (imitation of mosaic or tarsia work patterns B44F11/04); PAPERHANGING {(labels G09F; multi-step processes for making paper labels or tags B31D1/02)}
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B)
- B44F: SPECIAL DESIGNS OR PICTURES

## Abstract

A method for manufacturing decorative surfaces includes the steps of a) inkjet printing an image on a first thermoplastic foil using a pigmented UV curable inkjet ink; b) applying a second thermoplastic foil on the inkjet printed image; and c) heat pressing the first and second thermoplastic foils into a decorative laminate; wherein the pigmented UV curable inkjet ink contains a polymerizable composition having 30 to 70 wt % of monofunctional polymerizable compounds and 30 to 70 wt % of polyfunctional polymerizable compounds, the weight percentage wt % is based on the total weight of the polymerizable composition; and at least one of the first and second thermoplastic foils is a transparent foil.

## Claims

### Claim 1

A method for manufacturing a decorative surface, the method comprising, in order, the steps of:
inkjet printing and UV curing an image on a first thermoplastic foil using a pigmented UV curable inkjet ink to form an inkjet printed image;
applying a second thermoplastic foil on the inkjet printed image; and
heat pressing the first and second thermoplastic foils into a decorative laminate; wherein
the pigmented UV curable inkjet ink includes a polymerizable composition including 30 to 70 wt % of monofunctional polymerizable compounds and 30 to 70 wt % of polyfunctional polymerizable compounds, the weight percentage wt % based on a total weight of the polymerizable composition;
the pigmented UV curable inkjet ink includes a pigment in an amount from 0.1 to 20 wt % based on a total weight of the pigmented UV curable inkjet ink; and
at least one of the first and second thermoplastic foils is a transparent foil.

### Claim 2 (depends on 1)

The method according to claim 1, further comprising the step of:
cutting the decorative laminate into a decorative panel.

### Claim 3 (depends on 1)

The method according to claim 1, wherein the first and second thermoplastic foils include polyvinyl chloride.

### Claim 4 (depends on 1)

The method according to claim 1, wherein the pigmented UV curable inkjet ink is printed on the transparent foil.

### Claim 5 (depends on 1)

The method according to claim 1, wherein one of the first and second thermoplastic foils is an opaque foil, and the pigmented UV curable inkjet ink is printed on the opaque foil.

### Claim 6 (depends on 1)

The method according to claim 1, wherein the first and second thermoplastic foils include an opaque foil and the transparent foil.

### Claim 7 (depends on 1)

The method according to claim 1, wherein the decorative panel includes a base layer.

### Claim 8 (depends on 7)

The method according to claim 7, wherein the base layer substantially includes polyvinyl chloride and reinforcing fibers.

### Claim 9 (depends on 8)

The method according to claim 8, wherein the reinforcing fibers include glass fibers.

### Claim 10 (depends on 1)

The method according to claim 1, wherein the monofunctional and polyfunctional polymerizable compounds include more than 80 wt % of acrylates based on the total weight of the polymerizable composition.

### Claim 11 (depends on 1)

The method according to claim 1, wherein the step of heat pressing includes preheating the first and second thermoplastic foils to a temperature above 130° C.; and
using a cooled press to fuse the first and second thermoplastic foils into the decorative laminate.

### Claim 12 (depends on 1)

A decorative panel obtained by the method according to claim 1.

### Claim 13 (depends on 12)

The decorative panel according to claim 12, wherein the decorative panel includes a glueless tongue and groove joint capable of interlocking other decorative panels.

### Claim 14 (depends on 12)

The decorative panel according to claim 12, wherein the decorative panel has a thickness of 2 mm to 6 mm.

### Claim 15 (depends on 12)

The decorative panel according to claim 12, wherein the decorative panel includes a base layer, a decorative layer, a protective layer, and a polyurethane finishing layer on the protective layer.