Method, machinery, decorative film and embossable formulation to decorate and emboss a material
The method object of the invention involves printing an image on a flexible film, applying an embossable formulation, consisting of a photo-crosslinkable formulation containing at least one thermoplastic resin, on it, laminating the printed and coated film with the embossable formulation to the substrate to be decorated, embossing the substrate on which the printed and coated film with the embossable formulation has been previously applied.
1 . A process for decorating a material comprising the steps of:
(a) printing an image or a uniform color on at least part of a flexible film;
(b) curing or drying the ink;
(c) applying an embossable formulation consisting of a photo-crosslinkable formulation containing at least one thermoplastic resin to at least a portion of the printed flexible film, wherein said embossable formulation is applied in an amount of 50 to 250 g/m 2 ;
(d) substantially polymerizing said embossable formulation by photo-crosslinking;
(e) laminating the decorated and coated film with the embossable formulation onto at least part of a substrate to be decorated using heat and/or pressure; and
(f) mechanically embossing the embossable formulation and/or the combination of said substrate and said film laminated thereon by applying heat to said embossable formulation, wherein said mechanically embossing step (f) is performed after or simultaneously with said laminating step (e), and wherein said thermoplastic resin imparts thermoplastic embossability to said substantially polymerized photo-crosslinkable formulation.
2 . The process according to claim 1 wherein the flexible film decorated and coated with the embossable formulation and the substrate to be decorated are of the same chemical nature.
3 . The process according to claim 1 in which the lamination of the flexible film, decorated and coated with the embossable formulation, with the substrate to be decorated occurs solely by means of heat and/or pressure.
4 . The process according to claim 1 , wherein the lamination of the flexible film, decorated and coated with the embossable formulation, with the substrate to be decorated occurs with the aid of an adhesive.
5 . The process according to claim 1 , wherein a surface treatment is performed to the film before printing.
6 . The process according to claim 1 , wherein the uniform color is generated in-line.
7 . The process according to claim 1 , wherein one or more of liquid layers selected from primer, ink, embossable formulation, and topcoat are applied to the film and are of photo-crosslinkable nature.
8 . The process according to claim 1 , wherein one or more liquid layers selected from primer, ink, embossable formulation, and topcoat applied to the film undergo a dual-cure process.
9 . The process according to claim 1 , wherein the gloss of the embossed combination of said substrate and said film laminated on said substrate is determined by the embossing element.
10 . The process according to claim 1 , wherein the embossable formulation is applied by a single application step.
11 . The process according to claim 1 , wherein one or more liquid layers are applied to the film by means of a slot-die.
12 . The process according to claim 1 , wherein the embossable formulation is digitally textured and/or mechanically embossed.
13 . The process according to claim 1 , wherein the embossing takes place by means of an embossing element such as a flat press, a calender, a double belt press and a combination thereof.
14 . The process according to claim 1 , wherein the embossable formulation is digitally embossed by localized printing of a texturing fluid defining an embossing pattern on at least part of the surface thereof.
15 . The process according to claim 1 , wherein the embossing or texturing is made in registration with the image or the uniform color printed on said at least part of the flexible film.
16 . The process according to claim 1 , wherein the substrate consists of a finished floor element on which the interlocking system has already been generated or the interlocking system is generated subsequently by lamination of the flexible film coated with the embossable formulation.
17 . The process according to claim 1 , wherein the flexible film is made of polymers or paper or metal or a combination thereof.
18 . The process according to claim 1 , wherein the substrate consists of plastic materials selected from PVC, SPC, LVT, WPC, and polyolefins, wood derivatives selected from MDF, HDF, chipboard, and OSB, metal, or inorganic materials and combinations thereof.
19 . The process according to claim 1 , wherein the substrate to be decorated is in discrete form as a panel or board, or in continuous form as a roll.
20 . The process according to claim 1 , wherein the printing is of the analogue type selected from rotogravure, flexography, offset, intaglio, or silkscreen, or of the digital type selected from inkjet, toner, or liquid toner, or combinations thereof.
21 . A ready-to-laminate film comprising:
(a) a film made of plastic or paper or combinations thereof;
(b) a printed decoration or solid color applied to at least part of the said film; and
(c) an embossable formulation consisting of a photo-crosslinkable formulation containing at least one thermoplastic resin applied to at least a portion of said film.
22 . The ready-to-laminate film according to claim 21 , wherein said film is applied by means of pressure and/or heat to a substrate to be decorated.
23 . The ready-to-laminate film according to claim 22 , wherein after said film is applied to the substrate, said film is embossed.
24 . The ready-to-laminate film according to claim 22 , wherein said film is applied and mechanically embossed to the substrate to be decorated simultaneously.
25 . The ready-to-laminate film according to claim 22 , wherein said film is embossed in a subsequent step after application to the substrate to be decorated.
26 . The ready-to-laminate film according to claim 21 , wherein a heat-activatable adhesive is applied to at least part of the unprinted side of said film.
27 . A printing and coating machine comprising:
an unwinder;
a central impression drum on which there is at least one slot-die station to apply liquid layers and at least one inkjet printing station; and
a rewinder.
28 . The printing and coating machine according to claim 27 , wherein analog and/or digital applications are performed on two or more central impression drums in series.
29 . The printing and coating machine according to claim 27 , wherein flow of different coatings is machine regulated by a PLC or other logic system where parameters related to a desired specification of a decorated substrate are inputted.
30 . A process for decorating a material comprising the steps of:
(a) printing an image or a uniform color on at least part of a flexible film;
(b) curing or drying the ink;
(c) applying an embossable formulation consisting of a photo-crosslinkable formulation containing at least one thermoplastic resin, to at least a portion of the printed flexible film;
(d) substantially polymerizing said embossable formulation by photo-crosslinking;
(e) laminating the decorated and coated film with the embossable formulation onto at least part of a substrate to be decorated solely by means of heat and/or pressure without the use of adhesives, wherein said flexible film and said substrate are of the same chemical nature; and
(f) mechanically embossing the embossable formulation and/or the combination of said substrate and said film laminated thereon by applying heat.
31 . A process for decorating a material comprising the steps of:
(a) printing an image or a uniform color on at least part of a flexible film;
(b) curing or drying the ink;
(c) applying an embossable formulation consisting of a photo-crosslinkable formulation containing at least one thermoplastic resin, to at least a portion of the printed flexible film;
(d) substantially polymerizing said embossable formulation by photo-crosslinking;
(e) digitally texturing said embossable formulation by localized application of a texturing fluid;
(f) laminating the decorated and coated film with the embossable formulation onto at least part of a substrate to be decorated; and
(g) mechanically embossing said embossable formulation using an embossing element selected from a flat press, a calender, a double belt press, and combinations thereof,
wherein said embossable formulation is both digitally textured and mechanically embossed.
32 . A process for decorating a material comprising the steps of:
(a) printing an image or a uniform color on at least part of a flexible film;
(b) curing or drying the ink;
(c) applying an embossable formulation consisting of a photo-crosslinkable formulation containing at least one thermoplastic resin, to at least a portion of the printed flexible film;
(d) substantially polymerizing said embossable formulation by photo-crosslinking;
(e) laminating the decorated and coated film with the embossable formulation onto a finished floor element selected from a plank, a board, and a finished floor plank on which an interlocking system has already been generated or is generated subsequently to the lamination; and
(f) mechanically embossing the embossable formulation and/or the combination of said finished floor element and said film laminated thereon.