IP Library Granted Patent US 10,625,494
Granted Patent B2
US 10,625,494 · App. 16/337,441 · Granted Apr 21, 2020

Manufacturing of decorative surfaces

View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 10,625,494
App. No.
16/337,441
Granted
Apr 21, 2020
Kind
B2
Abstract

A method for manufacturing decorative surfaces includes, in order, the steps of a) inkjet printing an image on a first thermoplastic foil by jetting and UV curing one or more pigmented free radical UV curable inkjet inks on the first thermoplastic foil; b) applying on the inkjet printed image a second thermoplastic foil carrying a layer containing a vinylchloride-vinylacetate-vinylalcohol copolymer with the layer facing the inkjet printed image on the first thermoplastic foil; and c) heat pressing the first and second thermoplastic foils into a decorative laminate; wherein at least one of the first and second thermoplastic foils is transparent, and the one or more pigmented free radical UV curable inkjet inks contain a polymerizable composition having: 30 to 90 wt % of one or more compounds with one ethylenically unsaturated polymerizable group; 10 to 70 wt % of one or more compounds with two ethylenically unsaturated polymerizable groups; and 0 to 10 wt % of one or more compounds with three or more ethylenically unsaturated polymerizable groups.

Claims (26)

1. A method for manufacturing a decorative surface, the method comprising, in order:

a) inkjet printing an image on a first thermoplastic foil by jetting and UV curing one or more pigmented free radical UV curable inkjet inks on the first thermoplastic foil;

b) applying on the inkjet printed image a second thermoplastic foil including a layer including a vinylchloride-vinylacetate-vinylalcohol copolymer such that the layer faces the inkjet printed image on the first thermoplastic foil; and

c) heat pressing the first thermoplastic foil and the second thermoplastic foil into a decorative laminate; wherein

at least one of the first thermoplastic foil and the second thermoplastic foil is transparent; and

the one or more pigmented free radical UV curable inkjet inks includes a polymerizable composition including:

30 to 90 wt % of one or more compounds with one ethylenically unsaturated polymerizable group;

10 to 70 wt % of one or more compounds with two ethylenically unsaturated polymerizable groups; and

0 to 10 wt % of one or more compounds with three or more ethylenically unsaturated polymerizable groups, and all weight percentages wt % are based on a total weight of the polymerizable composition.

2. The method according to claim 1 , further comprising:

d) cutting the decorative laminate to form a decorative panel.

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

4. The method according to claim 1 , wherein the first thermoplastic foil is transparent.

5. The method according to claim 1 , wherein the first thermoplastic foil is opaque.

6. The method according to claim 1 , wherein the decorative surface includes a base layer;

when one of the first thermoplastic foil and the second thermoplastic foil is opaque, the base layer is attached to a side of the opaque thermoplastic foil; and

when both of the first thermoplastic foil and the second thermoplastic foil are transparent, the base layer is attached to a side of one of the transparent thermoplastic foils.

7. The method according to claim 6 , wherein the base layer includes polyvinyl chloride and reinforcing fibers.

8. The method according to claim 7 , wherein the reinforcing fibers include glass fibers.

9. The method according to claim 1 , wherein the one or more pigmented free radical UV curable inkjet inks includes at least one monomer selected from a N-vinyl-lactam and an acyclic-hydrocarbon monoacrylate.

10. The method according to claim 1 , wherein the step of heat pressing is performed by preheating the first thermoplastic foil and the second thermoplastic foil to a temperature above 130° C.

11. The method according to claim 1 , wherein the vinylchloride-vinylacetate-vinylalcohol copolymer in the layer includes more than 80 wt % of vinyl chloride and 1 to 15 wt % of vinylalcohol based on a total weight of the copolymer.

12. The method according to claim 1 , wherein the layer including the vinylchloride-vinylacetate-vinylalcohol copolymer has a dry weight of 1 to 10 g/m 2 .

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

14. The decorative panel according to claim 13 , wherein the decorative panel includes a tongue and groove joint that interlocks with another decorative panel.

15. The decorative panel according to claim 14 , further comprising a polyurethane finishing layer on the at least one of the first thermoplastic foil and the second thermoplastic foil that is transparent.

Assignments (2)
CHANGE OF LEGAL ENTITY Recorded Mar 1, 2024
From: UNILIN, BVBA
To: UNILIN BV
Reel/Frame 066710/0092 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 28, 2019
From: LENAERTS, JENS; WILLEMS, NADINE; VAN AERT, HUBERTUS
To: AGFA NV; UNILIN BVBA
Reel/Frame 048722/0712 →