Manufacturing of decorative surfaces by inkjet
View Patent ↗A method for manufacturing decorative surfaces includes the steps of inkjet printing a color pattern with one or more aqueous inkjet inks including a polyurethane based latex binder; impregnating a paper substrate with a thermosetting resin; and heat pressing the thermosetting resin impregnated paper substrate carrying the inkjet printed color pattern into a decorative surface.
1. A method for manufacturing decorative surfaces, the method comprising the steps of:
a) inkjet printing a color pattern with one or more pigmented aqueous inkjet inks including a polyurethane based latex binder;
b) impregnating a paper substrate with a thermosetting resin; and
c) heat pressing the thermosetting resin impregnated paper substrate including the inkjet printed color pattern into a decorative surface; wherein
the one or more pigmented aqueous inkjet inks includes a red pigmented aqueous inkjet ink including a color pigment selected from the group consisting of C.I. Pigment Red 254, C.I. Pigment Red 122, and mixed crystals thereof.
2. The method according to claim 1 , wherein the steps are performed in order of a), then b), and then c).
3. The method according to claim 1 , wherein the steps are performed in order of b), then a), and then c).
4. The method according to claim 1 , wherein the step of heat pressing includes heat pressing the thermosetting resin impregnated paper substrate including the inkjet printed color pattern between a protective layer including a thermosetting resin and a core layer, wherein the color pattern faces the protective layer.
5. The method according to claim 1 , wherein the step of heat pressing includes heat pressing the thermosetting resin impregnated paper substrate including the color pattern as a protective layer into a decorative surface, wherein the color pattern faces a core layer of the decorative surface.
6. The method according to claim 5 , wherein the color pattern includes a white ink layer as an outermost ink layer.
7. The method according to claim 5 , wherein the protective layer includes particles in an amount between 1 g/m 2 and 100 g/m 2 .
8. The method according to claim 5 , wherein the protective layer is embossed with a relief corresponding to the color pattern.
9. The method according to claim 1 , wherein the one or more pigmented aqueous inkjet inks define an aqueous inkjet ink set including:
a cyan pigmented aqueous inkjet ink including a copper phthalocyanine pigment;
the red pigmented aqueous inkjet ink;
a yellow pigmented aqueous inkjet ink including a color pigment selected from the group consisting of C.I. Pigment Yellow 151, C.I. Pigment Yellow 74, and mixed crystals thereof; and
a black pigmented aqueous inkjet ink including carbon black pigment.
10. The method according to claim 1 , wherein the thermosetting resin is a melamine based resin.
11. The method according to claim 1 , wherein the inkjet printing is performed using a single pass printing inkjet printing process.
12. A decorative panel obtained by the method according to claim 1 , wherein the decorative panel is selected from the group consisting of flooring, kitchen, furniture, and wall panels.
13. The decorative panel according to claim 12 , wherein the decorative panel includes a tongue and a groove mechanical joint that requires no glue.