Embossed and hot-melt laminated multilayer composite film
A multi-layered composite film is provided that includes immediately consecutive and mutually bonded layers A-B-C: A: on the visible side, a polymer layer comprising 1 to 100% by weight of extrudable thermoplastic polyurethane-containing polymer and/or ionomer; B: a tie layer comprising one or more modified plastics for the tie; C: on the substrate side, a decorative layer; wherein the layered composite is coextruded from the layers A and B and hot-melt laminated with the decorative substrate layer at a temperature above the fusion temperature of the layered composite, while simultaneously pattern(s) is/are plastically embossed on the visible side of the multi-layered composite film. The multi-layered composite films may be used as a floor covering, wall panelling or furniture film. A method for manufacturing the multi-layered composite films is also provided.
1. A multi-layered composite film, comprising at least the following immediately consecutive and mutually bonded layers A-B-C:
A: on a visible side, a polymer layer comprising 1 to 100% by weight of extrudable thermoplastic polyurethane-containing polymer and/or ionomer;
B: a tie layer comprising one or more modified plastics for the tie;
C: on a substrate side, a decorative layer;
characterised in that the layered composite of the layers A and B is coextruded and hot-melt laminated with the decorative layer at a temperature above the fusion temperature of the layered composite, while simultaneously one or more patterns is/are plastically embossed on the visible side of the multi-layered composite film in the same step; and
characterised in that an embossing depth index I P is at least 6.0 once the multi-layered composite film has cooled to room temperature, and the embossing depth index I P is dimensionless and defined as follows (all values being in micrometers):
I P =R Z (visible side)×1000/( R Z (substrate side)×thickness( A - B - C )).
2. The multi-layered composite film according to claim 1 , characterised in that the decorative layer comprises paper, plastic film or a combination of paper and plastic film which is printed on.
3. The multi-layered composite film according to claim 2 , characterised in that the decorative layer C comprises a primer.
4. The multi-layered composite film according to claim 1 , characterised in that the one or more embossed patterns is synchronized with the decorative layer.
5. The multi-layered composite film according to claim 1 , characterised in that it contains no PVC or melamine resin.
6. The multi-layered composite film according to claim 1 , characterised in that the polymer of the polymer layer A is an ionomer.
7. The multi-layered composite film according to claim 1 , wherein the modified plastic(s) for the tie comprise(s) one or more polymer(s) modified with maleic anhydride, alkylated maleic anhydride and/or carboxylic acid.
8. The multi-layered composite film according to claim 1 , characterised in that the decorative layer C contains an extrudable thermoplastic polymer selected from the group consisting of polyethylenes, polypropylenes and polybutylenes, polystyrene, polyamide, polyester and mixtures of the same.
9. The multi-layered composite film according to claim 1 , characterised in that the polymer layer A exhibits a thickness in the range of 1 to 500; and/or the tie layer B exhibits a thickness in the range of 1 to 100 μm; and/or the decorative layer C exhibits a thickness of 1 to 500 μm.
10. The multi-layered composite film according to claim 1 , characterised in that it comprises at least the consecutive and mutually bonded layers D-A-B-C, wherein the layer D denotes one or more mutually bonded layers and is connected to the layer A directly, via a bonding layer or adhesive layer, by lamination or by mechanical connecting elements.
11. The multi-layered composite film according to claim 10 , characterised in that the layer D comprises one or more of the following layers: a covering layer, a UV protection layer, a moisture protection layer, a mechanical protection layer, a layer which prevents slipping, or a (heat-melt) adhesive layer, wherein the layer D can be transparent and/or can comprise a surface profile.
12. The use of a multi-layered composite film in accordance with claim 1 , wherein the multi-layered composite film is used as a floor covering or in the manufacture of a floor covering, as wall panels or roof panels or in the manufacture of wall panels or roof panels, as furniture film.
13. A layered body comprising a multi-layered composite film in accordance with claim 1 , wherein the multi-layered composite film is used as a floor covering or furniture film.
14. The floor covering according to claim 13 , characterised in that it comprises at least one other layer E which is a substrate layer which adjoins the layer C and is connected to the layer C directly, via a bonding layer or adhesive layer, by lamination or by mechanical connecting elements.
15. The floor covering according to claim 14 , characterised in that the substrate layer E comprises one of the following layers: a layer which prevents slipping, a heat-insulating layer, an impact sound-absorbing layer, a heat-conducting layer, an adhesive layer, a plywood layer or chipboard layer, a wood-plastic composite (WPC) layer and a fibre-reinforced concrete layer.
16. A method for manufacturing a multi-layered composite film according to claim 1 , characterised in that the layered composite is coextruded from the layers A and B in a first step and hot-melt laminated with the decorative layer at a temperature above the fusion temperature of the layered composite in a second step, while simultaneously one or more patterns is/are plastically embossed on the visible side of the multi-layered composite film in the same step, wherein the temperature of the layered composite does not drop below the fusion temperature of the layered composite A-B between the first and second method steps.
17. The method according to claim 16 , characterised in that the second method step is performed at a temperature of 150 to 300° C.
18. The multi-layered composite film according to claim 7 , wherein the modified plastic(s) for the tie comprise(s) one or more copolymer(s) or grafted (co)polymers of monomers which support carboxylic acid functionality.
19. The multi-layered composite film according to claim 18 , wherein the modified plastic(s) for the tie comprise(s) maleic anhydride and/or alkylated maleic anhydride with polypropylene, polyethylene, ethylene-vinyl acetate (EVA), ethylene-butyl acrylate (EBA), ethylene-acrylic acid (EAA), ethylene-methacrylic acid (EMAA), maleic acetate (MAH) and/or polyacrylate rubber (ACM).
20. The multi-layered composite film according to claim 9 , characterised in that the polymer layer A exhibits a thickness in the range of 5 to 200 μm; and/or the tie layer B exhibits a thickness in the range of 5 to 20 μm; and/or the decorative layer C exhibits a thickness of 10 to 150 μm.
21. The multi-layered composite film according to claim 20 , wherein the tie layer B exhibits a thickness in the range of 6 to 10 μm.
22. The use of a multi-layered composite film in accordance with claim 12 , wherein the multi-layered composite film is used in the manufacture of a plywood board or chipboard and/or as a graphic film, or a printed graphic film.