Surfacing materials and method of manufacture, including a textured press plate for use in the manufacture of decorative laminate
A textured press plate for use in the manufacture of decorative laminate is provided. The textured press plate is manufactured by the method include the steps of applying a UV curable acrylate mixture to a surface of a press plate substrate, irradiating the UV curable acrylate mixture with LED precure by excimer UV to create a UV-irradiated layer having a surface exhibiting micro-folding, and fully curing the UV-irradiated layer to form a textured coating layer.
1. A textured press plate for use in manufacture of decorative laminate, the textured press plate being manufactured by the method comprising:
applying a UV curable acrylate mixture directly to a surface of a press plate substrate, the UV curable acrylate mixture comprising an aliphatic urethane triacrylate oligomer, an aliphatic urethane acrylate oligomer, and a reactive diluent;
irradiating the UV curable acrylate mixture that has been applied to the press plate substrate with an excimer emitter such that the UV curable acrylate mixture is only crosslinked on a surface thereof to create a UV-irradiated layer having a surface exhibiting micro-folding; and
fully curing the UV-irradiated layer to form a textured coating layer on the surface of the press plate.
2. The textured press plate according to claim 1 , wherein the step of irradiating includes treating the UV curable acrylate mixture so that the UV curable acrylate mixture is only crosslinked on a surface thereof to produce a supermatting surface through micro-convolution.
3. The textured press plate according to claim 2 , wherein the step of irradiating is achieved with the excimer emitter based on a Xe-emission spectrum at a wavelength of 172 nm in a presence of nitrogen.
4. The textured press plate according to claim 1 , wherein the UV curable acrylate mixture is a solvent-free and non-aqueous lacquer.
5. The textured press plate according to claim 1 , wherein the step of fully curing is by E-beam or UV irradiation.
6. The textured press plate according to claim 5 , further including a step of applying a TiB 2 hard coating to the textured coating layer.
7. The textured press plate according to claim 1 , wherein the step of applying includes applying the UV curable acrylate mixture to the press plate substrate with a roller.
8. The textured press plate according to claim 1 , wherein the step of applying includes applying the UV curable acrylate mixture to the press plate substrate with a layer thickness greater than 5 microns.
9. The textured press plate according to claim 1 , wherein the step of applying includes applying the UV curable acrylate mixture to the press plate substrate with a layer thickness of 30 to 100 microns.